REGATRON TC.ACS Application guide

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
[phone]
www.regatron.com
[email protected]

General Information
Usage of the Document
This document serves as a guide and also as a reference work. Familiarize yourself with the contents of the docu-
ment to operate the product efficiently. The document must be available at all times to the personnel who are
operating the product.
Copyright Information
© 2022 Regatron AG
This document is protected by copyright.
All rights, including translation, re-printing and duplication of this manual or parts of it, reserved. No part of this
work is allowed to be reproduced, processed, copied 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 reasons. In general we refer to the appli-
cable issue of our “Terms of delivery”.
Customer Support
If you have any questions, your Regatron AG sales partner will be pleased to be of assistance. However, you can
also reach Regatron Customer Support at [email protected].
For more information on Regatron Customer Support see section 7.2.

Table of Contents
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1 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Warning and Mandatory Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.2 Ordinances and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.3 Categorization of the hazard Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.3.1 Personnel Area ........................................................................................................................................... 10
1.3.1.1 Electric shock ....................................................................................................................................................... 10
1.3.1.2 Electrical Heating ................................................................................................................................................. 11
1.3.1.3 Arcing and sparking on opening Contacts ........................................................................................................... 11
1.3.1.4 Mechanical Injury ................................................................................................................................................ 11
1.3.1.5 Chemical Injury .................................................................................................................................................... 11
1.3.2 Systems and Material Area ........................................................................................................................ 12
1.3.2.1 Fire ....................................................................................................................................................................... 12
1.3.2.2 Electromagnetic Fields ........................................................................................................................................ 12
1.3.2.3 Noise and Noise Level .......................................................................................................................................... 12
1.3.2.4 Mechanical Damage ............................................................................................................................................ 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 Mode (Option) ................................................................................................................ 15
2.1.4 4-Quadrant Operation ............................................................................................................................... 15
2.1.4.1 Feeding Mode (positive Power) .......................................................................................................................... 15
2.1.4.2 Regenerative Mode (negative Power) ................................................................................................................. 15
2.2 Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.3 Model Identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3 Interfaces, Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Interfaces, Controls and Displays on the Front Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.1.1 Overview .................................................................................................................................................... 17
3.1.2 LED Indications and their Meanings .......................................................................................................... 18
3.2 Interfaces on the Rear Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

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3.2.1 Overview .................................................................................................................................................... 19
3.2.2 Integrated Safety Relay (TC.ISR) ................................................................................................................ 21
3.2.2.1 Range of Application ........................................................................................................................................... 21
3.2.2.2 General Function Description .............................................................................................................................. 21
3.2.2.3 Type of Connection ............................................................................................................................................. 21
3.2.2.4 Pin Definition ....................................................................................................................................................... 22
3.2.2.5 Dummy Plug X112 ............................................................................................................................................... 22
3.2.2.6 Application Example: Category 1 PL c ................................................................................................................. 23
3.2.2.7 Application Example: Category 3 PL e ................................................................................................................. 24
3.2.3 Pin Definition of Interface X609 ................................................................................................................. 25
4 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.2 Site Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
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 the Cooling Liquid .................................................................................................................... 33
4.5.2.3 Pressure Differences and Flow Rates .................................................................................................................. 34
4.5.3 Safety Advice ............................................................................................................................................. 34
4.5.4 Procedure .................................................................................................................................................. 34
4.6 Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
4.7 Connecting an external Signal Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
4.8 Starting the TC.ACS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4.8.1 Safety Advice ............................................................................................................................................. 36
4.8.2 Prerequisites .............................................................................................................................................. 36
4.8.3 Procedure .................................................................................................................................................. 36
4.9 Running a Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4.9.1 Prerequisites .............................................................................................................................................. 37

