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Manual

– TopCon TC.LAE

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2016-06-08

Using the manual

In its description the manual first provides an overview and then
discusses the details of a function or situation.

If necessary, instructions on how to perform actions are given step by
step after explanatory text, figures and tables.

This aspect is reflected in the layout, which is broken down as follows:

Fig. 2

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Summary of Contents for TopCon TC.LAE

Page 1: ...TopCon TC LAE Liquid to air heat exchanger Manual DO6410 0003 V00 90 Regatron AG Kirchstrasse 11 CH 9404 Rorschach Tel 41 71 846 67 44 Fax 41 71 846 67 77 www regatron com topcon regatron ch ...

Page 2: ...This 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 purpose of technical progress or product improvement without stating the reasons Identification Device hardware Information about the device is to be found on the type plate on the r...

Page 3: ...contents of these operating instructions to operate the device efficiently The TC LAE device is used as an Option for the TC ACS device The TC LAE is a liquid cooling device that transfers the internally generated heat energy from the attached device TC ACS out to the surrounding air To connect the TC LAE with the TC ACS device it is necessary to use the TC ACS manual too Availability of the manua...

Page 4: ...ew and then discusses the details of a function or situation If necessary instructions on how to perform actions are given step by step after explanatory text figures and tables This aspect is reflected in the layout which is broken down as follows 1 2 3 4 5 Fig 2 Example page layout of a page of the document ...

Page 5: ...e information on the item numbers used in the figure above 5 The footer contains the publication date the manual version and the current page number A short explanation of specific symbols in the manual Symbol Meaning Text in angle brackets refers to software and hardware buttons as well as tabs in the software Item numbers in descriptions in instructions on how to perform actions or in tables The...

Page 6: ...e device 11 1 4 Technical data 12 2 GENERAL INFORMATION ON SAFETY AND HAZARDS 13 2 1 Scope and applicability 13 2 2 Categorisation of the hazard areas 13 2 2 1 Personnel area 14 2 2 2 Systems and material area 14 2 2 3 Surrounding area 15 2 2 4 Transport area 15 2 2 5 Area related to interaction with the system 16 2 3 Safety pictograms used 16 3 LAYOUT AND FUNCTION 18 3 1 Function overview 18 3 1 ...

Page 7: ... 32 6 2 6 Fill up the system with coolant 33 6 2 7 Emptying the coolant from the device 39 6 3 Switching on and off the TC LAE device 44 6 3 1 Switching on the device 44 6 3 2 Switching off the device 44 7 MAINTENANCE 45 8 SUPPORT 46 8 1 Contact information 46 8 2 How to contact support 47 8 3 Determination of device information 48 8 4 Device return 48 9 APPENDIX 49 9 1 Ambient conditions 49 9 2 C...

Page 8: ... and inlets of the TC LAE and TC ACS cooling interfaces are connected together to a closed liquid cooling circuit system An additional delivered fill up set supports the coolant filling up in the system Restriction on usage The TC LAE is constructed for a single 1 to 1 connection with a TC ACS device To connect the cooling tubes in parallel or in serial with more than one TC ACS device is not allo...

Page 9: ...s voltage Fig 3 Structure of the model identifier 1 2 3 Model range The Model range has the same mains parameter Mains voltage V AC Connection order Power input Cooling power kW Frequency Type 380VAC 480 VAC 2 x L PE 200 VA 0 5 48 62 Hz TC LAE 5 400 100VAC 240 VAC L N PE 200 VA 0 5 48 62 Hz TC LAE 5 230 24 VDC DC DC PE 200 W 0 5 TC LAE 5 24 Tab 1 TC LAE Standardmodels For further information about...

Page 10: ...3 1 Overview of the front side of the device 1 Fig 4 Overview of the interfaces front side Overview of the interfaces front side 1 Main switch device rocker switch To switch on off the device For further information refer to chapter 4 page 20 Tab 2 Overview of the interfaces device front side ...

Page 11: ...nterface G1 2 for the filling hose Connect the filling hose to this 1 2 thread or to the equal threat on the top side of the filling block For further information refer to chapter 6 2 6 page 33 4 LC venting Interface G1 2 for the venting hose Connect the venting hose to this 1 2 thread or to the equal threat on the top side of the filling block For further information refer to chapter 6 2 6 page 3...

