MPS 24 TECHNICAL NOTE. MULTICHASSIS SWITCHING PSU FOR 15 kw MAGNETRON C.W. INCLUDES: SM18XX POWER MODULE AC 440 CONTROL MODULE.

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1 MPS 24 MULTICHASSIS SWITCHING PSU FOR 15 kw MAGNETRON C.W. INCLUDES: SM18XX POWER MODULE AC 440 CONTROL MODULE TECHNICAL NOTE (Issue May 2007)

2 CE Declaration of Conformity Dichiarazione di Conformità CE Manufacturer s Name: Nome del Costruttore: Manufacturer s Address: Indirizzo del Costruttore: ALTER s.r.l Via Curie, Reggio Emilia - Italy Declare that the microwave generator: Dichiara che il Prodotto: product name: nome del prodotto models: modello SM18xxT/U (power supply unit) and AC440T/U (filament control unit) SM18xxT/U (alimentatore elettrico) e AC440T/U (unità di controllo) SM1812T.xxx - SM1812U.xxx - SM1816T.xxx - SM1816U.xxx AC 440T.xxx - AC 440U.xxx Complies with the following norms: Soddisfa le seguenti norme: EN : A2: 1996 (EN 61010: A2: 1995) EN55011: 1991 PM 740 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, May Marco Garuti Presidente C.d.A. Rev. Revision note Date File 0 First emission November 2003 MPS24_r0eng 1 Voltage set January 2004 MPS24_r1eng 2 Version T/U and alarm code table May 2007 MPS24_r2eng 3 File: MPS24_r2eng - May Technical note for: MPS24 page 1 of 27

3 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 /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 of 15 May 2006, 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 1 st July 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: Cadmium: Pbb & Pbde: Cr-VI: Lead: not present, never used 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. may be present in some cables and insulating material in the past. We are using only RoHS compliant suppliers and products now. 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. 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. page 2 of 27 File: MPS24_r2eng - May Technical note for: MPS24

4 A Alarm code table 25 AC440 specifications 5 C CE Declaration 1 Cleaning 8 Components List AC Components List SM Contents D Description of external command 10 Display 11 E Environmental conditions 7 Equipment installation 8 Equipment operation 9 F Fuses replacement 8 Fuses specifications 7 G General Description 4 General Information 3 H Handling instructions 8 Handling Warnings 4 How to order 27 P Physical characteristics 7 Pin out of CONN. #1 SM Pin out of CONN. #1 AC Pin out of CONN. # 2, 3, 4 22 Pin out of CONN. #5 AC Pin out of Serials 24 Power up procedure 9 R RoHS conformity 2 S SM18xx specifications 6 Software menu description 12 Software Upgrading 11 T Technical Assistance 27 PM 740 General Information This equipment satisfies the European Standard EN (=CEI 66-5) (=IEC ) approved by CENELEC on 9/3/1993. With reference to EN 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 equipment 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 SM18xx and AC 440, when properly installed, comply with the limits of radio disturbance characteristic of a Group2, Class A equipment as stated by EN 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. WARNINGS Both the SM18xx and the AC440 are powered by AC main line. The SM1812 has high voltage output (close 12 kv), 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 manual 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. W Warnings 3 Wiring instructions 8 Working modes 10 File: MPS24_r2eng - May Technical note for: MPS24 page 3 of 27

5 Handling Warnings Both 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 appropriate base underneath the equipment! The handles will not withstand the off-center weight of the equipment (SM18xx=55 kg/121 lbs, AC440= 24 kg/ 53 lbs) General Description The MPS24 system is able to supply the power necessary to drive a 15 kw magnetron, like the NL15245 or equivalent, and includes the following: - no. 1 AC440T/U filament & electromagnet control unit - no. 1 SM18xxT/U power unit Both the units have been designed as a part of our Multichassis Project that allows to use multiple power modules to drive magnetron up to 90 kw with a single control unit. The two units, the control and the power, 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 MPS24 may be controlled: a) manually via the front panel keys on the AC440 b) remotely via a PLC with 0-10V analog signals of the AC440 c) by RS232 serial port of the AC440 AC 440 Description and Specifications The AC440 control unit is 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; - 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 AC440 comprises the following: - a 7 pins socket for the main supply (CONN. #1) [9] - a 14 pins socket for the signals from the remote microwave head (CONN. #2) [2] - a 15 pins D type socket to control the power units (bus link) (CONN: #3) [8] - a 7 pins socket to power the remote microwave head (CONN. #4) [4] - a 25 pins «D» type socket for the external control signals (CONN. #5) [5] - a 9 pins «D» type socket for the RS 232 port [7] - the fuses holders (F1, F2) [1] - the filter mesh of the outlet cooling air, which also reduces EMI noise [4] - the equipment label [6] 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 AC440 through the front panel and exits through the rear panel. The intake air flow is approx 100 m 3 /h. You must avoid mixing output air with inlet air. AC 440 FRONT PANEL page 4 of 27 File: MPS24_r2eng - May Technical note for: MPS24

