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MPS 96

MULTICHASSIS SWITCHING PSUFOR 60 kW MAGNETRON C.W.

INCLUDES:SM 1816 POWER MODULEAC 570 CONTROL MODULE

TECHNICAL NOTE(issue March 2008)

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File: MPS96_r3eng - March 2008 - Technical note: MPS96 page 1 of 27

MPS - MULTICHASSIS POWER SUPPLY SYSTEM

CE Declaration of ConformityDichiarazione di Conformità CE

Manufacturer’s Name: ALTER s.r.lNome del Costruttore:

Manufacturer’s Address: Via Curie, 8 - 42100 Reggio Emilia - ItalyIndirizzo del Costruttore:

Declare that the microwave generator: Dichiara che il Prodotto:

product name: SM1816 (power supply unit) and AC 570 (filament control unit) nome del prodotto SM1816 (alimentatore elettrico) e AC 570 (unità di controllo) models: SM1816T.xxx - SM1816U.xxx modello AC 570T.xxx - AC 570U.xxx Complies with the following norms: Soddisfa le seguenti norme: EN 61010-1: 2001; EN55011: 1999; EN55011/A1: 2000; EN55011/A2: 2003

The products listed above comply with the requirements of the Low Voltage Directive 73/23/EEC.I Prodotti sopraindicati sono conformi con la Direttiva di Bassa Tensione 73/23/EEC

Reggio Emilia, March 2008. Marco Garuti

Presidente C.d.A.

Rev. Revision note Date File 0 First emission December 2005 MPS96_r0eng 1 Upgraded diagrams pin out conn. & cooling water spec July 2006 MPS96_r1eng2 New Control Module AC570 with ver. 1 option February 2008 MPS96_r2eng

3 Update AC570 main voltage values March 2008 MPS96_r3eng


page 2 of 27 File: MPS96_r3eng - March 2008 - Technical note: MPS96

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Alter’ policy about Reduction on Hazardous Substances (RoHS) and Waste Electrical and Electronic Equipment (WEEE)

Law Reference• Directive 2002/96/EC of European Parliament (WEEE)• Directive 2002/95/EC of European Parliament (RoHS)• Decreto Legislativo D.L. n. 151 – 25/07/2005 (WEEE and RoHS)

Starting from September 2005 Alter has set the rule to accept only RoHS compliant components from its Suppliers.At the present date the 90% of components in our stock is RoHS compliant.The components still not compliant were hold in stock and still used for two reasons:

• there is not the same or equivalent product RoHS compliant, or• the product is a spare part for equipment produced and put on market before 1st July 2006.

Alter Risk Assessment on RoHS

Of the six substances forbidden from electronic equipment (Lead (Pb), Mercury (Hg), Cadmium (Cd), Hexavalent Cromium (Cr-VI), Polybrominated biphenyls (PBB), Polybrominated diphenyl ethers (PBDE)) only two are used in Alter’s current manufacturing process, Pb and Cr-VI, of whose lead is the more important.

Mercury: not present, never usedCadmium: was present as part of alloy on relay contact. We are using relay RoHS compliant now. Never used as anti-corrosion coating on metal parts.Pbb & Pbde: may be present in some cables and insulating material in the past. We are using only RoHS compliant suppliers and products now.Cr-VI: is used as anticorrosion layer on aluminium part. We are evaluating alternative coating. It is still

present within the limit of 0,1% in weight as set by Directive.Lead: it is largely used as an alloy for welding of electronic parts. We are already using alternative alloys

lead-free, but as we still have components that cannot be soldered without lead, we have to use some lead-alloy for welding. At present there are still general concerns about reliability over the time of a soldered electronic joint done without traditional Sn/Pb alloy. We are putting any effort on reducing lead weight within 0,1% of products as set by Directive.

Important information to User about disposal, recycling, reuse of this electronic equipment at the end of its useful life (WEEE Directive).

According to Annex IA and IB of EC Directive 200/96/EC this equipment is not included on the list of categories/products covered by the Directive (as a matter of fact it does not perform a function alone, must be included into a larger process equipment and it’s for stationary use).

Nevertheless we invite the User to respect the following Directive rules:• this WEEE is not a municipal waste and should be collected separately according to rules of your country

• the symbol means that this WEEE cannot be disposal in the same place and in the same way like municipal waste

• this WEEE may present risk for environment as well as for person in case of disposal in unauthorized place, due to content of hazardous substances

• for disposal of this WEEE in unauthorized area the User may be charged with a fine or prosecuted by law.



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ContentsAAlarm code table 25

CCE Declaration 1Cleaning 7Components List AC570 17Components List SM1816 19

DDescription of external command 10Display 11

EEnvironmental conditions 7Equipment installation 8Equipment operation 9

FFuses replacement 7Fuses specifications 7

GGeneral Description 4General Information 3

HHandling instructions 8Handling Warnings 3How to order 27

PPhysical characteristics 7Pin out of CONN. #1 SM1816 20Pin out of CONN. #1 AC570 21Pin out of CONN. # 2, 3, 4 22Pin out of CONN. #5 AC570 23Pin out of CONN. #6 AC570 24Pin out of Serials 24Power up procedure 9

RRoHS declaration 2

SSoftware menu description 12Software Upgrading 11 TTechnical Assistance 27

WWarnings 3Wiring instructions 8Working modes 10

General InformationThis equipment satisfies the European Standard EN 61010-1 (=CEI 66-5) (=IEC 1010-1) approved by CENELEC on 9/3/1993.

