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Device Manual

 

V04.60

TC.ACS

Full 4-Quadrant Grid Simulator
(optional Liquid to Air Heat Exchanger TC.LAE included)

Regatron AG
Feldmuehlestrasse 50
CH-9400 Rorschach
+41 71 846 67 67
www.regatron.com
[email protected]

Summary of Contents for TC.ACS

Page 1: ...anual V04 60 TC ACS Full 4 Quadrant Grid Simulator optional Liquid to Air Heat Exchanger TC LAE included Regatron AG Feldmuehlestrasse 50 CH 9400 Rorschach 41 71 846 67 67 www regatron com support regatron com ...

Page 2: ...d or distributed in any form also not for educational pur poses without the written approval of Regatron AG The information in this documentation corresponds to the development situation at the time of going to print and is therefore not of a binding nature Regatron AG reserves the right to make changes at any time for the pur pose of technical progress or product improvement without stating the r...

Page 3: ...age 12 1 3 2 5 Handling Storage Systems containing large Amounts of Energy 13 1 3 3 Mains Connection Area 13 1 3 4 Surrounding Area 13 1 3 5 Area related to Interaction with the Device 13 2 Introduction 14 2 1 Range of Application 14 2 1 1 Waveform Generator Mode 14 2 1 1 1 Basic Waveform Generator Mode 14 2 1 1 2 Full Waveform Generator Mode Option 14 2 1 2 Amplifier Mode 14 2 1 3 Load Simulation...

Page 4: ...3 Case Installation 28 4 4 Electrical Installation 29 4 4 1 Safety Advice 29 4 4 2 Prerequisites 30 4 4 2 1 Correct Size of Cables and Cable Ends 30 4 4 2 2 Electromagnetic Compatibility of Cables 31 4 4 3 Procedure 31 4 5 Connecting a Cooling System 32 4 5 1 Introduction 32 4 5 2 Requirements to a Cooling System 32 4 5 2 1 Specifications of the internal Heat Exchangerer 32 4 5 2 2 Requirements to...

Page 5: ...ing the Firmware 43 7 1 3 Replacing the Batteries of the Real time Clock in the Controller Board 43 7 2 Support 44 7 2 1 How can you contact Regatron Customer Support 44 7 2 2 What does Regatron Customer Support need to know 44 7 2 2 1 Contact Information 44 7 2 2 2 Device Information 45 7 2 2 3 Problem Description 45 8 Option Senseboard TC ACSUSense 46 8 1 Application 46 8 2 Interfaces 46 9 Optio...

Page 6: ...view 52 11 3 2 Case Installation 53 11 3 3 Setting up the Cooling Circuit 53 11 3 4 Connecting the TC LAE to the Mains 53 11 3 5 Filling of Cooling Liquid 54 11 3 5 1 Safety Advice 54 11 3 5 2 Prereqisites 54 11 3 5 3 Procedure 55 11 3 6 Starting the Pump of the TC LAE 56 11 3 6 1 Safety Advice 56 11 3 6 2 Prerequisites 56 11 3 6 3 Procedure 56 11 3 7 Emptying of Cooling Liquid 57 11 3 7 1 Safety ...

Page 7: ...6 12 5 1 Definitions 62 12 5 1 1 Direction of Transmission 62 12 5 1 2 Data Types 62 12 5 2 General Configurations 62 12 5 3 Message Attributes and their possible Values 62 12 5 4 Signal Attributes and their possible Values 63 12 5 4 1 Definition of TX Signals 64 12 5 4 2 Definition of RX Signals 65 ...

Page 8: ...ion which if not avoided could result in death or serious injury CAUTION Hazardous situation which if not avoided could result in minor or moderate injury CAUTION Hazardous situation which if not avoided could result in damage to the product or other items in its surroundings Hazard due to high voltage Hazard due to suspended load Hazard due to hot surface Hazard due to a substance or mixture of s...

Page 9: ...oid serious injuries or significant damage only appropriately qualified personnel who are familiar with industrial electrical power supplies are allowed to work on the devices These individuals must carefully read these operating instructions prior to installation and commissioning and follow the safety instructions Electronic devices are in principle not fail safe The user is responsible for ensu...

