REGATRON TC.P Quadro User manual

TopCon series DC power
supply
Regatron AG
Kirchstrasse 11
CH-9400 Rorschach
Tel [phone]
Fax[phone]
www.regatron.com
[email protected]
Distributor sticker
Manual for model TC.P Quadro

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General © 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 re-
produced 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.
Windows® (XP/Vista/Windows 7) are trademarks of Microsoft Inc.,
USA. LabView is a trademark of National Instruments.
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 stat-
ing the reasons.
Identification
Device hardware
Information on the device is to be found on the type plate on the rear
side of the TopCon TC.P. power supply.
Fig. 1 Example - information on the device type, serial number as well as
input and output data on the TopCon TC.P power supply.

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Manufacturer
Information on the manufacturer
Regatron AG
Tel. [phone]
Kirchstrasse 11
Fax [phone]
9400 Rorschach
www.regatron.com
SWITZERLAND
[email protected]
Instructions
Version overview
Operating instructions
Manual - TopCon Quadro; V04.52; 05.08.2016
For following modules:
TopCon MainDSP
From version V4.11.XX
HMI
From version V5.08.00
TopControl
From Version V4.01.66
Error list
From version V11.28
Table 1 Subject to technical change without notice.
xx: valid for all sub-versions.
General information on the manual
Purpose of the manual
This manual provides information on the usage of the TopCon TC.P DC
power supply. It serves as instructions and as a reference work. Famil-
iarise yourself with the contents of these operating instructions to oper-
ate the device efficiently.
Availability of the manual
The manual must be available at all times to the personnel who are op-
erating the device.

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Table of contents
GENERAL ...........................................................................................................................2
Identification .................................................................................................................................................... 2
General information on the manual............................................................................................................... 3
TABLE OF CONTENTS......................................................................................................4
1. GENERAL INFORMATION ON THE MANUAL...........................................................9
1.1. Safety and hazards............................................................................................................................. 9
1.1.1. Categorisation of the hazard areas.................................................................................................. 9
1.1.2. Personnel area............................................................................................................................... 10
1.1.3. Systems and material area............................................................................................................. 12
1.1.4. Line connection area...................................................................................................................... 14
1.1.5. Surrounding area............................................................................................................................ 14
1.1.6. Transport area................................................................................................................................ 15
1.1.7. Area related to interaction with the system .................................................................................... 17
1.1.8. Ordinances and regulations ........................................................................................................... 17
1.2. Pictograms used............................................................................................................................... 18
2. INTRODUCTION........................................................................................................20
2.1. Getting started with the TopCon power supply ............................................................................ 20
2.1.1. Setting up the hardware/connecting a TopCon power supply ....................................................... 21
2.1.2. Switching on and off a TopCon power supply................................................................................ 22
2.2. General information.......................................................................................................................... 23
2.2.1. Supplying electrical power using the TopCon power supply.......................................................... 23
2.2.2. Model range: overview of the standard models ............................................................................. 25
2.2.3. Control and internal controller structure......................................................................................... 27
2.2.4. Principle of the scope of operation/authorisation concept ............................................................. 28
2.2.5. Parameterisation –the process in principle................................................................................... 29
3. THE TOPCON QUADRO POWER SUPPLY (SINGLE DEVICE)...............................31
3.1. Technical data................................................................................................................................... 31
3.1.1. Device layout / views of the device ................................................................................................ 31
3.1.1.1. The front side of the device ................................................................................................... 31
3.1.1.2. Elements of the TopCon standard interface.......................................................................... 32
3.1.1.3. Controls on the Human Machine Interface /HMI (option)...................................................... 33
3.1.1.4. Device rear side..................................................................................................................... 34
3.1.2. Mains connection ........................................................................................................................... 35
3.1.3. Control............................................................................................................................................ 36
3.1.4. Output............................................................................................................................................. 37
3.1.5. Protection functions........................................................................................................................ 37
3.1.6. Ambient conditions......................................................................................................................... 38
3.1.7. Interfaces (standard) ...................................................................................................................... 38
3.1.7.1. RS-232 interface –X301 ....................................................................................................... 39
3.1.7.2. Analogue and digital inputs and outputs –X105................................................................... 39
3.1.7.3. CAN communication interfaces X101/X102 .......................................................................... 41
3.1.7.4. Sense X104........................................................................................................................... 42