With reference to EN 61010-1 standard, note:this appliance must be installed and serviced only by qualified personnel.The appliance must only be used by persons acquainted with the regulations covering the application.

Note about EMC regulation: The equipment described in this manual has been classified as industrial, scientific and medical (ISM) radio-frequency equi-pment and the related standard for the emission is EN55011 (=CEI110-6) (title: Limits and methods of measurement of radio disturbance characteristics of ISM equipment.)

With reference to the EN55011 standard, this equipment is included into Group 2 (Microwave generators, Thyristor command equipment, Welding equipment, Induction heating equipment or machine, Microwave industrial oven, etc.), Class A (industrial environment): for this reason this equipment shall not be used in the residential, commercial and light-industrial environment.

The SM1816 and AC 570, when properly installed, comply with the limits of radio disturbance characteristic of a Group2, Class A equipment as stated by EN55011.

A copy of the tests performed may be sent on request. Note that these tests cannot be used as a conformity certificate of the user’s final equipment.

WARNINGSBoth the SM1816 and the AC 570 are powered by AC main line and the SM1816 has high voltage output (close 16 kV): read carefully this manual before using. Be sure of that the equipment is correctly connected as described below.Failure to comply with the instructions enclosed in this ma-nual may involve considerable risks for the staff responsible for checking and using the equipment, as well as the risk of general malfunctions of the equipment itself.

Handling WarningsBoth units have two handles, on the front panel, to help unpacking and handling operations: never use the handles to lift the equipment but support the weight with an appro-priate base underneath the equipment!

The handles will not withstand the off-center weight of the equipment (SM1816=55 kg/121 lbs, AC 570= 16 kg/ 36 lbs)



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General DescriptionThe MPS 96 system is able to supply the power necessary to drive a 60 kW magnetron, like the S9460X or equivalent, and includes the following:- no. 1 AC570 filament & electromagnet control unit- no. 4 SM1816T power unitsBoth the units have been designed as a part of our “Multichas-sis Project” that allows to use multiple power modules to drive magnetron up to 90 kW with a single control unit.The control and the power units have to be assembled stacked, in a closed cabinet and wired according our specification: they swap signals throught a bus system, on rear of the units, with a specific cable supplied with them.

The MPS96 may be controlled:a) manually via the front panel keys on the AC570b) remotely via a PLC with 0-10V analog signals of the AC570c) by RS232 serial port of the AC570

AC 570 Description and Specifications (common to all versions)

The AC570 can be supplied in two versions, irrespective of input voltage:- AC570 standard version (vers. 0)- AC570 with Fast Alarm Recovery function (vers. 1) Both versions are built in a self-ventilated 19” wide rack, 3HE high, with a front panel comprising (see drawing):- a main switch [1];- a backlit LCD display showing a selected working parameter, [2] i.e. one of the following the output power, the forward microwave power the reflected microwave power as well as any of the alarms codes. It can be used to display set parameters such as language alarm levels etc;

REAR PANEL of standard version (vers. 0)

CONN #2

CONN #5

CONN #3RS 232

CONN #1

CONN #4

46PPAC570

2

87654

1 3

CURRENT

DATES/N

POWER

INPUT FREQ.

REGGIO E. - ITALYMODEL P/N

a retl

KVA

V

A

Hz

MAIN BREAKER

CONTROL UNIT AC 570

Esc

Enter

ADJUST

54321

FRONT PANEL AC570



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- 3 push-buttons for parameters settings [3] «escape» «scroll down» «enter»;- a rotating knob to adjust the chosen value [4];- pull off handles [5].

The rear panel of the AC570 vers. 0 comprises the following:- a 7 pins socket for the main supply (CONN. #1) [8]- a 14 pins socket for the signals from the remote microwave head (CONN. #2) [1]- a 15 pins “D” type socket to control the power units (bus link) (CONN: #3) [7]- a 7 pins socket to power the remote microwave head (CONN. #4) [3]- a 25 pins «D» type socket for the external control signals (CONN. #5) [2]- a 9 pins «D» type socket for the RS 232 port [6]

- the filter mesh of the outlet cooling air, which also reduces EMI noise [4]- the equipment label [5]In addition the AC570 version 1 includes- a 9 pins «D» type socket for monitor signals (CONN. #6) [9]

The function “Fast Recovery Alarm”, present only on version 1, allows to detect some transient alarms and restart auto-matically the inverters as fast as possible (typically within 1 second).

The reduced height of the rack (only 3 HE, corresponding to 133 mm) allows a small cabinet to be used. The user must provide a proper cooling flow: the cooling air enters into the AC570 through the front panel and exits through the rear panel. The intake air flow is approx 100 m3/h.

You must avoid mixing output air with inlet air.

