Apex Digital 5708009-C User Manual

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MANUAL

#RGZ

VQM9

%

(GDTWCT[

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)GPGTCVQT

Advanced Energy Industries,Inc.

1625 Sharp Point Drive

Fort Collins, CO 80525 USA

970.221.4670

technical.support@aei.com

7UGT/CPWCN

#RGZTM)GPGTCVQT

VQM9

5708009-C

Advanced Energy

Read this entire manual and all other publications pertaining to the work to be performed before you install, operate, or maintain this equipment. Practice all plant and product safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. All personnel who work with or who are exposed to this equipment must take precautions to protect themselves against serious or possibly fatal bodily injury.

Advanced Energy Industries, Inc., (AE) provides information on its products and associated hazards, but it assumes no responsibility for the after-sale operation of the equipment or the safety practices of the owner or user. This equipment produces or uses potentially lethal high-voltage, high-current, radio frequency (RF) energy. NEVER DEFEAT INTERLOCKS OR GROUNDS.

All information herein is subject to periodic updates. Inquiries concerning this manual should be directed to AE. Information provided by AE is believed to be correct and reliable. However, no responsibility is assumed by AE unless otherwise expressly taken.

Trademarks

Advanced Energy is a registered trademark of Advanced Energy Industries, Inc. AE is a registered trademark of Advanced Energy Industries, Inc. Apex is a trademark of Advanced Energy Industries, Inc. DeviceNet The Smith

SQS

2000

Copyright by Advanced Energy Industries Inc. All rights reserved. Without written permission, no part of this manual covered by copyright herein may be reproduced or copied in any form or by any means: graphic, electronic, or mechanical, including photocopying, recording, taping, or information and retrieval systems. Written permission must be granted by:

is a registered trademark of Advanced Energy Industries, Inc.

™

is a trademark of Open Vendor Association, Inc., Boca Raton, Fl.

chart shown is produced under a copyright license from Analog

Instruments Company, New Providence, New Jersey 07974

™

is a trademark of Tru-Connector Corporation, Peabody, MA

Advanced Energy Industries, Inc.

1625 Sharp Point Drive

Fort Collins, Colorado 80525 USA

4 5708009-C

Apex 1 to 5.5 kW Generator

Chapter 1. Introduction

Read This Section! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Using this Manual to Find Information for Your Generator . . . . . . . . . . . . . . . . . . . 1-1

Understanding PIN Numbers and Apex Configuration . . . . . . . . . . . . . . . . . .1-1

Using the PIN to Locate Information in the Manual . . . . . . . . . . . . . . . . . . . . 1-2

Using the PIN to Identify Apex Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Interpreting the Manual and Unit Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Type Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Icons (Symbols) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Product Safety/Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Directives and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Chapter 2. Theory

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Optional Water Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Chapter 3. Specifications

Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Input Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Output Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Other Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Cooling Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Graphical Representations of Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

5708009-C 5

Advanced Energy

Chapter 4. Interfaces and Indicators

Apex User Port Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

25-Pin Apex Standard User Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Satisfying Minimal Requirements for the 25-Pin User Port . . . . . . . . . . . 4-3

Interface Cabling Requirements for 25-pin user port . . . . . . . . . . . . . . . . 4-3

Pin Descriptions for the 25-Pin User Port . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Wiring Diagrams for the Standard 25-Pin User Port . . . . . . . . . . . . . . . . 4-9

15-Pin User Port (Exclusive—Option D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Satisfying Minimal Requirements for Option D 15-Pin User Port . . . . . 4-17

Interface Cabling Requirements for Option D user port . . . . . . . . . . . . . 4-17

Pin Descriptions for Option D User Port . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Wiring Diagrams for Option D 15-Pin User Port . . . . . . . . . . . . . . . . . . 4-20

15-Pin User Port (Exclusive—Option E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Satisfying Minimal Requirements for Option E 15-Pin User Port . . . . . . 4-27

Interface Cabling Requirements for Option E user port . . . . . . . . . . . . . 4-27

Pin Description for Option E User Port . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Wiring Diagrams for Option E User Port . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Apex Host Port Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Host Port—RS-232 With AE Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

RS-232, AE Bus Host Port Cabling Requirements . . . . . . . . . . . . . . . . 4-39

Communicating Through the RS-232, AE Bus Host Port . . . . . . . . . . . 4-39

AE Bus Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Creating an Ideal Communications Transaction . . . . . . . . . . . . . . . . . . 4-42

Host/Apex Communications Transaction Example . . . . . . . . . . . . . . . . 4-43

Command Status Response (CSR) Codes—RS-232, AE Bus Host . . . 4-44

Command Set for the RS-232, AE Bus Host Port . . . . . . . . . . . . . . . . . 4-45

Host Port—Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

AE Profibus Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Profibus/Apex Software Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Profibus Command Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Host Port—DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72

DeviceNet Interface Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

DeviceNet Rotary Switches: Baud Rate and Addressing . . . . . . . . . . . 4-74

DeviceNet Control Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

DeviceNet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

Apex Status Indicators (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Apex Panel Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Chapter 5. Installation, Setup, and Operation

Installing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Spacing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Mounting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Connecting Cooling Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

6 5708009-C

Apex 1 to 5.5 kW Generator

Installing the Optional Water Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Connecting Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

ODU Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

NonTerminated, four-Conductor Pigtail . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Harting Type Han-Q Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Connecting I/O and Auxiliary Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

To Control the Generator Through a User Port . . . . . . . . . . . . . . . . . . . 5-11

To Control the Generator through a Host port . . . . . . . . . . . . . . . . . . . . 5-11

To Use the Common Exciter (CEX) Feature (optional) . . . . . . . . . . . . . 5-12

First Time Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Understanding and Setting Up Pulsing Output . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Understanding Pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Enabling and Setting Pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Chapter 6. Troubleshooting and Customer Support

Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Checks with the Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Troubleshooting Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

AC On LED not Lit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Alarm LED Lit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Overtemp LED on Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Overtemp LED is Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Interlock LED is not Lit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

RF ON LED Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Power Limit LED is Lit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

External Load Checks - Open/Short RF Output Path . . . . . . . . . . . . . . . . . . . 6-6

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

AE Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Returning Units for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Authorized Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

5708009-C 7

Advanced Energy

8 5708009-C

Apex 1 to 5.5 kW Generator

List of Figures

Serial number identification tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Example configuration note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Theory of operation block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Flow Rate vs. Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Water flow vs. Inlet Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

User Port connector 25 Pin APEX Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

User port connector 15 Pin Exclusive for configuration D . . . . . . . . . . . . . . . . . . . . . . 4-17

User Port connector 15 pin exclusive for Configuration E . . . . . . . . . . . . . . . . . . . . . . 4-26

RS-232, AE Bus Host port connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Graphic representation of a RS-232, AE Bus message packet . . . . . . . . . . . . . . . . . 4-40

AE Bus communications transaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

AE Bus communications transaction example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Host port connector with Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

DeviceNet connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72

DeviceNet control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

Rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Apex dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Water control connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Optional water solenoid connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Output connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

ODU input connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Harting type Han-Q connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5708009-C 9

Advanced Energy

10 5708009-C

Apex 1 to 5.5 kW Generator

List of Tables

Apex PIN Positions and Associated Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Block Diagram Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Input Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Other Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Cooling Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Climatic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

User Port 25-Pin APEX Standard Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

User Port (15-pin) Connector Pins Exclusive for Configuration D . . . . . . . . . . . . . . . . 4-18

User Port (15-pin) Connector Pins Exclusive for Configuration E . . . . . . . . . . . . . . . . 4-28

RS-232, AE Bus Host Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

CSR Codes for RS-232, AE Bus Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Host Port Commands for RS-232 with AE Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Profibus Host Port Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Configuration of Download Bytes (Outbytes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Configuration of Profibus Upload Packet (Inbytes) . . . . . . . . . . . . . . . . . . . . . . . . . . .4-63

Upload Status Bytes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Profibus Host Port Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Host Port DeviceNet Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72

DeviceNet Voltage Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

MOD Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Network Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Poll Command Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Response Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78

LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Water Control Connector Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

ODU Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Nonterminated, Four-Conductor Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Harting Type Han-Q Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Global Support Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

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12 5708009-C

1Introduction

This chapter contains several kinds of introductory information.

•“Using this Manual to Find Information for Your Generator” on page 1-1 provides important instructions on locating the information in this manual that is applicable to your Apex unit.

•“Interpreting the Manual and Unit Labels” on page 1-9 provides information on interpreting the type conventions, safety warnings, and labels found in this manual and on the Apex unit.

•“Safety” on page 1-12, “Product Safety/Compliance” on page 1-12, and “Installation Requirements” on page 1-15 provide important safety and

compliance information about the Apex generator.

Apex 1 to 5.5 kW Generator

Chapter

READ THIS SECTION!

To ensure safe operation, you should read and understand this manual before you attempt to install or operate the Apex unit. At a minimum, read and heed “Safety” on page 1-13.

USING THIS MANUAL TO FIND INFORMATION FOR YOUR GENERATOR

The Apex generator can be ordered with many configurable options such as different output levels, input and output connectors, and so on. This manual covers many of these options, some of which will apply to your generator and some of which will not. This section of the manual is designed to help you quickly find the information that applies to your unit.

Note: This manual does not cover all the Apex generators; some units are covered in

other manuals. To make sure that you will be able to find the correct information, use the manual that came with that specific unit.

Understanding PIN Numbers and Apex Configuration

The options installed on any Apex generator (that is, the configuration of the generator) are defined by an PIN number that is located on the serial number tag of the generator. Figure 1-1 is an example of a serial number tag.

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Figure 1-1. Serial number identification tag

The PIN is a 17-position alpha-numeric that represents the configuration of your generator and identifies the options installed on it.

PIN positions

Configuration positions— A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

The “A” that precedes the PIN defines the product as an Apex generator, and it is not counted as one of the PIN positions. The 17 PIN positions that follow the “A” are used to identify the options installed on the generator.

Using the PIN to Locate Information in the Manual

This manual uses the PIN to help you identify the manual sections that apply to your unit. To begin using the manual, you will need to first find and record the PIN on your unit as you may want to refer to it frequently as you work with the manual.

Once you have located the PIN, you are ready to begin using the manual.

The manual provides two basic tools to help you use the PIN in locating correct information for your unit.

• The next section, “Using the PIN to Identify Apex Options”, provides a complete list of Apex features and their associated options, which are identified by each position in the PIN number. When appropriate, it also provides cross-references to the manual sections containing information for particular options. This table is the easiest place to find the appropriate section of the manual when you have a question about your unit.

• Throughout the manual, you will also see Configuration Notes similar to the following example. These configuration notes are placed at the beginning of many manual sections that provide option-specific information, and they provide information about the PIN position and option described in that section. These

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Apex 1 to 5.5 kW Generator

notes are best used to confirm that a particular section of the manual applies to the option installed on a specific Apex unit. They also refer back to Table 1-1, which provides complete configuration information

This section of the manual provides information for the:

DeviceNet option PIN position 6, (A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17) option 2.

(When identifying the PIN position, remember that the A at the beginning of the PIN is not counted as a position. The PIN option is the number or letter you should look for in the specified position.)

For more information about the PIN and for a complete list of how PIN positions correspond to Apex product options, see Table 1-1. on page 1-4.

Figure 1-2. Example configuration note

Using the PIN to Identify Apex Options

Table 1-1 shows all the options associated with each PIN position. When appropriate, it also provides cross references to help you locate the sections of the manual associated with your unit. For example, to find information about the output connector on your unit, look through the table to find the PIN position associated with output connectors, which is 11 (see row 11 of the table). Then find that position in the PIN for your Apex unit (remember, the A at the beginning of the PIN does not count as a position) and note the number or letter in that position. Using the right-most cell in the correct row, identify the option installed in your unit and use the cross-reference to locate the information on that option.

Note: Not all configurations are currently available and this manual does not cover all

currently available options. (Some options are covered in other manuals). Therefore, not all of the options listed in the table are covered in this manual. To make sure that you will be able to find the correct information for your unities the manual that came with that specific unit. Contact AE for any questions about availability of specific configurations. (For contact information, see “AE Customer Support” on page 6-11.)