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3.1.8. Mechanical properties.................................................................................................................... 42
3.1.8.1. Device weight ........................................................................................................................ 42
3.1.8.2. Installation height 6U for TopCon power supplies with 10/16 kW......................................... 43
3.1.8.3. Installation height 9 U for TopCon power supplies with 20/32 kW........................................ 44
3.2. Commissioning................................................................................................................................. 45
3.2.1. General information........................................................................................................................ 45
3.2.2. Safety information .......................................................................................................................... 45
3.2.3. Installation instructions................................................................................................................... 46
3.2.4. Electrical connections..................................................................................................................... 49
3.2.4.1. Electrical installation –general.............................................................................................. 49
3.2.4.2. System overview/connections............................................................................................... 51
3.2.4.3. Mains connection................................................................................................................... 54
3.2.4.4. Sense- remote voltage sensing connection .......................................................................... 55
3.2.4.5. Output connection/load connection....................................................................................... 60
3.2.4.6. System-internal CAN communication (X101/102)................................................................. 60
3.2.4.7. Digital/analogue control connection (X105/digital and analogue interface) .......................... 64
3.2.4.8. Interlock circuit with X101 and X105 ..................................................................................... 65
3.2.4.9. Control connection X301 (RS-232 on front).......................................................................... 67
3.2.5. Commissioning –electrical power supply...................................................................................... 68
3.2.6. Switching on the device.................................................................................................................. 68
3.3. Control............................................................................................................................................... 71
3.3.1. Interlock output inhibit .................................................................................................................... 71
3.3.2. Interface hierarchy.......................................................................................................................... 72
3.3.2.1. Interface hierarchy during power-up:..................................................................................... 72
3.3.3. Analogue control (X105)................................................................................................................. 73
3.3.3.1. Activation of the analogue interface for remote control......................................................... 73
3.3.3.2. Analogue remote programming............................................................................................. 74
3.3.3.3. Analogue remote programming –switching on/off the device .............................................. 75
3.3.3.4. Analogue remote programming for current and voltage........................................................ 75
3.3.3.5. Analogue remote programming for power limit and internal resistance simulation.............. 76
3.3.3.6. Digital outputs (relay contact)................................................................................................ 77
3.3.4. Diagnostic and control connection RS-232/DLL/ TopControl application...................................... 77
3.3.5. System-internal communication CAN (X101/102) ......................................................................... 78
3.3.6. Internal system status and troubleshooting.................................................................................... 78
3.3.6.1. Monitoring device-internal processes.................................................................................... 78
3.3.6.2. Indications on DEVICE and CONTROL LEDs ...................................................................... 80
3.3.6.3. Indications via digital outputs (relays) ................................................................................... 81
3.3.6.4. Monitoring function - current monitoring concept .................................................................. 81
3.3.6.5. Causes of errors.................................................................................................................... 82
3.3.6.6. Division into group and detail errors (warnings).................................................................... 82
3.3.6.7. Error and warning indication on the front panel LEDs........................................................... 82
3.3.6.8. Acknowledging an error......................................................................................................... 83
3.3.7. Versatile Limit Switch (VLS)........................................................................................................... 84
3.3.7.1. Description of VLS function ................................................................................................... 84
3.3.7.2. Programming VLS in TopControl........................................................................................... 87
4. OPTIONS AND SYSTEM OPTIONS..........................................................................89
4.1. Overview............................................................................................................................................ 89
4.2. Hardware options ............................................................................................................................. 91
4.2.1. Liquid cooling option (Liquid cooling LC) ....................................................................................... 91
4.2.1.1. Mechanical properties ........................................................................................................... 92
4.2.1.2. Characteristics of a water cooling circuit............................................................................... 93
4.2.1.3. Pressure difference/flow rates............................................................................................... 95
4.2.1.4. Filling cooling liquid circuit..................................................................................................... 96
4.2.1.5. Connection of a connection fitting ......................................................................................... 96
4.2.2. Air filter option (LF)......................................................................................................................... 98