Page 12: ...ind the latest version of the TC LAE data sheet on the web site www regatron com Technical data in the manual Technical data overview of references Ambient conditions See chapter 9 1 page 49 Coolant See chapter 9 2 2 page 50 Mechanical data See chapter 9 3 page 51 Electrical data See chapter 9 4 page 53 Interface description See chapter 9 4 3 page 55 Tab 4 Technical data overview of references ...

Page 13: ...of the rigorous application of specialist electrical rules The system is subject to the Low Voltage Directive it has to be operated by adequately trained and instructed personnel 2 2 Categorisation of the hazard areas The assessment of the effects of hazards from low voltage systems with a flow of energy for feed and possibly regeneration is divided into the following areas Fig 6 Categorizations o...

Page 14: ...material area Risk of fire In case of fire electrically isolate the system immediately on the one hand to interrupt the supply of energy and on the other hand to shut down the fans Fight the fire from bottom to top in accordance with the rules in your organisation using suitable firefighting equipment CO2 fire extinguisher If possible use fire extinguishers with asphyxiation action to keep the sec...

Page 15: ...pendent air supply at long time and high concentrations of vapour and aerosols Use protective cloves which are resistant against acids and solvents and safety gloves to avoid direct skin contact 2 2 3 Surrounding area TopCon TC LAE devices are air cooled The generated heat is blown out to the rear of the TopCon TC LAE device with the aid of internal fans 2 2 4 Transport area For the transport the ...

Page 16: ...erature range Temperatures above the specified values will reduce the service life of various modules 2 3 Safety pictograms used Important information in these operating instructions is marked with the following symbols Hazard and warning information Pictogram Meaning For an immediate hazard that will result in serious injuries or fatality For an immediate hazard that can result in serious injurie...

Page 17: ...stances H302 CAUTION possible health hazard due a substance or mixture of substances H361 H373 Tab 4 Symbols included in the table can be used for more specific depiction of warning information from Tab 3 Basic hazard and warning information Instructions Pictogram Meaning Important information Tab 5 Mandatory signs that are important for the operation of the device or the software General notes Pi...

Page 18: ...changer to the six rear mounted cooling fans The cooled working liquid is then returned out through the liquid outlet TC LAE is needed for systems with significant cooling demands and without a liquid cooling system net 3 2 4 4 3 5 1 6 7 Fig 8 Airflow through the TC LAE device 1 Rear side Hot air exhaust 2 Front side Cold air intake 3 Cooling fans blow the heated air to the rear side of device 4 T...

Page 19: ...n speed varies according the controller signals 4 The pump pumps the heated liquid from the connected device through the liquid to air exchanger and back to the connected device 5 The sensors measure the temperature at the inlet of the liquid interface and give that information back to the controller 3 2 Tube connections of inlets and outlets 3 4 1 2 Fig 10 Tube connection TC LAE device and TC ACS...

Page 20: ...d the device is switched on Switch position 0 pushed the device is switched off 2 Pump operation switch Rocker switch The pump switch is enabled when the main switch 1 is switched on Switch position 1 pushed the pump starts pumping the liquid Switch position 0 pushed the pump stops pumping the liquid Tab 7 Controls on the TopCon TC LAE device For further information under the key word device addre...

Page 21: ...ns can be divided into 3 main groups Hardware options Additional hardware that is built into the device attached to the device or that can be formed from device combinations system options Software options Functions that are enabled using an enable key Interface options Additional hardware interfaces mostly with additional software or protocols In this chapter Refer to chapter Connection variants ...

Page 22: ...2 Hose diameter Inside 13 mm Outside 16 mm 3 Quick release coupling connection system option For a non drip and secure hose connection Male thread G1 2 Hose diameter Inside 13 mm Outside 16 mm 4 L piece option L piece with male thread and female thread Male thread G1 2 Female thread G1 2 Tab 5 Examples for cooling liquid connections Installing a cooling liquid connection Apply thread sealant to th...