6 AC 440 REAR PANEL PM 740 AC440 specifications: AC440T AC440U Main supply (50/60 Hz): 2x400 V 2x480 V Minimum main voltage: 360 V 435 V Maximum main voltage: 440 V 525 V Transient overvoltage: overvoltage cat. II according IEC 664 Intake 400 V: 7 A rms 5 A rms Current controlled output to filament trafo: 5 A rms 5 A rms Stability of filament output: within 1% for input fluctuations within +/- 10% Controlled output to electromagnet: 50 V, 5 A Stability of electromagnet output: within 1% for input fluctuations within +/- 10% Filament control: with preset hardware curve or special curve stored in the CPU Filament preheating: automatic at power-on Enable microwave command: 24 Vdc (range 12 24Vdc) optoinsulated Load of the status contacts: max 130V - 0,5A Working mode of Alarm contact: a) unit in power OFF: contact open b) unit in power ON, no alarms: contact closed c) unit in power ON, alarm status: contact open Working mode of Ready output: 24V - 10mA a) unit in power OFF: high impedance b) unit in power-on, no alarms, filament ready (preheating completed): 24V c) unit in power ON, alarm status: high impedance Reference signal to adjust power: 0-10 Vdc (Z=100 KΩ) (optoinsulated) Management of alarm situations: a) by internal alarm relay, contact load: max 24V 100mA 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 connector: 24V 10mA max (optoinsulator) SM 18xx Description and Specifications The SM18xx 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 (10 LED, range 0-25 kv, each indicates 2,5 kv), the second showing the Anodic Current (10 LED range 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]. File: MPS24_r2eng - May Technical note for: MPS24 page 5 of 27

7 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 24 - the water inlet and outlet fittings [4] - the fans [5] - the fuses holders (F1, F2) [6] - thr hearth screw [7] - the equipment label [8] SM 18xx FRONT PANEL SM 18xx REAR PANEL CONN #3 CONN #2 A B ATTENZIONE! USCITA ALTA TENSIONE WARNING! HIGH VOLTAGE OUTPUT WARNUNG! HOCHSPANNUNGSAUSGANG F 1 F 2 COOLING WATER COLLEGARE ALLA TERRA DEL GENERATORE REMOTO CONNECT DIRECTLY TO GROUND OF MICROWAVE HEAD VERBINDER DIRECT MIT DER ERDUNG DES MIKROWELLEN GENERATOR alte r MODEL P/N REGGIO E. - ITALY CONN #1 S/N DATE POWER KVA CURRENT A INPUT V FREQ. Hz 46PP SM18xx specifications: SM1812T SM1812U SM1816T SM1816U Main supply (50/60 Hz): 3x400 V 3x480 V 3x400 V 3x480 V Minimum main voltage: 360 V 435 V 360 V 435 V Maximum main voltage: 440 V 525 V 440 V 525 V Transient overvoltage: overvoltage cat. II according IEC 664 Intake current: 40 A 400 V 36 A 480 V 40 A 400 V 36 A 400 V page 6 of 27 File: MPS24_r2eng - May Technical note for: MPS24

8 Environmental conditions Use: Indoor use only Altitude: 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 specifications The control and the power unit have fuses on the rear panel: AC 440T/U Fuse F1 and F2 specs: - Size, type: 10x32 mm, ceramic cartridge - Speed action: quick (F) - Rated current: 6 A - Rated voltage: 500 V minimum SM18xxt/u Fuse F1 and F2 specs: - Size, type: 10x32 mm, ceramic cartridge - Speed action: quick (F) - Rated current: 6 A - Rated voltage: 500 V minimum For instructions about fuse replacement please refer to related paragraph on the next page. Physical characteristics Front panel dimensions: AC 440: 19 x 3HE SM18xx: 19 x 7HE Rack total width: 475 mm Rack total height AC mm SM18xx 320 mm Rack depth (without handles): 440 mm Housing cabinet depth (minimum): 800 mm Weights: AC440: 24 kg (53 lbs) SM18xx 55 kg (121 lbs) Total weight MPS 24: 79 kg (174 lbs) Intake air flow: MPS 24: approx 700 m³/h PM 740 File: MPS24_r2eng - May Technical note for: MPS24 page 7 of 27