CONN #2

CONN #5CONN #3

RS 232

CONN #1

CONN #4

46PPAC570

CONN #6

79 2

8654

1 3

CURRENT

DATES/N

POWER

INPUT FREQ.


a retl

KVA

V

A

Hz

REAR PANEL of special version (vers. 1)

AC570 specifications: AC570T AC570UMain supply (50/60 Hz): 3x400 V 3x480 VMinimum main voltage: 360 V 435 VMaximum main voltage: 440 V 525 V Transient overvoltage: overvoltage cat. II according IEC 664 Intake current @ 400 V: 7 A rms 5 A rmsCurrent controlled output tofilament trafo: 5 A rms 5 A rmsStability of filament output: within 1% for input fluctuations within +/- 10%Controlled output to electromagnet: 50 V, 5 A 50 V, 5 AStability of electromagnet output: within 1% for input fluctuations within +/- 10%Filament control: with preset hardware curve or special curve stored in the CPUFilament preheating: automatic at power-onEnable microwave command: 24 Vdc (range 12 ÷ 24Vdc) optoinsulatedLoad of the status contacts: max 130V - 0,5A



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Working mode of Alarm contact:a) unit in power OFF: contact openb) unit in power ON, no alarms: contact closedc) unit in power ON, alarm status: contact open

Working mode of Ready coutput: 24V - 50mAa) unit in power OFF: contact openb) unit in power-ON, no alarms, filament ready (preheating completed): contact closedc) unit in power ON, alarm status: contact openReference signal to adjust power: 0-10 Vdc (Z=100 KΩ) (optoinsulated) Management of alarm situations: a) by internal alarm relay, contact load: max 24V 50mA b) by showing the alarm on display (see the alarm table

on next pages) c) by the emission of a 4-bit code on the signals con-

nector: 24V 50mA max

SM 1816 Description and Specifications

The SM1816 power unit is built in a self-ventilated 19” wide rack, 7 HE high, with a front panel comprising (see drawing):

- a main switch [1];- 2 analog LED bar, one showing Anodic Voltage (12 LED, range 0-16 kV, each indicates1,5 kV), the second showing the Anodic Current (12 LED range 0- 2.400 mA, each indicates 200 mA) [3].- a status LED bar, giving visual aid to user for the main system status, including the type of alarm. See next paragraph “Alarm Led explanation” [2].- intake air mesh [4].- pull off handles [5].

MAIN BREAKER

CURRENTVOLTAGE

ON

INTERLOCK OK

EXTERNAL ALARM

OVERVOLTAGE

INTERNAL ALARM

LEAKAGE

INTERNAL OVERTEMP

WATER OVERTEMP

AD ALARM

DRIVER ALARM

2.5

5.0

10.0

7.5

12.5

15.0

17.5

20.0

kV 25.0

22.5

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0 A

POWER UNIT SM 1816

54321

FRONT PANEL

REGGIO EMILIA - ITALYal

CONN #3

A

B

COOLING WATER

F 1

F 2

CONN #1

ATTENZIONE!USCITA ALTA TENSIONE

WARNING!HIGH VOLTAGE OUTPUTWARNUNG!HOCHSPANNUNGSAUSGANG

CONN #2

COLLEGARE ALLA TERRADEL GENERATORE REMOTO

VERBINDER DIRECT MIT DERDES MIKROWELLEN GENERATOR

ERDUNG

CONNECT DIRECTLY TO GROUNDOF MICROWAVE HEAD

46PP01816

CURRENT

DATES/N

POWER

INPUT FREQ.


a retl

KVA

V

A

Hz

REAR PANEL3 24

5 188 76



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The rear panel comprises the following:- a 7 pins socket for the main supply (CONN. #1) [1]- a 15 pins “D” type socket for the bus-link to the AC440 (CONN. #2) [2]- a 1pin socket for the high voltage output (CONN. #A)[3]- a 1pin socket for the high voltage input (CONN. #B)[3], not present on MPS 96- the water inlet and outlet fittings [4]- the fans [5]- the fuses holders (F1, F2) [6]- thr “hearth”screw [7]- the equipment label [8]

SM18xx specifications: SM1816T SM1816UMain supply (50/60 Hz): 3x400 V 3x480 VMinimum main voltage: 360 V 435 V Maximum main voltage: 440 V 525 VTransient overvoltage: overvoltage cat. II according

IEC 664 Intake current: 40 A rms@ 400 V 36 A rms

@ 400 V @ 480 V

Environmental conditionsUse: Indoor use onlyAltitude: tested up to 2,000 m (~6,000 ft)Temperature: 5°C to 40°C (41°F÷104°F)Relative Humidity: 80% for temperature up 31°C(88°F), decreasing linearly to 50% RH at 40°C (104°F)Pollution degree: 2, complies with the norm IEC664

Fuse specificationsThe power unit have fuses on the rear panel:

SM1816 Fuse F1 and F2 specs:- Size, type: 10x32 mm, ceramic cartridge- Speed action: quick (F)- Rated current: 5 A- Rated voltage: 500 V minimum

For instructions about fuse replacement please refer to related paragraph on this page.

Physical characteristicsFront panel dimensions: AC 570: 19” x 3HE SM1816: 19” x 7HE Rack total width: 475 mmRack total height AC 570 133 mm SM1816 320 mmRack depth (without handles): 440 mmHousing cabinet depth (minimum): 800 mmWeights: AC 570: 16 kg (36 lbs) SM1816 55 kg (121 lbs) Total weight MPS 96: 236 kg (519 lbs)

Cooling requirements

Intake air flow: MPS 96: approx 2800 m³/hWater flow rate: SM1816: 2 L/min each unitMax/Min water input temp: 35°C/12°C not condensing!

Equipment maintenance

CleaningCleaning of the air filter: verify once a month. In case you need to remove dust then proceed as follow: - remove main line from the unit - remove the cover - use pressurized air from inside to outside for short time: do not exceed or you may damage the fan - install the cover and then power-on again.