Page 23: ... device or emptying the coolant from the TC LAE device The set contains filling hoses coolant canister with coolant and funnel For further information refer to chapter 6 1 2 page 26 For further information about the coolant filling up procedure refer to chapter 6 2 6 page 33 For further information about the coolant emptying procedure refer to chapter 6 2 7 page 39 ...

Page 24: ...vice from the front If you place the device on the rails in the rack it can be simply pushed into the rack Possible damage Due to soiling and foreign bodies at the installation location Due to a build up of heat Prevention The installation location must be free of aggressive substances as well as moisture No foreign bodies such as drilling swarf or screws are to be allowed to fall into the system ...

Page 25: ...he original shipping packaging 1 Accessories box The accessories box is placed in front of the device 3 2 Cover Upper protective cover with space on the rear side for protruding device connections etc and recesses on the front side for protruding front panel 3 TopCon TC LAE device 4 Bottom Lower protective material with space on the rear side for protruding device connections etc and recesses on t...

Page 26: ... packaging 1 Safety coolant datasheet ANTIFREEZE FLUID N Base ethylene glycol EG 2 Coolant canister Base ethylene glycol EG Volume 2 5 l ANTIFREEZE FLUID N 30 3 Funnel Supports the filling up of the coolant 4 Fill up hoses transparent 2x Commissioned with fill up nipple and clamp 5 Filling material Paper air cushions etc 6 Cardboard box Shipping packaging Tab 7 Elements of the original shipping pa...

Page 27: ...t systems In the standard design TopCon TC LAE devices are intended to be installed in standard 19 cases and switch cabinets with an external air flow In this case they are placed on rails or shelves and fastened at the points provided on the front panel 1 1 Fig 15 Fastening positions 1 of the TC LAE Number of screws For 4 U devices typically 4 x screws M6 On installation in cases or switch cabine...

Page 28: ...trical installation is to be undertaken by personnel with electrical training Never connect or disconnect electrical connections while they are live Do not open the device if it is in operation as it contains live parts Lay cables carrying high currents using an adequate cable cross section Possible harm by the coolant Danger of serious damage to health by prolonged exposure through inhalation and...

Page 29: ...1 and plug 2 For necessary installation information refer to the following chapters Position of the interface chapter 1 3 2 page 11 For the technical data refer to chapter 9 4 2 page 54 Pin definition for power supply connector see chapter 9 4 3 1 page 55 For further information about the cross section of the plug AC line connection refer to chapter 9 4 1 page 53 ...

Page 30: ...a future use Loosen the union nut 2 from the connection fitting by turning to the left via open end wrench The union nut 3 pull over the coolant hose 4 Push 5 the coolant hose with the nut over the nipple 6 of the coolant interface Try to push the hose to the nipple base Tighten strongly 7 the nut by turning to the right Repeat the procedure for the other coolant interface Fill up the coolant in t...

Page 31: ...ull away 2 the coolant hose from the nipple of the coolant interface Take the union nut from the coolant hose 3 and tighten strongly 5 on the coolant interface by turning to the right via open end wrench Push 4 the sealed rubber stopper into the connection fitting Remember that a coolant rest may be in the device so the sealed rubber stopper must be strongly pushed in the connection fitting to avo...

Page 32: ... couplings 3 and nipples 2 Procedure dis connect the quick release coupling system Pulling back the retaining ring of the quick release coupling 1 until the following procedure steps are finished For device removal Pull out the nipple 2 from the female coupling 3 For device installation Push in the nipple 2 in the female coupling 3 Release the retaining ring 1 of the quick release coupling The ret...

Page 33: ...e equipment at existing concentrations of vapour and aerosols E g the respiratory protection and protective cloves which are resistant against solvents Close coolant vessels immediately 6 2 6 1 Checklist for the fill up with coolant Prepare the coolant mixture to 30 refer to chapter 9 2 2 page 50 Prepare the filling block refer to chapter 6 2 6 2 page 34 Mount the filling hoses refer to chapter 6 ...

Page 34: ...is in the horizontal position The device is switched off Preparation A 6 mm Allen wrench is necessary Procedure Removing of the Allen screws Remove both Allen screws 2 from the top 1 of the filling block The 1 2 thread 3 appears Keep on the Allen screws Procedure Fasten the Allen screws Screw the both Allen screws 2 in the drilling holes 3 Maximum torque 5 Nm ...