9 Equipment maintenance Cleaning Cleaning 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 whatever 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 page 7 Equipment installation The MPS24 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 equipment, 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 precautions 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 MPS 24 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 recommend that the following design criteria be adopted: - use a standard 19 wide enclosure with a depth of 800 mm (32 ) minimum; - 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; - if you install an air conditioner take care to garantee the air flow. Handling instructions The MPS 24 total weight is 79kg (174 lbs). Always lift from the bottom and use an adequate rugged support to avoid personal 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 instructions The MPS24 must be installed and serviced only by qualified personnel acquainted with the regulations covering the application. 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; III) SM18xxT/U: the main supply, 3 x400v/480v, depending from models, must be provided through connector #1: connect phases according to schematic at page 20. A 10 mm² wire must be used with this connector. AC440T/U: the main supply, 2x400V/480V, depending from models, 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. page 8 of 27 File: MPS24_r2eng - May Technical note for: MPS24

10 IV) Connect the AC440 to SM18xx by means of the 15 pins D type socket, marked CONN #3 (AC440) and CONN #2 (SM18xx), using the proper cable supplied. V) The magnetron head unit must be connected to the AC440 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 SM18xx power unit has to be connected to the magnetron s cathode by CONN #3. This voltage is near 12 kv for the SM1812 and near 16 kv for SM1816. Use a proper insulated cable with working voltage >25 kvdc and minimum gauge of 0.50 mm²; protect the wire with sheathing (armoured if possible). The reliability of the system begins with the high voltage connection, so this cable must be assembled professionally. ALTER can supply the HV cable with length on request. VII) On the AC440 the D type female CONN #5 has 25 pins and brings the I/O signals to the equipment. We suggest shielded ribbon cable be used for this purpose. Refer to wiring diagram on page 23 PM 740 VIII) On the AC440 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 23 IX) the user must provide an external cut-off device, to protect the MPS 24 from short-circuit and thermal runaway conditions; 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 EN 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 disconnecting device for the SM18xx and the AC440; XIII) the connector #1 must never be used as a switch-off device. Equipment operation Power-up procedure Before powering-up the equipment you must be sure: - 1 st ) to have cooling water open (!)* - 2 nd ) to have properly connected the equipment (look at the chapter Wiring Instruction in case of any doubt) then make the following steps in the sequence here described: - 3 rd ) set the AC440 front panel breaker in ON position, marked with 1 ** - 4 th ) set the SM1812 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 immediately into STAND-BY and remains in this state until the hibernate command is switched OFF. It s also possible to permanently disable the hibernate command: 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. 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 malfunctions of the equipment itself. File: MPS24_r2eng - May Technical note for: MPS24 page 9 of 27

11 * 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. Working modes The working capability of the MPS 24 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 automatically 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 generating 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. 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 % when the mode is manual and the power set is given by the panel knob. page 10 of 27 File: MPS24_r2eng - May Technical note for: MPS24

12 ) Status indicator: Standby DISPLAY Head warm up or reset wating - the program FlashPro32 to run under your PC, copies available on request - the latest version of software to upload into the AC440, copies available on request Ready Microwave ON Upgrading procedure: Alarm 2 ) SMxx units working (quantity) 3 ) Control mode: RS 232 Manual 4) Set point indicator 5) Software version External PM 740 Software upgrading Canbus The 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.); I) Switch OFF the AC440 - (Enable signal must be OFF). II) Connect the serial cable to PC serial port and to RS232 serial port on the AC440. III) Remove the top cover of the AC440. IV) Locate the CPU board installed on the front panel and set the programming switch to program. V) Switch ON the AC440. VI) The CPU is ready to upload the new program into its flash memory: this will cancel the existing program and settings VII) Run the FlashPro, select 78K micro 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 switch off the AC440 X) Set the programming switch to the RUN position XI) Replace the cover of the AC440. XII) Switch ON the AC440: one of the first messages will be the new version number. PROGRAM Programming Switch RUN File: MPS24_r2eng - May Technical note for: MPS24 page 11 of 27

13 Software menu description Page name: MAIN VIEW It 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 command. 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 page 12 of 27 File: MPS24_r2eng - May Technical note for: MPS24

