REGATRON TopCon TC.LAE User manual

TopCon TC.LAE
Liquid to air heat exchanger
Manual
DO6410.0003 V00.90
Regatron AG
Kirchstrasse 11
CH-9404 Rorschach
Tel [phone]
Fax [phone]
www.regatron.com
[email protected]

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General information
© 2016 Regatron AG
This document is protected by copyright.
All rights, including translation, re-printing and duplication of this manual
or parts of it, are reserved. No part of this document is allowed to be
reproduced or processed using electronic systems, copied or distributed
in any form (by photocopying, microfilming or any other process), also
not for educational purposes, without the written approval of Regatron
AG.
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 rear
side of the TopCon TC.LAE device.
LiquidAir HeatExchanger Unit
TC.LAE.5.400
1 x 400VAC 0.5 A
CoolingPower: 5kW 20 °C 10l/ min 250mbar
p:
12345678
Fig. 1 Example - information about the device type, serial number as well
as input and output data of the TopCon TC.LAE device.

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Manufacturer
Information on the manufacturer
Regatron AG
Tel [phone]
Kirchstrasse 11
Fax [phone]
CH-9404 Rorschach
www.regatron.com
Switzerland
[email protected]
Instructions
Version overview
Operating instructions
Manual - TopCon TC.LAE; V00.90; 08.06.2016
Tab.1 Subject to technical change without notice.
General information about the manual
Purpose of the manual
This manual provides information on the usage of the TopCon TC.LAE
device. Familiarise yourself with the 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 manual
The manual must be available at all times to the personnel who are
operating the device.
Manual changes
The TopCon TC.LAE is a new product that will change as it develops.
There may therefore be changes in operation and the scope of
operation.
You will find the latest version of the manual on the web site
www.regatron.com.

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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:
1
2
3
4
5
Fig. 2 Example page –layout of a page of the document.

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-1- The header
… contains the title of the instructions, the chapter numbers and
chapter headings with the related sub-chapters so that you do not lose
the overview even in the midst of explanations that cover several
pages.
-2- Informative text
… contains important notes, conditions for specific situations and
introduces you to specific topics.
-3- Figures
… say more than words to illustrate the majority of the topics. Important
details within the figure are referred to using item numbers, boxes and
arrows.
-4- Tables
… provide the information in concise form for reference and provide
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 dot is used to mark lists and instructions for
performing actions.
The result arrow marks the description of a
consequence of an action.
The double arrow marks preventive instructions in
information on hazards.
The single arrow is used as a result or reference
arrow in tables.
11
Item numbers with and without reference lines in
figures refer to important details.
Tab. 2 Explanation of symbols in the document.

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Table of contents
GENERAL INFORMATION.................................................................................................2
Identification .................................................................................................................................................... 2
General information about the manual.......................................................................................................... 3
TABLE OF CONTENTS......................................................................................................6
1. PRODUCT DESCRIPTION ..........................................................................................8
1.1. Product usage and restrictions......................................................................................................... 8
1.2. Features............................................................................................................................................... 9
1.2.1. Part of standard delivery.............................................................................................................. 9
1.2.2. Description of the model identifier ............................................................................................... 9
1.2.3. Model range................................................................................................................................. 9
1.3. Position of the interfaces................................................................................................................. 10
1.3.1. Overview of the front side of the device..................................................................................... 10
1.3.2. Overview of the rear side of the 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
3.1.1. The scope .................................................................................................................................. 18
3.1.2. Internal device controlling.......................................................................................................... 19
3.2. Tube connections of inlets and outlets.......................................................................................... 19
4. CONTROLS AND DISPLAYS (STANDARD) ............................................................20
5. OPTIONS AND VARIATIONS....................................................................................21
5.1. Overview............................................................................................................................................ 21
5.2. Connection variants –Examples.................................................................................................... 22
5.3. A coolant fill-up set (Option) ........................................................................................................... 23