Page 10: ... batteries Verify the voltage free status by measurement Connect to earth Report and instruct Work in the vicinity of live parts In these circumstances an increased hazard potential is to be expected Minimize the risks by means of Guards Covers Insulating encapsulation cladding Imposed separation by means of mechanical features protective grilles Supervision reporting Work on live equipment It is ...

Page 11: ...e destruction or fire on parts of the system The usage of appropriate DC contactors as isolating devices in DC circuits is recommended In case of doubt contact the related manufacturer Take into consideration that the protective devices on the TC ACS system cannot detect an arc as a fault condition as this situation may be a required function 1 3 1 4 Mechanical Injury As on all electrical installa...

Page 12: ...n objects in the immediate area Keep data carriers and PC based measuring environments at an adequate distance from live wires to prevent interference and data loss Protect highly sensitive sensors and instruments Test effects on communication networks in particular radio networks Make individuals with electronic implants aware that implants may be affected 1 3 2 3 Noise and Noise Level The induct...

Page 13: ...breakers to trip Here a modern make of residual current circuit breaker is to be used that will tolerate such asymmetries during the switch on process 1 3 4 Surrounding Area TC ACS power supply devices are generally forced air cooled some are water cooled in addition Despite the very high efficiency a power loss occurs in the components that must be dissipated in the form of heat to the surroundin...

Page 14: ...asic waveform generator mode the TC ACS device simulates a grid I e it generates a signal waveform that resembles the signal given by a grid i e a sine wave This signal can be configured and controlled via ACSControl 2 1 1 2 Full Waveform Generator Mode Option In the full waveform generator mode the TC ACS device simulates a grid or any other kind of electrical source I e it generates signal funct...

Page 15: ...lternating grids change between feeding mode and regenerative mode according to their reactive power by phase shifting between voltage and current 2 1 4 1 Feeding Mode positive Power In the feeding mode energy flows from the line to the device under test DUT 2 1 4 2 Regenerative Mode negative Power In the regenerative mode energy flows from the device under test DUT to the line 2 2 Control Interfa...

Page 16: ... 4 2022 16 66 2 3 Model Identifier For a specific TC ACS device the model identifier holds the following information Fig 1 Model identifier example The model identifier is given on the type plate on the rear of the device Detailed information on your product variant is given in the related data sheet ...

Page 17: ...erfaces displays and controls on the front side For more information on any of the individual interfaces see the related data sheet There is a specific data sheet with respect to the optional interfaces Interfaces displays and controls on the front side 1 Device address selection switch NOTE The selection switch is currently not used 2 LED indication indicates the current status of the device for ...

Page 18: ...OTE This is an intermediate state After successfully powering up the standby state is automatically assumed Standby The device is running There is no energy flow on the load side Ready The device is running and the intermediate circuit is charged There is no energy flow on the load side Switched on The device is running and power is supplied to drawn from the load There is energy flow on the load ...

Page 19: ...Controls and Displays Interfaces on the Rear Side REGATRON Performance Precision Quality TC ACS Device Manual V04 60 26 4 2022 19 66 3 2 Interfaces on the Rear Side 3 2 1 Overview Fig 3 Interfaces on the rear side ...

Page 20: ...be configured via the software ACSControl see the related software manual X609 Analog input and output for general usage NOTE To use the interface you need a specific plug Manufacturer PHOENIX CONTACT AG Order number 1430048 REGATRON item number 452 01244 For the pin definition see 3 2 3 4 Outlet interface for cooling circuit thread G1 2 with connection fitting 5 X10 AC line input terminal L1 L2 L...

Page 21: ...he interface X112 2 see 3 2 1 3 2 2 2 General Function Description When the TC ISR is triggered it disconnects the power electronics of the TC device from its controller electronics This way the energy flow is interrupted while the device remains accessible for communication 3 2 2 3 Type of Connection Fig 4 Type of connection of interface X112 2 D Sub 9 pin socket As the TC ISR operates on two cha...

Page 22: ...ummy plug X112 for the interface X112 2 Pin Signal I O Description 1 24 VDC O Low voltage internal supply 24 VDC 2 RELAY2 I Coil a of ISR relay 2 3 NC I O Relay contact NC 4 RELAY1 I Coil a of ISR relay 1 5 COMMON I O Common contact 6 GND O Low voltage 0 VDC 7 RELAY2 I Coil b of ISR 2 8 9 RELAY1 I Coil b of ISR 1 Cover Shield Cable screen tied to earth PE internally The polarity of relay coil pins...