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4.9.2 Procedure .................................................................................................................................................. 37
5 Multi-Device System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.2 Master-Slave Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.3 EtherCat and RS-485 Bus Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6 Transport, Packaging and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
7 Maintenance and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
7.1.1 Adjusting the Accuracy of the Output Values ............................................................................................ 43
7.1.2 Updating 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 Option: Digital I/O Interface (TC.ACS.DIG8IOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
9.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
9.2.1 Pin Definitions ............................................................................................................................................ 47
9.2.1.1 X640 Relay Contacts (output) .............................................................................................................................. 47
9.2.1.2 X641 digital Output ............................................................................................................................................. 48
9.2.1.3 X642 digital Input ................................................................................................................................................ 48
9.2.1.4 X645 auxilliary Voltage ........................................................................................................................................ 48

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10 Option: Analog I/O Adaptor (TC.ACS X609 Adapter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
10.2 Interfaces on the Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
10.3 Interfaces on the Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
10.4 Low Pass Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
11 Option: Liquid to Air Heat Exchanger TC.LAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
11.1.1 Application ............................................................................................................................................... 51
11.1.2 Model Identifier ....................................................................................................................................... 51
11.2 Interfaces, Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
11.3 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
11.3.1 Overview .................................................................................................................................................. 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 Advice ..................................................................................................................................................... 57
11.3.7.2 Prereqisites ........................................................................................................................................................ 57
11.3.7.3 Procedure .......................................................................................................................................................... 57
11.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
12 Option: TC.ACS.CANmp Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
12.2 Interfaces X652/X653 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
12.3 Interface X654 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
12.4 Connecting an external Control Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
12.5 Configuration of a CAN Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

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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

General Safety Information Warning and Mandatory Symbols
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1 General Safety Information
1.1 Warning and Mandatory Symbols
Throughout this document the following symbols are used, wherever necessary, to indicate and specify
hazardous or potentially hazardous situations:
Symbol Indication
DANGER
Indicates an immediate hazardous situation which, if not avoided, will result in death or serious
injury
WARNING
Indicates a possible hazardous situation 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 substances which cause eczema, allergies or poison-
ing. Avoid contact with skin!
Potentially lethal hazard due to a substance or a mixture of substances. Do not touch, do not
swallow, do not breathe in!
Wear a helmet!
Wear a light breathing protection for low concentrated short-term steams, fumes or aerosols!
Wear protective gloves!

General Safety Information Ordinances and Regulations
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1.2 Ordinances and Regulations
Follow the mounting and installation instructions during electrical installation!
In particular, in the countries of the European Union the following standard applies:
EN 62477-1 Safety requirements for power electronic converter systems and equipment
If you want to use the electrical power supply in special applications, you must comply with the related standards
and health and safety regulations.
Due to the high operating voltage and the high output voltages, an industrial electrical power supply represents a
mortal hazard.
To avoid 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 ensuring that the electrical power
supply, mains supplies and loads connected to it are placed in a safe state in the event of a failure of the device.
1.3 Categorization of the hazard Areas
The assessment of the effects of hazards from low-voltage systems with a flow of energy for supply and possibly
regeneration is divided into the following areas:
• Personnel Area (1.3.1)
• Systems and Material Area (1.3.2)
• Mains Connection Area (1.3.3)
• Surrounding Area (1.3.4)
• Area related to Interaction with the Device (1.3.5)

General Safety Information Categorization of the hazard Areas
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1.3.1 Personnel Area
The utmost attention is to be paid to the hazards for individuals. There are various risks and hazards, the most
important of which are mentioned here.
1.3.1.1 Electric shock
The system can produce electrical potentials that can be dangerous or even fatal for individuals. During work on
the system the following guidelines are to be observed:
• 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:
Electrically isolate.
Secure against switching back on.
Discharge and short-circuit capacitors, disconnect and isolate 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 imperative that this form of working is avoided. If it cannot be avoided, careful work preparation is essen-
tial. Pay attention to the following:
The personnel must be specially trained.
Work in accordance with recognized specialist methods.
Controlled personal protective equipment must be available (passive protection).
Organization of the working areas.
Supervision and preparatory measures (active protection).
Use appropriate protection against physical contact throughout.
Set up a suitable emergency stop chain and test it at regular intervals.
Mark all wires and cables to prevent mistakes.