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AE Techron 8500 Series, Operator'S Manual

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Contents

1 Introduction ....................................................................................................................................5

1.1 Features ................................................................................................................................

5

1.2  Configuration Options

............................................................................................................

5

2  Amplifier Unpacking and Installation

 ..............................................................................................6

2.1  Safety First ............................................................................................................................

6

2.2  Unpacking

 .............................................................................................................................

6

2.3  Check Contents .....................................................................................................................

6

2.4  8500 Series Placement .........................................................................................................

6

3  Connections and Startup

 ...............................................................................................................8

3.1  Testing Before Controlled-Current Operation 

 .......................................................................

8

3.2  Connecting the Load

 .............................................................................................................

8

3.3  Connecting the Input Signal

 ..................................................................................................

9

3.4  Other DIP Switch Settings ..................................................................................................

9

3.5  Monitor and Sense Ports ....................................................................................................

9

3.6  Connecting the AC Supply

 ....................................................................................................

9

3.7  Start-up Procedure

 ..............................................................................................................

11

4  Amplifier Operation

 ......................................................................................................................12

4.1  Front-Panel Controls and Indicators

....................................................................................

12

4.2   Back-Panel Controls & Connectors

 ....................................................................................

14

4.3   Back-Panel Safety Features

...............................................................................................

14

5  Advanced Configuration

 ...............................................................................................................15

5.1  DIP Switch Configurations

 ...................................................................................................

15

6  Applications

 ..................................................................................................................................19

6.1  Controlled-Current Operation

 ..............................................................................................

19

6.2  Driving Reactive Loads

 .......................................................................................................

22

7 Maintenance ................................................................................................................................23

7.1  Clean Amplifier Filter and Grills

 ...........................................................................................

23

8  Troubleshooting

 ...........................................................................................................................24

8.1  Introduction & Precautions

 ..................................................................................................

24

8.2  Visual Inspection

 .................................................................................................................

24

8.3  No Signal

 .............................................................................................................................

24

8.4  No LEDs Illuminated

............................................................................................................

24

8.5  Over/Under Line LED Lit

 .....................................................................................................

24

8.6  Run/Standby LED Remains Amber

 .....................................................................................

25

8.7  Amplifier Overheats (Over Temp Fault Condition)

 ...............................................................

25

8.8  Fault LED is Illuminated

 ......................................................................................................

25

8.9  Factory Service ...................................................................................................................

26

Summary of Contents for 8500 Series

Page 1: ...8500 Series Operator s Manual Wide Bandwidth High Power Digital Amplifiers Models 8508 8512 8516 and 8520 574 295 9495 www aetechron com 2507 Warren Street Elkhart IN 46516 ...

Page 2: ......

Page 3: ... of our authorized service centers of your need for warranty service you will receive an authorization to return the product for service All components must be shipped in a factory pack or equivalent which if needed may be obtained from us for a nominal charge We will take corrective actions and return the product to you within three weeks of the date of receipt of the defective prod uct or will m...

Page 4: ...re 11 4 Amplifier Operation 12 4 1 Front Panel Controls and Indicators 12 4 2 Back Panel Controls Connectors 14 4 3 Back Panel Safety Features 14 5 Advanced Configuration 15 5 1 DIP Switch Configurations 15 6 Applications 19 6 1 Controlled Current Operation 19 6 2 Driving Reactive Loads 22 7 Maintenance 23 7 1 Clean Amplifier Filter and Grills 23 8 Troubleshooting 24 8 1 Introduction Precautions 2...

Page 5: ... to driv ing reactive loads As frequencies increase the effective impedance of the load becomes a much larger part of the total load to be driven especially with inductive loads like coils However when driving reactive loads the 8500 series amplifier is capable of receiving reprocess ing and returning to the load up to 5X its rated power The result is a system capable of up to 100 kVA output while...