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4.2.3. PACOB option –Cover for TopCon output current bars............................................................... 99
4.2.4. Integrated safety relay option....................................................................................................... 101
4.2.5. Q14 ReGen option ....................................................................................................................... 104
4.2.6. Q14 ResPas option...................................................................................................................... 106
4.2.7. Q14 ResAct option....................................................................................................................... 108
4.2.8. Q13 ACLF option.......................................................................................................................... 109
4.2.9. Internal Resistance Extensions (IRXTS) option........................................................................... 110
4.2.10. TC.LIN (linear post-processing unit) option ............................................................................. 112
4.2.11. Specification extensions (mil spec/ruggedised) option............................................................ 114
4.3. Software options............................................................................................................................. 115
4.3.1. Function generator (TFE/TopCon Function Engine) option......................................................... 115
4.3.2. Solar Array Simulator (SAS) option - SASControl ....................................................................... 119
4.3.3. Akku-Control option –rechargeable battery maintenance charging curves ................................ 121
4.4. Interface options............................................................................................................................. 122
4.4.1. Functionality as a function of an optional interface...................................................................... 122
4.4.2. Overview of possible interface combinations............................................................................... 123
4.4.3. RS-232 REAR interface option –rear side of power supply........................................................ 124
4.4.4. RS-422 interface option –diagnostics and control connection.................................................... 125
4.4.5. USB interface option –Universal Serial Bus................................................................................ 126
4.4.6. CAN/CANOpen® interface option................................................................................................ 127
4.4.7. IEEE488 –GPIB option (General Purpose Interface Bus)........................................................... 128
4.4.8. RS-232-to-Ethernet converter option........................................................................................... 129
5. MULTI-UNIT SYSTEM .............................................................................................131
5.1. Introduction..................................................................................................................................... 131
5.2. Load connection on devices in multi-unit operation.................................................................. 132
5.2.1. Sense function in a multi-unit system........................................................................................... 133
5.3. Internal system communication.................................................................................................... 134
5.3.1. Hardware required for the multi-unit system................................................................................ 134
5.3.2. Interlock circuit in a multi-unit system .......................................................................................... 134
5.3.3. Multi-unit system with TopCon power supplies............................................................................ 136
5.3.3.1. Master-slave principle on power supplies in the multi-unit system ..................................... 136
5.3.3.2. Addressing on power supplies in the multi-unit system....................................................... 137
5.3.4. ID addresses on several HMI/RCU (option) in a multi-unit system.............................................. 139
5.3.4.1. Master-slave principle for HMI/RCU (option)....................................................................... 139
5.3.4.2. Addressing with HMI/RCU (option) in a multi-unit system................................................... 140
5.3.5. Examples for multi-unit system configurations of the hardware................................................... 141
5.3.6. Multi-unit system and TopControl application.............................................................................. 142
6. OPERATION ............................................................................................................143
6.1. Introduction and overview............................................................................................................. 143
6.2. Analogue interface ......................................................................................................................... 145
6.3. HMI and RCU................................................................................................................................... 145
6.3.1. Case designs................................................................................................................................ 145
6.3.2. Short description/terminology....................................................................................................... 146
6.3.3. Technical data on the HMI ........................................................................................................... 147
6.3.4. Operation of the HMI (option)/RCU (option)................................................................................. 148
6.3.4.1. Controls on the HMI/RCU.................................................................................................... 148
6.3.4.2. HMI/RCU navigation concept .............................................................................................. 149
6.3.4.3. Navigation overview –display level..................................................................................... 151
6.3.4.4. Navigation overview –menu level....................................................................................... 152