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6. INSTALLATION AND COMMISSIONING..................................................................24
6.1. Device transport and installation.................................................................................................... 24
6.1.1. Un-/pack sequence –TC.LAE standard packaging................................................................... 25
6.1.2. Unpack sequence –Coolant fill-up set (Option)........................................................................ 26
6.1.3. Disposal with due care for the environment............................................................................... 27
6.1.4. Case installation/delivery with case........................................................................................... 27
6.2. Device dis- /connections ................................................................................................................. 28
6.2.1. Safety information...................................................................................................................... 28
6.2.2. Mains connection....................................................................................................................... 29
6.2.3. Liquid cooling –device connection............................................................................................ 30
6.2.4. Liquid cooling –device disconnection ....................................................................................... 31
6.2.5. Dis-/connect a quick release coupling system (Option)............................................................. 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. Cooling .............................................................................................................................................. 49
9.2.1. Cooling power............................................................................................................................ 49
9.2.2. Coolant....................................................................................................................................... 50
9.2.3. Coolant filling quantity of the devices ........................................................................................ 50
9.3. Technical data –mechanical........................................................................................................... 51
9.3.1. Dimensions ................................................................................................................................ 51
9.3.2. Weight........................................................................................................................................ 53
9.3.3. Liquid cooling –interface........................................................................................................... 53
9.4. Technical data –electrical............................................................................................................... 53
9.4.1. Cross-section –Cable connections AC line............................................................................... 53
9.4.2. Mains connection....................................................................................................................... 54
9.4.3. Interfaces –pin definition........................................................................................................... 55

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1. Product description
1.1. Product usage and restrictions
Operation of a TC.LAE device
TC.LAE is a reverse cooling liquid to Air unit.
The outlets 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 allowed.

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1.2. Features
1.2.1. Part of standard delivery
A TC.LAE device according the Model range.
For further information refer to the type plate in figure Fig. 1 , page 2.
1.2.2. Description of the model identifier
TC
TopCon family
Device type
Cooling power
LAE 5
.. . 400 Mains voltage
Fig. 3 Structure of the model identifier.
1.2.3. Model range
The Model range has the same mains parameter:
Mains voltage (VAC)
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 the technical data, refer to chapter 9.4.2, page 54.
The models TC.LAE.5.400 and TC.LAE.5.230 are currently available.

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1.3. Position of the interfaces
1.3.1. 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.

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1.3.2. Overview of the rear side of the device
1 2 3 4 5
7
6
Fig. 5 Overview of interfaces - rear side.
Overview of interfaces - rear side
1
LC inlet , Interface nipple G1/2”
Non drip quick release coupling nipple to connect to the outlet of a device,
which will be cooled by the TC.LAE device.
For further information about the connection procedure,
refer to chapter 6.2.3, page 30.
2
LC outlet, Interface coupling G1/2”
Non drop quick release coupling to connect to the inlet of a device,
which will be cooled by the TC.LAE device.
For further information about the connection procedure,
refer to chapter 6.2.3, page 30.
3
LC filling, interface 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 33.
5
Mains connection, 3-pin socket
To connect the mains plug.
Pay attention to the label on the socket to get the according device variation
connection order.
For further information in the technical data,
refer to chapter 9.4.3.1, page 55 .
6
Pump operation switch, rocker switch
To switch on/ off the coolant pump.
For further information refer to chapter 4, page 20.
7
Earth , connection bolt M6
Connects the device to the protective earth.
Tab. 3 Overview of interfaces –device rear side.

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1.4. Technical data
The TopCon TC.LAE is a new product that will change as it develops.
The technical data may therefore change.
You will find 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.

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2. General information on safety and hazards
2.1. Scope and applicability
The general information applies to all TopCon low-voltage systems. The
user(s) has (have) the obligation to avoid the risks and hazards
mentioned by means 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 of the hazard areas.
The hazard areas stated are explained in the sub-chapters of this
chapter that follow.