Fuse replacement

To replace the fuses on the rear panel proceed as follow: - switch-off the main breaker on front panel or wha- tever device is provided to remove main line from the equipment; - unscrew the fuseholder cap; - replace the fuse with a new one with the same electrical characteristics; - also inspect the fuseholder: if it’s oxidised or it has burn marks then replace it; - install the fuseholder cap and screw tight. - fuse values are given in Fuse Specs paragraph on this page



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Equipment installationThe MPS96 cannot operate on a bench: it must be installed into a proper cabinet such as a commercial 19” standard enclosure. The equipment is intended for industrial use only, not for laboratory use, and the user must respect the wiring norms and prescriptions as described into next paragraph (“Wiring instruction”).The equipment must not operate cantilevered, it must be safely fixed inside a cabinet by means of screws on the front panel and supported by means of a proper frame on the bottom for, at least, 3/4 of the total depth.Usually two “L” shaped supports on each side of the equip-ment, having a dimension of mm 10(h) x 30(l) x 1.5 (thick) are suitable for this purpose.

The rear side of the equipment must be protected by a fixed panel which can be removed only by means of tools or by a door with security micro-switch: when the door is opened the micro-switch must shut-off the main line. This safety precau-tions must be taken to avoid operation on rear fuses or on connectors while the unit is still powered.

Special attention must be taken on designing the cooling air flow whenever several units are stacked in the same cabinet.Note that each SM1816 has its own fans which supplies approx 700 m³/h: the outlet of the exhaust air is on the back of the equipment.

When designing a cabinet to house several units we recom-mend that the following design criteria be adopted: - use a standard 19” wide enclosure with a depth of 800 mm (32”); - allow free intake of the cooling air from the front of the cabinet and exhaust air from back;

- in case of ambient air with high degree of dust and moisture, install a proper air conditioner; if you cannot do this, then you have to use suitable air filters and instruct the user about their cleaning; - provide a separation between the air intake duct and the air outlets, in order to avoid air-recycling.

Handling instructionsThe MPS 96 total weight is 236kg (519 lbs). Always lift from the bottom and use an adequate rugged support to avoid perso-nal injury and damage to equipment itself.In the case of shipping, use the original package or a wooden case and a proper filler: movement of the equipment inside the package must be avoided.

Warning: use handles only for helping during installation. Never use handles to lift the rack: the handles will not withstand the off-center weight of the rack!To lift always lean the rack over a proper supporting base.

Wiring instructionsThe MPS96 must be installed and serviced only by qualified personnel acquainted with the regulations covering the applica-tion. For safety operations the following rules must be adopted:

I) the equipment must be grounded through connector #1 using pin 4 (see the wiring diagram at pages 20, 21);

II) connect the ground screw on panel rear (indicated by “ground” symbol) directly to the remote microwave generator head by a separate yellow/green wire gauge 2.5 mm²;



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III) SM1816T: the main supply, 3 x400V must be provided through connector #1: connect phases according to schematic at page 20. A 10 mm² wire can be used with this connector.AC570T: the main supply, 3x400V must be provided through connector #1: connect phases according to schematic at page 21. Up to 4 mm² wire can be used with this connector.

IV) Connect the AC570 to SM1816 by means of the 15 pins “D” type socket, marked CONN #3 (AC570) and CONN #2 (SM1816), using the proper cable supplied.

V) The magnetron head unit must be connected to the AC570 control unit by: - CONN #2 (signals): up to 1 mm² wire can be used with this connector. Use cable with insulation 300V/500V. Refer to wiring diagram on page 22; - CONN #4 (power): up to 1.5 mm² wire can be used with this connector. Use cable with insulation 450V/750V. Refer to wiring diagram on page 22.

VI) The high voltage output from the SM1816 power unit has to be connected to the magnetron’s cathode by CONN #3. This voltage is near 17 kV.Use a proper insulated cable with working voltage >25 kVdc and minimum gauge of 0.25 mm²; protect the wire with shea-thing (armoured if possible).

ALTER can supply the HV cable with length on request.

VII) On the AC570 the “D” type female CONN #5 has 25 pins and brings the I/O signals to the equipment. We suggest shiel-ded ribbon cable for this purpose.Refer to wiring diagram on page 23

VIII) On the AC570 the “D” type female connector RS232 has 9 pins and is a standard serial port. It can be used to upgrade the software using a PC and, in future release, to drive the system. The pin-out connections are given on page 24

IX) the user must provide an external cut-off device, to protect the MPS 96 from short-circuit and thermal runaway condi-tions; this external protection device must also allow the main line to be isolated for maintenance operations;

X) the external circuit breaker must be a 3-pole breaker and must comply with EN61010-1 specifications;

XI) the external circuit breaker must be in close proximity to the equipment and within easy reach of the operator;

XII) the external circuit breaker must be marked as the discon-necting device for the SM1816 and the AC570;

XIII) the connector #1 must never be used as a switch-off device.

Failure to comply with these instructions may involve considerable risks for the staff responsible for checking and using the equipment, as well as the risk of general malfunc-tions of the equipment itself.

Equipment operation

Power-up procedure

Before powering-up the equipment you must be sure:- 1st) to have cooling water open (!)*- 2nd) to have properly connected the equipment (look at the chapter “Wiring Instruction” in case of any doubt)- 3rd) set the AC440 front panel breaker in “ON” position, marked with “1” **- 4th) set the SM1816 front panel breaker in “ON” position, marked with “1” **

*Note for cooling water circuit: do not hold water flowing for period over 30 minutes when the system is powered off to avoid water condensing inside the equipment.