Page 6: ...iding it CAUTION 2 2 Unpacking Your amplifier will be delivered to the ship to ad dress enclosed in a wooden crate and transported on a special shock absorbing pallet With the addition of packaging the amplifier can weigh up to 700 pounds 318 kg To avoid serious injury and or product damage use a heavy duty lift or other suitable equipment to unpack and move the product to its place of installatio...

Page 7: ...96 8005549_3 18 21 Information subject to change 7 8508 OPERATOR S MANUAL SECTION 2 Figure 2 2 Clearance Recommendations for Amplifier Placement ...

Page 8: ...he output Never connect the output of the amplifier to any other model amplifier power sup ply signal source or other inappropriate load fire can result Figure 3 1 8500 series I O Panel back panel ELECTRIC SHOCK HAZARD Output potentials can be lethal Make connections only with AC Power OFF and input signals removed WARNING POTENTIAL SHOCK AND FIRE HAZARD Torque 3 8 nuts on output terminals to 10 l...

Page 9: ...l applica tions See the Advanced Configuration section of this manual for more informaiton Before operating the amplifier check to make sure all DIP switches are set as intended See Figure 5 1 for the factory default setting for all DIP switches 3 5 Monitor and Sense Ports The amplifier provides three additional ports on the back I O panel Current Monitor BNC connector Voltage Monitor BNC connecto...

Page 10: ...mains barrier strip as shown in Figure 3 6 See Appendix B for wiring dia grams of the complete AC power systems 6 If connecting to an AC power cord verify con nector wiring for phases neutral and safety ground Verify that proper phase neutral and safety ground connections have been made at the AC mains breaker The risk of lethal ELECTRICAL SHOCK exists when connecting AC mains Disconnect the sourc...

Page 11: ...t panel is in the ON position not depressed 3 Make sure the back panel access door is closed and the breaker switch near the bottom of the amplifier rear is in the ON position 4 Press the front panel POWER switch to turn the amplifier ON 5 Wait until the Run Standby indicator turns solid green 6 Adjust your input signal level to achieve the desired output level Figure 3 6 Three Phase AC Mains Wiri...

Page 12: ...andby mode The indicator will be lit solid am ber The amplifier will be placed in Standby when one of the following conditions occurs Figure 4 1 Front Panel Controls and Indicators 1 High Low Line error 2 Overtemp condition 3 Fault condition 4 The user presses the front panel power switch to the OFF O position In Standby mode the amplifier s low voltage trans former is energized but the high volta...

Page 13: ...ifier back panel breaker and reset or turn the breaker on if needed If the error does not clear check the voltage from the AC mains Once the fault condition has been cleared the amplifier will return automatically to Run mode If the High Low Line indicator does not turn off or if the amplifier does not return from Standby the amplifier may require servicing See the Trouble shooting section for mor...

Page 14: ...line with up to 4V of correction The Remote Sense port can be useful when the voltage at the load must be precise If the cables connecting the amplifier and the load are very long or under sized the voltage drop between the amplifier and load can be corrected up to 4V Output Terminals Connect output lines from the load to this pair of high current output terminals using 3 8 inch ring terminals 4 3...

Page 15: ...aster ampli fier module Most configuration settings can be made using these DIP switches See Figure 5 1 for DIP switch settings and descriptions To locate the Master amplifier module disconnect the amplifier from the AC source and then open 8500 Series Default DIP Switch Settings Master Amplifier Module Red Default DIP SWITCH SETTINGS UP DOWN 1 UNBALANCED INPUT ON OFF 2 BALANCED INPUT ON OFF 3 DC S...

Page 16: ...or other coils When the DC Servo DIP switch is in the UP position the DC Servo function is enabled When this switch is in the DOWN position default the DC Servo function is disabled ELECTRIC SHOCK HAZARD Follow these safety precautions before opening the amplifier s back access door Disconnect the AC power supply Wait at least 3 5 minutes after disconnecting AC power before opening the access door...

Page 17: ... is tuned with an RC network The Compensation Network 1 switch enables the factory default RC network This provides 100k ohm resistance and 2 2 nF capacitance and should be used with loads that are 75 μH to 500 μH If this default network is not adequate for your application and load the Compensation Network 1 switch can be turned off and the Compensation Network 2 switch can be used to enable a ne...