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Table 1-1. Apex PIN Positions and Associated Options

Apex Feature Options, Descriptions, and Cross-References

Position

1 Output frequency 0—N/A

1—4 MHZ, ±0.005%

2—12.56 MHz, ±0.005%

3—13.56 MHZ, ±0.005%

4—27.12 MHz, ±0.005%

5—40.68 MHz, ±0.005%

For more information on frequency and other specifications, see “Electrical Specifications” on page 3-5.

2 Power output A—1000 W

B—1500 W

C—2000 W

D—3000 W

E—4000 W

F—5500 W

G—8000 W

H—10000 W

J—5000 W

K—1000 HALO

L—1500 HALO

M—3500 W

N—7000 W

For more information on power output and other specifications, see “Electrical Specifications” on page 3-5.

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Apex 1 to 5.5 kW Generator

Table 1-1. Apex PIN Positions and Associated Options (Continued)

Apex Feature Options, Descriptions, and Cross-References

Position

3 Input voltage 0—208 V nominal, 187 to 229 Vac, 3φ, 47 to 63 Hz, with

breaker

1—400 V nominal, 360 to 440 Vac, 3

φ, 47 to 63 Hz, with

breaker

2—reserved

3—208 V nominal, 187 to 229 Vac, 3

φ, 47 to 63 Hz,

without breaker

4—400 V nominal, 360 to 440 Vac, 3

φ, 47 to 63 Hz,

without breaker

5—220,208 to 229 Vac, 1 phase, 47/63 Hz w/o breaker

For more information on input voltage and other specifications, see “Electrical Specifications” on page 3-5.

4 Packaging A—frame mount (

≤ 5500 W)

B—frame mount with rack ears (1/2 rack) (utilities)

C—integrated rack mount

D—1/2 integrated rack mount (left)

E—1/2 integrated rack mount (right)

F—exclusive option #1

G—exclusive option #2

H—exclusive option #3

J—exclusive option #4

K—on board frame mount, opposite end LED’s

L—on board frame mount, opposite end LED’s w/4 handles

M—on board frame mount, opposite end LED’s w/2 handles

N—frame mount w/ rack ears (1/2 rack) (opposite)

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Table 1-1. Apex PIN Positions and Associated Options (Continued)

Apex Feature Options, Descriptions, and Cross-References

Position

5 Panel 0—none (on-board, frame mount)

1—integrated rack mount with blank panel

2—integrated rack mount with passive digital display

(see “Apex Status Indicators (LEDs)” on page 4-79)

3—N/A

4—exclusive option #1

For panel illustrations, see “Apex Panel Illustrations” on page 4-80.

6 Serial I/O 0—default (RS-232 with AE Bus) (see “Host Port—RS-

232 With AE Bus” on page 4-37)

1—Multidrop RS-485 with AE Bus (Currently NOT available)

2—DeviceNet (see “Host Port—DeviceNet” on page 4-72)

3—Profibus (see “Host Port—Profibus” on page 4-58)

4—exclusive option #1

5—DeviceNet (serial)

6—exclusive option #3

7—exclusive option #2

7 Serial Port 2 0—default (no secondary serial port)

1—RS 232

2—RS 485

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Apex 1 to 5.5 kW Generator

Table 1-1. Apex PIN Positions and Associated Options (Continued)

Apex Feature Options, Descriptions, and Cross-References

Position

8 User port options A—no User port

B—25-pin APEX standard (see “25-Pin Apex Standard

User Port” on page 4-2)

C—25-pin custom RFG compatible

D—15-pin, exclusive option #2 (see “15-Pin User Port

(Exclusive—Option D)” on page 4-16)

E—15-pin, exclusive option #3 (see “15-Pin User Port (Exclusive—Option E)” on page 4-26)

F—N/A

G—exclusive option #4

9 Output

A—50

impedance

B—exclusive option #1

C—exclusive option #2

D—exclusive option #5

Ω

10 On-board RF

output connector location

E—exclusive option #6

F—exclusive option #3

G—exclusive option #4

H— exclusive option #7

J—exclusive option #8

0—opposite end from water connections

1—utilities end (near water connections)

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Table 1-1. Apex PIN Positions and Associated Options (Continued)

Apex Feature Options, Descriptions, and Cross-References

Position

11 Output connector 0—exclusive option #1

1—7/16 connector)

2—SQS

 connector

3—LC connector

4—HN

5—N

6—exclusive option #2

For further information see “Connecting Output Power” on page 5-5.

12 RF measurement 0—directional coupler

1—V/I sensor

13 AC power input A—ODU connector (see “ODU Connector” on page 5-7)

B—Non-terminated 3 m, 4-conductor, shielded pigtail

(see “NonTerminated, four-Conductor Pigtail” on page 5-8)

C—Non-terminated 12

“NonTerminated, four-Conductor Pigtail” on page 5-8)

D—Harting Type Han-Q (see “Harting Type Han-Q Connector” on page 5-9)

E—4-terminal, stud mount

F—15´ 4-conductor, with a Hubbell CS8365C plug

G—5´ Harting

H—Term 3m, 4 cond, shielded pigtail Marinco 3015P

J—5’ terminated, 4 conductor, SH with contact LS1 BF.F6 5+PE (30A)

K—ODU connector with 20 degree rotation

L—Harting Type Han-Q (16A) rotated 180 degrees

M—6’,4 conductor with #10 ring lugs on each wire

14 Pulsing 0—no pulsing

1—pulse (see “Understanding and Setting Up Pulsing

Output” on page 5-13)

′, 4-conductor, pigtail (see

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Apex 1 to 5.5 kW Generator

Table 1-1. Apex PIN Positions and Associated Options (Continued)

Position

15 CEX 0—default (no CEX)

16 Water fitting

17 Custom

Apex Feature Options, Descriptions, and Cross-References

1—CEX add (see “To Use the Common Exciter (CEX) Feature (optional)” on page 5-12)

2—CEX w/1 Meter Cable (see “To Use the Common Exciter (CEX) Feature (optional)” on page 5-12)

0—default to 3/8 BSP female (metric threads)

threads

configuration

1—3/8 NPT female

2—3/8 BSP to 1/2" NPT

For information on connecting the water, see “Connecting Cooling Water” on page 5-4.

A—standard configurations

B—exclusive option #1

C—exclusive option #2

D—exclusive option #3

E—exclusive option #4

INTERPRETING THE MANUAL AND UNIT LABELS

The following sections provide information to help you interpret the use of type in the manual as well as frequently used graphics in the manual. It also provides a reference chart to help you understand the labels that may be used on the Apex unit.

Type Conventions

To help you quickly find what is being discussed, the manual presents certain words and phrases in type that are different from the rest of the text. We use the following type conventions:

• Pin and signal names appear in capitalized italics (DUTY CYCLE.A).

• Labels that are on the unit (switches, indicators, etc.) generally appear in boldface

capital letters (MODIFY); however they appear as you see them on the unit. Exceptions are port names, which simply begin with a capital letter (User port).

• Commands (162) and command names (setpoint) appear in boldface lowercase letters.

• Italic refers to any new or unfamiliar term.

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Icons (Symbols)

This symbol represents important notes concerning potential harm to people, this unit, or associated equipment. It is found whenever needed in the manual.

We include this symbol in Danger, Warning, and Caution boxes to identify specific levels of hazard seriousness.

This box identifies hazards that could result in severe personal injury or death.

This box identifies hazards or unsafe practices that could result in personal injury.

This box identifies hazards or unsafe practices that could result in product or property damage.

The following symbols could appear on labels on your unit.

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Apex 1 to 5.5 kW Generator

Capacitor charge

Hazardous Voltage

Short circuit protected

High voltage

Protective earth ground

Earth ground

CE label

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Non-ionizing radiation

Hot surface

Warning (refer to manual)

NRTL

SAFETY

Do not attempt to install or operate this equipment if you have not first acquired proper training.

• Ensure that this unit is properly grounded.

• Ensure that all cables are properly connected.

• Verify that input line voltage and current capacity are within specifications before

turning on the power supplies.

• Use proper ESD precautions.

• BE CAREFUL AROUND THIS EQUIPMENT

PRODUCT SAFETY/COMPLIANCE

Certain options of the Apex have been tested for and comply with the following Directives and Standards.

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Directives and Standards

The following tables list the Electromagnetic Compatibility (EMC) and Safety directives and standards.

Table 1-2. Electromagnetic Compatibility (EMC)

Directive Description

89/336/EEC EC Council directive on the approximation of the laws of the

Member States relating to electromagnetic compatibility (EMC Directive).

47 CFR Part 18 Code of Federal Regulations - Limits and Methods of

Measurement of Radio Interference Characteristics of Industrial, Scientific, and Medical Equipment.

EN 50082-2 Electromagnetic Compatibility (Generic Immunity Standard—

Industrial)

EN 55011 Limits and Methods of Measurement of Radio Disturbance

Characteristics of Industrial, Scientific, Medical (ISM) Radio Frequency Equipment (Class A, Group 2) (CISPR 11).

Table 1-3. Safety

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). SEMI S2-0200 Safety Guidelines for Semiconductor Manufacturing Equipment UL 1012 Power units other than class 2 EN 50178 Electronic Equipment For Use In Electrical Power Installations CSA C22.2

No. 107.1-95

This device must be installed and used only in compliance with the standards listed in addition to VDE 0113, EN 60204 (IEC 204), and applicable requirements.

General Use Power Supplies—Industrial Products

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Certification

Certain options of this product are certified by:

• Canadian Standards Association (CSA) (NRTL/C)

• CE marking is self addressed by AE Compliance Engineering

• EMC measurements verified by TÜV Product Services

For more information, refer to the letter of conformance (US) or declaration of conformity (EU) accompanying the product.

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Apex 1 to 5.5 kW Generator

INSTALLATION REQUIREMENTS

In order for proper installation to be completed on the Apex generator, please take note of the following warning boxes and the information contained in them. By meeting all the criteria in these boxes, proper installation of the Apex generator will be accomplished.

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.

RISK OF DEATH OR BODILY INJURY. Disconnect and LOCK-OUT/TAGOut all sources of input power before working on this unit or anything connected to it.

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Conditions of Use

To be in compliance with the stated directives and standards, you must meet the following conditions of use.

• This device must be used in an overvoltage category II installation only.

• Before making any other connection, connect the auxiliary Protective Earth

ground conductor on the rear panel.

• Use only a shielded cable on the input power connector.

• Use only a shielded power cable on the output power connector.

• Install and operate this device only in a pollution degree 2 or better environment,

which means an indoor location such as a computer room, office, or factory floor where only non-conductive pollution occurs during operation. Occasionally, a temporary conductivity caused by condensation occurs when the device is not operating.

• Non-standard connectors for input and/or output power must be inaccessible to the user.

• If your unit does not have a circuit breaker, install and operate it with a circuit breaker on the ac input to provide over current protection. The circuit breaker must have a trip value as specified in the line current section of Table 3-2. on page 3-5.

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2Theory

GENERAL DESCRIPTION

The Apex™ product line consisting of generators and delivery system products defined by a matrix of features and capabilities that can be easily custom configured to specific requirements and applications.

Apex 1 to 5.5 kW Generator

Chapter

The Apex products can be configured to three basic package styles. The Apex products may be configured with integrated SwitchMatch sophisticated VI sensor instrumentation in place of standard power measurement. The Apex products feature a powerful microprocessor for flexible and accurate operation. The microprocessor also facilitates the addition of one of several optional serial communications protocols in addition to the standard AE Bus host port. Several parallel digital/analog I/O choices are also available. Apex products are designed to be used in clean room environments and are water cooled.

Other optional features include high repetition rate, variable duty cycle pulsing and common exciter (CEX) phase lock operation.

FUNCTIONAL DESCRIPTION

In the following section, an overview of the functional description about the Apex products is discussed. Covered in the section is regulation, cooling, interlock, optional water solenoid, grounding and protection. These general descriptions are important to the User since they allow the User to become familiar with the functions of the Apex generator.

Regulation

™

matching networks and

The Apex generator regulates on forward power, delivered power, or bias voltage measured at the output of the generator. Mode selection is made through a designated pin in the interface connector or by receiving a command through a digital interface option.

Cooling

Apex generators are water-cooled only.

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Interlock

The Apex generator provides a system interlock connection through the User port. The RF output connector is also interlocked by a series switch that is part of the system interlock.