Page 23: ...Displays Interfaces on the Rear Side REGATRON Performance Precision Quality TC ACS Device Manual V04 60 26 4 2022 23 66 3 2 2 6 Application Example Category 1 PL c Fig 6 Wiring diagram using a two channel external safety loop ...

Page 24: ...s Interfaces on the Rear Side REGATRON Performance Precision Quality TC ACS Device Manual V04 60 26 4 2022 24 66 3 2 2 7 Application Example Category 3 PL e Fig 7 Wiring diagram using an external safety module two channel safety loop ...

Page 25: ... 3 AIN3 Analog input 3 filtered or unfiltered 4 AIN4 Analog input 4 filtered or unfiltered 5 GNDA_ISO Analog ground 6 10V_ISO 10V reference voltage 7 10V_ISO 10V reference voltage 8 GNDA_ISO Analog ground 9 AOUT1 Analog output 1 unfiltered 10 AOUT2 Analog output 2 unfiltered 11 AOUT3 Analog output 3 unfiltered 12 AOUT4 Analog output 4 unfiltered Measurands may be configured via the software ACSCon...

Page 26: ...est 4 9 DANGER Electric shock Avoidance Without the optional discharge feature XCDBox mobile operation is not permitted Connecting an external Signal Generator is necessary only if you want to operate the TC ACS device in Amplifier Mode see 2 1 2 For installing and commissioning the Option Liquid to Air Heat Exchanger TC LAE see 11 3 if necessary The TC ACS device is to be used exclusively as a bu...

Page 27: ... provided in front of the open door This is independent of the 850 mm distance Distance at the rear to the nearest wall or large surface area body 850 mm For access to the rear as well as for exhaust of the cooling air NOTE If there is a cabinet door an escape route of 600 mm width must be provided behind the open door This is independent of the 850 mm distance Environmental conditions Maximum alt...

Page 28: ...ue to soiling and foreign bodies at the installation location Due to a build up of heat Avoidance The installation location must be free of conductive and aggressive substances as well as moisture No foreign bodies such as drilling swarf or screws are to be allowed to fall into the system The site conditions see technical datasheet must be met The ventilation openings on the front panel and rear w...

Page 29: ...ctric shock Avoidance For secure grounding the device must be connected to a grounding network of type TN TT or IT systems are not permitted CAUTION Possible damage to the device Due to conductive aggressive substances in the installation location Due to a larger amount of moisture in the installation location Due to foreign objects within the system Avoidance If necessary clean the installation l...

Page 30: ...ble ends rigid cable ends cable ferrules In any case the cable ends must meet the following conditions regarding their cross section and their stripping length Fig 9 Cable end with diameter d and stripping length a Cables carrying high currents must have an adequate cable cross section area If necessary refer to your national standards and the information on the type plates in order to determine t...

Page 31: ...ology earthing suitable for EMI of the device 4 4 3 Procedure To electrically install the TC ACS do the following Connect the mains via the X10 AC line input terminal see 3 2 1 Connect the load to the X20 AC load output terminal see 3 2 1 Connect the earthing connector PE of the X20 AC load output terminal to earth Connect the additional earthing stud on the rear of the device see 3 2 1 to earth C...

Page 32: ...eat Exchangerer The Option Liquid to Air Heat Exchanger TC LAE is designed to be used as an external cooling system with the TC ACS Any other external cooling system has to to meet specific requirements see 4 5 2 CAUTION Possible damage to the device Due to condensation inside the device or on the supply tube Avoidance Keep the inlet temperature of the cooling liquid at a temperature level above t...

Page 33: ...ating with foreign substances and as a result degradation of the heat transfer Due to the deposition of foreign bodies on the heat exchanger surfaces Avoidance Never use deionised water as a cooling liquid Use fine filters to keep back fine sludge particles Meet the following requirements Requirements to the Cooling Liquid Parameter Unit Limit value ph value 6 8 Total hardness dH 2 15 Carbonate ha...

