Manuals / Apex Digital / Lawn and Garden / Portable Generator

Apex Digital 5708009-C manual Troubleshooting and Customer Support, Troubleshooting Guide

Models: 5708009-C

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Troubleshooting and Customer Support

Apex 1 to 5.5 kW Generator

Chapter

6

Troubleshooting and Customer Support

This Chapter addresses the troubleshooting of the Apex unit. It can be used best by knowing what problem you have and then finding the information within each heading item laid out in this chapter. The list of items below will direct you to the section of the chapter in order for quick reference. Here are the following topics covered:

•“Troubleshooting Questions” on page 6-3: This section contains questions that can be easily answered and will guide you through any implications that may be incurred with the Apex generator.

•“Troubleshooting Procedures” on page 6-4: This section explains the procedures needed to get your Apex unit to work while explaining what specific LEDs mean and how they can be handled. The procedure explains what the error means, what can cause the error and how to fix the error.

•“AC On LED not Lit” on page 6-4: This section contains a full list of codes and how they can be solved.

•“AE Customer Support” on page 6-11: This section provides phone numbers and addresses for AE support centers around the world.

TROUBLESHOOTING GUIDE

Before calling AE Customer Support, perform the following steps or procedures. Use this section if you are experiencing any LED issues or operating failures. The guide will help you through the process of getting your Apex unit running.

RISK OF DEATH OR BODILY INJURY. Disconnect all sources of input power before working on this unit or anything connected to it.

Checks with the Power Off

Before troubleshooting the Apex unit make sure the following are completed:

1.Ensure the power to the unit is off.

2.Check for visible damage to the unit, cables, and connectors.

3.Ensure all unit connectors are installed correctly and are fastened tightly.

5708009-C

6-1

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Apex Digital 5708009-C manual Troubleshooting and Customer Support, Troubleshooting Guide, Checks with the Power Off