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6.3.4.5. DISPLAY level –windows and their information ................................................................. 153
6.3.4.6. MENU level –windows and their information...................................................................... 156
6.3.5. Troubleshooting using the Human Machine Interface (HMI) ....................................................... 169
6.3.5.1. Acknowledging warning and error messages...................................................................... 169
6.3.5.2. Error during initialisation...................................................................................................... 169
6.3.5.3. Error during operation.......................................................................................................... 170
6.3.5.4. Warnings during operation .................................................................................................. 170
6.4. TopControl application .................................................................................................................. 171
6.4.1. Introduction................................................................................................................................... 171
6.4.2. Hardware and software requirements.......................................................................................... 172
6.4.2.1. Hardware ............................................................................................................................. 172
6.4.2.2. Software............................................................................................................................... 173
6.4.3. Installation of the software............................................................................................................ 173
6.4.3.1. Connection between PC and TopCon power supply........................................................... 173
6.4.3.2. Start/communication with the TopCon power supply.......................................................... 174
6.4.4. Function areas of the software user interface.............................................................................. 175
6.4.5. TopControl - user levels and password control............................................................................ 175
6.4.5.1. The user level concept ........................................................................................................ 176
6.4.5.2. Menu bar - user level and functionality................................................................................ 177
6.4.5.3. Tabs - user level and functionality....................................................................................... 178
6.4.6. Using the software –menu bar .................................................................................................... 179
6.4.6.1. Menu –File.......................................................................................................................... 179
6.4.6.2. Menu –Window................................................................................................................... 181
6.4.6.3. Menu –Info.......................................................................................................................... 183
6.4.7. Using the software –tabs............................................................................................................. 184
6.4.7.1. Tab –<CONTROL>............................................................................................................. 184
6.4.7.2. Tab –<STATUS>................................................................................................................ 187
6.4.7.3. Tab –<FUNCGEN> (option)............................................................................................... 189
6.4.7.4. Tab –<SCOPE>.................................................................................................................. 205
6.4.7.5. Tab –<CONFIG> ................................................................................................................ 223
6.4.7.6. Tab –<PROTECT>............................................................................................................. 229
6.4.7.7. Tab –<ADJUST 1> ............................................................................................................. 231
6.4.7.8. Tab –<ADJUST 2> ............................................................................................................. 233
6.4.7.9. Tab –<PARAMETERS> ..................................................................................................... 235
6.4.7.10. Tab –<I/O>.......................................................................................................................... 243
6.4.7.11. Tab –<DEVICE INFO> ....................................................................................................... 245
6.5. LabView: TopCon as a “virtual instrument” ................................................................................ 247
6.6. The function library (DLL).............................................................................................................. 249
7. MAINTENANCE.......................................................................................................250
7.1. Maintenance of the hardware........................................................................................................ 250
7.1.1. Air filter (option)............................................................................................................................ 250
7.1.1.1. Air filter mats........................................................................................................................ 250
7.1.1.2. Ordering replacement air filter mats.................................................................................... 251
7.1.1.3. Replacing the air filter mats................................................................................................. 252
7.1.2. Fans.............................................................................................................................................. 253
7.1.3. Electrolytic capacitors................................................................................................................... 253
7.2. Maintenance of the software and firmware.................................................................................. 254
7.2.1. Version of the TopControl application.......................................................................................... 254
7.2.2. TopCon firmware version............................................................................................................. 255
7.3. Disposal with due care for the environment................................................................................ 255