Page 34: ... cooling liquid on site at the rear side of the device Pressure difference Flow rate 0 02 bar 2 5 l min 0 04 bar 3 5 l min 0 07 bar recommended 5 l min 0 12 bar 7 l min Connection with quick release isolating valves Heat sink with internal pipework ready for connection of cooling liquid on site at the rear side of the device plus 2 quick release isolating valves on customer request inside diameter...

Page 35: ... interface X605 see 3 2 4 7 Connecting an external Signal Generator In order to be operate the TC ACS device in Amplifier Mode you need to connect an external signal generator to the software ACSControl You can connect the external signal generator via the interfaces X610 X611 and X612 on the rear of the TC ACS device see 3 2 The software ACSControl is included in the scope of delivery If you do n...

Page 36: ...accidental contact No maintenance work must be carried out Warning signs must be used and the area must be cordoned off CAUTION Possible damage to the device Due to condensation inside the device or on the supply tube of the cooling system Avoidance If there is any water condensation it will show on the rear side of the device especially between the input and the output interface for cooling circu...

Page 37: ...started see 4 8 The software ACSControl is running and it is connected to the TC ACS The TC ACS has no error 4 9 2 Procedure To run a function test do the following via the software ACSControl Open the tab Basic Waveform Generator Specify amplitude voltages frequency and number of phases in the respective fields In the toolbar click on On the front of the TC ACS the LED for VOLTAGE ON see 3 1 2 li...

Page 38: ...e principle states that necessarily one and only one device in a system is considered the master All other devices within the system are considered slaves Fig 11 Multi device system of 4 devices with one master and three slaves Here the master device is the communication interface between the external control and the slave devices i e it passes on the parameter input values via the internal system...

Page 39: ...from the master device and runs through all slave devices serially each from interface X602 to X601 or vice versa Both ends are terminated by the termination resistor RS 485 EtherCAT The connection runs from the signal output of the Ethercat extension Beckhoff EK1110 through the master device and then through all slave devices serially each from interface 604 ECAT OUT to interface 603 ECAT IN An S...

Page 40: ...ing slings Use the eyelet rings to lift the TC ACS Make sure that the angle between hoist and device top side is greater than 72 Pay attention to tipping angle 85 during the cabinet transport via forklift CAUTION Possible damage Before transporting a TC ACS the following points are to be regarded All cables must be removed Protruding parts such as main switch controls and fan covers must not be da...

Page 41: ...ed in a standard packaging Fig 13 Standard shipping packaging 1 Box of accessories 2 Upper cover 3 TC ACS device 4 Lower protective support 5 Cardboard box 6 Transport pallet You can order new shipping packaging from Regatron Customer Support Here you can also get additional package protection for the front and the sides if necessary e g for overseas shipping ...

Page 42: ...evice Manual V04 60 26 4 2022 42 66 6 3 Disposal When disposing a TopCon power supply the following points are to be regarded Electrical equipment is too valuable for household waste Disposal with due care for the environment On the disposal of electrical equipment comply with national laws ...

Page 43: ...ing the Accuracy of the Output Values The accuracy of the device output values can be adjusted by Regatron AG If necessary please contact support regatron com 7 1 2 Updating the Firmware You can update the firmware of the TC ACS device via the software ACSControl if necessary For more information see the related software manual 7 1 3 Replacing the Batteries of the Real time Clock in the Controller...

Page 44: ...ow To help you in a most efficient way Regatron Customer Support needs the following information Contact Information 7 2 2 1 Device Information 7 2 2 2 Problem Description 7 2 2 3 7 2 2 1 Contact Information Contact information is the following Name of your company Name of a contact person i e the person with whom further contact will be made E mail address telephone number extension of the contac...

Page 45: ...evice is controlled further information may be provided by the software or by the human machine interface TC HMI 7 2 2 3 Problem Description A problem description should document the actual technical problem using measured results logs photographs screenshots etc In specific answers to the following questions would be of help How exactly is the device applied What kind of load is connected What is...

Page 46: ...voltage directly at the load Thus the voltage can be controlled more accurately and the voltage drop over the load cables can be compensated 8 2 Interfaces Fig 14 Senseboard optional Interfaces of the senseboard 1 X606 Service interface RS232 only used for software update NOTE This interface requires a cable with braided shield 2 X614 Digital input interface currently not supported 3 X615 Sense in...

