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L-828/L-829 - CHF, 4-70kW and SGRS Powerpack

Contents

1. E 8 5 5 2 e 5 OUTPUT NOTE H Sg FOR 30KW 208V amp 240V OUTPUT CONNECTIONS VR1 E 8 USE F1 amp F2 FOR INPUT 21 DO NOT USE TB3 LAND E AND VR2 UNLESS TERMINAL 83 0 BLOCKS OR SCO IS USED s 5 402 8 403 ON 400 401 ols SIDE OF FUSE BLOCKS NOTE LAND ALL CAP BANK WIRES AS CLOSE ASON 208 200 240 55 AS POSSIBLE TO THE CENTER OF THE a ee 2 eee Ney Anak UP tates zii BANK ALSO NOTE 4 he soni RES Ei TB3 CVM 1 8 gas 8z Ela 5 TO T9 20 ERE 15 401 CVM DANGER i i 9 202 213 525 LETHAL VOLTAGES M m 3 35 2 ARE PRESENT 1 URI Os 4 VR2 WIO MTR 4 255 m F2 cin
2. IMPORTANT KEEP WIRES 100 s amp 300 s AWAY FROM CORE OUTPUT NOTE OUTPUT CONNECTIONS ON VR1 0 TN 50KW CORE AND VR2 UNLESS TERMINAL 70KW 480VAC 365 INN BLOCKS OR SCO IS USED 4 BANKS 304 WA o 208 012 UT H dar 5 347 152 528 TB1 NEU ATTACH OUTPUT TAG 2 PLC S V 2E L3 IRMS OUT FIBER CABLE o GRY 9 i3 904 i 1 NOTE LAND ALL CAP Bh 1 5 201 oto 3 TB1 GND B OV oe 1012 72 102 BANK WIRES AS CLO NA RE 102 5 T9 DANGER EE n AS POSSIBLE TO THE 103 9 ASIC SEENOTE 4 10 3540308 LETHAL VOLTAGES L 29 CENTER OF THE CAP H H E alc pee 222 220 2 i omar SO 22 A MEME CAN 101 55 6 103 H ty t 307 301 5 gt f ae POS IS MID AN 8 9 1 ML UA puer er Ln E N i 204 3 At P DooR sw 308 7 MS Drs comer 291 202 5015016 sois
3. l E IMPORTANT SEE NOTE 12 FOR 3 SC1 1 8 2 INPUT WIRE LUG ASSEMBLY 5 STA H2 W CVM EY De ee es als 4 30 KW 240V 8 i 3 p REM DM ME i i gt 1 CVM amp IRMS Options Ol ot TORQUE 5 6 NM 2 PLC S NOTE LAND ALL CAP OPTION lo 1 8 Bene T i ola BANK WIRES AS CLOSE e 6 6A WIRING SEE T7 sec PRIM EI E P AS POSSIBLE TO THE NOTE 10 ICVM OPTION CVM BELOW FOR 20 G4 O Bs it CENTER OF THE CAP BANK H1 527 5 o d si 82 TB3 5 SEE NOTE 13 i 2 5 35A0346 OR 48 MER J5 528 TB1 NEU X 610317 30 pg EES E 700 5 LETHAL VOLTAGES IRMS OUT FIBER CABLED GRY i 2 5 227 1 3 APE PRESENT FIBER CABLE BLU i E 52 8 554 INSULATORS REQ D FOR 14 i lo NOTE 11 Oo pix oR 30KW 6 6ACVMONLY 7 ESCS 12 s
4. s 25 7 ITEM NO PART NUMBER DESCRIPTION 8 5 5 5 8 5 5 8 3 8 amp 5 5 8 5 IXT POWER CORE LIST 10 15KW 35A0705 15KW IXT PWR TX 480V 6 6A 1 35A0263 CURRENT TX 6 6 6 6 L828 1 5 1 1 1 1 1 RM 1 1 35A0706 10KW IXT PWR 480V 6 64 2 35A0548 TX CURRNT SENSE 6 6A 66mA w TWISTD LEADS 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 35 0707 7 5 PWR 480V 6 6 3 4240525 3 ROTARY SWITCH LABEL 3 STEP FERRO 111 111 1111 1 1 1 1 35 0711 1SKWIXTPWRTX 4809 000000 3 42305255 ROTARY SWITCH LABEL 5 STEP FERRO Wine 545 lle lps d d 3540717 15KW IXT PWR 480 347V 6 6 4 4280269 LABEL L828 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Mad AE A PWR T 480 307 5 44A6006 0007 FIBER OPTIC CABLE ASSEM X 7 FEET 11123 2 1 2 2 ECHO SES 6 44A6056 2 MEDIUM CABINET ASSEMBLY 1411 141 ae 130 pd 35A0729 15KW IXT PWR TX 208 220 240V 6 7 44 6139 2 ASSY CCF ACE2 E 7 5 30KW 1 1 1 a 1 1 1 1 3540730 10KW IXT PWR TX 208 220 240V 6 64 8 4446178 PCB ASSY 34 PIN HDR SW ADAPTOR E 111 111 11 fafa fafa fa fafa 3540731 7 5KW P
5. VER n jo II E T a 1 p OV LY X 27 o MB 4 F Top View 19 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D 6 9 11 Dimensions 5 E 20 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 3 0 Installation 3 1 Unpacking 3 2 Installation 3 2 1 Wiring Connections and Startup Installation L 828 L 829 CCR Installation WARNING Read installation instructions in their entirety before starting installation Refer to the FAA Advisory Circular AC 150 5340 26 Maintenance of Airport Visual Aids Facilities for instructions on safety precautions Observe all safety regulations To avoid injuries always disconnect power before making any wiring connections or touching any parts Become familiar with the general safe
6. SECTION 9 op 4 p 0 099 ES MEINTE E 55 55700006055 ooo 3 5 STEP 1 828 SHOWN 1 828 VERSION SHOWN gt T 1 gt OOO OD 6 PLACES ti 2400 800 0 T o dip ooo lo T SECTION CC 24 SCALE 2 fe SECTION 8 8 c E NOTES 1 SEE SHEET 2 FOR BOM AND ISOMETRIC VIEW 2 51 OPTION IS ADDED AT COMPONENT PLATE LEVEL 940341 o Li 3 SMI amp SMR OPTIONS ARE ADDED AT COMP PLT LEVEL 9440334 9440335 o 4 A LEGIBLE COPY OF 4343736 WIRING SCHEMATIC IS TO BE PERMANENTLY MOUNTED IN AN UNOBSTRUCTED PLACE INSIDE THE 1 P CONTROL CABINET 5 DIGITAL POWER METER OPTION IS ADDED AT THE COM
7. CE M re e ure o oA s SE Qoo SED gt gee 44A6136 1 2 FERRO CNTRL PNL WIRE HARNESS SM amp MED LG FRAME 2 44A6139 1 2 FERRO ACE WIRE HARNESS SM amp MED LG FRAME 3 ez 94 0561 POWER WIRE KIT IXT FERRO CCR 9 5 o E 43A3128 WIRING DIAGRAM ACE2 TO URCII 1 PCB ia u DESCRIPTION 49 lt 20 RELATED DOCUMENTS EHI ist 66 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Wiring Schematics Figure 45 Ferroresonant L828 L829 50 70kW Internal Wiring Schematic 43A3736 5070 1 of 1
8. Columbus Ohio 43230 55 555 555 s 5 5 gt e CONSTANT CURRENT REGULATOR 25 CHG 88405814 TO 5 100 2ISEPIO 99 30KW SIGNATURE SERIES IXT AC PRODUCTION RELEASE JEG 6 6 AMP 208 480 VOLT DRAWN REV FINAL ASSEMBLY REVISION DESCRIPTION BY DATE REV ECO LEVEL NUMBER 4446391 pm m Gafrey O9APR10 16 10 2 2010 ADB Airfield Solutions All Rights Reserved 63 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Parts and Mechanical Drawings 6 9 11 Figure 42 20 30 kW CHF6630 XXXX
9. e 0 e 50 e 0 e e ITEM NO PART NUMBER DESCRIPTION 58551558 85 BS BR 2882882888822 8 822 22 tie itc EIEE EEEE EEIE E cii I T ja 24 Pss T T X E zh d T ds Ojo OF 1 35A0548 TX CURRNT SENSE 6 6A 66mA wiTWISTD LEADS A po perpe eps opa DP 2 42A0525 3 ROTARY SWITCH LABEL 3 STEP FERRO dc eT trage pee praet e Ds 3 42A0525 5 ROTARY SWITCH LABEL 5 STEP FERRO 1111111111111111 4 4280269 LABEL 1828 1111111111111111111411111111111111 5 44 6006 0007 FIBER OPTIC CABLE ASSEM X 7 FEET 4 1 213 11213 112131 1112 3 6 4446032 2 LARGE CABINET ASSEM IXT 111111111111111111111111111111111 7 44461392 HARN ASSY CCF 2 7 5 30KW 832224 15 24 554011 55 e rs 8 4446178 ASSY 34 PIN HDR SW ADAPTOR 3 5 STEP 11111131111117 a ate ote aa 9 44 6391 335 COMP PNLASSEMBLY 30KW 6 6A 480V L 829 IRMS z eal oe z p 9 4446391 320 COMP PNL ASSEMBLY 30KW 6 6A 240V L 828 fe ee e ren Feci e o E Se 4 9 4446391 323 COMP ASSEMBLY 30KW 6 6A 240V L 829 111 1 1 1 1 1 1 111 9 4446391 324 COMP PNLASSEMBLY 30KW 6 6A 240V L 828 IRMS 9 4446391 325 COMP PNLASSEMBLY 30KW 6 6A 240V L 829 IRMS 1 1 111 1 1 1 1 1 1 111 9 4446391 330 COMP PNLASSEMBLY 30KW 6 6A 480V L 828
