Apex Digital 5708009-C User Manual

USER

MANUAL

#RGZ6/)GPGTCVQT

VQ M9

%

(GDTWCT[

Advanced Energy Industries, Inc.

1625 Sharp Point Drive

Fort Collins, CO 80525 USA

970.221.4670

[e-mail]

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

is a registered trademark of Advanced Energy Industries, Inc.

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

The Smith® chart shown is produced under a copyright license from Analog Instruments Company, New Providence, New Jersey 07974

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

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:

Advanced Energy Industries, Inc.

1625 Sharp Point Drive

Fort Collins, Colorado 80525 USA

4

5708009-C

Apex 1 to 5.5 kW Generator

Table of Contents

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

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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

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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

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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

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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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Chapter

1

Introduction

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.

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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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

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

PIN	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, 3φ, 47 to 63 Hz, with
		breaker
		2—reserved
		3—208 V nominal, 187 to 229 Vac, 3φ, 47 to 63 Hz,
		without breaker
		4—400 V nominal, 360 to 440 Vac, 3φ, 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)

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

PIN	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 Ω
	impedance	B—exclusive option #1
		C—exclusive option #2
		D—exclusive option #5
		E—exclusive option #6
		F—exclusive option #3
		G—exclusive option #4
		H— exclusive option #7
		J—exclusive option #8
10	On-board RF	0—opposite end from water connections
	output connector	1—utilities end (near water connections)
	location

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

PIN	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′, 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
		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)

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

PIN	Apex Feature	Options, Descriptions, and Cross-References
Position
15	CEX	0—default (no CEX)
		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)
16	Water fitting	0—default to 3/8 BSP female (metric threads)
	threads	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.
17	Custom	A—standard configurations
	configuration	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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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		General Use Power Supplies—Industrial Products
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.

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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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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/TAG- Out 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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Chapter

2

Theory

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.

The Apex products can be configured to three basic package styles. The Apex products may be configured with integrated SwitchMatch™ matching networks and 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

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″ x 18 tapped hole. Either hole 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 (limiting) occurs as required by the generator protection circuits.

•Any internal over current condition not directly related to the output load condition as protected by current limiting or fuse.

•Excessive internal temperature. (This condition may be caused by lack of proper cooling water flow, excessive ambient operating temperature, or other causes.)

•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.

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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