Contents

MANUAL #RGZ6/GPGTCVQTVQM9 GDTWCTPage 5708009-C 7UGT/CPWCN#RGZTMGPGTCVQT VQM9 Trademarks Chapter 2. Theory Table of ContentsChapter 3. Specifications Chapter 1. IntroductionCommand Status Response CSR Codes-RS-232, AE Bus Host Chapter 4. Interfaces and IndicatorsChapter 5. Installation, Setup, and Operation Chapter 6. Troubleshooting and Customer Support 5708009-C Advanced EnergyList of Figures 5708009-C Advanced EnergyList of Tables 5708009-C Advanced EnergyREAD THIS SECTION USING THIS MANUAL TO FIND INFORMATION FOR YOUR GENERATORUnderstanding PIN Numbers and Apex Configuration IntroductionFigure 1-1. Serial number identification tag Using the PIN to Locate Information in the ManualFigure 1-2. Example configuration note Using the PIN to Identify Apex OptionsOptions, Descriptions, and Cross-References Table 1-1. Apex PIN Positions and Associated OptionsApex Feature Options, Descriptions, and Cross-References Table 1-1. Apex PIN Positions and Associated Options ContinuedApex Feature Options, Descriptions, and Cross-References Apex FeatureTable 1-1. Apex PIN Positions and Associated Options Continued Options, Descriptions, and Cross-References Apex FeatureTable 1-1. Apex PIN Positions and Associated Options Continued Options, Descriptions, and Cross-References Apex FeatureTable 1-1. Apex PIN Positions and Associated Options Continued Table 1-1. Apex PIN Positions and Associated Options Continued INTERPRETING THE MANUAL AND UNIT LABELSType Conventions The following symbols could appear on labels on your unit Icons Symbols5708009-C Capacitor charge Hazardous Voltage Short circuit protectedHigh voltage Protective earth ground Earth ground CE label Apex 1 to 5.5 kW GeneratorPRODUCT SAFETY/COMPLIANCE SAFETYTable 1-2. Electromagnetic Compatibility EMC Table 1-3. SafetyDirectives and Standards Canadian Standards Association CSA NRTL/C CertificationEMC measurements verified by TÜV Product Services Certain options of this product are certified byINSTALLATION REQUIREMENTS Conditions of Use Regulation TheoryGENERAL DESCRIPTION FUNCTIONAL DESCRIPTIONProtection InterlockOptional Water Solenoid GroundingMeasure Figure 2-1. Theory of operation block diagramTable 2-1. Block Diagram Explanation 5708009-C Advanced EnergyPHYSICAL SPECIFICATIONS SpecificationsDescription Table 3-1. Physical SpecificationsPIN Option-Specification RF Connector location Table 3-1. Physical Specifications ContinuedAC power input connector RF output connectorconnector Table 3-1. Physical Specifications ContinuedPIN Option-Specification Water control connectorsTable 3-1. Physical Specifications Continued ELECTRICAL SPECIFICATIONSInput Power Specifications Table 3-2. Input Power SpecificationsTable 3-3. Output Specifications Output Electrical SpecificationsTable 3-2. Input Power Specifications Continued Description Table 3-3. Output Specifications ContinuedPIN Option and Specification Description Table 3-3. Output Specifications ContinuedPIN Option and Specification Output power regulation accuracyTable 3-3. Output Specifications Continued Other Electrical SpecificationsTable 3-4. Other Electrical Specifications Temperature COOLING SPECIFICATIONSTable 3-4. Other Electrical Specifications Continued Table 3-5. Cooling SpecificationContaminates Table 3-5. Cooling Specification ContinuedHeat removal PSI , y xn Graphical Representations of Flow RateFigure 3-1. Flow Rate vs. Pressure Drop Flow GPM1513 Figure 3-2. Water flow vs. Inlet Temperature5513 3013Overvoltage ENVIRONMENTAL SPECIFICATIONSTable 3-6. Climatic Specifications Table 3-7. Environmental SpecificationsInterfaces and Indicators 25-Pin Apex Standard User Port Figure 4-1. User Port connector 25 Pin APEX StandardAPEX USER PORT OPTIONS PIN DESCRIPTIONS FOR THE 25-PIN USER PORT SATISFYING MINIMAL REQUIREMENTS FOR THE 25-PIN USER PORTINTERFACE CABLING REQUIREMENTS FOR 25-PIN USER PORT Type Table 4-1. User Port 25-Pin APEX Standard Pin DescriptionsSETPOINT Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions ContinuedRF PWR ON Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions Continued SignalSignal DC BIAS/POWERReturn SignalSignal Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions ContinuedReturn SignalSignal Table 4-1. User Port 25-Pin APEX Standard Pin Descriptions ContinuedTable 4-1. User Port 25-Pin APEX Standard Pin Descriptions Continued WIRING DIAGRAMS FOR THE STANDARD 25-PIN USER PORTSignal Signal4-10 Wiring Diagram 4-1. Forward/Load power monitor pins 3 andWiring Diagram 4-2. RFL PWR monitor pins 2 and Advanced Energy5708009-C Wiring Diagram 4-3. Setpoint