Page 35: ...efer to chapter 6 2 6 2 page 34 Procedure Mounting the hoses for the filling up Mount the blue filling hose 1 in the left side of the block The hose with its mounting nipple is part of delivery Mount the venting hose 2 in the left side of the filling block The hose with its mounting nipple is part of delivery Procedure Removing of the hoses after the filling up Remove the filling hose 1 from the l...

Page 36: ...hose It is part of delivery The main switch is switched on on the front side Switch position 1 The pump switch is switched off on the rear side Switch position 0 Procedure Fill up the expansion reservoir with the cooling liquid Carefully fill in the coolant via funnel 1 and vessel After a short time the coolant level in the transparency hose will appear Finish the filling 5 at the half way of the ...

Page 37: ...pansion reservoir repeat the filling and pumping procedure according the steps before If the coolant fill up the expansion reservoir follow the following steps Switch off the device main switch on the device front side Switch position 0 Let the pump switch in position 1 switched on Remove the filling hose refer to chapter 6 2 6 3 page 35 Fasten the Allen screws in the filling block For the procedu...

Page 38: ...reservoir Procedure Check the coolant level in the internal expansion reservoir Check via a torch 1 the coolant level in the internal expansion reservoir 2 For a full filled expansion reservoir 2 with the blue coolant nothing is to do and the system can be started For a not full filled expansion reservoir 2 with blue coolant refer to the fill up procedure in chapter 6 2 6 4 page 36 ...

Page 39: ...ective equipment at existing concentrations of vapour and aerosols E g the respiratory protection and protective cloves which are resistant against solvents Close coolant vessels immediately 6 2 7 1 Checklist for emptying the coolant from device Prepare the fill up set refer to chapter 6 1 2 page 26 Prepare the filling block refer to chapter 6 2 6 2 page 34 Mount the filling hoses refer to chapter...

Page 40: ...he device is switched off Preparation A 6 mm Allen wrench is necessary Procedure Removing of the Allen screws Remove both Allen screws from the rear 1 and the top 2 of the filling block The 1 2ʺ thread appears Keep the Allen screws for the later closing Procedure Fasten the Allen screws Screw the both Allen screws 2 in the drilling holes 1 and 2 Maximum torque 5 Nm ...

Page 41: ...crews refer to chapter 6 2 7 2 page 40 Procedure Mounting the hoses for pumping out Mount the filling hose 2 in the left side of the block 3 The hose with its mounting nipple Insert the hose side without the nipple in the collection vessel Procedure Removing of the hoses after the pumping out Remove the filling hose 2 from the left side of the block Empty the content of the hose 2 into the availab...

Page 42: ...ws in the vessel 1 Switch position 1 Switch off the pump switch 4 Switch position 0 Check the coolant level in the internal expansion reservoir on the device front side For the procedure refer to 6 2 6 5 page 38 If the coolant expansions reservoir is not empty repeat the pumping out procedure according the steps before If the coolant expansion reservoir is empty follow the following steps Switch o...

Page 43: ...ure Check the coolant level in the internal expansion reservoir Check via a torch 1 the coolant level in the internal expansion reservoir 2 For a full filled expansion reservoir 2 with the blue coolant repeat the emptying procedure via checklist in chapter 6 2 7 1 page 39 For an empty expansion reservoir 2 Nothing is to do Remember that coolant level of the device is only reduced for the transport...

Page 44: ...be switched on first Then the TC ACS master device must be switched on 6 3 1 Switching on the device Switch on the main switch on the front side of the TC LAE device Main switch set to position 1 Check for switched on position 1 of the pump switch on the rear side vice Switch on the TC ACS device Switch positon 1 6 3 2 Switching off the device Switch off the TC ACS device Switch off the main switc...

Page 45: ...lycol Corrosion protection duration time 15 Years 25 mixing ratio with H2O Tab 9 Corrosion protection expectancy However the following components require maintenance interval Maintenance interval of cooling fans General at operation time All 40 000 h Maintenance work device cleaning Fan exchange Tab 10 Maintance intervall Cooling fans In dirty surroundings the maintenance interval may be reduced C...