Optional Water Solenoid

The Apex generator provides water solenoid control circuitry that can be accessed through a connector on the rear of the generator. When an optional water control solenoid is connected to the water solenoid control circuitry, the Apex generator controls operation of the solenoid and water flow. This feature minimizes condensation in the generator when the RF output is off and cooling water is still circulating through the generator.

Grounding

The Apex generator has two holes located on the rear panel to attach the system RF ground to. One is a tapped M-6 hole, the other is a 5/16 may be used to provide an appropriate ground. Select the appropriate hole depending on whether you use metric or American fasteners.

Protection

The Apex generator protects itself from damage from the following conditions.

• Any unmatched load condition at the generator output. Output power fold-back

• Any internal over current condition not directly related to the output load

• Excessive internal temperature. (This condition may be caused by lack of proper

• Any combination of input ac line phase drop out.

• Input line brown-out (under voltage) or over voltage.

• Any User/ port pin shorted to chassis or another port pin.

″ x 18 tapped hole. Either hole

(limiting) occurs as required by the generator protection circuits.

condition as protected by current limiting or fuse.

cooling water flow, excessive ambient operating temperature, or other causes.)

THEORY OF OPERATION

In this section a bock diagram is designed to help the User understand the process by which the Apex generator works. Following the diagram is an explanation of the diagram in a table to help the User utilize the Apex unit as well. Figure 2-1 and Table 2-1 describe the basic operation of the Apex generator.

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Apex 1 to 5.5 kW Generator

(2) Driver/ Exciter

(3)

Amplifiers

(1)

User

Port

Host

Port

Analog

I/O

(5)

Digital

Controller

(6)

Sensor

Electronics

Figure 2-1. Theory of operation block diagram

(4)

Measure

RF Output

Table 2-1. Block Diagram Explanation

(1) User port (Analog

This section provides user interface and CEX functions.

I/O) (2) Driver/Exciter This section generates power at the designated output frequency

to drive the main RF sections. (3) RF Amplifier This section generates RF power. (4) RF Measurement This section samples the output signal and sends it to the sensor

electronics. (5) Digital

Controller

This section is the main processor and data acquisition section. It

also provides host communications through an RS-232 port. (6) Sensor Electronics This section detects RF samples and sends them to the

microprocessor.

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2-4 5708009-C

3Specifications

This chapter lists the specifications of the Apex generator in the following sections:

•“Physical Specifications” on page 3-1

•“Electrical Specifications” on page 3-5

•“Cooling Specifications” on page 3-10

•“Environmental Specifications” on page 3-14

In some cases, specifications for all Apex units are the same, but in other cases, the unit specifications vary depending on the options installed on the unit. In such cases, the manual refers to the PIN position that defines those specifications, lists the PIN and configuration options that are available, and when appropriate, provide cross references to more information on those specific options. For more information on using the PIN to identify information applicable to your unit, see “Using this Manual to Find Information for Your Generator” on page 1-1.

Apex 1 to 5.5 kW Generator

Chapter

PHYSICAL SPECIFICATIONS

Table 3-1 describes the physical specifications of the Apex generator. In some cases, the specifications for all 1 to 5.5 kW Apex units are the same, but in other cases, the unit specifications vary depending on the options installed. In such cases, the specification table refers to the PIN position that defines those specifications, lists the PIN and configuration options that are available and, when appropriate, provides cross references to more information on those options. For more information on using the PIN to identify information applicable to your Apex unit, see “Using this Manual to Find Information for Your Generator” on page 1-1.

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Table 3-1. Physical Specifications

Description PIN Option—Specification

Packaging

Note: Varies according to the

option defined by PIN position 4.

A—frame mount (

≤ 5500 Watts)

B—frame mount w/rack ears (1/2 rack) (rack ears on same end of the unit as the water connectors)

C—integrated rack mount

D—1/2 dual integrated rack mount (left)

E—1/2 dual integrated rack mount (right)

F—exclusive option #1

G—exclusive option #2

H—exclusive option #3

J—exclusive option #3

K—on-board frame mount, opposite end LEDs

L—on-board frame mount, opposite end LEDs, with 4

handles

M—on board frame mount, opposite end LEDs, with 2 handles

N—frame mount with rack ears (1/2 rack) (opposite end from water connectors)

Size 13.34 cm (H) x 21.6 cm (W) x 48.47 cm (D)

″ (H) x 8.5″ (W) x 19.19″ (D) See Figure 5-1 on

5.25 page 5-3

Note: The size of the unit depends on configuration of

your Apex unit. These dimensions are for the drawing in Chapter 5. See Figure 5-1 on page 5-3.

Weight 18.2 kg (40 lbs.) Clearance No special requirements

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Table 3-1. Physical Specifications (Continued)

Description PIN Option—Specification

AC power input connector

Note: Varies according to the

option defined by PIN position 13.

A—ODU connector (see “ODU Connector” on page 5-7)

B—Non-terminated 3 m, 4-conductor, shielded pigtail (see “NonTerminated, four-Conductor Pigtail” on page 5-8)

C—Non-terminated 12¢, 4-conductor, pigtail (see “NonTerminated, four-Conductor Pigtail” on page 5-8)

D—Harting Type Han-Q (see “Harting Type Han-Q Connector” on page 5-9)

E—4-terminal, stud mount

F—15´ 4-conductor, with a Hubbell CS8365C plug

G—5´ Harting

H—Term 3m, 4 cond, shielded pigtail Marinco 3015P

J—5’ terminated, 4 conductor, SH with contact LS1

BF.F6 5+PE (30A)

K—ODU connector with 20 degree rotation

L—Harting Type Han-Q (16A) rotated 180 degrees

RF output connector

Note: Varies according to the

option defined by PIN position 11.

RF Connector location

Note: Varies according to the

option defined by PIN position 10.

M—6’,4 conductor with #10 ring lugs on each wire 0—exclusive option #1

1—7/16 connector (see “Connecting Output Power” on

page 5-5)

2—SQS‘connector (see “Connecting Output Power” on page 5-5)

3—LC connector (see “Connecting Output Power” on page 5-5)

4—HN (see “Connecting Output Power” on page 5-5)

5—N (see “Connecting Output Power” on page 5-5)

6—exclusive option #2 0—opposite end from water connections

1—utilities end (near water connections)

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Table 3-1. Physical Specifications (Continued)

Description PIN Option—Specification

Water control connectors Switchcraft™ #L712A

User port (analog I/O) connector

Note: Varies according to the

option defined by PIN position 8.

Host port (serial I/O) connector

Note: Varies according to the

option defined by PIN position 6.

A—no analog port

B—25-pin APEX standard (see “25-Pin Apex Standard

User Port” on page 4-2)

C—25-pin custom RFG compatible

D—15-pin, exclusive option #2 (see “15-Pin User Port

(Exclusive—Option D)” on page 4-16)

E—15-pin, exclusive option #3 (see “15-Pin User Port (Exclusive—Option E)” on page 4-26)

F—N/A

G—exclusive option #4 0—9-pin, shielded, female, subminiature-D (see “Host

Port—RS-232 With AE Bus” on page 4-37)

1—9-pin, shielded, female, subminiature-D (Currently NOT available)

2—5-pin, male, Lumberg RSF 5/0.5 or Turck FS 4.5 (see “Host Port—DeviceNet” on page 4-72)

3—9-pin, shielded, female, subminiature-D (see “Host Port—Profibus” on page 4-58)

4—exclusive option #1

5—5-pin, male, Lumberg RSF 5/0.5 or Turck FS 4.5

6—9-pin, shielded, female, subminiature-D

7—exclusive option #2

CEX connector Female LIMO#EPL.00.250.NTN

Coolant connectors

Note: Varies according to the

option defined by PIN

0—3/8 BSP female

1—3/8 NPT adapters (adapters from 3/8 BSP female

threads in the manifold)(increases unit length)

position 16.

2—3/8 BSP to 1/2

″ NPT

For information on connecting the water, see “Connecting Cooling Water” on page 5-4.

3-4 5708009-C

Apex 1 to 5.5 kW Generator

Table 3-1. Physical Specifications (Continued)

Description PIN Option—Specification

Panel

Note: Varies according to the

option defined by PIN position 5.

RF measurement option

Note: Varies according to the

option defined by PIN position 12.

0—on-board frame mount

1—Integrated rack-mount with blank panel

2—Integrated rack-mount with passive digital display

3—Integrated rack-mount with active digital display

4—exclusive option #1 0—Coupler

1—V/I probe

ELECTRICAL SPECIFICATIONS

Table 3-2, Table 3-3, and Table 3-4 describe the input power, output power, and other electrical specifications for the Apex generator. In some cases, the specifications for all 1 to 5.5 kW Apex units are the same, but in other cases, unit specifications vary depending on the options installed. In such cases, the specification table refers to the PIN position that defines those specifications, lists the PIN and configuration options that are available and, when appropriate, provides cross references to more information on those options. For more information on using the PIN to identify information applicable to your Apex unit, see “Using this Manual to Find Information for Your Generator” on page 1-1.

Input Power Specifications

Table 3-2 describes the input power specifications for the Apex generator.

Table 3-2. Input Power Specifications

Description PIN Option and Specification

Line voltage

Note: Varies according to the

option defined by PIN position 3.

5708009-C 3-5

0—208 V nominal, 187 to 229 Vac, 3

1—400 V nominal, 360 to 440 Vac, 3φ

2—n/a

3—208 V nominal, 187 to 229 Vac, 3

4—400 V nominal, 360 to 440 Vac, 3φ

Advanced Energy

Table 3-2. Input Power Specifications (Continued)

Description PIN Option and Specification

Line frequency 47 to 63 Hz

Line current Typical A/

208 Vac nominal input (PIN position 3, options 0 and 3)

• 1500 W/13.56 MHz—9 A/

• 3000 W/13.56 MHz—14 A/

• 5500 W/13.56 MHz—25 A/

Typical A/ 400 Vac nominal input (PIN position 3, option 1)

• 3000 W/13.56 MHz—9 A/

• 5500 W/13.56 MHz—15 A/

φ and circuit breaker rating for units with

Output Electrical Specifications

Table 3-3 describes the output specifications for the Apex generator.

Table 3-3. Output Specifications

Description PIN Option and Specification

φ; 15 A breaker

φ; 25 A breaker

φ; 40 A breaker

φ; 15 A breaker

φ; 25 A breaker

Regulation modes • Forward power

• Load power

• External feedback (dc bias, for example)

Output frequency

Note: Varies according to the

option defined by PIN position 1.

0—N/A

3—13.56 MHZ, ±0.005%

3-6 5708009-C

Apex 1 to 5.5 kW Generator

Table 3-3. Output Specifications (Continued)

Description PIN Option and Specification

Full-rated output power

(Minimum into a 50

Ω, non-

reactive load)

Note: Varies according to the

option defined by PIN position 2.

Output impedance

Note: Varies according to the

option defined by PIN position 9.

A—1000 W

B—1500 W

C—2000 W

D—3000 W

E—4000 W

F—5500 W

J—5000 W

K—1000 W high accuracy low output (HALO)

L—1500 W HALO minimum into a 50

Ω, non-reactive

load

M—3500 W A—50

Ω

B—exclusive option #1

C—exclusive option #2

D—exclusive option #5

Delivered power into 2:1 VSWR loads

Note: Varies according to the

option defined by PIN position 2.

Delivered power into 3:1 VSWR loads

Note: Varies according to the

option defined by PIN 2.

E—exclusive option #6

F—exclusive option #3

G—exclusive option #4

H—exclusive option #7

J—exclusive option #8 B—1.5kW = 1125W

D—3kW = 2000W

F—5.5kW = 3350W

B—1.5kW = 650W

D—3kW = 1200W

F—5.5kW = 1900W

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Table 3-3. Output Specifications (Continued)

Description PIN Option and Specification

Output protection—Apex generators sense and employ several parameters for protection

Reflected power limit 20% of maximum forward power for units rated for less

than 5500 W. 1000 W for 5500 W units. (PIN position 2

defines the maximum forward power rating for the unit.) Dissipation limit Maximum PA dissipation—non-latching alarm LED Low/high line bus Bus voltage outside spec window—latching alarm LED Over-temperature Over-temp condition—latching alarm LED preceded by

non-fault warning (user setting). Output power range All generators except the HALO will allow setpoints

between 1% and 100% of full scale. The exception is the

HALO 1.5k generator depicted by “L” in position 2 of the

PIN number. This allows setpoints from 5 watts to 1500

watts.