Page 18: ...ching func tion progressively increases impedance from the voltage gain as current increases up to a mami mum 0 20 ohm increase This allows the amplifier modules to operate in parallel without the use of separate ballast resistors When the Electronic Gain Matching DIP switch is in the DOWN position the function is disabled When this switch is in the UP position default Gain Matching is enabled SW ...

Page 19: ...er s ability to create the required voltage Use this mode if you want the output cur rent waveform to be like the input waveform see Figure 6 2 6 1 2 Safety and Operation Consider ations for Controlled Current Operation When an AE Techron amplifier is configured as a Controlled Current source care needs to be exercised in its operation Any voltage controlled current source should never be turned o...

Page 20: ...ode safely and effectively STEP 1 Check Amplifier Operation in CV mode We recommend that you power up and enable the amplifier in Controlled Voltage mode without at taching a load before configuring your amplifier for Controlled Current operation This will allow you to verify that the input signal and the amplifier are operating correctly Once this initial check is completed power down the amplifi...

Page 21: ...electing and enabling your choice of Com pensation Network check to ensure that the Operation Mode DIP switch is set to CC DOWN then power up the amplifier without signal input To begin testing input a square wave with a fre quency of 100 Hz to 1 kHz or a squared pulse at a low level typically 0 25 to 2 0 volts A limited rise time repetitive pulse of low duty cycle is preferred Observe the output ...

Page 22: ...eries ampli fiers are able to reuse the energy returned from reactive loads Unlike purely resistive loads loads with some reactance either capacitive or induc tive will store energy during part of a cycle and then release some of this energy back later This energy is transferred back to the load through the amplifier s power supply This allow the amplifier to deliver continuous apparent power that...

Page 23: ...he grill to release each one from the front panel 3 Remove the filter located behind the front grill 4 Using a vacuum cleaner vacuum the front ventilation grill and the grill filter 5 Using a damp cloth clean the amplifier mod ule s front panel Also use the damp cloth to clean the front grill and filter If necessary these can be immersed in warm soapy water 6 Open the back access door on the ampli...

Page 24: ...epair 8 3 No Signal Missing Output signal may be caused by one of the following 1 The Control Configuration DIP switch 7 on the Master amplifier module is set to the Follower down position This DIP switch should be set to the Master up position See the Advanced Configuration section in this manual for more information 2 A signal source is not connected to either in puts on the amplifier See the Am...

Page 25: ...low To check for ad equate airflow proceed with the following steps 8 7 2 Check for Inadequate Airflow 1 Check air filters Over time they can become dirty and worn out It is a good idea to clean the air filters periodically with a mild detergent and water 2 Visually inspect fans to assure correct op eration while amplifier is On I When an OverTemp fault occurs the amplifier fans will automatically...

Page 26: ... fees duties and or taxes Please review the Warranty at the beginning of this manual for more information All service units must be given Return Authoriza tion by AE Techron Inc before being returned Return Authorizations can be requested on our website or by contacting our Customer Service Department Please take extra care when packaging your am plifier for repair It should be returned in its ori...

Page 27: ...OFF ON ON 36 88 ON ON ON OFF ON OFF ON ON 36 72 ON ON ON OFF ON OFF ON 36 56 ON ON ON OFF ON OFF OFF ON 36 41 ON ON ON OFF ON OFF OFF OFF 36 25 ON ON ON OFF OFF ON ON ON 36 10 ON ON ON OFF OFF ON ON 35 94 ON ON ON OFF OFF ON ON 35 79 ON ON ON OFF OFF ON 35 63 ON ON ON OFF OFF OFF ON ON 35 47 ON ON ON OFF OFF OFF ON 35 31 ON ON ON OFF OFF OFF OFF ON 35 16 ON ON ON OFF OFF OFF OFF OFF 35 00 ON ON OF...

