Flexibility isn’t just a Word!

Given the complex application profiles of customers, it becomes clear whether the much-cited flexibility of products is really a company culture and not just an advertising slogan. Complete solutions of any complexity from a single source – a reality from REGATRON.

Our customer requires a universal power supply consisting of a G5 power supply unit with a rated output of 36 kW for the higher voltage range and a slightly smaller G5 power supply unit with 18 kW for the low-voltage / high amp range. The two power supply units are to be used both for product development and for testing series products. For the development work, the customer wants to make use of the versatile programming and setting options of the G5 power supply units, while for the series tests he needs to run standardised voltage levels as well as current and power limits, which can be called up very easily via two independent selector switches. Another requirement is the fact that the system is to be used for internal and external transport to different locations.

The REGATRON Solution

The following design values are based on the above requirement profile:

  • The required mobile use is realised by installing the components in a special mounting frame.
  • A «flight case» provides mechanical protection during the transport phases.
  • The specific selection of current/voltage/power parameters is achieved by means of REGATRON peripheral units.
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The Realisation

REGATRON offers «flight case» solutions for the regularly mobile use of power supply units. These systems include a 19-inch mounting frame which protects the installed modules during transport by means of shock and vibration absorbers. The outer shell can be completely enclosed for transport and storage of the power supplies. This eliminates the need for labour-intensive and costly transport packaging.

REGATRON offers various system options for the flight case solutions, which above all simplify system operation and leave nothing to be desired in terms of safety. For mobile use, for example, the systems can be equipped with plug-in terminals for the mains connection, DC power and also for sense measurements.

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The two pictures on the left show the Flight Case housing ready for transport. To operate the power supply, the front and rear covers can be removed quickly and easily with butterfly fasteners. The retaining device on the side provides easy storage of the covers during operation and ensures a tidy test environment.

All systems are equipped with a lockable AC main switch and an emergency stop button as standard. The safety circuit also offers external interfaces to the higher-level emergency stop circuit of the test bench or for the safety network of several REGATRON systems. Depending on the equipment, the emergency shutdown offers a performance level c or e (PL c / PL e) in accordance with DIN EN ISO 13849-1. If residual voltages are present on the load side due to capacitive storage elements or rotating mass components after the emergency shutdown or the ‘Voltage OFF’ command, the DC Discharge Unit (DDU) can be used to absorb the energy within a desired time. Finally, LED indicators provide the user with information on whether dangerous voltages are present on both the mains and load sides. The Voltage Level Indicator (VLI) can perform the voltage measurement on the DC side without an auxiliary supply. This offers the great advantage that voltages from energy storage devices such as batteries can be displayed regardless of whether the system is switched off on the mains side.

To simplify operation, the system offers selector switches for both the high-voltage and the low-voltage power supply unit. These allow the user to choose between MANUAL or AUTO operation. In the MANUAL position, the two power supply units can be controlled as usual via the HMI/RCU operating display, the G5.Control operating and service software, REGATRON’s application software or via external digital interfaces such as CANmp, EtherCAT, SCPI, .NET or WebAPI (REST) with any setpoint and limit values. This gives engineers the flexibility they need to qualify the test object during the development phase. The AUTO 1…3 positions offer the selection of pre-programmed setpoints, which greatly simplifies operation for series testing and prevents costly incorrect entries. The selector switches interact with the G5 firmware and are each wired to the I/O interface and read in. The desired setpoints are programmed via a password-protected area of the G5.Control software. If the pre-programmed setpoints are controlled via the I/O interface, the new «Active Interface» selection of the G5.Control software offers restriction options for additional control interfaces to prevent setpoints from being accidentally overwritten during operation.

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Overview of all interfaces and operating options. The HMI of the G5 18 kW unit shows an example of how the “Active Interface” works. If the system is controlled with pre-programmed parameter sets via the I/O interface, the operation of other communication interfaces can be disabled.

Our “Playground”

Do you have additional requirements regarding the system functions described above?
Are test bench-specific interfaces or increased environmental requirements necessary?


REGATRON’s experts are at the customer’s side. REGATRON’s customised and turnkey test systems are always developed in close contact between our application engineers and the customer. This applies from the initial concept discussion through to demanding factory acceptance tests and product training.


We Think of:

Environmental conditions

  • Increased protection up to IP54 for air- or liquid-cooled systems
  • Increased protection against shock and vibration during frequent transport thanks to sophisticated «flight case» design

Convenient handling

  • Pluggable AC and DC cables
  • DC switch panel for manual reconfiguration of single, parallel, series or mixed series/parallel operation (matrix) up to 3000 VDC and 8000+ A
  • Automated switching from parallel to series/matrix and vice versa
  • Power distribution unit (PDU) for separate arrangement of the DC connection point in the test bench and the power supply in the technical room
  • Mains adaptation to 220, 600, and 690 VAC with auto-transformer
  • Integration of third-party products with optional AC supply
  • Laptop drawer

Safety

  • Absorption of residual energy from rotating loads by the additional DC discharge unit (DDU) after switching off the test bench
  • Insulation monitoring: remote activation of the insulation measurement, actual insulation value and warning/error status are provided via the CANmp interface
  • Residual current monitoring (RCD) for earthed systems up to 3000 VDC
  • Simplified and safe operation thanks to pre-programmed overvoltage protection and digital fuses with instantaneous and I2t tripping. Different protection levels for individual DUTs are either programmed by the user’s test automation system or activated manually by digital input signals or, even more conveniently, wired to various selector switch positions
  • Customised safety interfaces and safety wiring for multi-system operation
Flight case for REGATRON programmable power supplies – durable transport and protection solution

Have Questions or Looking to Tackle a Similar Challenge?

Reach out to our team — we’re happy to support you with technical expertise, detailed guidance, and solution-oriented consultation.

REGATRON Performance. Precision. Quality.

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