Output power regulation accuracy

Into 50

Ω non-reactive load • ± 1% of setpoint or ± 0.1% of full-rated output,

whichever is greater (all PIN position 2 options but K and L)

≤ ±1% of setpoint or 0.25 W, whichever is greater

•

(PIN position 2, option K & L)

Into 3:1 VSWR nonreactive load

± 3% of setpoint (load power regulation), over all load

phase angles, or ± 0.25% of full-rated output, which ever is

greater

Load regulation as a function of line regulation

Less than 0.1% change in output power for 10% change in

ac line voltage

Load regulation as a function of temperature—(performance in accordance with the output power regulation accuracy)

Ambient air temperature

°C to +40°C

+5 range

Cooling water temperature

°C to +35°C

+5 range

Spurious outputs—Referenced to fundamental signal at full-rated output when operated in a

Ω non-reactive load

Harmonic related -40 dBc Non-harmonic related -50 dBc

3-8 5708009-C

Apex 1 to 5.5 kW Generator

Table 3-3. Output Specifications (Continued)

Description PIN Option and Specification

Warm up Approximately 2 s from ac-on to RF-on RF On Response time < 7 ms (6.4 ms typical) Turn-off/decay time 10 µs until output decays to 1% of maximum rated value.

Power repeatability

Power cycles, standard options

Note: Applies to units with

options 0 through 5 in PIN position 6.

Power Cycles with DC heating option

Note: DC heating option applies

only to units with option 6 or 7 in PIN position 6.

≤ 0.5% over time for same generator for setpoints

> 500 W. 1% generator to generator as measured against AE calorimetric standard

6 million cycles, 0 to full power into a matched load

360 kilocycles, 0 to full power into high dissipation load

30 million cycles, 0 to full power into a matched load

5 million cycles, 0 to full power into high dissipation load

Other Electrical Specifications

Table 3-4 describes the other electrical specifications for the Apex generator.

Table 3-4. Other Electrical Specifications

Description PIN Option and Specification

Efficiency (line to load) 60%, typical @ full-rated power, nominal line Power factor > 0.96 Maximum leakage current 3.5 mA Master - Slave / CEX (The Apex generator automatically locks the RF output signal phase

to the common exciter—CEX—input signal phase when the following conditions are met.)

Phase relationship (RF output inphase with the CEX input signal)

5708009-C 3-9

° ± 5°

Advanced Energy

Table 3-4. Other Electrical Specifications (Continued)

Description PIN Option and Specification

CEX In • Required signal amplitude range of +2 dBm to +10

dBm

• Generator operating frequency

• Input impedance of 50

CEX Out • Output signal amplitude range of +3 dBm to +7

dBm

• Generator operating frequency

• Output impedance of 50

Ω, less than 1.5:1 VSWR

±0.005%

Ω, less than 1.5:1 VSWR

COOLING SPECIFICATIONS

Table 3-5 describes the cooling specifications for the Apex generator.

Do not use de-ionized water for cooling purposes. De-ionized water causes both corrosion and erosion of cooling manifolds.

Table 3-5. Cooling Specification

Description Specification

Temperature +35

Flow rate

Note: Varies according to the

option defined by PIN position 2.

Pressure

Minimum pressure differential (supply to drain) required to achieve specified minimum flow rates)

3-10 5708009-C

°C (+95°F)

Note: Maximum water temperature at minimum flow rate

and maximum ambient air temperature (+40

≤ 3kW 7.6 1pm (2 gpm)

For For > 3kW 11.4 1pm (3 gpm)

≤ 3kW 0.9 Bar (13psi)

For For > 3kW 2 Bar (29 psi)

° C).

Apex 1 to 5.5 kW Generator

Table 3-5. Cooling Specification (Continued)

Description Specification

Maximum pressure

6.9 Bar (100 psi)

rating

Heat removal • For 1.5 kW, 3410 BTU/hour, 1000W at full rated

output power

• For 3 kW, 6825 BTU/hour, 2000W at full rated output power

• For 5.5 kW, 12,500 BTU/hour, 3660W at full rated RF output power

Contaminates The following specifications are recommended for the

water used to cool the Apex generator:

• pH between 7 and 9

• Total chlorine < 20 ppm

• Total nitrate < 10 ppm

• Total sulfate < 100 ppm

• Total dissolved solids < 250 ppm

• Total hardness expressed as calcium carbonate

equivalent less than 250 ppm

• Specific resistivity of 2500

Ω/cm or higher at 25°C

• Total dissolved solids (TDS) as estimated by the following:

TDS

≤ 640,000

specific resistivity (Ω/cm)

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Graphical Representations of Flow Rate

The following graph shows how flow (gpm) lessens as the pressure (psi) drops.

5.2

GPM

Flow (GPM)

0.1 0

0102030405060708090

0 PSI y xn,

Pressure drop (PSI)

Figure 3-1. Flow Rate vs. Pressure Drop

82.83

3-12 5708009-C

Apex 1 to 5.5 kW Generator

The following graph shows how Water Flow vs. Inlet Temp for all three Apex Units. It represents the inlet temperature rising as flow rate increases.

Inlet Temp - Degrees C

0 0.5 1 1.5 2 2.5 3

Water Flow vs Inlet Temp

Apex Generator

5513

3013 1513

Flow - gpm

Figure 3-2. Water flow vs. Inlet Temperature

Note: 5513 = 5500W and 13.56 MHz

3013 = 3000W and 13.56 MHz 1513 = 1500W and 13.56 MHz

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ENVIRONMENTAL SPECIFICATIONS

Table 3-6 and Table 3-7 provide climatic and other environmental specifications for the Apex generator.

Table 3-6. Climatic Specifications

Temperature Relative Humidity Air Pressure

Operating

Class 3K3

°C to +40°C

°F to +104°F

+41

Class 3K2

10% to 85%

+2 g/m3 to +25 g/m

Class 3K3

80 kPa to 106 kPa

800 mbar to 1060 mbar (approximately 2000 m above sea level)

Storage

Class 1K4

°C to +55°C

-25

°F to +131°F

-13

Class 1K3

5% to 95%

+1 g/m

to +29 g/m

Class 1K4

80 kPa to 106 kPa

800 mbar to 1060 mbar (approximately 2000 m above sea level)

Transportation

Class 2K3

°C to +70°C

-25

°F to +158°F

-13

Class 2K3

95%

+60 g/m

3 3

Class 2K3

66 kPa to 106 kPa

660 mbar to 1060 mbar (approximately 3265 m above sea level)

Non-condensing

Maximum relative humidity when the unit temperature slowly increases, or when the unit

temperature directly increases from -25°C to +30°C

Maximum absolute humidity when the unit temperature directly decreases from +70°C to

+15°C

Table 3-7 shows other environmental specifications for the Apex generator.

Table 3-7. Environmental Specifications

Description Specification

Overvoltage Category II Pollution Degree 2

3-14 5708009-C

Apex 1 to 5.5 kW Generator

4Interfaces and Indicators

This chapter contains information on the Apex communication interfaces and status indicators (LEDs). It also contains representative drawings of the front and rear panels of the unit. The chapter is divided up into sections as follows.

• The first section of the chapter, “Apex User Port Options” on page 4-2, contains a subsection for each of the User port options available with the Apex 1 to 5.5 kW generator. These subsections are:

–“25-Pin Apex Standard User Port” on page 4-2

–“15-Pin User Port (Exclusive—Option D)” on page 4-16

–“15-Pin User Port (Exclusive—Option E)” on page 4-26

Chapter

• The second section of the chapter, “Apex Host Port Options” on page 4-37, contains a subsection for each of the serial Host port options available with the Apex 1 to 5.5 kW generator. These subsections are:

–“Host Port—RS-232 With AE Bus” on page 4-37

–“Host Port—Profibus” on page 4-58

–“Host Port—DeviceNet” on page 4-72

• The third section of the chapter, “Apex Status Indicators (LEDs)” on page 4-79,

contains information on interpreting the LED indicators that appear on some Apex units.

• The final section of the chapter, “Apex Panel Illustrations” on page 4-80, provides illustrations of Apex front and rear panels.

Not all of these sections apply to any one Apex unit. To identify the sections that apply to your unit, see “Using this Manual to Find Information for Your Generator” on page 1-1. Each of the option-specific sections of this chapter also contain PIN configuration notes, which help you confirm whether or not a particular section applies to your unit.

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Advanced Energy

APEX USER PORT OPTIONS

The following sections provide information for each of the User port options available with the 1 to 5.5 kW Apex generator. These options are:

•“25-Pin Apex Standard User Port” on page 4-2

•“15-Pin User Port (Exclusive—Option D)” on page 4-16

•“15-Pin User Port (Exclusive—Option E)” on page 4-26

Not all of these sections apply to any one Apex unit. To identify the section that applies to your unit, see “Using this Manual to Find Information for Your Generator” on page 1-1. Each of these sections also contains a PIN configuration note, which will help you confirm whether or not a particular section applies to your unit.

25-Pin Apex Standard User Port

The following section describes the Apex standard 25-pin User port. To determine if your Apex unit has this interface, use the configuration PIN from your Apex unit and the following Configuration Note.

This section of the manual provides information for the:

Apex standard 25-pin User port option PIN position 8, (A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17) option B.

For more information about the PIN and for a complete list of how PIN positions correspond to Apex product options, see Table 1-1. on page 1-4.

This User port is the standard option.

The User port uses a 25-pin, shielded, female, subminiature-D connector.

Figure 4-1. User Port connector 25 Pin APEX Standard

4-2 5708009-C

Apex 1 to 5.5 kW Generator

Unless otherwise specified, all analog signals are 0 to 10 V while all digital signals are 5 to 24 V, opto-coupled (open-collector signals with return lines non-referenced to ground).

Ground/Return lines are floating and need to be connected as close to the system as possible.

SATISFYING MINIMAL REQUIREMENTS FOR THE 25-PIN USER PORT

Regardless of whether you are controlling and monitoring the generator through the User port or through another port, two User port signals must be satisfied for the Apex unit to be operational: RF PWR ON (pin 4) and INTERLOCK LOOP (pins 10 and 23). In other words, even if you are controlling the generator through the serial port interface, the RF signal must be enabled and the interlock satisfied.

Note: If you are controlling your generator through a port other than the User port,

make sure that the control mode is set appropriately (to host mode to control through the Host port, for example) before powering up the unit. The control mode can be set through a Host port command.

If you are not using the User port to control or monitor the unit, you can use a “dummy” or “cheater” plug to satisfy these two signals, thereby ignoring the User port. To make such a plug, solder two jumpers on a mating connector: one between pins 4 and 9 to satisfy the RF PWR ON signal and one between pins 10 and 23 to satisfy the INTERLOCK LOOP signal. To determine the physical location of these pin numbers on the User port, see Figure 4-1 on page 4-2.

If desired, you can add an emergency off switch in series with the RF PWR ON signal (pin 4) or tie your system interlocks in series with the generator INTERLOCK LOOP signal (pins 10 and 23) by following the connections for those pins described in “Pin Descriptions for the 25-Pin User Port” on page 4-3 and “Wiring Diagrams for the Standard 25-Pin User Port” on page 4-9.

INTERFACE CABLING REQUIREMENTS FOR 25-PIN USER PORT

The cable used to connect the Apex generator’s User port to the system controller must be a shielded, 25-wire I/O cable. Twisted-pair wiring may be used but is not mandatory. Signal losses should be minimized by keeping the cable length as short as possible. The maximum recommended cable length between the generator and the controller is 10 meters (33´). To minimize interference from adjacent electrical equipment, the EMI shield in the cable must be terminated to the metal shells of the cable’s connectors. Additionally, the chassis of the Apex generator must be tied to a local earth ground through an adequately sized copper grounding strap.

PIN DESCRIPTIONS FOR THE 25-PIN USER PORT

Table 4-1 provides the connector pin descriptions for this User port interface. The pin numbers are arranged in signal pairs.