10. 88 gt 5 28 Dies 23 POWER PAK WIRING FOR 94A0399 53 es X DOOR NOT CLOSED INDICATOR PREVIOUS MOLDED STYLE CVM WIRING 600 OB LEE F6 924 gi SC3 12 PPF STAB CONN SC3 11 PPF STAB CONN 529 m 1 Opti Hi si wet attaching wires 7 ge 5 GRY T2 T3 and meter not used DOOR SWITCH 2 i K2 NC 5 2 1 200 201 A2 534 5 1 536 4 NO1 aM HH ADD WIRES 541 amp 542 PREVIOUS IRMS W RES WIRING diii B Slee IRMS IN FIBER CABLE O BLU IRMS ME en FS IRMS OUT FIBER CABLE O GRY ONES eee P TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER AS x LISTED ON COMPONENT LABEL 72 0017 TERM BLK 35 in lbs 72A0071 TERM BLK 50 72A0306 1 amp 2 HARTING CONN S 48 in Ibs REVISION DESCRIPTION Use wrench to hold RES when attaching wires V ECO 2449 CTRL WIRE CONN CORRECTION 090 9 PREVIOUS SCR WIRE COLOR CODING 185 07 W 2154 CHNGS FOR SHORTER GNDS 513 RED a WIRE SIZES 512 WHT O 102 105 PRIMARY POWER SEE TABLE 514 134 200 206 HIGH VOLTAGE 12AWG 25 150C 89A0086 1 5 41
11. 3 2 1 Abouttliis manual ete eei eres i 3 2 1 1 How to work with the 3 2 1 2 Record of changes m 0 alist D i s 3 2 2 Product Introduction baie epe v gen 4 2 3 Compliance with Standards 2 4 2 4 Features ioa Re ed et b etudes e end 4 2 5 Electrical Supply iiic eio erit e oe ae oO Det m aerea ce qe 5 2 5 1 Remote Control iUe exeat tutes 5 2 5 2 Total Harmonic Distortion THD 5 2 5 3 Theory of Operation Introduction eseseennes 5 2 6 SAGE2 nice tue MG ogee EE POR RE REPRE Ea Re tice 5 2 7 Environmental Operating Conditions seen 6 2 7 5 6 2 7 2 Application Notes eee t elie eect Ea oen 6 2 8 Theory of Operation ssc cn deett e die d eee Pre ce 8 2 8 1 Power CIFCUIU 5226 correr ee co rete e cand cen tees 8 2 8 2 Output Measurement esessssssseseseeeeeneee nennen nnne nnne nnne nnns 8 2 8 3 Universal Regulator Controller URC eee 8 2 8 3 1 URC PCB Inputs Outputs sesseseeeeeeeenneeeneenene nnne 8 2 8 4 Output Current Monitor Circuitry esee 9 2 8 5 Local Control Position Detection 2 9 2 8 6 Gontactot DIIV6 PRU RUP
12. Figure 5 SGRS Powerpack with ACE2 2 p E 222 TES e je E 5 5 i 0 5 Gla INPUT INPUT VR 7 12 TB3 5 TB3 SNUBBER Ir 4 i o 4 j a ceca i d 6 o e TB1 D EINES 5 oF 8 S ES gaps bu 9 Br B 7 E E 7 aa fan ONO RON ACE not shown Installed on inside front of SGRS door SGRS Powerpack Rotary Switch Installed on front of SGRS door Circuit Breaker Series Circuit Stab Connector Input Power and control wiring stab connector URC Circuit Board Roller Wheels 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Universal Regulator Controller 2 12 Universal See Figure 6 below The Universal Regulator Controller URC is a PC board that is designed Regulator Controller to provide all regulator and control functions for Ferroresonant L 828 L 829 CCRs manufactured by ADB Airfield Solutions This is accomplished with an 8 bit embedded microcontroller and interface circuitry contained on a single 8 x 8 inch 203 mm x 203 mm through hole type printed circuit board The universal regulator controller PCB performs the functions listed below e Produces SCR drive
13. f Stu Fon oan as AIRFIELD 33 HT eee B 5 8 SCO OPTION OPT DQOR SW 30s _ pu 1 T5 ros current 3201 49 8 g ime cy Lu C2 i am umor amp 56 SEE DETAIL A 9440358 KIT dA i 20A 3540528 TEE 1 MICROSWITCH VR7 vR8 xs n SEE DETAR AT SAA0SSE EXE 86340283 DIGITAL POWER METER Q WIRING SEE DETAIL A 2 f H CxU METER 5 2 88 54448 43 OPTION 5 1 VR3 7 Ps J i NOTE 3 2 PROD ONLY Br i BE i PEE _ 34383088 SC VRE VR5 Hn X Ti ja IF VARISTORS ARE PLATE MOUNTED sebi L 9 Jm 8 GND PLATE TO EARTH GND x 41111143 FOR PREVIOUS FB WINDING ini EH CONNECTIONS SEE PG 2 X H IHE iii FEEDBACK JUMPER A H E 8 18AWG ue 0 20A WIRING FR ES Q a a LS 19 8 ROTARY SWITCH 5 Boxe 8 6 i 9 8 Y 20668 8 8 1 F5 5A 250V SLO BLO 47A0119 d 8 ATTACH TO FOOT OF T4 24 EA 6 8 5 2 PLACES TOIRMS a WIRE 531 MUST TIED TO BLU X a TODPM T8 S D IF UN KEYED MATING CONN WAS USED gw 4 E J JoAte7e TERM 9 WIRE NOT TO ANOTHER GND Lee
14. NOT BE 26 018 S H3TII3 dOL 86898409 1 92v09 Installation 9 21 OOHLNOS 85 4000 SS09V vb Lr S3oVld 8 GNLS qM 91 2 1 X 08 9 1 VLAD 21512385 HOS 1V 14 V SS09V y 33S SNINIHOVIN HOOQ SONTONI SADNVHO SOvid 230690 WOHd 02 29 0689 ued TIVISNI g 908 21 M3U9S 3ALLd V9 ODHLNOS 912 99991 HHVO WOW 31VOIH8V3 STONVWOLLYSA 8 6E92v09 2010 ADB Airfield Solutions All Rights Reserved 28 96A0408 Rev D 6 9 11 4 0 Operation 4 1 Introduction 4 2 CCR Control Procedures 4 2 1 Local Control CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Operation WARNING A Read the instructions in their entirety before starting installation Contents are static sensitive Must be grounded when handling PCB Operation of a Regulator while overloaded at any step may result in equipment failure or equipment damage This section provides the operational procedures listed below for the L 828 L 829 constant current regulator CCR 4 70 kW 6 6 A or 20 A CCR control procedures CCR shutdown procedures CCR adju