** Note: Once set to OFF (position “zero”) wait at least five seconds before setting it ON again.This rule must be applied even in case the power is switched by an external contactor (and the panel breaker has always left in ON state): the OFF state, between two consecutive ON state, must last 5 seconds.

At power on the unit enters into “POWER-ON” state for few seconds to performs some internal checks and then goes imme-diately into “STAND-BY” and remains in this state until the “hibernate” command is switched OFF.

It’s also possible to permanently disable the “hibernate” com-mand: in this case the system performs the filament heating immediately after the “POWER-ON” state, provided there are no alarm conditions present.

At the end of the heating cycle the unit enters the “READY” mode: the power supply may now power the magnetron to generate microwave when it receives the enable command.

Any type of alarms will force the unit to exit the “READY” state and to enter the “ALARM” state.

In absence of any alarm the power supply may be left in the “Ready” state continuously (but after 30 minutes stop water cooling recirculating, to avoid condensing inside, on the heatsink): when it receives the enable command (ON) it enters into “RF-ON” state and generates output power, when the enable command is removed (OFF) the unit comes back to the “READY” state.



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Working modes

The working capability of the MPS 96 depends upon its “working mode”: it has several modes each with a different meaning and functionality. These modes are:

POWER-ON: it goes in this mode at power-on, when the main breaker is set to 1: the CPU performs some internal controls, display the factory’s logotype and after few seconds, the unit enters the Stand-By mode.

STAND-BY: This is a waiting state, the unit is powered but not yet ready to generate microwave as the magnetron filament is not powered. In this mode all of the working parameters can be set from Operator Panel; the unit enters in Stand-By from the previous Power-On state or from a Reset state. The unit exits from Stand-by and goes to Preheating only if there are no alarms present, and the “hibernate” command is OFF.

PREHEATING: This is a temporary state, controlled by an internal timer, whitch allows the filament to be heated. Entrance in this mode is done by an external command or automatically after the end of the Power-On state. When the timer has elapsed the unit goes into the Ready mode.

READY: The unit waits for the external enable command to generate power to the magnetron. The magnetron filament has been heated. The unit may remain in this state as long as needed: it auto-matically exits should any alarm be generated or when the ”hibernate” command is set. When the ENABLE command is set the unit enters into the “MW-ON” state.

MW-ON: When this appears on the LCD screen the unit is gene-rating microwave emission at the preset power level.The unit exits from this mode if: * the enabling command is set OFF. It will now enter the Ready state.

* any ALARM signal is generated. It goes into the Alarm state. * Hibernate signal is set ON. ALARM: In this state the output power and the filament is immediately shut-off. The alarm type is indicated on the display. The unit will exit the Alarm mode and enter the Reset Waiting state only when the alarm cause is removed by a “RESET” signal (CONN#5) pulse.

RESET WAITING: The unit enters in this state when the alarm cause is cancelled and the enable command is still present (ON). The unit exits from this condition and enter in Reset mode, only when the enable command is switched OFF.

RESET: This is a temporary state, driven by a two seconds timer. When the timer is elapsed the Reset state ends and the system automatically enters the Stand-By status.

Description of the external commands.

HIBERNATE: has value ON/OFF. - If ON the magnetron’s filament is not powered and the system goes into the Stand-by state.- If OFF the filament is heated and when the related timer has elapsed, the unit enters the Ready mode. The heating timer value can be preset from the front panel.- If a user does not wish to use the Hibernate function, it may remain disconnected and the system will treat it as in OFF condition.

POWER ENABLE: has value ON/OFF.This signal will depend on the state of the HIBERNATE signal:

a) ENABLE OFF and HIBERNATE OFF the unit performs filament preheating and goes in Ready state but does not generate output power;b) ENABLE OFF and HIBERNATE ON the unit is in the Stand-by state but does not generate output power;c) ENABLE ON and HIBERNATE OFF the unit awaits the end of preheating sequence and then starts to generate output power provided that the power set signal is > 10%.d) ENABLE ON and HIBERNATE ON the unit is the Stand-by state but does not generate output power.

POWER SET: This is an analog input signal and set the level of out power.When its value is lower than 9% of full value the unit does not generate any output power, when its value is greater than 9% of full value the unit generates power proportional to signal value:the signal is 0-10V or 10-100% when the mode is “manual” and the power set is given by the panel knob.



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1 2 3 4

5

DISPLAY1) Status indicator

Standby Head warm up or reset wating Ready Microwave ON

Alarm

2 ) SMxx units working (quantity)

3 ) Control mode

RS 232 External

Manual Canbus

4) Set point indicator 5) Software version

Software upgradingThe software stored on the CPU can be upgraded to a newer version through the RS232 serial port provided on the unit.To perform this upgrade the following items are required:

- a PC- a serial cable with 9 pin D type connectors, one male on the equipment side, the female for the PC side. Wiring of connectors must be 1:1 (pin 1 to pin 1, pin 2 to pin 2, etc.);

- the program “FlashPro32” to run under your PC, copies available on request- the latest version of software to upload into the AC570,copies available on request

Upgrading procedure:

I) Switch OFF the AC570 - (Enable signal must be OFF).II) Connect the serial cable to PC serial port and to RS232 serial port on the AC570.III) Remove the top cover of the AC570.IV) Locate the CPU board installed on the front panel and set the programming switch to program.V) Switch ON the AC570.VI) Move the arm switch as indicated: The CPU is ready to upload the new program into its “flash” memory: this will cancel the existing program.VII) Run the FlashPro and download from the PC the new software: this will takes few minutes and FlashPro will indicate the end of the upload.VIII) During this operation the LCD will display a random pattern. This is normal.IX) When the procedure has been completed, return the switch to its normal position.X) Install the cover of the AC570.XI) Switch off the AC570 and wait 30 secs.XII) Switch ON the AC570: one of the first messages will be the new version number.