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8. REGATRON SUPPORT...........................................................................................256
8.1. Contact information........................................................................................................................ 256
8.2. How to contact support ................................................................................................................. 257
8.3. Determination of the system information .................................................................................... 257
8.3.1. Software versions......................................................................................................................... 257
8.3.2. Firmware versions and device information................................................................................... 258
8.4. Enabling software options............................................................................................................. 259
8.5. Producing a standard scope ......................................................................................................... 260
8.6. Device return................................................................................................................................... 262
8.6.1. Packaging sequence –standard packaging ................................................................................ 262
8.6.2. Optional packaging protection...................................................................................................... 263
9. APPENDIX ...............................................................................................................264
9.1. Error list........................................................................................................................................... 264
9.1.1. Introduction................................................................................................................................... 264
9.1.2. Overview of group error codes and group warning codes ........................................................... 266
9.1. Error groups.................................................................................................................................... 268
9.1.1. 0) Internal ..................................................................................................................................... 268
9.1.2. 1) Internal (PDSP)........................................................................................................................ 270
9.1.3. 2) Output current .......................................................................................................................... 272
9.1.4. 3) Output voltage.......................................................................................................................... 274
9.1.5. 4) Supply ...................................................................................................................................... 276
9.1.6. 5) Temperature............................................................................................................................. 280
9.1.7. 6) Communication........................................................................................................................ 282
9.1.8. 7) Internal (Modulator).................................................................................................................. 285
9.1.9. 8) Internal (AD overrange 1) ........................................................................................................ 288
9.1.10. 9) Internal (AD overrange 2).................................................................................................... 290
9.1.11. A) Internal (AD underrange 1).................................................................................................. 292
9.1.12. B) Internal (AD underrange 2).................................................................................................. 294
9.1.13. C) Login.................................................................................................................................... 296
9.1.14. D) Configuration....................................................................................................................... 301
9.1.15. E) Configuration 2.................................................................................................................... 304
9.1.16. F) Miscellaneous...................................................................................................................... 306
9.1.17. G) IBC System......................................................................................................................... 309
9.1.18. H) IBC Supply .......................................................................................................................... 310
9.1.19. J) IBC Communication............................................................................................................. 311
9.1.20. K) IBC Power ........................................................................................................................... 312
9.1.21. L) IBC Inverter.......................................................................................................................... 313
9.1.22. M) IBC Miscellaneous.............................................................................................................. 314
9.1.23. N) IBC Inverter 2...................................................................................................................... 315
9.1.24. Q) Configuration 4.................................................................................................................... 316
9.1.25. R) Miscellaneous 2 .................................................................................................................. 318
9.1.26. S) Supply 2............................................................................................................................... 320
9.1.27. T) Login 2................................................................................................................................. 321
9.1.28. U) Configuration 3.................................................................................................................... 323
9.1.29. V) Communication 3 ................................................................................................................ 326
9.1.30. W) Internal 2............................................................................................................................. 329
9.1.31. X) Communication 2 ................................................................................................................ 330

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1. General information on the manual
1.1. Safety and hazards
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 men-
tioned by means of the rigorous application of specialist electrical rules.
The system is subject to the Low voltage directive, it is to be operated
by adequately trained and instructed personnel.
1.1.1. Categorisation 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:
Fig. 2 Categorisation of the hazard areas.
The hazard areas stated are explained in the sub-sections of this chap-
ter that follow.

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1.1.2. 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 men-
tioned here.
Electric shock
A low-voltage system can produce electrical potentials that can be dan-
gerous or even fatal for individuals. During work on the system the fol-
lowing 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
After shut down, the short-circuiting of the outputs and earthing
are particularly important for safety reasons if reactive loads or
loads that store energy
(rechargeable batteries, capacitors, ULTRACAP etc.) are used
b) Work in the vicinity of live parts
In these circumstances an increased hazard potential is to be ex-
pected. Minimise the risks by means of:
1. Guards
2. Covers
3. Insulating encapsulation, cladding
4. Impose separation by means of mechanical features, protective
grilles
5. Supervision, reporting