15. fis document m whole or pats 3 STEPIS STEP 3 0721 30KWIXTPWRTX 480 347V 20Nh sulle 35A0727 30KW PWR TX 208 220 240V 6 6A INTIAL ADATE 35A0728 20KW IXT PWR TX 208 220 240V 6 6A 20KW IXT PWR TX 208 220 240V 20 irfield Solutions PO BOX 30829 Tel eu 861 1304 977 Gahanna Parkway 614 864 2069 20 240 480V SHOWN OTHER VOLTAGE INPUTS ARE CONFIGURED SIMALARLY Columbus Ohio 43230 CONSTANT CU GULATO INSTANT CURRENT REGULATOR 4 e le ba lalala Thee o ems la lala B 2526 CHG 94A0561 4 10 5 27SEP10 20 30KW SIGNATURE SERIES IXT ae 9 9 a S 8 8 8 8 8 8 8 8 8 8 PRODUCTION RELEASE JEG J 09APR10 6 6 AMP 208 480 VOLT ITEMNO PARTNUMBER DESCRIPTION 1S lelg uir REVISION DESCRIPTION oR aae FINALASSEMBLY d 8 S S 8 8 E E S S E 818 RR im Cate THE jejejejeje jejejeje 446391 4486390 y 09 10 7 pu I e 16 20F2 o o O oO JO O nomion on is rang 9055 in jose for whicl jas submitted Any disclosure L 829 DOOR mE USTO POWER TORES nonin sy hie B CHE 6 6 3 0 44 6390 P PLI 20KW 6 0 4 4 4 4 lutions Inc may otherwise agree in writing 4457025 20 Y 20
16. d 8 53 34 7 CAAT s go 117 5 8 EHE 58 SEE NOTE 10 8h 22 SEE NOTE 3 57 IRMS Pan DE scr 83 1 1 551 9 Ve 5 83 9 r 2 F5 ON Es ess K2 NOTE LAND ALL CAP 4255 D oS 20 WIRING uu 44 cr at 55 EE SH 700 700 402 1 2 104 BANK WIRESAS CLOSE f ter BER 2 a FIBER GABLE GRY 45 39 TB1 GND N VRI 1 ORS 8401 Sii S m AS POSSIBLE TO THE 8 0850 dea j Vae 1 NOTE44 Os 225 CENTER OF THE TE REIN 1i 804 Be p 255 BANK 207 308 200 6 6969 69 EL Ses MES i 55 6 55 sc1 2 aer sA 8 a8 Gi ang 5 308 rz NOTE 2147 V COMP PANEL 12 295 VAG INPUT m 5 2 1 SC26 i 50KW BOVAC 3 BANKS m at T1 ICVM OPTION CVM 2 22 22 252 4 pr DOOR SW TO1 SEENOTE 13 TL iQ c Oo A 8 E A2 1 1 535 L DANGER 1 5 ACE amp IRMS OPTIONS DO UU ITE 25 1 l 8 2 480 VAC INPUT VR2 T4 FIBER CABLE 20A 3500528 i 09 A BLK I 506 200 7 orit OPNON g 7 RED BLK Corwen 532 T2s 14 i 2 NOTE 2 35A0528 9 9 2 3 NOTE 3 RED
17. 30 4 5 1 Output Current Adjustment senem 31 4 5 2 Overcurrent Adjustment ssssssseeeeeeeene nennen 32 4 6 SCO Cutout Working Positions 33 4 7 Application Notes erede udu 35 4 8 Digital Power Meter Calibration optional 36 4 9 1 Display ico 36 4 8 2 Function Buttons nei tte e reete 36 4 8 3 0 DISplays DP RR eben 36 4 8 4 Calibration Procedure 37 5 0 Maintenance and Repair 41 5 1 Maintenance Schedule ssssssssesssseeeeeenneeennee nennen nennen 41 51 1 Shoft Circuit Test tne etr emere e deer edente d 42 5 1 2 Open Circuit Test aet ede ade eres 42 5 2 ro bleshootln iius cii cdita i ates ftr ere rere tnus 43 5 2 1 Preliminary 43 5 2 2 Troubleshooting FUSES tite rie tete eee cd 44 5 2 3 L 828 General Troubleshooting 51 5 3 Additional L 829 General Troubleshooting Procedures 52 5 4 Component Replacement Procedures sese 53 5 4 1 Removing and Replacing URC sse 53 5 4 2 Removing and Replacing Dual SCR Module Assembly 53 5 4 3 Removing and Repl
18. 57 NO GND REQ D EE BLK BRN DIGITAL PWR METER PWR METER OPTIONAL SCO WIRING B 28 xj 509 33 NOTE 5 2 3 3 C 226 506 204 205 Bg E RED BLU 531 3 HV SC1 2 85 5 5 Zo 7 821 88482808 NOTE42 277 90 NOTE 4 s m HV SC2 8 8 05 O i ROTARY SWITCH VR2 g CONNECTION sg slg NOTE 12 is 5 4 3 2 1 8 7 6 5 4 31 2 1 i y z F5 5A 250V SLO BLO 47A0119 A T m 9 GND TO FRAME USING 509 o 550 9 6AWG WIRE 8 5 Oil IF UN KEYED MATING CONN WAS USED 8 8 TOIRMS PIN 1 RED STRIPE IS ON THE LEFT SIDE DEDE 85 5088 03 8 06 SAME FOR ROTARY SWITCH E 3 9 28 Oa IF KEYED MATING CONN IS USED 5 8 8 E PIN 4 RED STRIPE IS ON THE RIGHT SIDE 9 SNUBBER ASSY 70KW CORE SAME FOR ROTARY SWITCH CONN 58 AJ 1 z x9 NA 46149 lt 44 6035 1 55 gt E URC II ASSY 2 1 305 2 2 4 4 J5 C II PC 13 8046 0222 111033 201 a NOTE 1 E ES 561 on 805 104 522 gt 55 1 scar of gt Por sme DP JERNET e Ee d A gt CHASIS GND rag MEE PIE 514 2 8 478 25 J3 J2 J1 J z a309 NOTE 11 11213 112131 41518 1 2 3 4 5 6 7 8 s a FAN NEUTRAL 10 1 a PES PESE 4446178 SWITCH ADAPT A
19. CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller User Manual URC 96A0408 Air Cooled 4 70kW 6 6A 20A Retain for future use Rev D 6 9 11 ETL Certified to FAA Specification 150 5345 10 Airfield Solutions CHF Ferroresonant L 828 L 829 Constant Current Regulator 96A0408 Rev D 6 9 11 Disclaimer This manual could contain technical inaccuracies or typographical errors ADB Airfield Solutions reserves the right to revise this manual from time to time in the contents thereof without obligation of ADB Airfield Solutions to notify any person of such revision or change Details and values given in this manual have been compiled with care They are not binding however and ADB Airfield Solutions disclaims any liability for damages or detriments suffered as a result of reliance on the information given herein or the use of products processes or equipment to which this manual refers No warranty is made that the use of the information or of the products processes or equipment to which this manual refers will not infringe any third party s patents or rights Warranties Products of ADB Airfield Solutions manufacturer are guaranteed against mechanical electrical and physical defects excluding lamps for a period of one year from the date of installation or a maximum of 18 months from date of shipment and are guaranteed to be merchantable and fit for the ordinary purposes
20. n e 515644 9 44 6391 333 COMP PNL ASSEMBLY 30KW 6 6A 480V L 829 ee fons s re Jos or e E re 9 4446391 334 COMP PNLASSEMBLY 30KW 6 6A 480V L 828 IRMS 1 1 1 1 1 111 1 1 1 1 1 1 111 10 44A6508 1110 ACE Il INTERNAL LCD DISPLAY WITH LOM 8 pw Pea ae a 110 11 44A1026 30 CAP PLT ASSEM 20 30 KVA SIGNATURE SERIES 111111111111111111111111111111111 12 44A7045 L SHIPPING STRAP 20 30KW IXT SUB ASSE Pal ala at ts aaa tea ate 13 44AT050 XXX 1 828 METER KIT SIG SRS REGULATORS 11217 1 54221241 14 6044143 SUPPORT ANGLE IXT FERRO fesse ie fe ee e ao 93212 15 61 0340 KNOB 3FLUTE 1 8 SHAFT ALUM BLK 111111111 art tla fa fa aya la pa ya 16 64 0173 10 14 20 X 5 8 HX HD 21 121 22 21 21 21 21 22 21 21 21 21 21 21 21 21 21 446528 FROM KIT 940425 17 64A0191 8 8 32 X 1 2 PAN HD PHIL 2 2 2 2 2 2 2 2 21212122 2 2 2 2 18 64A0198 6 6 32 X 3 8 PAN HD PHIL 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 60A2658 5 FROM KIT 9440425 19 64A0947 EYEBOLT 1 2 13X1 5 1 1910 2600 414141414141414141414141414141414 20 65A0015 24 14 20 HX NUT SS 81818181818181818181 818181818181 8 21 65A0015 33 112 13 HX NUT 414141414141414141414141414141414 DIGITAL POWER METER DETAIL 22 65A0347 4 14 20 SS NYLON INSERT NUT uiua uiu ta ta a a4 ta 23 66 0015 33 1 2 FLATWASHER 414141414141414141414141414141414 24 66A0015 24 1 4 FLATWASHER 414141414141 4141414141414141