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2.2.1. Personnel area
The utmost attention is to be paid to the hazards for individuals. There
are various risks and hazards, of these the most important are
mentioned here.
Electric shock
A low-voltage system can produce electrical potentials that can be
dangerous or even fatal for individuals. During work on the systems the
following guidelines are to be observed:
a) Work in electrically isolated state
This is the recommended way of working, it should be rigorously
applied during all connection and wiring work. Follow the rules:
1. Electrically isolate
2. Secure against switching back on.
3. Short-circuit
4. Connect to earth
5. Report and instruct
2.2.2. Systems and 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 secondary damage low.
Noise and noise level
The fans on the TC.LAE produce a lower or higher noise level
dependent on the temperature of the heat sink. However, in the
immediate vicinity of the cabinet this noise is under the tolerance limit
that would make acoustic protection equipment necessary.
The usage of acoustic protection equipment or acoustic insulation
measures can, however, be necessary in specific circumstances.
Mechanical damage
Incorrect operation of the systems can result in mechanical damage to
the downstream equipment and systems.

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Chemical risk of injury
While handling with coolant, open doors and windows and ensure the
room is well ventilated also on the ground level.
Avoid work which leads to the formation of aerosols.
Use, if necessary the personal safety equipment:
Use the respiratory protection at short time and existing low
concentrations of vapour and aerosols.
Use breathing apparatus with independent 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 TopCon TC.LAE device there are no further
transport and positioning aids required, e.g. carrying handles.
Fig. 7 View of the TC.LAE device from the front.
If you place the rear side of the device on the rails in the rack, it can be
simply pushed into the rack.

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2.2.5. Area related to interaction with the system
Compliance with the design data for the specific system is a condition
for malfunction-free operation.
Load systems operated using a TC.LAE can have significant effects on
the power source. The following points are to be noted.
The maximum temperature specified is not allowed to be
exceeded.
The system is always to be operated within the permissible
temperature 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 injuries or fatality.
For a possibly hazardous situation that can
result in serious injuries or fatality.
For a possibly hazardous situation that could
result in damage to the product or another
item in its surroundings.
Tab. 3 Basic hazard and warning information.
DANGER
WARNING
CAUTION
CAUTION

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Further warning and hazard information
Pictogram
Meaning
DANGER, WARNING or CAUTION due to
electrical power
DANGER, WARNING or CAUTION related to
suspended load
DANGER, WARNING or CAUTION due
heated areas
health hazard due a substance or mixture of
substances (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
Pictogram
Meaning
Tip, for working efficiently with the device.
Tab. 6 Additional information, to find any important information quickly.

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3. Layout and function
3.1. Function overview
3.1.1. The scope
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. It receives the heat energy via a tube connected to the
liquid inlet and transfers the heat energy via a heat exchanger 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
67
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- The liquid to air exchanger transfers the internally heated
liquid to the surrounding air.
-5- Prevent air short circuit.
-6- Depth to the front wall: ≥100 mm.
-7- Depth to the rear wall: ≥100 mm.

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3.1.2. Internal device controlling
Control
Power supply
24 V
DC
Mains
Temp.
Speed
1
2
6 x Fan
Pump
4
3
5
TC.LAE
Fig. 9 Airflow through the TC.LAE device.
-1 The power supply supports all components with 24 VDC.
-2- The controller controls the fan speed according the
measured temperature by the sensors -5-.
-3- Cooling fans blow the heated air to the rear side of device.
The fan 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 device for a closed
cooling circuit.
The outlet of TC.ACS -1- is connected -3- to inlet of TC.LAE -2-.
The inlet of TC.ACS -1- is connected -4- to outlet of TC.LAE -2-.
For further information about the connection,
refer to chapter 6.2.3, 30.

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4. Controls and displays (standard)
1 2
Fig. 11 Standard controls –front side and rear side of the device.
No
Controls
1
Main switch, Rocker switch
Switch position "1" (pushed): 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 addresses”,
see the TopCon device manuals.