Page 28: ... OFF OFF OFF ON 30 31 ON ON OFF OFF OFF OFF OFF ON 30 16 ON ON OFF OFF OFF OFF OFF OFF 30 00 ON OFF ON ON ON ON ON ON 29 85 ON OFF ON ON ON ON ON OFF 29 69 ON OFF ON ON ON ON OFF ON 29 54 ON OFF ON ON ON ON OFF OFF 29 38 ON OFF ON ON ON OFF ON ON 29 22 ON OFF ON ON ON OFF ON OFF 29 06 ON OFF ON ON ON OFF OFF ON 28 91 ON OFF ON ON ON OFF OFF OFF 28 75 ON OFF ON ON OFF ON ON ON 28 60 ON OFF ON ON OF...

Page 29: ...OFF OFF ON OFF 22 81 ON OFF OFF ON OFF OFF OFF ON 22 66 ON OFF OFF ON OFF OFF OFF OFF 22 50 ON OFF OFF OFF ON ON ON ON 22 35 ON OFF OFF OFF ON ON ON 22 19 ON OFF OFF OFF ON ON ON 22 04 ON OFF OFF OFF ON ON 21 88 ON OFF OFF OFF ON OFF ON ON 21 72 ON OFF OFF OFF ON OFF ON 21 56 ON OFF OFF OFF ON OFF OFF ON 21 41 ON OFF OFF OFF ON OFF OFF OFF 21 25 ON OFF OFF OFF OFF ON ON ON 21 10 ON OFF OFF OFF OFF...

Page 30: ...N ON OFF OFF OFF OFF OFF 15 00 OFF ON OFF ON ON ON ON ON 14 85 OFF ON OFF ON ON ON ON OFF 14 69 OFF ON OFF ON ON ON OFF ON 14 54 OFF ON OFF ON ON ON OFF OFF 14 38 OFF ON OFF ON ON OFF ON ON 14 22 OFF ON OFF ON ON OFF ON OFF 14 06 OFF ON OFF ON ON OFF OFF ON 13 91 OFF ON OFF ON ON OFF OFF OFF 13 75 OFF ON OFF ON OFF ON ON ON 13 60 OFF ON OFF ON OFF ON ON OFF 13 44 OFF ON OFF ON OFF ON OFF ON 13 29 ...

Page 31: ...F OFF ON OFF ON ON ON ON 7 35 OFF OFF ON OFF ON ON ON OFF 7 19 OFF OFF ON OFF ON ON OFF ON 7 04 OFF OFF ON OFF ON ON OFF OFF 6 88 OFF OFF ON OFF ON OFF ON ON 6 72 OFF OFF ON OFF ON OFF ON OFF 6 56 OFF OFF ON OFF ON OFF OFF ON 6 41 OFF OFF ON OFF ON OFF OFF OFF 6 25 OFF OFF ON OFF OFF ON ON ON 6 10 OFF OFF ON OFF OFF ON ON OFF 5 94 OFF OFF ON OFF OFF ON OFF ON 5 79 OFF OFF ON OFF OFF ON OFF OFF 5 6...

Page 32: ...ON OFF 2 19 OFF OFF OFF OFF ON ON OFF ON 2 04 OFF OFF OFF OFF ON ON OFF OFF 1 88 OFF OFF OFF OFF ON OFF ON ON 1 72 OFF OFF OFF OFF ON OFF ON OFF 1 56 OFF OFF OFF OFF ON OFF OFF ON 1 41 OFF OFF OFF OFF ON OFF OFF OFF 1 25 OFF OFF OFF OFF OFF ON ON ON 1 10 OFF OFF OFF OFF OFF ON ON OFF 0 94 OFF OFF OFF OFF OFF ON OFF ON 0 79 OFF OFF OFF OFF OFF ON OFF OFF 0 63 OFF OFF OFF OFF OFF OFF ON ON 0 47 OFF ...