21. 1 12 4487047 320 10 KVA COMP PLT ASSEM 6 6A 208 480V SIG SRS 2526 SEEECO 25890 DRAWING TITLE 444 7069 323 75 PLT ASSEM 6 6A 208 480 SIG SRS xt pe Ja m Ee 148 e gt 447047323 10 COMP PLT ASSEM 6 6A 208 480 SIG SRS esse ees tos dre cre etr tre CONSTANT CURRENT REGULATOR 44470653247 75 KVACOMPPLTASSEM 66A 208 180 IG SS zeugen 57 rne 5205 44A7047 324 ioRACOMPPIIASSEM GGA 208 480 5655 1 111 1 1 1 1 1 1 131 A00 75 RV CAPRELITY 100060 1OKVA 7 5 SIGNATURE SERIES 44 7069 325 7 5_KVACOMP PLT ASSEM 6 6A 208 480 SIG SRS 1 1 111 1 1 1 1 1 1 111 1 1 1 44A7047 325 10 KVA COMP PLT ASSEM 6 6A 208 480 SIG SRS 5 1 552118 Toe 55 5 4 5 A PRODUCTION RELEASE Jo7mavio 208 480VOLT 6 6 amp 20AMP 44 7069 330 75 PLT ASSEM 6 6A 208 480 SIG SRS me esce Ex E ee 4447047 330 10KVA COMP PLT ASSEM6 6A 208 480V SIG SRS ERES ER FE ERE EE IRE ECO REVSON DESCRIPTION DRAWN REV L 828L 829 DPM ACEI 447069 333 7 5 PLT ASSEM 6 6A 208 480V SIG SRS 1 1 447047 333 10 KVA COMP PLT ASSEM 6 6A 208 480V SIG 585 5 1 t 4 1 LEVEL NUMBER BY DATE FINAL ASSEM
22. I INTIAL amp DATE KE Ig rel ADB Airfield Solutions 22 7 PO BOX30829 614 861 1304 9 2866 SEE ECO CHNG LOC OF CVM Dm 977 Gahanna Parkway 614 864 2069 Columbus Ohio 43230 5 4 5 D 2964 SEEECO DR 231000 fa C 6 AC DRAWNGTILE 5 55 584 OTt Bf ADD 7 5KVA CAPABILITY EG mI CONSTANT CURRENT SE 3 15KVA 7 5 SIGNATURE SERIES A PRODUCTION RELEASE 208 480VOLI 6 6 amp 20AMP S REVISION DESCRIPTION DRAWN RW L8281 829 DPM ACEI FINAL ASSEMBLY LC 1 829 SHOWN 447046 4343736 JIM GAFFNEY O7MAY10 15 1083 Information contained on this drawing is to be used expressly in H PLACES accord m purpose for which it was submitted Any disclosure I of this information is strictly prohibited except as ADB Airfield Solutions Inc may otherwise agree in writing Copyright 2009 ADB Airfield Solutions CHF661 5 XXXX E 60 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Parts and Mechanical Drawings Figure 39 CHF 7 10 15 kW CHF6615 XXXX
23. o Be INA ____ 11 4 30 KW 480V 11213 2 5 11213415678 4 WIRE 531 MUST TIED BLU WIRE TO ANOTHER GND Eu F4 T4 22175 ale ESI eee a oz 5 ATTACH TO FOOT OF sr s s o BLK GRY 506 T1 5 5 50 515155 8 8 6 ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES 2 658 58 g gt N 2116 LOCATE ON FRONT SIDE 54 3g EE WIRE 400 amp 401 TO TOP SIDE OF amp F4 2 2 2 HRS REDIBLK 7 532 OF PANEL c w TO TB1 NEU Sim 7 REMOVED REV n Ha oo 8 SEE BILL OF MATERIALS FOR NUMBER OF MOV s OR SURGE SUPPRESSORS E 9 ab SII via re m REQ D IN EACH LEG o g 5 BRN r 1 8 9 GROUNDING NOTES E ille c GND EACH PANEL TO THE FRAME J 509 COPPER BAR JUMPER JUMPER INTERNAL GND LUG EXTERNAL GND LUG 2 5 m m 10 IF A JUMPER IS NEEDED FOR ANY CORE LEAD USE HIGH VOLTAGE 89A0086 1 WIRE 5 neo SII commo eee 11 IF OUTPUT GOES THRU SGRS BAYS USE 89A0087 1 5 o 58 5 WINDINGS 51281 o os 12 REFERENCE ASSY DWG 44 6292 1 FOR WIRE LUG ASSY 8 B 5 5 E 2 DWS 5 8 ale 514 1 13 FOR ICVM WIRING SEE DWG 8 44 6687 5 2 o 88 5 14 SEE SYSTEM PACKAGE FOR WIRING OF 44 6007 HARTING STAB CONNECTOR 2 UB s an 8 i 58 g 3 o o a 5 um i 5 1 4 30KW 240V CCF 200
24. 5A 250V SLO BLO 4740119 28808 bes XR 8 A bal 304 2 G1 S E S x ale SEE GND ING NOTES ABOVE F X ore 2 9 4 KO OX T 5 2 3 3 3 221 1 09 ge 1 2 FA O EB 11 5599 ty H 8188 Pd q 28A0054 SCR ASSY 30KW SHOWN X 111 X E eee EI 2840056 SCR ASSY 4 10KW 22 CREEP M 2 i amp 28A0055 SCR ASSY 20KW amp 28A0057 SCR ASSY 15KW a T 5 S 225 2 E C 5 8 15882151 0 19 BLU G1 8 5 8 5 8 8 55 7 9 9 2 YEL K1 TB1 As TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER AS 3 BLU T G1 E 88 LISTED COMPONENT LABEL ro O Kt D 25 5 STEP WIRING 585 2 i BE 2 IN MC OR lcd ep 67 9 3 STEP CONN S IN s 2145 ul 2 0017 TERM BLK 35 111 5 355 PUR 2 sq Ev 2 519510 5188 8402 72A0071 TERM 50 in Ib s zEE T NO GND 2 5 ORG G2 r uS 82 COPPER BAR JUMPER COPPER BAR JUMPER 805 105 VARIATIONS OPTIONS 3955 4 FERES Hy 8596 aw 2010 ADB Airfield Solutions All Rights Reserved 65 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulato
25. 6 6A 20A 66A 20A 6 6A 20A 66 20 66 20A aw 324011 32A011 32401 32 011 Ay 323011 5 5 5 5 5 75 32 011 32 011 324011 324011 324011 5 5 5 5 5 823011 324011 32011 32A011 1 4 324011 5 5 5 5 5 15 32011 32 011 324011 32A011 2 011 324011 32A011 32A011 32 011 32A011 4 5 4 5 4 5 4 5 4 5 ookw 323011 323011 32A011 32A011 32A011 32A011 32011 32A011 32A011 32A011 4 5 4 5 4 5 4 5 4 5 gokw 323011 323011 32A011 32A011 32A011 32A011 32011 32A011 32A011 32A011 4 4 4 4 4 4 4 4 4 4 50kw N A N A NA NA N A NA NA N A N A NA NA NA NA N A N A 48 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Troubleshooting 4 Surge Arrestor 6kV 1 Surge Arrestor 6kV Table 32 T5 Current Sensing Transformer CHF XXXX Current Sensing Transformer T5 SIZE 6 6A 35A0548 Transformer Current Sensing 6 6A to 66mA 20A 35A0528 Transformer Current Sensing 20A to 66mA Table 33 4 Power Transformer CHF XXXX Power Transformer T4 35A0539 240 347 480 V to 120 24 V 5A 4 7 5 10 kW 35A0546 Table 34 240 347 480 V to 120 24 V 5
26. 7 5kW 28A0056 28A0056 28A0056 28A0056 28A0056 10kW 28A0056 28A0056 28A0056 28A0056 28A0056 15kW 28A0057 28A0057 28A0057 28A0057 28A0057 46 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC CHF XXXX Dual SCR Block SCR Troubleshooting SIZE 208 V 220 V 240 V 347 V 480 V 20kW 28A0055 28A0055 28A0055 28A0055 28A0055 30kW 28A0054 28A0054 28A0054 28A0054 28A0054 50kW N A N A N A N A 28A0037 70kW N A N A N A N A 28A0037 28A0037 Dual SCR Module 50 70 kW 28A0054 Dual SCR Module 30 kW 28A0055 Dual SCR Module 20 kW 28A0056 Dual SCR Module 4 7 5 10 kW 28A0057 Dual SCR Module 15 kW Table 28 Power Transformer T1 CHF XXXX Power Transformer T1 Core SIZE 208 V 208 V 220 220V 240V 240V 347V 347V 480V 480V 6 6A 20A 6 6A 20A 6 6A 20A 6 6A 20A 6 6A 20A AkW 35A073 35A073 35A073 35A072 35A070 2 2 2 0 8 7 5kW 35A073 35A073 35A073 35A071 35A070 1 1 1 9 7 10kW 35A073 35A073 35A073 35A073 35A073 35 073 35 071 35A072 35 070 35A0712 0 6 0 6 0 6 8 4 6 15kW 35A072 35A073 35A072 35A073 35A072 35 073 35 071 35A072 35 070 35 0711 9 5 9 5 9 5 7 3 5 20kW 35A072 35A073 35A072 35 073 35A072 35 073 35A071 35A07