Page 46: ...n If you compile the following information in an e mail and send this e mail to support in advance support will then have this information available already when you ring Contact data 1 Name of company The name of your company 2 Contact person Your name or the name of the person responsible for the problem in your company with whom further contact will be made 3 Contact details E mail address tele...

Page 47: ...or multi unit systems 2 Description of error Information that documents the situation and the state of the system using measured results logs scope screenshots and photographs Tab 9 Important system information for support 8 2 How to contact support Regatron AG TopCon Support Kirchstrasse 11 CH 9404 Rorschach Switzerland E mail tc support regatron ch Tel 41 71 846 67 44 Fax 41 71 846 67 77 Web www...

Page 48: ...400 VAC 0 5 A Cooling Power 5kW 20 C 10l min 250 mbar p 12345678 Fig 28 Example information on the device type serial number as well as mains data and cooling power on the TC LAE device 8 4 Device return Use the original packaging to return the device If you no longer have the device packaging at hand you can order new packaging via Regatron support For further Information of packaging of the devi...

Page 49: ...n operation 0 40 C Atmospheric humidity 0 90 non condensing Tab 10 Ambient conditions for the TopCon TC LAE device 1 With full filed ethylene glycol based coolant in a mixure of 30 9 2 Cooling 9 2 1 Cooling power Cooling power TC LAE device Cooling Power 1 5kW 20 C Flow rate max 10 l min Pressure difference Δp pout p in 250 mbar Tab 11 Cooling power TC LAE device 1 Cooling power at ambient tempera...

Page 50: ...aging of the coolant fill up set For further Information about the coolant safety datasheet contact Support according the address in chapter 8 2 page 47 9 2 3 Coolant filling quantity of the devices Coolant filling quantity for an empty device Required coolant volume TC LAE 1 45 l TC ACS 0 33 l Coolant hoses between TC ACS and TC LAE devices 0 10 l m Delivered coolant volume Quantity of the coolan...

Page 51: ...pendix 51 56 2016 06 08 9 3 Technical data mechanical 9 3 1 Dimensions Front view 465 101 8 37 5 36 8 Fig 29 Front view of TopCon TC LAE Dimensions in mm Rear view 76 5 60 19 Fig 30 Rear view of TopCon TC LAE Dimensions in mm ...

Page 52: ...TC LAE Dimensions in mm Top view 483 5 2 604 41 649 Fig 32 Top view of TopCon TC LAE Dimensions in mm Dimensions Width front panel housing 483 mm 19 443 mm Height front panel housing 176 1 mm 4 HU 173 2 mm Depth with terminals housing 649 mm 601 mm Tab 14 Information on the device dimensions ...

Page 53: ...les Regatron recommends attaching cable ferrules at the connection cables for the plugs at the interface AC line 1 2 3 a d Fig 33 Cable connections AC line Cable types 1 Flexible 2 Rigid 3 Ferrule Pay attention to the cross section of the line A π d 2 4 The mechanical specifications about cross section and the required stripping length for the according connector types can be found in the followin...

Page 54: ... LAE 5 230 TC LAE 5 24 Line voltage 380 480 VAC 100 240 VAC 24 VDC Voltage tolerance 10 10 10 0 Line frequency 48 62 Hz Input power 200 VA 200 VA 200 W Mains connection type 2 L PE L N PE DC DC PE Power factor 0 98 0 98 1 Current 0 5 A Leakage current L to PE 10 mA Tab 17 Mains connection TC LAE devices ...

Page 55: ...el TC LAE 5 400 Pin Signal I O Description 1 L1 I Phase L1 2 L2 I Phase L2 3 PE I Earth Tab 18 Pin definition mains input model TC LAE 5 400 230 VAC Variation Pin definition mains input model TC LAE 5 230 Pin Signal I O Description 1 L I Phase L1 or L2 or L3 2 N I N line 3 PE I Earth Tab 19 Pin definition mains input model TC LAE 5 230 For further information about the cross section of the connect...

Page 56: ...mains input model TC LAE 5 24 Pin Signal I O Description 1 I DC positive max 24 VDC 2 I DC negative GND 3 PE I Protected earth Tab 20 Pin definition mains input model TC LAE 5 24 For further information about the cross section of the connection mains refer to chapter 9 4 1 page 53 ...

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