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Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions

Signal

Return

Name Signal

1 SETPOINT STATUS

RETURN

215RFL PWR

MONITOR

316FWD/LOAD PWR

MONITOR

Type

Digital Output

Analog

output

Analog

output

Description

See signal pin 14

This signal provides a linearly scaled read back of reflected power.

0 to 10V = 0 to maximum rated power output as defined by configuration PIN in Table 1-1 position 2 in Table 1-1.

See Wiring Diagram 4-2.

Pin 15 must be grounded. This signal provides a linearly

scaled read back of forward power when the generator is operated in forward power regulation mode or the load power when operated in the load power regulation mode.

0 to 10V = 0 to maximum rated power output as defined by configuration PIN position 2 in Table 1-1.

See Wiring Diagram 4-1. for wiring diagram.

Pin 16 must be grounded

4-4 5708009-C

Apex 1 to 5.5 kW Generator

Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions (Continued)

Signal

Return

Name Signal

417RF PWR ON Digital

518SETPOINT Analog

Type

input

Description

When a positive voltage between 4 and 30 V is applied to this pin RF output is enabled. Once the output is ON, a voltage of 1.5 Vdc or less disables the RF output.

See Wiring Diagram 4-5.

Note: The interlocks must be

satisfied and the setpoint must be within the Output power range before unit will deliver power. See Table 3-3. on page 3-6 for the Output power range specification.

This pin linearly controls the RF output of the generator.

0 to 10V = 0 to maximum rated power output as defined by configuration PIN position 2 in Table 1-1.

See Wiring Diagram 4-3.

Note: Setpoint must be greater

than 1% of full rated output before unit will deliver power.

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Advanced Energy

Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions (Continued)

Signal

Return

Name Signal

619DC BIAS/POWER

REGULATION

Type

Digital

input

Description

This pin is used in conjunction with signal pin 7 to allow the generator to regulate its power based on an external feedback signal. When a positive voltage between 4 and 30 V is connected to this pin (reference to ground pin 19), the generator regulates on the input voltage signal on pin 7 (DC BIAS INPUT).

0 to 10V = 0 to maximum rated power output as defined by configuration PIN position 2 in Table 1-1.

See Wiring Diagram 4-6.

Note: When using this

regulation feature, the setpoint must be given at pin 5 (SETPOINT). Setpoints cannot be established through the serial interface at this time.

4-6 5708009-C

Apex 1 to 5.5 kW Generator

Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions (Continued)

Signal

Return

Name Signal

720DC BIAS INPUT Analog

821FWD/LOAD PWR

REGULATION

Type

input

Digital

input

Description

This pin is used in conjunction with signal pin 6 to allow the generator to regulate its power based on an external feedback signal. This User defined 0 to 10 V signal provides an input which you can use for closing the power control loop around external components in the RF path. Usually used for bias regulation with this input signal being a scaled representation of the dc bias measured at match network.

See Wiring Diagram 4-4.

Note: When using this

regulation feature, the setpoint must be given at pin 5 (SETPOINT). Setpoints cannot be established through the serial interface at this time.

Applying a positive dc voltage between 4 and 30 V to this pin causes the generator to regulate on load power. No connection to this pin causes the generator to default to forward power regulation.

See Wiring Diagram 4-7.

9 OVERTEMP

RETURN

Digital Output

See Signal pin 22

10 23 INTERLOCK LOOP This pin when connected

externally to pin 23 closes the interlock and allows the RF output to be enabled.

See Wiring Diagram 4-12.

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Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions (Continued)

Signal

11 DC BUS OK

Return

Name Signal

RETURN

Type

Digital Output

12 25 CEX LOCK Digital

output

13 21 +15 VDC Analog

output

14 1 SETPOINT STATUS Digital

output

Description

See Signal Pin 24

When the generator is successfully phase-locked to an external oscillator, a low (optocoupler output) impedance is created between this pin and return pin 25. (6 mA max)

See Wiring Diagram 4-11. This pin, referenced to ground,

provides a +15 Vdc auxiliary supply for external use.

See Wiring Diagram 4-13. When the output is equal to the

requested setpoint, a low (optocoupler output) impedance is created between this pin and pin 1. (6 mA max).

15 RFL POWER

MONITOR RETURN

16 FWD/LOAD PWR

MONITOR RETURN

17 RF PWR ON

RETURN

18 SETPOINT

RETURN

Analog

output

Analog

output

Digital

input

Analog

input

19 DC GROUND Chassis

ground

20 DC BIAS INPUT

RETURN

Analog

input

21 CHASSIS GROUND Chassis

ground

See Wiring Diagram 4-8.

Note: This condition is also

referred to as the generator being at setpoint.

See pin 2

See pin 3

See pin 4

See pin 5

This pin represents DC ground connection common to chassis ground.

See pin 7

Chassis ground connection common to dc ground

4-8 5708009-C

Apex 1 to 5.5 kW Generator

Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions (Continued)

Signal

Return

Name Signal

Type

22 9 OVERTEMP Digital

output

23 10 INTERLOCK LOOP

RETURN

24 11 DC BUS OK Digital

output

Description

When an internal overtemperature shutdown condition is detected, a low (opto-coupler output) impedance is created between this pin and pin 9 (6 mA max).

See Wiring Diagram 4-9.

Note: This pin only detects a

overtemp shutdown condition. The warning indication described in the Overtemp LED section is not reported on this pin.

See Pin 10.

When the interlocks are satisfied and the AC input voltage is within its specification, a low (opto-coupler output) impedance is created between this pin and pin 11 (6mA max).

See Wiring Diagram 4-10.

25 CEX LOCK

RETURN

Digital Output

See pin 12

WIRING DIAGRAMS FOR THE STANDARD 25-PIN USER PORT

The diagrams in this section provide wiring information to properly connect to the Apex standard 25-pin User port.

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Wiring Diagram 4-1. Forward/Load power monitor (pins 3 and 16)

Wiring Diagram 4-2. RFL PWR monitor (pins 2 and 15)

4-10 5708009-C

Apex 1 to 5.5 kW Generator

Wiring Diagram 4-3. Setpoint (pins 5 and 18)

Wiring Diagram 4-4. DC Bias Input (pins 7 and 20)

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Wiring Diagram 4-5. RF Power On (pins 4 and 17)

Wiring Diagram 4-6. DC Bias/Power Regulation (pins 6 and 19)

4-12 5708009-C

Apex 1 to 5.5 kW Generator

Wiring Diagram 4-7. FWD/Load Power Regulation (pins 8 and 21)

Wiring Diagram 4-8. Setpoint Status (pins 14 and 1)

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Advanced Energy

Wiring Diagram 4-9. Overtemp (pins 22 and 9)

Wiring Diagram 4-10. DC Bus OK (pins 24 and 11)

4-14 5708009-C

Apex 1 to 5.5 kW Generator

Wiring Diagram 4-11. CEX Lock (pins 12 and 25)

Wiring Diagram 4-12. Interlock Loop (pins 10 and 23)

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Advanced Energy

Wiring Diagram 4-13. +15 Vdc (pins 13 and 21)

15-Pin User Port (Exclusive—Option D)

To determine if your Apex unit has this interface, use the configuration PIN from your Apex unit and the following Configuration Note. The diagrams in this section provide wiring information to properly connect to the Apex standard 25-pin User port.

This section of the manual provides information for the:

Apex 15-pin User port, option D PIN position 8, (A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17) option D.

For more information about the PIN and for a complete list of how PIN positions correspond to Apex product options, see Table 1-1. on page 1-4.

This 15-pin User port option offers only basic control and monitoring capability.

The User port uses a 15-pin, shielded, female, subminiature-D connector.

4-16 5708009-C

Apex 1 to 5.5 kW Generator

Figure 4-2. User port connector 15 Pin Exclusive for configuration D

SATISFYING MINIMAL REQUIREMENTS FOR OPTION D 15-PIN USER PORT

Regardless of whether you are controlling and monitoring the generator through the User port or through another port, two User port signals must be satisfied for the Apex unit to be operational: RF POWER ENABLE (pins 4 and 9) and INTERLOCK (pins 11 and 6). In other words, even if you are controlling the generator through the serial port interface, the RF signal must be enabled and the interlock satisfied.

Note: If you are controlling your generator through a port other than the User port,

make sure that the control mode is set appropriately (to host mode to control through the Host port, for example) before powering up the unit. The control mode can be set through a Host port command.

If you are not using the User port to control or monitor the unit, you can use a “dummy” or “cheater” plug to satisfy these two signals, thereby ignoring the User port. To make such a plug, solder two jumpers on a mating connector: one between pins 4 and 9 to satisfy the RF POWER ENABLE signal and one between pins 11 and 6 to satisfy the INTERLOCK signal. To determine the physical location of these pin numbers on the User port, see Figure 4-2 on page 4-17.

If desired, you can add an emergency off switch in series with the RF POWER ENABLE signal (pins 4 and 9) or tie your system interlocks in series with the generator INTERLOCK signal (pins 11 and 6) by following the connections for those pins described in “Pin Descriptions for Option D User Port” on page 4-18 and “Wiring Diagrams for Option D 15-Pin User Port” on page 4-20.

INTERFACE CABLING REQUIREMENTS FOR OPTION D USER PORT

The cable used to connect the Apex generator’s User port to the system controller must be a shielded, 15-wire I/O cable. Twisted-pair wiring may be used but is not mandatory. Signal losses should be minimized by keeping the cable length as short as possible. The maximum recommended cable length between the generator and the controller is 10 meters (33´). To minimize interference from adjacent electrical equipment, the EMI shield in the cable must be terminated to the metal shells of the cable’s connectors. Additionally, the chassis of the Apex generator must be tied to a local earth ground through an adequately sized copper grounding strap.

5708009-C 4-17

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Unless otherwise specified, all analog signals are 0 to 10V while all digital signals are 0 to 5V.

PIN DESCRIPTIONS FOR OPTION D USER PORT

Table 4-2 provides the connector pin descriptions for the User port interface.

Table 4-2. User Port (15-pin) Connector Pins Exclusive for Configuration D

Signal

Return

Name Signal

16POWER LIMIT

STATUS

26REFLECTED

POWER MONITOR

36FORWARD/LOAD

POWER MONITOR

Type

Digital

output

Analog

output

Analog

output

Description

When a +5 V signal is present at this pin a power limit is encountered; signal low represents normal operation.

See Wiring Diagram 4-19. This analog signal provides a

linearly scaled readback of the reflected power (1 V per 1 kW reflected power).

See Wiring Diagram 4-15. This analog signal provides a

linearly scaled readback of the forward power (when the generator is operated in forward power regulation mode) or the load power (when operated in load power regulation mode). (1 V per 1 kW forward/load power).

See Wiring Diagram 4-14.

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Table 4-2. User Port (15-pin) Connector Pins Exclusive for Configuration D (Continued)

Signal

Return

Name Signal

46RF POWER

ENABLE

56FORWARD/LOAD

POWER SETPOINT

Type

Digital

input

Analog

input

Description

RF output is enabled when a 4 to 30 V input (pin 9, RF ON BIAS, can be used as a voltage source) is present on this pin.

Note: The interlocks must be

satisfied and the setpoint must be within the Output power range before unit will deliver power. See Table 3-3. on page 3-6 for the Output power range specification.

See Wiring Diagram 4-17. This analog signal provides a

linearly scaled control of the forward or load output power depending on the regulation mode (1 V per 1 kW output power).

6 SIGNAL COMMON Chassis

ground

76RF ON STATUS Digital

output

86EXTERNAL BIAS Voltage

reference

See Wiring Diagram 4-16.

Note: The interlocks must be

satisfied and the setpoint must be within the Output power range before unit will deliver power. See Table 3-3. on page 3-6 for the Output power range specification.

This pin is Signal Common. Also connected to Apex generator chassis ground.

+ 5 Vdc on this pin represents RF ON.

See Wiring Diagram 4-18. +15 Vdc provided to the User

port through a 5.62 k

Ω resistor.

See Wiring Diagram 4-20.

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Table 4-2. User Port (15-pin) Connector Pins Exclusive for Configuration D (Continued)

Signal

Return

Name Signal

Type

96RF ON BIAS Voltage

reference

10 UNASSIGNED 11 6 INTERLOCK Analog

Input

12 6 RESERVED for

PULSING ENABLE

13 6 FWD/LOAD

POWER

Digital

Input

Digital

Input

REGULATION

Description

+15 Vdc provided to the User port through a 1.1 k

Ω resistor. It

can be used for a switch or relay contact closure to enable RF ON (pin 4).