27. INPUT MONITORING PLUS 4 FIELD CIRCUIT MONITORED INPUT MONITORING PLUS 5 FIELD CIRCUIT MONITORED MONITORING OPTIONS 0 NONE SCANNING MONITOR INTERFACE NOTE 3 2 SCANNING MONITOR READY NOTE 4 3 182 4 IRMS ONLY e 5 1 829 AND IRMS 6 DIGITAL PANEL METER NOTE 5 INPUT VOLTAGE 1 208 n 2 24 i 3 480 4 347 1 52220 L QUTPUT RANGE 3 STEP WITHOUT S1 CUTOUT 1 2 y PANEL LABEL AND ER AMMETER KITTED FOR REV H 8 00 REF CONFIGURE FOR 6 6 20 Lak F66 or F20 ma ronm USE 35A0528 IF 20A CHF IS REQD HIS SIDE 3 4 3 STEP WITH 51 CUTOUT NOTE 2 LT 5 5 STEP WITHOUT 51 CUTOUT 6 5 STEP WITH 51 CUTOUT NOTE 2 35A0308 F 20A E ol 1 828 o o 0 celle off ooo SECTION C C SECTION G G 3540346 FROM KIT S 94 0425 DPM OR94A0334 SMR SECTION H H MOUNT WITH 4 EA 6440173 10 AND 65A0347 4 SEE NOTE 4 AND NOTES 8 FROM DPM KIT 9440
28. L 829 Constant Current Regulator with Universal Regulator Controller URC The manual shows the information necessary to e Install Out Maintenance Out Troubleshooting on the CCF Ferroresonant L 828 L 829 Constant Current Regulator in the manual referred to as the equipment 1 Familiarize yourself with the structure and content 2 Carry out the actions completely and in the given sequence PAGE REV DESCRIPTION NO APPROVED DATE A New manual JC 10 05 09 C Full update JC 12 16 10 All D Updated fuses and added capacitor 3285 RH JC 06 09 11 plate info 2010 ADB Airfield Solutions All Rights Reserved 3 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Product Introduction 2 2 Product Introduction 2 3 Compliance with Standards 2 4 Features 6 9 11 WARNING Read the instructions in their entirety before starting installation This section describes the ADB Airfield Solutions Signature Series Ferroresonant L 828 L 829 constant current regulators CCRs These CCRs are manufactured according FAA specification AC 150 5345 10 latest edition FAA L 828 L 829 AC 150 5345 10 Current Edition ETL Certified ICAO Aerodrome Design Manual Part 5 para 3 2 1 4 to 3 2 1 6 Military UFC 3 535 01 NAVAI
29. SP Low t SP Hi 1743 Cnt 49289 L ad 225 e 2010 ADB Airfield Solutions All Rights Reserved 39 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D 6 9 11 Digital Power Meter Calibration optional O pej m 5 40 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 CHF Ferroresonant 5 0 Maintenance and Repair This section L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Maintenance and Repair provides maintenance and repair instructions for the L 828 and L 829 CHF Air cooled CCRs WARNING Read the instructions in their entirety before starting installation Only personnel authorized to work on high voltage equipment should perform maintenance on the regulator Operate regulator under local control using rotary switch when performing maintenance tasks on the regulator This will prevent the regulator from accidentally being turned on and causing serious injury or death De energize regulator by turning rotary switch to OFF and remove input power to regulator by turning off disconnect switch or main circuit breaker before opening access door to service regulator If the regulator experiences an overvoltage or an over current fault it will enter protective shutdown mode In this mode the regulator turns off un
30. This is to protect personnel from coming into contact with high voltage electronics NOTE Power to the output terminals is now off and the regulator cannot be energized by remote control signals Power is still present on the input power terminals and on the internal control circuitry To bypass the interlock pull out the plunger of the interlock switch This will allow remote and local control of the CCR with the door open See Figure 16 To shut down the CCR set the rotary switch to position OFF The door interlock removes power to the CCR when the door is opened Pull out the plunger fully to bypass NOTE Power to the output terminals is now off and the regulator cannot be energized by remote control signals Power is still present on the input power terminals and on the internal control circuitry To remove input power disengage disconnect switch or external circuit breaker This subsection provides regulator adjustment procedures NOTE The regulator has been adjusted at the factory to provide the nominal output current levels as given in Table 16 If the current level settings need to be adjusted read the following warning statement before proceeding WARNING A Read the instructions in their entirety before starting installation Only personnel qualified to work on high voltage systems should attempt to make any adjustments on the constant current regulator Turn the rotary selector switch on the front panel of the
31. Top CCR 5 a 2 5 26 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 SGRS Style Powerpacks Optional 3 4 SGRS Style Powerpacks CAUTION Optional A Read installation instructions in their entirety before starting installation SGRS Style Powerpacks should be installed using Powerpack lift device For information on installing SGRS Powerpacks refer to the SGRS Installation Manual Document number 96A0303 Figure 14 Powerpack Installation in SGRS c 2 g xS T 7 1 Upper Bay Powerpack 2 Lower Bay Powerpack 2010 ADB Airfield Solutions All Rights Reserved 27 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Frames 6 9 11 1 401 1 Sais 2 8 H3HSVM NOTAN OH 86 311491 NOT 5 7 X ZE 0L Ze gt 5 6 6 23 o 290 2505 Qaivoiuava 39 OL STANVd OVE 3015 6 HOS 1300W 335 3 5 Frames uaria 4 92vo9 uvad 969209 s30v1d HOS SarmiHd 5