Page 47: ...nitions see 9 2 1 2 3 X642 Digital input for pin definitions see 9 2 1 2 4 X645 Auxiliary voltage supply 24 V for pin definitions see 9 2 1 4 Order of Pins Pin Signal Description 1 Relay 8 14 Relay 8 NO parallel to digital output 8 2 Relay 8 12 Relay 8 NC parallel to digital output 8 3 Relay 8 11 Relay 8 COM parallel to digital output 8 4 Relay 7 14 Relay 7 NO parallel to digital output 7 5 Relay ...

Page 48: ...4 Digital output 4 5 Output 5 Digital output 5 parallel to relay 5 6 Output 6 Digital output 6 parallel to relay 6 7 Output 7 Digital output 7 parallel to relay 7 8 Output 8 Digital output 8 parallel to relay 8 Order of Pins Pin Signal Description 1 Input 1 Digital input 1 2 Input 2 Digital input 2 3 Input 3 Digital input 3 4 Input 4 Digital input 4 5 Input 5 Digital input 5 6 Input 6 Digital inpu...

Page 49: ... I O adaptor front from right to left bold letters indicate the status of delivery The input and output of the TC ACS X609 adaptor can be filtered by a low pass filter if necessary see 10 4 Interfaces on the front of the analog I O adaptor Interface Type Pins of X609 of TC ACS Signal Description X631 8 pin multipole connector Pins 1 8 AIN1 Analog input 1 filtered or unfiltered AIN2 Analog input 2 ...

Page 50: ...o transient in step response Whether or not an individual signal is filtered is determined by the position of a related jumper inside the adaptor box Here the jumpers JU1 4 belong to the inputs AIN1 4 and the jumpers JU5 8 belong to the outputs AOUT1 4 Each jumper can be set to one of two positions 1 2 or 2 3 Here the following holds Jumper is set to position 1 2 signal is filtered Jumper is set t...

Page 51: ...The heat energy generated in the TC ACS is transported to the TC LAE via cooling liquid Here the heat energy is transferred to the surrounding air via an integrated liquid to air heat exchanger and the rear mounted cooling fans The cooled cooling liquid is then returned to the TC ACS 11 1 2 Model Identifier For a specific TC ACS device the model identifier holds the following information Fig 17 Mo...

Page 52: ... up the Cooling Circuit 11 3 3 Connecting the TC LAE to the Mains 11 3 4 Filling of Cooling Liquid 11 3 5 Starting the Pump of the TC LAE 11 3 6 Interfaces controls and displays rear side 1 Interface Outlet thread G1 2 2 Interface Inlet thread G1 2 3 Interface Fill thread G1 2 NOTE For practical reasons these interfaces are duplicated on the top 4 Interface Ventilate thread G1 2 5 Mains connection...

Page 53: ...2 to outlet interface for cooling circuit of the TC LAE see 11 2 11 3 4 Connecting the TC LAE to the Mains To connect the TC LAE to the mains do the following Connect the TC LAE to the mains via the mains connection on the rear side see 11 2 CAUTION Possible damage Due to soiling and foreign bodies at the installation location Due to a build up of heat Avoidance The installation location must be f...

Page 54: ...11 3 7 for Emptying of Cooling Liquid WARNING Possible harm by cooling liquid According to the GHS the recommended cooling liquid Antifrogen N 30 is classified as being hazardous in the following ways Harmful if swallowed H302 May cause damage to organs through prolonged or repeated exposure H373 Avoidance When handling with cooling liquid do the following pay attention to the warning signs on the...

Page 55: ...The cooling liquid fills the internal circuit of the TC LAE device At some point it appears in the venting hose i e the one attached to the interface Ventilate Once the cooling liquid has reached half way of the venting hose stop filling Start the pump of the TC LAE see 11 3 6 The cooling liquid is being pumped into the greater cooling circuit including the TC ACS device When no more cooling liqui...

Page 56: ...e 11 3 3 The TC LAE is connected to the mains see 11 3 6 11 3 6 3 Procedure To start the pump of the TC LAE do the following Switch on the pump switch on the rear side 11 2 Switch on the pump switch on the front side 11 2 DANGER Electric shock Avoidance Device and load must be isolated against accidental contact No maintenance work must be carried out Warning signs must be used and the area must b...