See Wiring Diagram 4-21.

When connected together, these pins close the interlock and allows RF output to be enabled.

See Wiring Diagram 4-23. This pin is currently reserved for

future use.

Note: Pulsing parameters are set

via the digital/serial interface.

Load Power Regulation is enabled when a 4 to 30V input is present on this pin.

14 UNASSIGNED 15 UNASSIGNED

WIRING DIAGRAMS FOR OPTION D 15-PIN USER PORT

The diagrams in this section provide wiring information to properly connect to the Apex 15-pin configuration D User port.

Note: Forward Power

Regulation is the default.

See Wiring Diagram 4-22.

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Wiring Diagram 4-14. Forward/Load Power monitor (pins 3 and 6)

Wiring Diagram 4-15. Reflected power monitor (pins 2 and 6)

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Wiring Diagram 4-16. Forward/Load Power setpoint (pins 5 and 6)

Wiring Diagram 4-17. RF power enable (pins 4 and 6)

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Wiring Diagram 4-18. RF on status (pins 7 and 6)

Wiring Diagram 4-19. Power limit status (pins 1 and 6)

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Wiring Diagram 4-20. External bias (pins 8 and 6)

Wiring Diagram 4-21. RF on bias (pins 9 and 6)

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Wiring Diagram 4-22. FWD/LOAD Power Regulation (pins 13 and 6)

Wiring Diagram 4-23. Interlock (pins 11 and 6)

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15-Pin User Port (Exclusive—Option E)

The following section describes the Apex 15-pin User port (configuration E). To determine if your Apex unit has this interface, use the configuration PIN from your Apex unit and the following Configuration Note.

This section of the manual provides information for the:

Apex 15-pin User port (configuration E) option PIN position 8, (A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17) option E.

For more information about the PIN and for a complete list of how PIN positions correspond to Apex product options, see Table 1-1. on page 1-4.

Figure 4-3. User Port connector 15 pin exclusive for Configuration E

This 15-pin User port option offers only basic control and monitoring capability.

The User port uses a 15-pin, shielded, female, subminiature-D connector.

Unless otherwise specified, all analog signals are 0 to 10 V, while all digital signals are 0 to 15 V.

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SATISFYING MINIMAL REQUIREMENTS FOR OPTION E 15-PIN USER PORT

Regardless of whether you are controlling and monitoring the generator through the User port or through another port, two User port signals must be satisfied for the Apex unit to be operational: RF POWER ENABLE (pins 4 and 9) and INTERLOCK (pins 11 and 12). In other words, even if you are controlling the generator through the serial port interface, the RF signal must be enabled and the interlock satisfied.

Note: If you are controlling your generator through a port other than the User port,

make sure that the control mode is set appropriately (to host mode to control through the Host port, for example) before powering up the unit. The control mode can be set through a Host port command.

If you are not using the User port to control or monitor the unit, you can use a “dummy” or “cheater” plug to satisfy these two signals, thereby ignoring the User port. To make such a plug, solder two jumpers on a mating connector: one between pins 4 and 9 to satisfy the RF POWER ENABLE signal and one between pins 11 and 12 to satisfy the INTERLOCK signal. To determine the physical location of these pin numbers on the User port, see Figure 4-3 on page 4-26.

If desired, you can add an emergency off switch in series with the RF POWER ENABLE signal (pins 4 and 9) or tie your system interlocks in series with the generator INTERLOCK signal (pins 11 and 12) by following the connections for those pins described in “Pin Description for Option E User Port” on page 4-27 and “Wiring Diagrams for Option E User Port” on page 4-32.

INTERFACE CABLING REQUIREMENTS FOR OPTION E USER PORT

PIN DESCRIPTION FOR OPTION E USER PORT

Table 4-3 provides the connector pin information for the User port interface.

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Table 4-3. User Port (15-pin) Connector Pins Exclusive for Configuration E

Signal

Return

Name Signal

1 +24V (User Provided) Voltage

26REFLECTED POWER

Analog

MONITOR

36FORWARD / LOAD

Analog

POWER MONITOR

Type

Input

output

Description

+24V provided by user for devicenet LEDs, used for DeviceNet isolation.

See Wiring Diagram 4-24. This analog signal

provides a linearly scaled readback of reflected power.

0 to 10V = 0 to maximum rated power output as defined by configuration PIN in Table 1-1 position 2 in Table 1-1.

See Wiring Diagram 4-25. This analog signal

provides a linearly scaled readback of the forward power (when the generator is operated in forward power regulation mode) or the load power (when operated in load power regulation mode).

0 to 10V = 0 to maximum rated power output as defined by configuration PIN in Table 1-1 position 3 in Table 1-1.

See Wiring Diagram 4-26.

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Table 4-3. User Port (15-pin) Connector Pins Exclusive for Configuration E (Continued)

Signal

Return

Name Signal

4 RF POWER ENABLE Digital

56FORWARD / LOAD

POWER SETPOINT

Type

input

Analog

input

Description

This pin represents RF output being enabled when a 4 to 30V input (pin 9, RF ON BIAS, can be used as a voltage source) is present on this pin.

See Wiring Diagram 4-27.

Note: The interlocks must

be satisfied and the setpoint must be within the Output power range before unit will deliver power. See Table 3-

3. on page 3-6 for the Output power range specification.

This analog signal provides a linearly scaled control of the forward or load output power depending on the regulation mode.

0 to 10V = 0 to maximum rated power output as defined by configuration PIN in Table 1-1 position

See Wiring Diagram 4-28.

Note: The interlocks must

be satisfied and the setpoint must be within the Output power range before unit will deliver power. See Table 3-

3. on page 3-6 for the Output power range specification.

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Table 4-3. User Port (15-pin) Connector Pins Exclusive for Configuration E (Continued)

Signal

Return

Name Signal

6 SIGNAL COMMON Chassis

ground

78 RF ON STATUS Digital

8 RF ON STATUS

RETURN

9 +15 Vdc Voltage

reference

Type

output

Digital

output

Description

Common for signal pins 2, 3, and 5. Connected to the Apex generator chassis ground.

When an RF ON STATUS condition is detected, a low (optocoupler output) impedance is created between this pin and pin 8 (6mA max).

See Wiring Diagram 4-29. See pin 7

+15 Vdc provided to the User port through a 1.1k

Ω

resistor. Can be used for a switch or relay contact closure to enable RF ON (pin 4).

10 MODULE STATUS

LED OUTPUT

(GREEN)

Digital

output

See Wiring Diagram 4-30. This pin provides the

output for remote DeviceNet LED and is connected to the emitter of an opto-coupler. The User must limit the current draw through this pin to 45mA or less.

Note: Defined by

DeviceNet Specification, Release 2.0

See Wiring Diagram 4-24.

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Table 4-3. User Port (15-pin) Connector Pins Exclusive for Configuration E (Continued)

Signal

Return

Name Signal

Type

Description

11 12 INTERLOCK When connected

externally, these pins close the interlock and allows RF output to be enabled.

See Wiring Diagram 4-31. 12 INERLOCK RETURN See pin 11 13 NETWORK STATUS

LED OUTPUT

(GREEN)

Digital

output

This pin provides the

output for remote

DeviceNet LED and is

connected to the emitter of

an opto-coupler. The User

must limit the current

draw through this pin to

45mA or less.

Note: Defined by

DeviceNet Specification, Release 2.0

See Wiring Diagram 4-24.

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Table 4-3. User Port (15-pin) Connector Pins Exclusive for Configuration E (Continued)

Signal

Return

Name Signal

14 MODULE STATUS

LED OUTPUT

(AMBER)

15 NETWORK STATUS

LED OUTPUT

(AMBER)

Type

Digital

output

Digital

output

Description

This pin provides the output for remote DeviceNet LED and is connected to the emitter of an opto-coupler. The User must limit the current draw through this pin to 45mA or less.

Note: Defined by

DeviceNet Specification, Release 2.0

See Wiring Diagram 4-24. This pin provides the

output for remote DeviceNet LED and is connected to the emitter of an opto-coupler. The User must limit the current draw through this pin to 45mA or less.

Note: Defined by

DeviceNet Specification, Release 2.0

See Wiring Diagram 4-24.

WIRING DIAGRAMS FOR OPTION E USER PORT

The diagrams in this section provide wiring information to properly connect to the Apex 15-pin User port configuration E.

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Wiring Diagram 4-24. DeviceNet LEDs (pins 1,10,13,14 and 15)

Wiring Diagram 4-25. Reflected power monitor (pins 2 and 6)

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Wiring Diagram 4-26. Forward/Load Power Monitor (pins 3 and 6)

Wiring Diagram 4-27. RF Power Enable (pin 4 and 6)

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Wiring Diagram 4-28. Forward/Load Power Setpoint (pins 5 and 6)

Wiring Diagram 4-29. RF on status (pins 7 and 8)

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Wiring Diagram 4-30. +15 Vdc (pins 9 and 6)

Wiring Diagram 4-31. Interlock (pins 11 and 12)

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APEX HOST PORT OPTIONS

The following sections provide information for each of the Host port options available with the 1 to 5.5 kW Apex generator. These options are:

•“Host Port—RS-232 With AE Bus” on page 4-37

•“Host Port—Profibus” on page 4-58

•“Host Port—DeviceNet” on page 4-72

Not all of these sections apply to any one Apex unit. To identify the section or sections that apply to your unit, see “Using this Manual to Find Information for Your Generator” on page 1-1. Each of these sections also contains a PIN configuration note, which will help you confirm whether or not a particular section applies to your unit.

Host Port—RS-232 With AE Bus

This section describes the RS-232, AE Bus Host port interface, which is the standard Apex option. To determine if your Apex unit has this serial interface, use the PIN from your Apex unit and the following Configuration Note.

This section of the manual provides information for the:

RS-232, AE Bus Host port option PIN position 6, (A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17) option 0.

For more information about the PIN and for a complete list of how PIN positions correspond to Apex product options, see Table 1-1. on page 1-4.

This Apex Host port, which is the standard, or default option, uses an RS-232 signal format and AE Bus communication protocol. Refer to “Communicating Through the RS-232, AE Bus Host Port” for details on the communications protocol.

AE manufactures an interface software, Virtual Front Panel, which allows you to use a computer to communicate with the Apex unit through the RS-232 AE Bus port. For more information about this software, or to obtain a limited-time evaluation copy,

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contact AE Global Support or your AE sales representative. (For contact information, see “AE Customer Support” on page 6-11.) AE can also provide a simple host software for this port. For information, contact AE Global Support.

Note: Before controlling/monitoring the Apex generator through this port, you need

The RS-232, AE Bus Host port is a 9-pin, female, shielded, subminiature-D connector.

to ensure that the required User port inputs are satisfied and that the control is properly set. The required User port inputs are identified under the Satisfying Minimal Requirements section for your User port. To determine which User port you have, see the information for PIN position 8 in Table 1-1. on page 1-4. The control mode is usually set to the User port as default when this host port option is installed. To change the control mode to host, see commands 14 (sets control mode) and 155 (reads control mode) in the Command Set for the RS232, AE Bus Host Port on page 4-45. The control mode setting is stored in volatile memory so it will need to be set whenever the AC input is powered up.

Figure 4-4. RS-232, AE Bus Host port connector

The signals available at the RS-232, AE Bus Host port conform to the RS-232 interface standards. Each generator is factory preset for a baud rate of 19.2 kb and Table 4-4 describes the RS-232, AE Bus Host pin signals.

To Connect the Computer to the Apex unit:

Use a standard RS-232 cable that is no longer than 50 feet in length. This cable has a 9-pin, shielded, female, subminiature-D end and a 9-pin male, subminiature-D end. AE does NOT supply a cable. If you do NOT have the appropriate cable, you can purchase a standard serial cable at a local computer or electronics store.

Note: The cable must be intended for use between a computer and a peripheral, that is

a cable that is wired straight through (pin 1 on one connector is connected with pin 1 on the other connector, pin 2 is connected to pin 2 and so on.) A cable meant to create an interface between two computers will NOT work in this connection.