32. 1 2 PAN 2 2 2 2 2 2 22 64A0947 EYEBOLT 1 2 1910 2600 4 4 4 4 4 4 23 65A0015 24 1 4 20 HX NU 8 8 8 8 8 8 24 65A0015 29 3 8 16 HX NU 2 2 2 2 2 2 25 65A0180 5 SPRING NUT 3 8 16 10 26 65A0180 6 SPRING NUT 1 2 13 4 27 65A0347 4 1 4 20 SS NYLON INS 16 28 66A0015 29 3 8 FLATWAS 29 66A0015 33 2 FLATWAS 30 66A0026 24 4 SPLIT LOCKWASHEI 31 66A0026 29 3 8 SPLIT LOCKWASHE 32 66A0026 33 2 SPLIT LOCKWASHEI 33 66A0039 5 8 EXT LOCKWASHER 55 34 72A0010 GROUND LUG 35 89A0209 24 IBBON CABLE ASSY 34 POS W CONNS 24 36 91A0033 BL 1828 DANGER HIGH VOLTAGE 37 94 0433 3 SURGE ARR KIT SIG SRS REGULATOR 38 94A0561 1241 WR WIRE KIT IXT 4KW 240V W ACE 39 SEE CORE LIST 4 7 5KW IXT PWR TX XXXV 6 6A 40 94 0561 2482 WR WIRE KIT 7 5 amp 10KW 480V W ACE 1 41 44 7050 828 METER KIT SIG SRS REGULATORS CHF6604 X X X X CONTROLLED COPY 4446528 from 9440425 Usted oats probed nile in RED ink below indicates authorized copy HIGH EFFICIENCY FERRO FIELD CIRCUITS MONITORED 60 2658 5 from KITH 9440425 0 NO INPUT MONITORING NO FIELD CIRCUIT MONITORING SINGLE CHANNEL LAMPS OUT MONITORING MONTORNGOPTONS 1 SCANNING MONITOR INTERFACE NOTE 3 ADB l i i 2 SCANNING MONITOR READY NOTE 3 AD Atela souon TET erent 977 Gahanna Parkway Fax 614 864 2069 5 L829 AND IRMS Columbus Ohio 43230 E POWER METER 2866 SEE ECO MOVE CVM DIR 070 0 CONSTANT CURRENT REG
33. 14 61A0340 KNOB 3FLUTE 1 8 SHAFT ALUM BLK 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 64A0173 10 1 4 20 X 5 8 HX HD 18 7 17 17 17 121 117 21 17 17 17 17 17 17 17 17 17 117 117 16 64A0178 16 1 2 13X 1 HX HD 4 4 4 4 4 4 4 41414 4 17 6440947 EYEBOLT 1 2 13X1 5 1 1910 2600 4 414 4 4 414 41414 4 18 65A0015 24 1 4 20 HX NUT 55 8 8 8 8 8 8 8 8 8 8 8 8 19 65A0347 4 1 4 20 SS NYLON INSERT NUT 11 10 10 10 10 14 10 14 10 10 10 10 10 10 10 10 110 10 10 20 66A0015 33 1 2 FLATWASHER 4 4 4 4 4 4 414 41414 4 21 66A0026 33 1 2 SPLIT LOCKWASHEI 4 414 4 4 414 414 41414 4 22 66A0026 24 1 4 SPLIT LOCKWASHEI 15 15 15 15 18 15 115 15 15 115 115 15 15 15 115 15 15 15 15 23 72 0010 GROUND LUG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 24 89A0209 24 RIBBON CABLE ASSY 34 POS W CONNS 24 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 25 91 0033 LBL 1828 DANGER HIGH VOLTAGE 2 12 5 2 102 1 dee PDS 152 1 de 152 527 2 112 11212212 26 94A0433 6 SURGE ARR KIT SIG SRS REGULATOR 6KV OE SE E 1 21 1 27 SEE CORE LIST 10 15KW IXT PWR TX 208 480V 6 6A 20A fa fafa fafa fafa fa fafa fafa fa fa 29 94A0561 4XYX PWR WIRE KIT 20 amp 30KW QOOQV W ACE fa fafa 32 66 0039 4 6 EXT LOCKWASHER 2121212121212121212121212121212121212 D 3 4437050 1 828 METER KIT SIG SRS REGULATORS 1 11 11 1 1 1 34 66A0039 5 8 EXT LOCKWASHER SS 62 6
34. 15 drop in the load Low VA 2010 ADB Airfield Solutions All Rights Reserved 7 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Theory of Operation 2 8 Theory of Operation 2 8 1 Power Circuit 2 8 2 Output Measurement 2 8 3 Universal Regulator Controller URC 2 8 3 1 URC PCB Inputs Outputs 6 9 11 This subsection describes the L 828 CCR theory of operation See Figure 2 A Ferroresonant network consisting of T1 C1 and the SCRs draws from the input lines This network is capable of drawing a limited amount of power It can be routed to one of two places The first is the output leads to the airfield The second is a resonant tank comprised of C1 and part of T1 As more power is allowed to flow into the resonant tank less is available to flow to the field It is by regulating the current in this tank that the SCRs regulate throughput current to the airfield It is important to note that the output of the regulator will be the smallest when the SCRs are conducting 100 of the time This is the opposite of what is seen in simple SCR regulators where the SCRs are used to directly control the output of the regulator NOTE C1 is actually a bank of capacitors located near T1 The components of the Ferroresonant network are designed to deliver an output current slightly higher than 6 6 A 20 A for the minimum input voltage while the SCRs are fully off
35. 15KW 0 SEE 43A2616 5070 FOR 50 70KW WIRING e Sere NO 2 2 RELATED DOCUMENTS 85 5 POWER WIRING FOR 9440399 DOOR 2 E 5 8 CLOSED INDICATOR BS 988 5 PREVIOUS IRMS W RES WIRING 8148 28 S 8 8 514 423 IRMS IN FIBER CABLEO BLU IRMS im g 8 8 IRMS OUT FIBER CABLEJO GRY agi Bug w Q SC3 12 PPF STAB CONN SC3 11 PPF STAB CONN 48 i 28A0011 SCR 4KW O NOTE 14 14 gt gt o 3 mo 512 578 8 8 fhe g x s5 Tos 105 5 4 5 8 400 A1 K2 Nc DOOR SWITCH SC2 1 Use wrench to hold RES when attaching wires 5 9 e 2 2 ov s 8 2 8 age A2 2 COM1 536 14 7 3 v 2 1 O 2 NO1 PREVIOUS MOLDED STYLE CVM WIRING 5 E E 4 515 6 28 ADD WIRES 541 amp 542 ON m m 5 8 5 600 E 2 48 5 F ACE Potted CVM IRMS Options 8 56 2N P Use wrench to hold RES when al xg S LE 4 330 Cv attaching wires 4 8 5 z TB1 L2 GRY T2 T3 and meter not used amp g a g al a CVM 1 N 200 201 8 FIBER CABLE x 5 gg gt 4 2 p PREVIOUS SCR WIRE COLOR CODING PO 513 RED 512 WHT O 5 4 AN 5 67 O 5 B v TE e Ze 445 0210 S a 5 D CN B 515 gos g PM 2010 ADB Airfield Solutions All Rights Reserved 69 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Un
36. 4 nuts and lock washers to anchor the CCR to the concrete floor NOTE Make sure the clearance behind the CCR is far enough from the wall for easy access to the regulator Figure 11 Anchor Bolt Template A B D CCR A B D Small 22 50 23 50in 23 75in 24 75 Medium 27 50 28 50 28 75in 29 75 in Large 31 50in 32 50 32 75 33 75 24 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Stacking CCR s Optional Figure 12 Location of Bolts for Stacking CCRs D ES T 7 Hex Head Bolts and Split Lock washers Ve x 3 3 4 inch HILTI Anchor Bolt Location 1 Remove the 4 eye bolts from the anchored CCR 2 Stack the second CCR by positioning its 4 holes carefully on top of the holes of the CCR anchored to the concrete floor 3 Install the 4 hex head bolts and split lock washers See Figure 12 Item 1 and Figure 14 Item 1 2010 ADB Airfield Solutions All Rights Reserved 25 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D 6 9 11 Stacking CCR s Optional Figure 13 Stacking Bolt 1 Stacking Bolt 2 Bottom CCR Anchored to Concrete 3