Page 57: ...pumped out of the cooling circuit and flows into the vessel As soon as no more cooling liquid flows into the vessel switch off the pump WARNING Possible harm by cooling liquid According to the GHS the recommended cooling liquid Antifrogen N 30 is classified as being hazardous in the following ways Harmful if swallowed H302 May cause damage to organs through prolonged or repeated exposure H373 Avoi...

Page 58: ...r to make sure that there is enough cooling liquid in the cooling circuit do the following in regular intervalls of 6 month Visually check the filling level of the cooling liquid in the internal expansion reservoir here highlighted pink If the filling level has fallen below the minimum level marked on the expansion reservoir fill up the cooling liquid see 11 3 5 ...

Page 59: ...us for the communication between the TC ACS device and other devices The digital I O interface X654 provides additional digital inputs and outputs which are programmable via ACSControl Generally to a CAN bus the following applies The maximum possible bus length depends on the baud rate e g 30 m 1 Mbit s 100 m 500 Kbit s It is possible to connect 32 bus members In case of distance reduction and tra...

Page 60: ...hrough 7 CAN H I O Signal Dominant High 8 O n c signal will be looped through 9 CAN V n c signal will be looped through Cover Shield Connected to earth Order of Pins Pin Signal Description 1 Input 1 Digital input 2 Output 1 Digital output 3 Input 2 Digital input 4 Output 2 Digital output 5 Input 3 Digital input 6 Output 3 Digital output 7 Input 4 Digital input 8 Output 4 Digital output 9 Input 5 D...

Page 61: ...h 16 bit The length of a signal may vary between 16 and 64 bit depending on the used data type The number of configurable signals in a message may be different because the payload has a maximum length of 64 bit Here a message can be configured with respect to the following attributes CAN ID DLC data length code number of bytes of payload Type of message i e RX message receives a message TX message...

Page 62: ...3 decimal places signal factor 1 0 1 0 01 0 001 or a multiplication of the signal value with 10 100 or 1000 are default configurations Is this not sufficient then up to 3 customised signal factors can be configured There are no limitations for the configurable values CAN ID Valid ID s are 0 0x7FF 29 bit identifier is currently not supported A received message with an ID greater than 0x7FF would be...

Page 63: ...al factor It can be used to represent the number of decimal places or to multiply the signal value with low accuracy requirements in a 16 bit signal which would require at least a 32 bit signal Uint32 Sint32 Float32 0 to 3 decimal places signal factor 1 0 1 0 01 0 001 or a multiplication of the signal value with 10 100 or 1000 are default configurations Is this not sufficient then could be configu...

Page 64: ...power VA phase L1 ActActivePowerPhaseL1 Actual active power W phase L1 ActReactivePowerPhaseL1 Actual reactive power var phase L1 ActSenseVoltagePhaseL1 Actual sense voltage Vrms phase L1 ActVoltagePhaseL2 Actual voltage V phase L2 ActCurrentPhaseL2 Actual current A phase L2 ActApparentPowerPhaseL2 Actual apparent power VA phase L2 ActActivePowerPhaseL2 Actual active power W phase L2 ActReactivePo...

Page 65: ...top 3 discharge 4 clear error 99 reset SetSynchronisation Enable Synchronous Mode only possible if TC ACS is stopped Disable Synchronous Mode is always possible Bit 0 Phase A L1 Bit 1 Phase B L2 Bit 2 Phase C L3 SetFuncGenCommand Set Waveform Generator command 0 none 1 stop 2 start 3 discontinue 4 continue 5 pause 6 resume 7 block change 99 Reset Waveform Generator configuration SetFuncGenCreateBl...

Page 66: ...block Bit 1 Set trigger set the trigger output on a block change to this block Bit 2 Sync to Grid Select phase for Synchronous Mode enabling Synchronous Mode see signal SetSynchronisation Bit 3 Phase failure Power output is switched to high impedance for this block Bit 4 15 Res Uint16 Signal factor 1 SetFuncGenBlockDuration Block duration time s 0 duration time 0 duration time is infinite Sint16 S...

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