Note: To reduce EMI, avoid routing the cable close to ac input or dc output cables.

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Table 4-4. RS-232, AE Bus Host Port Pin Descriptions

Signal

1 RESERVED Reserved for future use 2 TXD RS-232 transmit data 3 RXD RS-232 receive data 4 RESERVED Reserved for future use 5 COM Data Common 6 RESERVED Reserved for future use 7 RESERVED Reserved for future use 8 RESERVED Reserved for future use 9 RESERVED Reserved for future use

Name Description

RS-232, AE BUS HOST PORT CABLING REQUIREMENTS

The cabling requirements for the RS-232 and AE Bus requires a standard DB-9 male to female extension cable.

COMMUNICATING THROUGH THE RS-232, AE BUS HOST PORT

The communications capability of the serial AE Bus Host port is limited to the following parameters:

• RS-232 protocol

• Baud rate of 19.2 kbps

• Apex generator unit address of 1

• Odd parity

• One start bit, eight data bits, one stop bit

• Low-order bytes are transmitted before high-order bytes.

The time-out period for the Apex generator is factory set at 0.02 s (that is, no more than 0.02 s can elapse between bytes, or the unit will reset and begin looking for a new message packet). This value can be changed using command 40.

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)

The host computer must finish one transaction with the Apex generator before it initiates another one, either with the same unit or any other unit.

Note: The Apex generator sends data through pin 2 (TXD.D). This pin must be

AE BUS PROTOCOL

The AE Bus protocol uses pure binary data (nothing is coded in ASCII) and is designed to facilitate direct communications between a host computer and the Apex generator.

The AE Bus message packet combines chunks of information in such a way that groups of information can be sent over communications lines at one time. Five types of information (fields) make up communications message packets (see Figure 4-5.):

• Header (address and the length of Data field)

connected to the receive pin (RXD.D) on the host computer’s PC serial connector. The receive pin is normally pin 2 for a standard, 9-pin PC serial port and normally pin 3 for a standard, 25-pin PC serial port.

• Command (see the AE Bus command list later in this chapter)

• Optional length byte

• Data

• Checksum (aids in error checking)

Figure 4-5. shows the organization of these data fields in the AE Bus message packet. The subsequent paragraphs describe each data field in detail.

ommand

0-FFh

76543210765432107654321076543210 7654321076543210765432101076543

Header

5-bit address

3-bit length

Optional Checksum

Data(0-255 bytes

113

Figure 4-5. Graphic representation of a RS-232, AE Bus message packet

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Header

The first byte in each packet contains two pieces of information: five bits contain the packet address, and three bits contain the data byte count. If the message packet originates with the host computer (master), the address specifies the packet’s destination (to an Apex generator, for example). If the packet is going to the host, the address specifies the packet’s origin (from the Apex generator). The address section of the Header field is five bits long (bits 3-7), which allows a total of 32 distinct addresses. Address 0 (zero) is reserved for the network 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 (bits 0, 1, and 2) tell the receiving unit how long the Data field is so that the unit can determine when the entire message has been received.

Note: The value in these bits should refer only to the number of actual data bytes. Do

not include the checksum byte when calculating the value for these bits (see “Checksum” on page 4-42).

Command

This field contains a one-byte value: 00h to FFh (0 to 255). If the message packet originates with the host computer, this value specifies the purpose of the message packet. If the message originates with the Apex generator, the value specifies the command to which it is responding. See “Host Port Commands for RS-232 with AE Bus” on page 4-45 for a complete list of commands.

Optional Length Byte

This field supplements the Header field and exists only when the length bits in the Header field contain a value of 7. Under those circumstances, the Optional field contains a one-byte value (between 0 and 255) indicating the number of data bytes.

Data (Data Bytes)

The Data field can contain from 0 to 255 bytes of binary data, which are interpreted in various ways, depending on the value that appears in the Command field. The Data field typically contains data or a Command Status Response (CSR) (see “Creating an Ideal Communications Transaction” on page 4-42), depending on what was requested. Since some commands do not require data, sometimes the Data field is not present.

If the value specified in the length bits of the Header field is 0 to 6, the Apex generator expects 0 to 6 bytes of data. However, if the value in the Header field is 7, the Apex generator looks for an additional eight-bit byte after the Command field (the Optional field) and uses this value for the data byte count.

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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 exclusive-or (XOR) of all bytes of the packet up to, but not including, the checksum value. The receiving unit accumulates the XOR of all bytes of the packet, including the checksum. If the result is zero, the packet has likely been received intact.

Only after the checksum of a message packet is validated (having no parity errors, and the address is valid) will the Apex generator act on the message (which consists of the contents of the command and, if appropriate, the data fields).

CREATING AN IDEAL COMMUNICATIONS TRANSACTION

Figure 4-6. is a simplified graphic showing the steps in an ideal communications transaction between a host computer and the Apex generator.

Host

Apex generator

Figure 4-6. AE Bus communications transaction

First, the host computer sends a message packet to the Apex generator. The packet contains one of the following:

• A command that requests data or status information

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• A command and data that change a parameter setting

• An executable command

Once the Apex generator receives the message packet, the Apex generator verifies that the message is intended for it and not for another unit on the network. At this time, the Apex generator also analyzes the checksum to verify that the message was received correctly.

If the address does not match, the Apex generator does not respond to the host; the Apex generator resets and resumes waiting for a message addressed to it. If the address matches but the exclusive-or (XOR) sum of the bytes in the packet (including the checksum) is not zero, the Apex generator sends a negative acknowledgment (NAK), hex code 15h, to the host. If the address matches and the message is intact, the Apex generator sends an acknowledgment (ACK), hex code 06h, to the host.

If the Apex generator receives a request for data or status information, it gathers and sends the requested information. Otherwise, it evaluates the incoming command and sends a message-packet that contains a 1-byte data value (CSR code) to the host (see “Command Status Response (CSR) Codes” that follow). CSR code 0 is sent when the command has been accepted.

If the host receives a NAK from the Apex generator, the host either retransmits the packet or does whatever else it has been programmed to do in this situation. If the host receives an ACK, it waits for the requested data or status information or for the CSR code telling it whether or not the new parameter was accepted. If the host receives no response within a reasonable period, it takes whatever action it has been programmed to take.

Meanwhile, the Apex generator has prepared a message packet with the requested information or appropriate CSR code, which it then transmits to the host. The host determines by means of the checksum if the message is complete. If the host detects an error in the transmission (by using the Checksum), it can request the packet be sent again by transmitting a NAK.

If the Apex generator receives an ACK, it returns to the normal waiting state. If the Apex generator receives a NAK, it retransmits the message packet. The Apex generator continues to retransmit in response to NAK transmissions until the host stops the cycle. If the Apex generator receives no response, it assumes an ACK and returns to the waiting state.

HOST/APEX COMMUNICATIONS TRANSACTION EXAMPLE

Figure 4-7 is a simplified graphic showing the steps in an example communications transaction between a host computer and an Apex generator.

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Figure 4-7. AE Bus communications transaction example

COMMAND STATUS RESPONSE (CSR) CODES—RS-232, AE BUS HOST

When the host sends an executable command or a command requesting a change in a parameter setting, the Apex generator returns a command status response (CSR) code indicating whether the command was accepted or rejected and, if rejected, why. Table 4-5 defines how these CSR codes should be interpreted.

Table 4-5. CSR Codes for RS-232, AE Bus Host

Valu e Meaning

0 Command accepted 1 Wrong control mode 2 Output is on 3 Output is off 4 Data is out of range 5 User off active 7 Active fault(s) exist

9 Data byte count is incorrect 14 CMD not accept 16 T life 19 Recipe active 30 EPROM read/write 50 Frequency out of range

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Table 4-5. CSR Codes for RS-232, AE Bus Host

51 Duty cycle out of range 52 Minimum on/off time violated (on/off

time must be

≥ 10 µs).

99 Command not implemented

COMMAND SET FOR THE RS-232, AE BUS HOST PORT

Table 4-6 lists the command set for the RS-232, AE Bus Host port.

Table 4-6. Host Port Commands for RS-232 with AE Bus

Command

RF off

RF on

regulation

select

fwd pwr

limit

refl pwr

limit

ext

feedback

limit

Description

Requests RF output off; request is always honored regardless of which interface has control. (Readback command is 162.)

Requests RF output on; host control must have been selected.

Sets the method of output regulation (forward power (6), load (7), and ext. (8)). (Readback command is 164.)

Specifies maximum forward power that can be delivered; accepts a value of 0 to 8000 W (for the 8 kW option) or 0 to 10000 W (for the 10 kW option). (Readback command is

169.) Specifies maximum reflected power that can

be tolerated; accepts a value of 0 to 2000 W. (Readback command is 170.)

Specifies the maximum external feedback level; accepts a value from 0 to the maximum external feedback value. (Readback command is 171.)

Number of

Host Data

Bytes

Number of

Response

Data Bytes

1 data byte

8-bit value

2 data bytes

16-bit value

2 data bytes

16-bit value

2 data bytes

16-bit value

Note: This command sets the value at which

the setpoint is limited during external regulation

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Table 4-6. Host Port Commands for RS-232 with AE Bus (Continued)

Command

setpoint

max ext

feedback

11 select active

target

Description

Specifies the output setpoint level for whatever method of output regulation has been selected. Accepts a value of 0 to 8000 W (for the 8 kW option) or 0 to 10000 W (for the 10 kW option) when forward or load power regulation is selected. Regular units report in units of watts. HALO units report in units of tenths of watts.

Specifies the external feedback value that corresponds to 10 V on the User port; requires data bytes arranged as follows:

• First/second byte = a 16-bit value in the range of 500 to 5000.

• Third byte = the number of decimal places (0 to 4) used to display the external feedback signal on the operator panel.

Specifies which target is active; accepts a value of 1 to 4. (Readback command is 156.)

Number of

Host Data

Bytes

2 data bytes 16-bit value

3 data bytes 16-bit value

8-bit value

1 data byte 8-bit value

Number of

Response

Data Bytes

set target

life

Sets the life (in kWh) of the target you specify. Requires five data bytes arranged as follows:

5 data bytes

8-bit value

32-bit value

• First byte = the target number

• Second, third, fourth, fifth bytes = target

life in kWh

Note: A decimal is implied—to get 1 kWh,

send a value of 100.

(Readback command is 157.)

control

transfer

out-of-

setpoint

timer

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Sets the active control mode of the generator; possible choices are: 2 = host, 4 = User port (analog).

Specifies how long the generator can produce output that is not equal to the programmed setpoint level. Accepts a value of 0 to 599 s. (Readback command is 184.)

1 data byte 8-bit value

2 data bytes 16-bit value

Apex 1 to 5.5 kW Generator

Table 4-6. Host Port Commands for RS-232 with AE Bus (Continued)

Command

allowable

deviation

number of

recipe

steps

recipe step/

setpoint

recipe step/

run time

Description

Specifies a percentage that the generator can be out of setpoint before it starts the out-ofsetpoint timer. Accepts a value of 1 to 99%. (Readback command is 185.)

Specifies the number of recipe steps. Send 1 data byte that indicates the number of recipe steps (0 through 5).

Specifies setpoint for a recipe step. Send 3 data bytes.

• byte 1 = recipe step number (can be 1 through 7)

• bytes 2 and 3 = setpoint value (send least significant byte first); the value must be within the operating range of the Apex unit (see “Output Electrical Specifications” on page 3-6)

Sets the run time for the specified recipe step. Send 3 data bytes.

• byte 1 = recipe step number (1 through

• bytes 2 and 3 = run time in hundredths of seconds or in joules (if the recipe is set for joules mode; see CMD 28 to set recipe type); send least significant byte first

Number of

Host Data

Bytes

1 data byte 8-bit value

3 data bytes

8-bit value

16-bit value

3 data bytes

8-bit value

16-bit value

Number of

Response

Data Bytes

recipe type

Sets the recipe for time or joules mode. Send one data byte indicating the recipe type:

1 data byte 8-bit value

• 1 = time mode

• 2 = joules mode

host port

timeout

Sets the Host port timeout value. Accepts a value of 2 to 500, representing 0.02 to 5.0 s. (Readback command is 140.)