Page 33: ...Y STOP BUTTON 8500 FOLLOWER 8500 MASTER BACK PANEL G UNBAL BAL IMON VMON G UNBAL BAL IMON VMON AMP MODULE AMP MODULE G UNBAL BAL IMON VMON SENSE REMOTE SENSE REMOTE G SENSE REMOTE NEUTRAL GND LINE OUTPUT GND OUTPUT GND POWER CORD 3 PHASE AC OUTPUT GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ON ON ON ON ON ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 10AW...

Page 34: ...LOWER 8500 MASTER BACK PANEL G UNBAL BAL IMON VMON G UNBAL BAL IMON VMON AMP MODULE AMP MODULE G UNBAL BAL IMON VMON SENSE REMOTE SENSE REMOTE G SENSE REMOTE NEUTRAL GND LINE OUTPUT GND OUTPUT GND POWER CORD 3 PHASE AC OUTPUT GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ON ON ON ON ON ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 10AWG 4 CON SERIAL CABLE D...

Page 35: ...NBAL BAL IMON VMON AMP MODULE AMP MODULE G UNBAL BAL IMON VMON SENSE REMOTE SENSE REMOTE G SENSE REMOTE NEUTRAL GND LINE OUTPUT GND OUTPUT GND POWER CORD 3 PHASE AC OUTPUT GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ON ON ON ON ON ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 10AWG 4 CON SERIAL CABLE DB9 MALE MALE 22AWG 3CON RED SHIELD BLACK 22AWG 2CON RE...

Page 36: ...ULE AMP MODULE G UNBAL BAL IMON VMON SENSE REMOTE SENSE REMOTE G SENSE REMOTE NEUTRAL GND LINE OUTPUT GND OUTPUT GND POWER CORD 3 PHASE AC OUTPUT GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ON ON ON ON ON ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 10AWG 4 CON SERIAL CABLE DB9 MALE MALE 22AWG 3CON RED SHIELD BLACK 22AWG 2CON RED BLACK BNC 50 ohm 4 AWG B...

Page 37: ...E REMOTE G SENSE REMOTE NEUTRAL GND LINE OUTPUT GND OUTPUT GND POWER CORD 3 PHASE AC OUTPUT GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ON ON ON ON ON ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 10AWG 4 CON SERIAL CABLE DB9 MALE MALE 22AWG 3CON RED SHIELD BLACK 22AWG 2CON RED BLACK BNC 50 ohm 4 AWG BLACK 4 AWG RED BLACK GREEN WHITE 10AWG 3CON 10AWG BLAC...

Page 38: ...UTRAL GND LINE OUTPUT GND OUTPUT GND POWER CORD 3 PHASE AC OUTPUT GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ON ON ON ON ON ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 10AWG 4 CON SERIAL CABLE DB9 MALE MALE 22AWG 3CON RED SHIELD BLACK 22AWG 2CON RED BLACK BNC 50 ohm 4 AWG BLACK 4 AWG RED BLACK GREEN WHITE 10AWG 3CON 10AWG BLACK 10AWG GREEN 10AWG WHITE ...

Page 39: ...TPUT GND POWER CORD 3 PHASE AC OUTPUT GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ON ON ON ON ON ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 10AWG 4 CON SERIAL CABLE DB9 MALE MALE 22AWG 3CON RED SHIELD BLACK 22AWG 2CON RED BLACK BNC 50 ohm 4 AWG BLACK 4 AWG RED BLACK GREEN WHITE 10AWG 3CON 10AWG BLACK 10AWG GREEN 10AWG WHITE 16AWG BLACK 8520 208V WIRING...

Page 40: ...E AC OUTPUT GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ON ON ON ON ON ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 10AWG 4 CON SERIAL CABLE DB9 MALE MALE 22AWG 3CON RED SHIELD BLACK 22AWG 2CON RED BLACK BNC 50 ohm 4 AWG BLACK 4 AWG RED BLACK GREEN WHITE 10AWG 3CON 10AWG BLACK 10AWG GREEN 10AWG WHITE 16AWG BLACK 8520 400V WIRING DIAGRAM 8500 FOLLOWER G U...

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