14 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 (as percentage of 0-10V input signal) 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) PM 740 Page name: UNIT SETUP (position 1.2A) This page allow to modify some parameters. Press TAB to move selection (in a loop between first row and the last Prev), rotate panel KNOB to choose a value, press ENTER to confirm 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 first row and the last Prev), rotate panel KNOB to choose a value, press ENTER to confirm 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 Power POWER UNITS: number of installed SMxx power units FILAMENT CONTROL MODE: Hot Resistance (means the system holds filament res. constant) or by presetted curve If either highlight NEXT or PREV, by pressing ENTER you go to pag 1.2A. File: MPS24_r2eng - May Technical note for: MPS24 page 13 of 27

15 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 allows modification of important parameters) all the passwords have to be entered Press TAB to move selection (in a loop between first 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 first 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 filament 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 confirm, press ESC to go back to ADV MENU. page 14 of 27 File: MPS24_r2eng - May Technical note for: MPS24

16 Page name: CURVES SETUP (position 2.1B) 1 of 10 steps This page allow to modify working parameters in AUTOMATIC MODE. The first upper row indicates the power set-point of the step (i.e.reference 10% is the first step). Press TAB to move selection (in a loop between first 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 allows modification of important parameters) all the passwords have to be entered Press TAB to move selection (in a loop between first 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. PM 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 confirm the new value or press ESC to go back. Parameters: FIL. HOT RES.: Filament Hot Resistance in (mohm) not implemented till vers included. - WARM UP TIME: Last time of filament 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 confirm. ESC and TAB buttons don t have any effect. File: MPS24_r2eng - May Technical note for: MPS24 page 15 of 27

17 AC440 COMPONENT LAYOUT page 16 of 27 File: MPS24_r2eng - May Technical note for: MPS24

18 AC440 Component list (See drawing pag.16) Pos. Q.ty Description P/N Note 1 1 Main switch IA3RV1421/1KA Canbus board M Main filter FL6FCD CPU board M Digital potentiometer RSHRPG/AD3259R 6 2 Handles AR Filament control board M Electromagnet control board Fan, dim. 80x80x25 mm VE8412NGH 10 2 Fuseholder for fuse10x38 mm FUP Fuse 10X38 mm, 6A 500 V, cer. quick act. FU10X38/6A pins Socket, AMP/CPC MOCPC07/ Conn.# pins Plug, AMP/CPC (*) MOCPC07/ (*) 13 5 Female pin, size lll MOCPCX/ Male pin, size PM lll 740 MOCPCX/ pin Socket. AMP/CPC MOCPC14/ Conn.# pin Plug. AMP/CPC MOCPC14/ (*) Male pin, size lll MOCPCX/ Female pin, size lll MOCPCX/ Interface board M Connector, 9 pins MODCS09F RS232 1 Connector, 25 pins MODCS25F Conn.# pins Socket, AMP/CPC MOCPC07/ Conn.# pins Plug, AMP/CPC (*) MOCPC07/ Female pin, size lll MOCPCX/ Male pin, size lll MOCPCX/ Transformer 42ATT440A 25 1 Air filter File: MPS24_r2eng - May Technical note for: MPS24 page 17 of 27

19 MPS - MULTICHASSIS POWER SUPPLY SYSTEM SM18xx COMPONENT LAYOUT (Sides Views without cover & wall) page 18 of 27 File: MPS24_r2eng - May Technical note for: MPS24

20 SM18xx Component list (See drawing pag.18) Pos. Q.ty Description P/N Note 1 1 H. V. Socket, GES MOHB31 Conn.#3 1 H. V. Plug, GES (*) MOHS Control board M Main filter FL50FCD Main breaker IA3RV1331/4HC IGBT driver board M IGBT board M Transformer for low and aux voltage 42ATT230/ pins Socket, AMP/CPC MOCPC07/ Conn.# pins Plug, AMP/CPC (*) MOCPC07/ Female pin, size lll (*) MOCPCX/ 4 Male pin, size lll MOCPCX/ Fuseholder for fuse10x38 mm FUP Fuse 10X38 mm, 6A FU10X38/6A 10 1 Connetctor 15 pin, D type MODFL15M Conn.# Fan, diam. 150x55 mm VE7450ES/ 2 Grid PM 740 VELZ241/ 12 1 L. V. Snubber capacitors board M Board for measuring Va M L. V. inductor 42FI1816UA/BTR SM1816U 15 1 H. V. inductor 452FI1812A 16 1 H. V. transformer 42FT1816TD SM1816T 42FT1816UA SM1816U 17 1 H. V. board M Note: Components marked with (*) are included on the connector set p/n 44SETMPS24 to be ordered separately File: MPS24_r2eng - May Technical note for: MPS24 page 19 of 27