2 data bytes 16-bit value

value

5708009-C 4-47

Advanced Energy

Table 4-6. Host Port Commands for RS-232 with AE Bus (Continued)

Command

set serial

port

address

and baud

rate

Description

Sets the serial port address and baud rate. Send 3 data bytes:

• byte 1: bits 0 through 4 set serial port address

(addresses 1 through 31 are supported)

bits 5 and 6 are unused

bit 7 selects communication protocol (0 = RS-232, 1 = RS-485)

• Bytes 2 and 3 = baud rate (send least

significant byte first)

Valid baud rates depend on the communication protocol selected in byte 1:

For RS-232, send 1200, 4800, 9600, or 19200

Number of

Host Data

Bytes

3 data bytes

8-bit value

16-bit value

Number of

Response

Data Bytes

For RS-485, send 9600, 19200, 38400, or 57600

Read back with CMD 212.

4-48 5708009-C

Apex 1 to 5.5 kW Generator

Table 4-6. Host Port Commands for RS-232 with AE Bus (Continued)

Command

Set point

diode 1

latch

Description

Sets the pin diode 1 latch. Send 1 data byte.

• byte 1 = latch

Note: byte 1 bits on a standard 5 pin unit:

0: Series 3 1: Series 1 2: Shunt 1 3: Shunt 2 4: Series 2 5: chamber / 50 ohm 6: Unused 7: Unused

Note: byte 1 bits on a 2 pin unit:

0: Unused 1: Series 1 2: Unused 3: Shunt 2 4: Unused 5: Unused 6: Unused 7: Unused

Number of

Host Data

Bytes

1 data byte 8-bit value

Number of

Response

Data Bytes

set pulsing

frequency

set pulsing

duty cycle

119

Profibus

Reset/

Explicit

Fault clear

128

supply type

129

supply size

Sets the RF pulsing frequency in Hz. Accepts a value of 150 to 50000. Read back with command 193.

Sets the RF pulsing duty ON time in increments of 1%. This value can range from 10% to 90%. Minimum On or OFF time is >= 10uS.

Clears profibus fault and error code register

Requests the generator type; returns 4 ASCII characters.

Requests the output capacity of the generator; returning packet contains 4 ASCII characters.

4 data bytes 32-bit value

2 data bytes

0 4 data bytes

4 ASCII

characters

4 ASCII

characters

5708009-C 4-49

Advanced Energy

Table 4-6. Host Port Commands for RS-232 with AE Bus (Continued)

Command

130

read

mainframe

software

version

number

140

report host

time-out

value

154

report

regulation

mode

155

read control

method

Description

Requests the version number of the mainframe software. The returning packet contains 7 ASCII characters—a 7-digit number. This command is used in conjunction with CMD 198 to obtain the version/revision number of the mainframe software.

Requests the serial Host port time-out value (002 to 500 representing 0.02 to 5.00 s).

Requests regulation mode (set with CMD 3). Returning values:

• 6 = Forward

• 7 = Delivered or Load

• 8 = External (DC Bias)

Requests control mode (set by CMD 14). Returning values: 2 = host, 4 = analog

Number of

Host Data

Bytes

Number of

Response

Data Bytes

07 data bytes

7 ASCII

characters

02 data bytes

16-bit value

1 data byte 8-bit value

01 data byte

8-bit value

156

read active

target

157

read target

life

Requests the number of the active target (set by CMD 11)

Requests the amount of life remaining in the target you specify (set by CMD 12). This command requires 1 data byte to specify the number of the target you request (1 to 4).

Note: A decimal is implied—100 = 1 kWh,

01 data byte

8-bit value

1 data byte 8-bit value

4 data bytes 32-bit value

4-50 5708009-C

Apex 1 to 5.5 kW Generator

Table 4-6. Host Port Commands for RS-232 with AE Bus (Continued)

Command

162

read

process

status

Description

Requests report on process status; returning packet contains the following bytes arranged as follows.

1st status byte:

0 = unassigned 1 = unassigned 2 = recipe run is active 3 = unassigned 4 = unassigned 5 = output power (0 = off, 1 = on) 6 = RF on requested 7 = setpoint status (0 = within tolerance,

1 = out of tolerance)

2nd status byte:

0 = end of target life 1 = unassigned 2 = unassigned 3 = overtemperature 4 = unassigned 5 = unassigned 6 = unassigned 7 = interlock open

Number of

Host Data

Bytes

0 4 data bytes

Number of

Response

Data Bytes

4—8-bit

values

3rd status byte—fault flags

0 = nonmaskable interrupt 1 = bus fault 2 = high bus voltage 3 = unassigned 4 = low bus voltage 5 = out of setpoint 6 = unassigned interrupt 7 = unassigned

4th status byte—fault flags

0 = current limit 1 = contactor failure 2 = Profibus error 3 = unassigned 4 = unassigned 5 = unassigned 6 = unassigned 7 = CEX is locked

5708009-C 4-51

Advanced Energy

Table 4-6. Host Port Commands for RS-232 with AE Bus (Continued)

Command

164

read

setpoint/

regulation

mode

165

read

forward

power

166

read

reflected

power

167

read

delivered

power

168

read ext

feedback

(dc bias)

169 read fwd pwr limit

Description

Requests output setpoint level (set by CMD

8) and whatever method of output regulation has been selected (set by CMD 3). The return packet is arranged as follows:

• First and second bytes = setpoint value

• Third byte = method of output regulation

Requests a snapshot of forward power level at that instant. Regular units report in units of watts. HALO units report in units of tenths of watts.

Requests a snapshot of reflected power level at that instant. Regular units report in units of watts. HALO units report in units of tenths of watts.

Requests a snapshot of load power level at that instant

Note: Response contains 2 data bytes. Both

bytes represent delivered power or real power (LSB first). It returns the delivered power in watts if measurement system is a Directional Coupler. If measurement system is a VI sensor, it returns real power in watts.

Requests a snapshot of external feedback level at that instant. Data bytes 1 and 2 represent External feedback (LSB first). It returns the external feedback (DC Bias).

Requests programmed limit for forward power (set by CMD 4).

Note: The response returns the user forward

power limit in watts.

Number of

Host Data

Bytes

Number of

Response

Data Bytes

03 data bytes

16-bit value

8-bit value

02 data bytes

16-bit value

02 data bytes

16-bit value

02 data bytes

16-bit value

02 data bytes

16-bit value

2 data bytes 16-bit value

170

read refl

pwr limit

Requests reflected power limit (set by CMD 5).

Note: The response contained in data bytes 1

2 data bytes 16-bit value

and 2 represent user reflected power limit in watts.

4-52 5708009-C

Apex 1 to 5.5 kW Generator

Table 4-6. Host Port Commands for RS-232 with AE Bus (Continued)

Command

171

read ext

feedback

limit

173 report

power

dissipation

184

read out-of-

setpoint

interval

Description

Requests external feedback limit (set by CMD 6)

Note: The response in data bytes 1 and 2

represent the user external feedback limit (LSB first). It returns the user external feedback limit.

Reports dissipated power

Note: The response in data bytes 1 and 2

represent dissipated power (LSB first). It returns dissipated power.

Requests how long the generator is programmed to produce output that is not equal to the programmed setpoint level before shutting output off (set with CMD 15).

Note: Data bytes 1 and 2 represent the

unsigned integer value for out of setpoint time interval (LSB first). It reports how many seconds the generator will produce output that is not equal to the setpoint before turning the output off.

Number of

Host Data

Bytes

Number of

Response

Data Bytes

2 data bytes 16-bit value

185

read

allowable

Requests what percentage the generator can be out of setpoint before it starts the out-ofsetpoint timer (set with CMD 16).

1 data byte 8-bit value

deviation

Reports the allowable setpoint deviation

Note: The response reports the percentage (1

to 99) and the supply can be out of setpoint before turning on the out-ofsetpoint timer.

5708009-C 4-53

Advanced Energy

Table 4-6. Host Port Commands for RS-232 with AE Bus (Continued)

Command

188

report

recipe step

setpoints/

run times

189

report recipe steps,

status, and

mode

Description

Reports the setpoints and run times for each recipe step. The number of data bytes returned depends on the number of steps in the recipe. For each recipe step, 4 data bytes returned, indicating:

• First 2 bytes = recipe step setpoint in watts

• Second 2 bytes = recipe step run time in hundredths of seconds or joules, depending on the recipe mode (recipe mode is reported by CMD 188)

Reports the number of steps in the recipe, the status of the most recent recipe run, and the recipe mode (time or joules). Returns 3 data bytes:

• Byte 1 = number of recipe steps

• Byte 2 = recipe status:

bit 0 indicates ignition (1 = ignition

detected; 0 = ignition not detected)

bits 1, 2, and 3 indicate the most

recently completed step number

bits 4–7 are reserved or unassigned

• Byte 3 = recipe mode (1 = time, 2 = joule)

Number of

Host Data

Bytes

Number of

Response

Data Bytes

Varies; sends

4 data bytes

for each

recipe step

193

read

pulsing

frequency

Requests the RF pulsing frequency in Hz (set with CMD 93).

Note: The response contains 4 data bytes. All

4 data bytes 32-bit value

represent frequency (LSB first).

196

read

pulsing

duty cycle

Requests the duty cycle in% ON time

Note: The response contains 2 data bytes

which represent duty cycle (LSB first)

2 data bytes 16-bit value

in percent on time.

198

read

mainframe

software

revision

level

4-54 5708009-C

Requests the revision level of the mainframe software. The returning packet contains three ASCII characters—one letter, followed by a two-digit number. Used in conjunction with CMD 130 to obtain the version/revision of the mainframe software.

3 data bytes

3 ASCII

characters

Apex Digital 5708009-C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

is a registered trademark of Advanced Energy Industries, Inc.

Advanced Energy Industries, Inc.

1625 Sharp Point Drive

Fort Collins, Colorado 80525 USA

Table of Contents

List of Figures

List of Tables

1Introduction

This chapter contains several kinds of introductory information.

READ THIS SECTION!

USING THIS MANUAL TO FIND INFORMATION FOR YOUR GENERATOR

Understanding PIN Numbers and Apex Configuration

Figure 1-1. Serial number identification tag

Configuration positions— A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Using the PIN to Locate Information in the Manual

Once you have located the PIN, you are ready to begin using the manual.

Figure 1-2. Example configuration note

Using the PIN to Identify Apex Options

1 Output frequency 0—N/A

1—4 MHZ, ±0.005%

2—12.56 MHz, ±0.005%

3—13.56 MHZ, ±0.005%

4—27.12 MHz, ±0.005%

5—40.68 MHz, ±0.005%

2 Power output A—1000 W

B—1500 W

C—2000 W

D—3000 W

E—4000 W

F—5500 W

G—8000 W

H—10000 W

J—5000 W

K—1000 HALO

L—1500 HALO

M—3500 W

N—7000 W

3 Input voltage 0—208 V nominal, 187 to 229 Vac, 3φ, 47 to 63 Hz, with

2—reserved

5—220,208 to 229 Vac, 1 phase, 47/63 Hz w/o breaker

4 Packaging A—frame mount (

B—frame mount with rack ears (1/2 rack) (utilities)

C—integrated rack mount

D—1/2 integrated rack mount (left)

E—1/2 integrated rack mount (right)

F—exclusive option #1

G—exclusive option #2

H—exclusive option #3

J—exclusive option #4

K—on board frame mount, opposite end LED’s

L—on board frame mount, opposite end LED’s w/4 handles

M—on board frame mount, opposite end LED’s w/2 handles

N—frame mount w/ rack ears (1/2 rack) (opposite)

5 Panel 0—none (on-board, frame mount)

1—integrated rack mount with blank panel

3—N/A

4—exclusive option #1

6 Serial I/O 0—default (RS-232 with AE Bus) (see “Host Port—RS-

1—Multidrop RS-485 with AE Bus (Currently NOT available)

4—exclusive option #1

5—DeviceNet (serial)

6—exclusive option #3

7—exclusive option #2

7 Serial Port 2 0—default (no secondary serial port)

1—RS 232

2—RS 485

8 User port options A—no User port

C—25-pin custom RFG compatible

F—N/A

G—exclusive option #4

B—exclusive option #1

C—exclusive option #2

D—exclusive option #5

E—exclusive option #6

F—exclusive option #3

G—exclusive option #4