37. 41414 25 66A0026 33 1 2 SPLIT LOCKWASHER 41414 4 41414 414 41414 26 66A0026 15 8 SPLIT LOCKWASHER 28 3 3131313 313 3313 1 3 27 66A0026 24 1 4 SPLIT LOCKWASHER 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 28 72 0010 GROUND LUG 111111111111111111111111111111111 29 89A0209 24 RIBBON CABLE ASSY 34 POS WICONNS 24 111111111111111111111111111111111 30 91 0033 LBL L828 DANGER HIGH VOLTAGE 111111111111111111111111111111111 31 94A0433 6 SURGE ARR KIT SIG SRS REGULATOR 6KV 111111111111111111111111111111111 32 SEE CORE LIST 20 30KW IXT PWR TX 208 480V 6 6A 20A 33 94A0561 5 PWR WIRE KIT IXT 15KW XXX 41111 131111111 111115411154141111412414 34 66A0039 4 6 EXT LOCKWASHER 2 21 912 2 2 21 1 121 91 2 21 10 iF INPUT MONITORING IS SPECIFIED DRIVE 44A6508 1111 6 1 820 SHOWN Ns i BUILD 20KW CCR S USING THIS DRAWING AND CONFIGURING THE PARTS BELOW FOWERCORELIST20 30 IXT FOR 20A REGULATORS CCF2030 XXXX CONFIGURE THE FOLLOWING 35A0703 30KW IXT PWR 480V 6 6A 1 POWER CORE SEE CORE LIST 35A0704 20KW IXT PWR 480V 6 6A 2 SURGE ARRESTOR 6 6A 32A0114 20A 3240115 35A0709 30KW IXT PWR TX 480V 2048 3 CURRENT SENSING TRANSFORMER 35A0528 FOR 20A 35 0710 20KWIXTPWRTX 480V 20h 4 44 7050 35A0715 30KW PWR TX 480 347V 6 64 CONTROLLED COPY 35A0716 20KW IXT PWR TX 480 347V 6 6A
38. 6 6 42 0525 3 Y SWITCH LABEL 3 STEP FERRO 4230525 5 Y SWITCH LABEL 5 STEP FERRO 4280269 1828 44 6006 0007 FIBER OPTIC 7 FEET 4446051 CABINET ASSEMBLY 44 6139 1 N ASSY CCF 4KW 44A6178 X ASSY 34 PIN HDR SW ADAPTOR 3 5 5 44A7035 04 AP PLATE 55 IXT SMALL FRAME 66A0039 4 6 EXT LOCKWASHEI 44A7052 320 COMP PLT IXT 3 55 240V 6 6A L 828 44A7052 323 COMP PLT IXT 3 55 240V 6 6A L 829 333A 3340 335A 44A7052 324 3 55 240V 6 6A L 828 IRMS 1 44 7052 330 244705233 44 7052 334 3 55 480V 6 6A L 828 IRMS 60A2634 REF 44 7052 335 COMP PLT IXT 3 55 480V 6 6A L 829 IRMS 60 3114 SURGE ARRESTOR MTG BRACKET 61A0340 KNOB 3FLUTE 1 8 SHAFT ALUM BLK 64A0173 10 1 4 20 X 5 8 64A0176 12 3 8 16 X 3 4 2 2 2 2 2 2 64A0176 16 3 8 16 X 1 HX 8 8 8 8 8 8 64A0178 16 1 2 13 X 1 HX 4 4 4 4 4 4 20 64A0191 6 X3 8 PAN 6 2 6 2 6 2 1 829 SHOWN 21 64A0198 8 6 32 X
39. KW 200 ADB Ald Solutons PER B 64 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Wiring Schematics 7 0 Wiring Schematics This section provides wiring schematics for the ADB L 828 L 829 Ferroresonant constant current regulators CCRs 4 70 kW 6 6 A 20 A with universal regulator controller URC cards NOTE For the ACE to URC PCB internal wiring diagram for Ferroresonant CCRs 3 and 5 Step refer to the Wiring Schematics section in Advanced Control Equipment ACE manual 96A0287 or Advanced Control Equipment ACE2 manual 96A0357 For Powerpack internal wiring diagram for Ferroresonant CCRs 3 and 5 Step refer to the Wiring Schematics drawing 43A3736 Sheet 1 amp 2 Figure 43 L828 L829 4 30kW 6 6A 20A Internal Wiring Schematic 43A3736 1 of 2
40. LB IN IE AAWG GRRIVER WIREIS NOT 518444 5 11 IF A JUMPER IS NEEDED FOR ANY CORE LEAD USE AVAILABLE USE B8A0232 8 way RUN UNDER CAP BANK HIGH VOLTAGE 89 0086 1 WIRE WRAP WITH GREEN ELECTRICAL lal a 1 amp 12 IF OUTPUT GOES THRU SGRS BAYS USE 40KV 89A0087 1 WIRE SHOWN cHASIs GND CHASIS GND ialo ela _ 2 E 13 FOR ICVM WIRING SEE DWG 44 6687 CONNECTION AREA O Of a zxz 5 STEP WIRING 14 SEE SYSTEM PACKAGE FOR WIRING 44 6007 HARTING STAB CONNECTOR 7 USE EXT WASHER FIRST ig of N OR GRIND PAINT OFF IN eo gaala ale 20 CONNECTION AREA 83 508555504 26 05 2 2 i 82 5 33 T Te 43A2616 WIRING DIAGRAM SGRS 4 30KW 6 6 amp 20A Seo D 29994 4446796 SGRS WIRE HARNESS 50 70KW W CCT PCB ws N co gm 94A0368 5 POWER WIRE KIT FERRO SGRS 50KW o a y N NOTE 1 4 2 94A0368 6 POWER WIRE KIT FERRO SGRS 70KW 2 gt 5 lt DOC NO DESCRIPTION 3 5 o eo RELATED DOCUMENTS 86805 a pw 70 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Wiring Schematics Figure 49 Powerpack 50 70kW 43A2616 5070 page 2 of 2
41. Monitoring ACE Includes FAA L 829 monitoring equipment If application is for connection to ADB L 890 ALCMS Add a A to end of Ordering Code The ACE unit will then be programmed to provide monitoring data via dual redundant communication links If application is for a stand alone L 829 CCR Ordering Code is not changed The ACE unit is programmed to activate a dry contact closure if a fault is present The fault alarm can then be connected to any external monitoring system 4 Insulation Resistance Monitoring System IRMS Ready This option adds an IRMS board in the CCR Application connection to externally mounted ADB ACE unit 5 L 829 Monitoring ACE Includes FAA L 829 and IRMS equipment and IRMS e If application is for connection to ADB L 890 ALCMS Add a A to end of Ordering Code The ACE unit will then be programmed to provide monitoring data via dualredundant communication links e If application is for a stand alone L 829 CCR with Insulation Resistance Monitoring Ordering Code is not changed The ACE unit is programmed to activate a dry contact closure if a fault is present The fault alarm can then be connected to any external monitoring system 6 L 828 with Digital Power Meter This option replaces the analog ammeter with a Digital Power Meter The Digital Power Meter is used on L 828 CCRs to indicate True RMS output current voltage VA and watts It can also be set to activate an alarm if there is a 10 or