21 Pin out CONN. #1 of SM 18xx page 20 of 27 File: MPS24_r2eng - May Technical note for: MPS24

22 Pin out CONN. #1 of AC 440T/U PM 740 File: MPS24_r2eng - May Technical note for: MPS24 page 21 of 27

23 Pin out of CONN. # 2, 3, 4 page 22 of 27 File: MPS24_r2eng - May Technical note for: MPS24

24 Pin out of CONN. #5 PM 740 File: MPS24_r2eng - May Technical note for: MPS24 page 23 of 27

25 Pin out of serial port page 24 of 27 File: MPS24_r2eng - May Technical note for: MPS24

26 ALARM CODES TABLE from software vers Alarm MSB bit #3 bit #2 bit #1 LSB Description Cause/Solution bit #0 NO ALARM No alarm MAGN. OVERTEMP Magnetron over temperature AIR FLOW Low Air Pressure from head 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 Check head air filter. WATER FLUX Low Water Flow in magnetron head Check water flow is > 2l/min. PM 740 INTERLOCK Open Interlock MAGN. COIL Supply of electromagnet is incorrect FILAMENT Filament resistance out of range EXTERNAL Alarm coming from SM181x inverter 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 - Overcurrent or Undercurrent on the electromagnet - Overtemperature inside the AC unit - Incorrect wiring of filament trafo: check input connection - Open circuit (primary or secondary of filament trafo) - Filament trafo out of spec. (wrong IN/OUT current ratio) - Fuse blown on M268 board - An inverter sent the alarm: look for alarm type on the inverter File: MPS24_r2eng - May Technical note for: MPS24 page 25 of 27

27 ALARM CODES TABLE from software vers Alarm MSB bit #3 bit #2 bit #1 LSB Description Cause/Solution bit #0 MAX REV POWER MIN FWD POWER RAM Maximum set Reverse Power Exceeded Minimum set Forward Power reached Internal memory corruption The reverse power threshold has been exceeded. Check the threshold limit setting or reduce the power setting. Setting threshold to zero disable this alarm. 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. With 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 UNDERVALUE Communications interrupted Low output current detected MODING Anodic Voltage over limit ARC DETECTOR An arc in the waveguide has been detected The unit was running in remote control mode and the communication failed. Check: a) RS232 cable is connected correctly b) remove any suspend or low power mode on the PC c) disable any screen saver on the PC d) do not move the FrontPanel window on your desktop. e) Increase the communication timeout setting on the FrontPanel. 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 again A value of current set on the control table exceed the max current available: - verify the current table 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 Check magnetron antenna condition. If any signs of arcing clean and retry. page 26 of 27 File: MPS24_r2eng - May Technical note for: MPS24

28 How to order Power supplies: MPS24y.xxxjb, where: y: T = 3 x 400 U = 3 x 480 xxx: j (version code): b (interface bus code): I.e: MPS 24T = MPS 24U.xxx75 = the code used for a customized unit; 0 = standard version, for NL15245 magnetron 75 = for CWM 75L magnetron 0 or nul= standard version standard version, without bus interface, 400V version for CWM75L magnetron, 480V, no bus Cable set connecting MPS system with MW Head: Includes high voltage cable, main line cables, head cables, signals cable and plugs on psu side. p/n for MPS24T p/n for MPS24U p/n for MPS48T p/n for MPS48U p/n for MPS72T p/n for MPS72U p/n for MPS96T p/n for MPS96U p/n for MPS120T p/n for MPS120U Standard lenght is 3 mt; other lengths available on request Please specify at time of order the value of the reference signal required: 0-10 V (standard) Filament transformer: p/n FIL500F Parts included with each MPS system: Connector/plug set: 1 AC440T/U controller 1 or more SM18xx PM 740 power module according to the total power of the system (i.e. MPS24 includes no. 1 SM18xx, MPS48 includes no. 2 SM18xx, and so on) 1 bus cable (CONN# 2) 1 H. V. cable trunk to make serie connection of multiple SM module (excluded MPS24 that includes only one SM module) p/n 44SETMPS24 3 port isolator with dummy load: several models available: ask for quote and type. 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. Technical Assistance: Alter s.r.l Reggio Emilia - ITALY Tel: ; fax Web: File: MPS24_r2eng - May Technical note for: MPS24 page 27 of 27