pins 5 andWiring Diagram 4-4. DC Bias Input pins 7 and Apex 1 to 5.5 kW Generator4-12 Wiring Diagram 4-5. RF Power On pins 4 andWiring Diagram 4-6. DC Bias/Power Regulation pins 6 and Advanced Energy5708009-C Wiring Diagram 4-7. FWD/Load Power Regulation pins 8 andWiring Diagram 4-8. Setpoint Status pins 14 and Apex 1 to 5.5 kW Generator4-14 Wiring Diagram 4-9. Overtemp pins 22 andWiring Diagram 4-10. DC Bus OK pins 24 and Advanced Energy5708009-C Wiring Diagram 4-11. CEX Lock pins 12 andWiring Diagram 4-12. Interlock Loop pins 10 and Apex 1 to 5.5 kW Generator15-Pin User Port Exclusive-Option D Wiring Diagram 4-13. +15 Vdc pins 13 andINTERFACE CABLING REQUIREMENTS FOR OPTION D USER PORT Figure 4-2. User port connector 15 Pin Exclusive for configuration DSATISFYING MINIMAL REQUIREMENTS FOR OPTION D 15-PIN USER PORT PIN DESCRIPTIONS FOR OPTION D USER PORT reference Return WIRING DIAGRAMS FOR OPTION D 15-PIN USER PORTSignal Signal5708009-C Wiring Diagram 4-14. Forward/Load Power monitor pins 3 andWiring Diagram 4-15. Reflected power monitor pins 2 and Apex 1 to 5.5 kW Generator4-22 Wiring Diagram 4-16. Forward/Load Power setpoint pins 5 andWiring Diagram 4-17. RF power enable pins 4 and Advanced Energy5708009-C Wiring Diagram 4-18. RF on status pins 7 andWiring Diagram 4-19. Power limit status pins 1 and Apex 1 to 5.5 kW Generator4-24 Wiring Diagram 4-20. External bias pins 8 andWiring Diagram 4-21. RF on bias pins 9 and Advanced Energy5708009-C Wiring Diagram 4-22. FWD/LOAD Power Regulation pins 13 andWiring Diagram 4-23. Interlock pins 11 and Apex 1 to 5.5 kW Generator15-Pin User Port Exclusive-Option E Figure 4-3. User Port connector 15 pin exclusive for Configuration EApex 1 to 5.5 kW Generator SATISFYING MINIMAL REQUIREMENTS FOR OPTION E 15-PIN USER PORTINTERFACE CABLING REQUIREMENTS FOR OPTION E USER PORT PIN DESCRIPTION FOR OPTION E USER PORTMONITOR REFLECTED POWERPOWER MONITOR +24V User ProvidedName SignalSignal ReturnName SignalSignal ReturnName SignalSignal ReturnReturn WIRING DIAGRAMS FOR OPTION E USER PORTSignal Signal5708009-C Wiring Diagram 4-24. DeviceNet LEDs pins 1,10,13,14 andWiring Diagram 4-25. Reflected power monitor pins 2 and Apex 1 to 5.5 kW Generator4-34 Wiring Diagram 4-26. Forward/Load Power Monitor pins 3 andWiring Diagram 4-27. RF Power Enable pin 4 and Advanced Energy5708009-C Wiring Diagram 4-28. Forward/Load Power Setpoint pins 5 andWiring Diagram 4-29. RF on status pins 7 and Apex 1 to 5.5 kW Generator4-36 Wiring Diagram 4-30. +15 Vdc pins 9 andWiring Diagram 4-31. Interlock pins 11 and Advanced EnergyRS-232, AE Bus Host port option APEX HOST PORT OPTIONSHost Port-RS-232 With AE Bus To Connect the Computer to the Apex unit Figure 4-4. RS-232, AE Bus Host port connectorTable 4-4. RS-232, AE Bus Host Port Pin Descriptions RS-232, AE BUS HOST PORT CABLING REQUIREMENTSCOMMUNICATING THROUGH THE RS-232, AE BUS HOST PORT Figure 4-5. Graphic representation of a RS-232, AE Bus message packet AE BUS PROTOCOLData Data Bytes CommandHeader Optional Length ByteFigure 4-6. AE Bus communications transaction ChecksumCREATING AN IDEAL COMMUNICATIONS TRANSACTION HOST/APEX COMMUNICATIONS TRANSACTION EXAMPLE Value COMMAND STATUS RESPONSE CSR CODES-RS-232, AE BUS HOSTFigure 4-7. AE Bus communications transaction example Table 4-5. CSR Codes for RS-232, AE Bus HostHost Data COMMAND SET FOR THE RS-232, AE BUS HOST PORTTable 4-6. Host Port Commands for RS-232 with AE Bus Table 4-5. CSR Codes for RS-232, AE Bus HostNumber of Table 4-6. Host Port Commands for RS-232 with AE Bus ContinuedCommand timerNumber of Table 4-6. Host Port Commands for RS-232 with AE Bus ContinuedCommand timeoutNumber of Table 4-6. Host Port Commands for RS-232 with AE Bus ContinuedCommand Number ofCommand Table 4-6. Host Port Commands for RS-232 with AE Bus ContinuedCommand Table 4-6. Host Port Commands for RS-232 with AE Bus ContinuedNumber of Table 4-6. Host Port Commands for RS-232 with AE Bus ContinuedCommand Number ofCommand Table 4-6. Host Port Commands for RS-232 with AE Bus ContinuedCommand Table 4-6. Host Port Commands for RS-232 with AE Bus ContinuedCommand Table 4-6. Host Port Commands for RS-232 with AE Bus Continuedoutput Table 4-6. Host Port Commands for RS-232 with AE Bus Continuedoutput on Number of Table 4-6. Host Port Commands for RS-232 with AE Bus ContinuedCommand Number of219 Returns the condensed snapshot of generator dataTable 4-6. Host Port Commands for RS-232 with AE Bus Continued cont’d Host Port-ProfibusTable 4-6. Host Port Commands for RS-232 with AE Bus Continued snapshot ofAE PROFIBUS