RUNPROGRAM

Programming Switch



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Software menu description

Page name: MAIN VIEWIt’s the default view at POWER ON. If the system is in MANUAL MODE the panel knob is active and adjusts the power; in all the other MODE the knob is not active and the display shows the status driven by external com-mand.The buttons ENTER and TAB are not active.Pressing button ESC you exit MAIN VIEW and go to MAIN MENU.The upper line inform of the software version (V.....)

Page name: MAIN MENU’ (position 1)This page give you access to submenu: press TAB to move selection, press ENTER to select the sub-menu you’ve highlighted, press ESC to go back to MAIN VIEW. Sub-menu:- INFORMATION: go to page 1.1A INFO1- SETUP: go to page 1.2A UNIT SETUP- ADVANCED SETTINGS: go to page1.3 ADV. SETTINGS- MANUAL MODE: go to page 1.4 MANUAL MODE

Page name: INFO 1 (position 1.1A)It’s a read only page. The button TAB alternates the selection between NEXT and PREV command (lower line of display): use ENTER to go next page 1.1B or previous 1.1D. There are 4 pages of information, from A to D.Pressing button ESC you exit INFO1 and go to MAIN MENU. This page displays the followings: Fialment Voltage (V) and Current (A), electromagnet Coil Current (mA), Anodic Voltage (V) and Current (mA).

Page name: INFO 2 (position 1.1B)It’s a read only page. The button TAB alternates the selection between NEXT and PREV command (lower line of display): use ENTER to go next page 1.1C or previous 1.1A. There are 4 pages of information, from A to D.Pressing button ESC you exit INFO2 and go to MAIN MENU.This page displays the followings: level of External Setpoint (%), Enable Signal status (ON/OFF), serial port (PC) or Canbus when present



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Page name: INFO 3 (position 1.1C)It’s a read only page. The button TAB alternates the selection between NEXT and PREV command (lower line of display): use ENTER to go next page 1.1D or previous 1.1B. There are 4 pages of information, from A to D.Pressing button ESC you exit INFO3 and go to MAIN MENU.This page displays the followings: Forward Power (%) and Reverse Power (%) if these signals are supplied to the system, Filament Hot Resistance (mOHM)

Page name: INFO 4 (position 1.1D)It’s a read only page. The button TAB alternates the selection between NEXT and PREV command (lower line of display): use ENTER to go next page 1.1A or previous 1.1C. There are 4 pages of information, from A to D.Pressing button ESC you exit INFO4 and go to MAIN MENU.This page displays the followings: Magnetron Hours, Magnetron Type/Name, Last Alarm recorded (in the example Arc Detector)

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Page name: UNIT SETUP (position 1.2A)This page allow to modify some parameters. Press TAB to move selection (in a loop between fi rst row and the last Prev), rotate panel KNOB to choose a value, press ENTER to confi rm the new value or press ESC to go back. Press ESC twice bring you to MAIN VIEW. Parameters:

- LANGUAGE: ENGLISH (only one language is imple mented in current sw vers. of Nov ‘03)- COMUNICATION TIME OUT: in seconds, valid only for PC or Canbus command- MAX REVERSE POWER: threshold in % of related signal: when passed the system stops and enters in Alarm. Set to zero to disable alarm.- MIN FORWARD POWER: threshold in % of power set signal:when not reached the system stops and enters in Alarm. Set to zero to disable alarm. If you either highlight NEXT or PREV, by pressing ENTER you go to pag 1.2B.

Page name: UNIT SETUP 2 (position 1.2B)This page allow to modify some parameters. Press TAB to move selection (in a loop between fi rst row and the last Prev), rotate panel KNOB to choose a value, press ENTER to confi rm the new value or press ESC to go back. Press ESC twice bring you to MAIN VIEW. Parameters:- CONTROL: Manual, External, PC or Canbus- SHOW: select what is showed in MAIN VIEW 1: Power, Anodic Current or Voltage, FWD Power or REV PowerPOWER UNITS: number of installed SMxx power unitsFILAMENT CONTROL MODE: Hot Resistance (means the system holds fi lament res. constant) or by presetted curveIf either highlight NEXT or PREV, by pressing ENTER you go to pag 1.2A.



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Page name: ADV. SETTINGS (position 1.3)This page allow to enter the 4 passwords, each of 4 digits maximum. Factory setting is 0 for all the passwords. To reach the ADVANCED MENU (which al-lows modifi cation of important parameters) all the passwords have to be enteredPress TAB to move selection (in a loop between fi rst row and the last), rotate panel KNOB to modify the value; press OK when done or CLEAR to reset passwords.To go back press ESC.

Page name: MANUAL MODE (position 1.4)This page allow to modify some parameters. Press TAB to move selection (in a loop between fi rst row and the last Prev), rotating panel KNOB modify the value; press ESC to go back. Press ESC twice bring you to MAIN VIEW. The Enter button does not have any effect. Parameters:- POWER: it’s a read only parameter (kW)- ANODE VOLTAGE: it’s a read only parameter (V)- VOLTAGE SET: allow to modify the max voltage set point and set the Moding threshold alarm. If the anodic voltage is higher than the voltage set -100V Moding alarm is triggered.- COIL CURRENT:* allows to modify the electromagnet current- FILAMENT CURRENT:* allows to modify the fi lament current- ANODE CURRENT:* allows to modify the anode current*Note: the knob modify the value immediately!