PROTOCOL Figure 4-8. Host port connector with ProfibusTable 4-7. Profibus Host Port Pins Table 4-7. Profibus Host Port Pins Setting the Network Address with the Profibus DIP SwitchProfibus Type Files GSD Files Profibus Baud Rate Profibus Master Reset CommandProfibus Watch Dog Timer Profibus TerminationProfibus Data Consistency Profibus-Specific ErrorsProfibus Download Packet PROFIBUS/APEX SOFTWARE COMMANDSTable 4-8. Configuration of Download Bytes Outbytes Table 4-9. Configuration of Profibus Upload Packet InbytesDescription Table 4-10. Upload Status BytesTable 4-9. Configuration of Profibus Upload Packet Inbytes Byte4-65 Apex 1 to 5.5 kW Generator5708009-C Table 4-11. Profibus Host Port Commands PROFIBUS COMMAND SETallowable Table 4-11. Profibus Host Port Commands Continuedlife Number of Table 4-11. Profibus Host Port Commands ContinuedCommand DescriptionNumber of Table 4-11. Profibus Host Port Commands ContinuedCommand DescriptionNumber of Table 4-11. Profibus Host Port Commands ContinuedCommand DescriptionNumber of Table 4-11. Profibus Host Port Commands ContinuedCommand DescriptionHost Port-DeviceNet Figure 4-9. DeviceNet connectorTable 4-12. Host Port DeviceNet Pins CANH DEVICENET INTERFACE CHARACTERISTICSTable 4-13. DeviceNet Voltage Ranges Table 4-12. Host Port DeviceNet PinsFigure 4-10. DeviceNet control panel DEVICENET ROTARY SWITCHES BAUD RATE AND ADDRESSINGDEVICENET CONTROL PANEL LEDS Devicenet Module Status LEDTable 4-15. Network Status LED Devicenet Network Status LEDTable 4-14. MOD Status LED Table 4-15. Network Status LED Continued DEVICENET OPERATIONDeviceNet Response Message DeviceNet Poll Command MessageTable 4-16. Poll Command Message Byte Table 4-17. Response MessageAC ON APEX STATUS INDICATORS LEDSTable 4-18. LED Status Indicators POWER LIMITOVERTEMP Table 4-18. LED Status Indicators ContinuedAPEX PANEL ILLUSTRATIONS ALARMHost port connector Figure 4-11. Front PanelLED status indicators may be absent or on the rear panel User port connector varies Circuit breaker optionalAdvanced Energy Figure 4-12. Rear panelLED status indicators may be absent or on the rear panel Output connector varies may be on front panelGrounding Installation, Setup, and OperationINSTALLING THE GENERATOR UnpackingDo not attempt to turn on power until the generator is grounded Spacing Requirements5708009-C Figure 5-1. Apex dimensionsApex 1 to 5.5 kW Generator To Connect Cooling Water Connecting Cooling WaterInstalling the Optional Water Control Mounting the GeneratorTable 5-1. Water Control Connector Pins Connecting Output PowerFigure 5-2. Water control connector Figure 5-3. Optional water solenoid connectorFigure 5-4. Output connector Connecting Input PowerODU CONNECTOR Table 5-2. ODU Pin Descriptions Figure 5-5. ODU input connectorNONTERMINATED, FOUR-CONDUCTOR PIGTAIL Ground Green or Green/yellow stripe HARTING TYPE HAN-Q CONNECTORTable 5-3. Nonterminated, Four-Conductor Pin Descriptions 1 Phase black 2 Phase black 3 Phase blackTable 5-4. Harting Type Han-Q Pin Descriptions Connecting I/O and Auxiliary ConnectorsFigure 5-6. Harting type Han-Q connector TO CONTROL THE GENERATOR THROUGH A HOST PORT TO CONTROL THE GENERATOR THROUGH A USER PORTFIRST TIME OPERATION TO USE THE COMMON EXCITER CEX FEATURE OPTIONALNORMAL OPERATION UNDERSTANDING AND SETTING UP PULSING OUTPUTPulsing option Enabling and Setting PulsingUnderstanding Pulsing Checks with the Power Off Troubleshooting and Customer SupportTROUBLESHOOTING GUIDE 6. Ensure ground connections are adequate and secure 3. Is the Overtemp LED flashing? Troubleshooting Questions2. Is the Alarm LED lit? 1. Is the AC On LED lit?Overtemp LED on Solid TROUBLESHOOTING PROCEDURESAlarm LED Lit AC On LED not LitRF ON LED Flashing Power Limit LED is LitInterlock LED is not Lit External Load Checks - Open/Short RF Output Path Error Code Description ERROR CODESTable 6-1. Error Code Table Error CodeE016 Table 6-1. Error Code Table ContinuedE011 E012Solution Table 6-1. Error Code Table ContinuedError Code Error Code DescriptionSolution Table 6-1. Error Code Table ContinuedError Code Error Code DescriptionE105 AE CUSTOMER SUPPORTTable 6-2. Global Support Locations Table 6-1. Error Code Table ContinuedTable 6-2. Global Support Locations Continued RETURNING UNITS FOR REPAIRAuthorized Returns WARRANTYWarranty Statement 4-22 SymbolsNumerics 4-214-39 command data data bytes 4-41 header optional length bytefiling a claim 4-134-32 1 VSWR loads4-32 1 VSWR loadsauthorized returns returning units 6-13 statement 4-264-16 terminal pin descriptions non-terminated 3m and 12’ pigtail