Page name: ADVANCED MENU’ (position 2)This page give you access to sub-menu: press TAB to move selection, press ENTER to select the sub-menu you’ve highlighted, press ESC to go back to MAIN MENU. Sub-menu:- CURVES SETUP: go to page 2.1A CURVES SETUP- PWD CHANGE: go to page 2.2 PASSWORD CHANGE- OTHER SETTINGS: go to page 2.3 OTHER SETTINGS- RESET UNIT: go to page 2.4 MANUAL MODE

Page name: CURVES SETUP (position 2.1A)This is a read only page, before entering into the curves setup: press TAB to move selection between OK and BACK, press ENTER to confi rm, press ESC to go back to ADV MENU.



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Page name: CURVES SETUP (position 2.1B) 1 of 10 stepsThis page allow to modify working parameters in AUTOMATIC MODE. The fi rst upper row indicates the power set-point of the step (i.e.Reference 10% is the fi rst step). Press TAB to move selection (in a loop between fi rst row and the last one), rotating panel KNOB modify the value; when done press OK to store the value in memory. NEXT bring you to the next step and PREV to the previous step. Press ESC to go back. *Note: the knob modify the value immediately!

Page name: PASSWORD CHANGE (position 2.2)This page allows to modify the 4 passwords, each of 4 digits maximum. Factory setting is 0 for all the passwords. To reach the ADVANCED MENU (which al-lows modifi cation of important parameters) all the passwords have to be enteredPress TAB to move selection (in a loop between fi rst row and the last), rotate panel KNOB to modify the value; press ENTER on SAVE. To go back press ESC or select EXIT and then ENTER.

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Page name: OTHER SETTINGS (position 2.3)This page allows to modify some parameters. Press TAB to move selection (in a loop between rows), rotate panel KNOB to choose a value, press ENTER to confi rm the new value or press ESC to go back. Parameters:- FIL. HOT RES.: Filament Hot Resistance in (mOHM). - WARM UP TIME: Last time of fi lament preheating (seconds) - VOLTAGE LIMITER: Voltage threshold on actual anode voltage (V). Suggestion: do not modify!

Page name: RESET UNIT (position 2.4)This page allows to reset the system: all customized parameters are cleared and the CPU goes in System Init Mode (pos. 0.2). Press TAB to move selection (in a loop between OK and BACK), press ENTER on OK reset the system, BACK or ESC bring you back.

Page name: INIT SYSTEM (position 0.2)This page allows to load default data from the magnetron library already stored. Rotate panel KNOB to select different magnetron types. Press ENTER to con-fi rm. ESC and TAB buttons don’t have any effect.



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COMPONENT LAYOUT AC570



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Component list AC570 (See drawing pag.16)

Pos. Q.ty Description P/N Note1 1 Main switch IA3RV1421/1KA102 1 Canbus board M265 8000002653 1 Main filter FL6FCD104 1 CPU board M292 8000002925 1 Digital potentiometer RSHRPG/AD3259R6 2 Handles AR36360107 1 Filament control board M268 8000002688 1 Electromagnet control board M367 8000003679 1 Fan, dim. 80x80x25 mm VE8412NGH

10 1 Transformer 130VA 42TV570A11 1 7 pins Socket, AMP/CPC MOCPC07/2113981 Conn.#412 1 7 pins Plug, AMP/CPC (*) MOCPC07/2114001(*)13 5 Female pin, size lll MOCPCX/163088114 5 Male pin, size lll MOCPCX/163086115 1 14 pin Socket. AMP/CPC MOCPC14/1826411 Conn.#216 1 14 pin Plug. AMP/CPC MOCPC14/1826491 (*)17 14 Male pin, size lll MOCPCX/163086118 14 Female pin, size lll MOCPCX/163088119 1 Interface board M266 800000266

1 Connector, 9 pins MODCS09F RS2321 Connector, 25 pins MODCS25F Conn.#5

20 1 7 pins Socket, AMP/CPC MOCPC07/2061371 Conn.#121 1 7 pins Plug, AMP/CPC (*) MOCPC07/206136122 4 Female pin, size lll MOCPCX/066740223 4 Male pin, size lll MOCPCX/066261424 1 Auxliary P. S. board M319 800000319

Note: Components marked with (*) are included on the con-nector set p/n 44SETMPS96 to be ordered separately



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SM18xx COMPONENT LAYOUT (Sides Views without cover & wall)



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Pos. Q.ty Description P/N Note

11 H. V. Socket, GES MOHB31 Conn.#31 H. V. Plug, GES (*) MOHS31

2 1 Control board M300 8000003003 1 Main filter FL50FCD104 1 Main breaker IA3RV1331/4HC105 1 IGBT driver board M311 8000003116 1 IGBT board M301 8000003017 1 Transformer for low and aux voltage 42ATT230/005

8

1 7 pins Socket, AMP/CPC MOCPC07/2061371 Conn.#11 7 pins Plug, AMP/CPC (*) MOCPC07/20613614 Female pin, size lll (*) MOCPCX/4 Male pin, size lll MOCPCX/1939914

92 Fuseholder for fuse10X38 mm FUP18912 Fuse 10X38 mm, 6A FU10X38/6A

10 1 Connetctor 15 pin, “D” type MODFL15M Conn.#2

112 Fan, diam. 150x55 mm VE7450ES/2 Grid VELZ241/

121 L. V. Snubber capacitors board M307 800000307 SM1816T1 L. V. Snubber capacitors board M307/A 800000307/A SM1816U

13 1 Board for measuring Va M305 80000030514 1 L. V. inductor 42FI1816UA/BTR SM1816U15 1 H. V. inductor 452FI1812A

16 1 H. V. transformer42FT1816TD SM1816T42FT1816UA SM1816U

17 1 H. V. board M306 800000306

SM18xx Component list (See drawing pag.18)

Note: Components marked with (*) are included on the con-nector set p/n 44SETMPS96 to be ordered separately



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Pin out CONN. #1 of SM 1816



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Pin out CONN. #1 of AC 570



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Pin out of CONN. # 2, 3, 4



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Pin out of CONN. #5



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Pin out of CONN. #6

Pin out of serial port



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Alarm MSBbit #3 bit #2 bit #1

LSBbit #0

Description Cause/Solution

NO ALARM 0 0 0 0 No alarm

MAGN.OVERTEMP.

0 0 0 1 Magnetron over temperature

a) Check water flow and incoming water temperature.b) Check magnetron thermoswitch (contact grounded=OK, open=alarm).c) Check setting of magnetron thermocouple: if latter isn’t present the alarm threshold must be set = 0.d) Check air flow.e) Excess of reverse power. Reduce power

AIR FLOW 0 0 1 0Low Air Pressure

from head Check head air filter.

WATER FLUX 0 0 1 1Low Water Flow

in magnetron head Check water flow is > 2l/min.

INTERLOCK 0 1 0 0 Open Interlock

There are 2 interlocks.- On CONN #5 pins 25 and pin 10 must be connected together for interlock to occur- A safety switch in the magnetron unit cover (internal) must be closed

MAGN.COIL

0 1 0 1 Supply of electro-magnet is incorrect

- Overcurrent or Undercurrent on the electro-magnet- Overtemperature inside the AC unit

FILAMENT 0 1 1 0Filament resistance

out of range

- Incorrect wiring of filament trafo: check input connection- Open circuit (primary or secondary of fila-ment trafo)- Filament trafo out of spec. (wrong IN/OUT current ratio)- Fuse blown on M268 board

EXTERNAL 0 1 1 1

Alarm coming from SM181x inverter

- An inverter sent the alarm: look for alarm type on the inverter

ALARM CODES TABLE from software vers. 1.05



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ALARM CODES TABLE from software vers. 1.05

Alarm MSBbit #3 bit #2 bit #1

LSBbit #0

Description Cause/Solution

MAX REV POWER

1 0 0 0Maximum set

Reverse Power Exceeded

The reverse power threshold has been exceeded. Check the threshold limit setting or reduce the power setting.Setting threshold to zero disable this alarm.

MIN FWD POWER

1 0 0 1Minimum set

Forward Power reached

The min forward power threshold has been reached. Check the threshold limit setting or increase the power setting. Check power sensor feedback.Setting threshold to zero disable this alarm.

RAM 1 0 1 0Internal memory

corruptionWith the unit switched OFF check that the battery is properly located (it’s a “click in” battery installed over the CPU Ram) and that its voltage >2.8V. Restart the unit.

COM 1 0 1 1Communications

interrupted

The unit was running in “remote control mode” and the communication failed. Check:a) RS232 cable is connected correctlyb) remove any “suspend” or “low power mode” on the PCc) disable any screen saver on the PCd) do not move the FrontPanel window on your desktop.e) Increase the communication timeout setting on the FrontPanel.

UNDERVALUE 1 1 0 0Low output

current detected

The total power requested exceed the available power of the MPS because an inverter is out of service (OFF or alarm condition):- reduce power setting or- reset the inverter SM in alarm and put it on service againA value of current set on the control table exceed the max current available:- verify the current table

MODING 1 1 0 1 Anodic Voltage over limit

The anodic voltage has reached the limit set with parameter “VOLTAGE SET”, causes:- Magnetron failure- threshold is too low: increase it- electromagnet current is too high: reduce it

ARCDETECTOR 1 1 1 0

An arc in the waveguide has been detected

Check magnetron antenna condition. If any signs of arcing clean and retry.



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Technical Assistance:

Alter s.r.l42100 Reggio Emilia - ITALY

Tel: ++39 0522 553 820; fax ++39 0522 553 577Web: www.altersystem.com

How to order Power supplies: MPS96y.xxxjb, where:

y: T = 3 x 400 U = 3 x 480

xxx: the code used for a customized unit;

j (version code): 0 = standard version 1 = special version with Fast Alarm

Recovery function

b (interface bus code): 0 or nul= standard version

I.e: MPS 96 = standard version, without bus interface

Please specify at time of order the value of the reference signal required: 0-10 V (standard)

Connector/plug set: p/n 44SETMPS96

Cable set with plugs: p/n 44 1384 237 Includes high voltage cable (from

last unit to head), main line cables, head cables, signals cable and plugs on psu side. Standard lenght is 5 mt; other lengths available on request

Alter reserves the right to improve or modify this products, at any time, without any obligation to notify any person or entity of such changes.No part of this publication may be reproduced without the express written consent of Alter.

All rights reserved.

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