42. NO S PER CCR KW RATING B EZ E u mel SEUDISTUSEDE 4 75KW 10KW 15 KW 20KW 30KW poco er AU EAE 2840056 2840056 28A0056 28 0057 2840055 28A0054 8 1 5 21 ATTACH OUTPUT TAG 2 LOSS amp STE 8 8 35 0346 bi 0 200 ol ales P A E 82 55216 8122 3 eae 0 ory 8 3 88 INPUT PWR FUSES 1 amp 2 PER CCR INPUT VOLTAGE amp CCR KW RATING TX T4 FUSES F3 amp F4 RATINGS a B 0 7 NOTE 3 PG 2 PROD ONLY CCR INPUT 8 VOLTAGE 8 4 KW 7 5 KW 10 KW 15 KW 20 KW 30 KW 4 10 KW 15 40 KW 2 3 T a IF VARISTORS ARE PLATE 5 m Jr MOUNTED 208 220V 30A 250V 50A 250V 70A 250V 110A 250V 125A 250V 200A 250V 2A 250V NA 82 E 7 GND PLATE TO EARTH GND Fl m 8 9 240V 25A 250V 45A 250V 60A 250V 80A 250V 110 250 175A 250V 2A 250V NA 2 g 5 8 un S 347 480V 12A 600V 25A 600V 30A 600V 50A 600V 60A 600V 90A 600V TA 500V 3A 500V 5 15 0 48 2 5 8 83 28 z 54 g Coarse 8 55 59 S 2 3 2 8 masai ligeng 18934118 88885 318633 83886 8 ee 7 8 5 DIGITALPOWERMETER 5 4 TL c CLOSED 5 5 4 5 555 44 6528 3988888988898880 22890922 2 82599 CONNECTIONS TO BPM ES z Bg
43. O BOX 30829 Tel 614 861 1304 977 Gahanna Parkway 614 864 2069 Columbus Ohio 43230 CONSTANT CURRENT REGULATOR 15 10KVA 7 5KVA SIGNATURE SERIES 208 480VOLT 6 6 amp 20AMP L 828 L 829 DPM ACEI FINAL ASSEMBLY 7 5KW CORE LOADING Pies eee Information contained on this drawing is 10 be used expressly in accord with purpose for which it was submitted Any disclosure of this information is strictly prohibited except as ADB Airfiel Solutions Inc may otherwise agree in writing Copyright 2009 CH F661 5 XXXX E ADB Airfield Solutions 62 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Parts and Mechanical Drawings Figure 41 CHF 20 30 kW CHF6630 XXXX rte fh pe a EH60A3112 e 0 n e oe 0 O 32A0115 IF 20A REGULATOR CCF2030 XXXX CHF6630 XX XX HIGH EFFICIENCY FERRO Le FIELD CIRCUITS MONITORED NO INPUT MONITORING NO FIELD CIRCUIT MONITORING NO INPUT MONITORING 1 FIELD CIRCUIT MONITORED INPUT MONITORING 1 FIELD CIRCUIT MONITORED ITORING OPTIONS NE L 828 SCANNING MONITOR INTERFACE NOTE 3 SCANNING MONITOR READY NOTE 3 RS ONLY 829 AND IRMS DIGITAL POWER METER NOTE 2 T VO
44. ON position Restore primary power to the CCR at the breaker panel Turn the CCR local switch to the REM position 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 5 4 3 Removing and 1 Figure 33 CCR Power Contactor Replacing Contactor Component Replacement Procedures Turn CCR local switch to the OFF position Contactor 0 401 102 p7 7 400 103 Retaining Screw SIEMENS sz 2 42 15 104 105 501 531 Label the wires Remove and lock out tag out primary power to the CCR at the breaker panel Lock out tag out the SCO in the maintenance position Open the CCR front door by loosening the 3 door screws Loosen the wire retaining lugs for 102 103 104 and 105 and disconnect See Internal Wiring Schematic 43A2522 dwg in Wiring Schematics on page 65 Label any wires not labeled prior to disconnecting them 8 2 Remove wires 400 401 from the top connectors of the contactor Remove the wires 531 and 501 from the contactor coil connections at the bottom of the contactor 10 Remove the 3 mounting screws until the contactor is free 11 Replace the contactor Tighten the contactor retaining screws on the contactor plate 12 Connect wires 531 and 501 to the contactor coil connecti
45. PIN 1 RED STRIPE IS ON THE LEFT SIDE es E 3 len amp 6 3 5 516 J6 SAME FOR ROTARY SWITCH CONN mene 3 38 NN T Ble CVM E Wk T4 347VAC INPUT T1 4 30KW 347 amp 480V 0 1 KEYED MATING CONN IS USED i o E 2 g pe PIN 1 RED STRIPE IS ON THE RIGHT SIDE i DANGER 8 EB 22 2 NOTES SAME FOR ROTARY SWITCH CONN LETHAL VOLTAGE ON HARNESS 5 313 o BK O A ARE PRESENT 1 0 FASTON TERM 8 518 so2 7 2 5 i iR 8 8 E to 44A7075 1 PCB l se Qnm D 8 8 eae USE FIRMWARE 90A0083C 5 196800 higher 09 amp 9 9 104 347V 3 i 8 3 24 28 ss 8 8 99 2 34 r 1 CAUTION INPUT SIDE FEEDBACK o ag 508 14 35A0539 546 1 am SERE i Bae ASSY NOTE 1 PG 2 e e ej e se e amp 8 3 Beg 2 81812 ugs O 33 2 218 5814 37 i 1 2 3 11213 4 5 8 11213 14 5 86 17 8 z 2222 oe 1 e ss ee PREECE T1 4 30KW 480V ONLY 28 o 3d E 2 58 TO TB1 NEU EE 25 5 Ne 6 i g 2 3 i 3 3 087 i 5 2 lt e Z res s S ACE CVM E ae 1 9 CONNECTIONS i G 2 3 3d4 COPPER BAR JUMPER A _ SEE WIRING DIAGRAM 5 258 i OX 43A2550 or 433128 FOR 888 82 i X F6
46. Regulator Controller URC 96A0408 Rev D CCR Door Interlock Optional 4 2 2 Remote Control 4 3 CCR Door Interlock Optional 4 4 CCR Shutdown Procedure 4 5 CCR Adjustment Procedures 30 6 9 11 Table 18 Output Current from Rotary Switch 5 Step 20 A id rotary switch to the The result is B1 8 5 A current output B2 10 3 A current output B3 12 4 A current output B4 15 8 A current output B5 20 A current output See Figure 16 Refer to Table 19 for instructions on how to set up and use remote control Table 19 Remote Control If Then The rotary switch is set to Remote control of the regulator is possible position REM and remote control wiring is connected to remote control terminal block TB1 on the The output current of the regulator will correspond to the brightness regulator setting energized by remote 120 Vac or 48 Vdc control signals Remote control signals will not operate the regulator that is turn the Switchs SENIO OEE regulator on to a particular brightness setting or turn the regulator off No remote control connections exist on terminal block TB1 switch is set to REM The position REM becomes an additional OFF position that is the regulator is de energized The optional door interlock disables remote and local control of the CCR when the door is opened If the door is opened while the CCR is running the CCR will shut OFF
47. Relative Humidity Altitude Without monitoring circuitry 40 to 55 C 40 to 131 F With monitoring circuitry 0 to 55 C 18 to 131 F 10 to 95 non condensing Sea level to 6 600 ft 2000 m L 828 CCRs have the following protection devices Output open circuit protection Output overcurrent protection Lightning arrestors on output terminals and bushings Lightning arrestors on input terminals Fuse protection of AC supply voltage of the URC PCB and brightness control voltage for Remote control The regulator includes an open circuit protective device to open the primary switch within 2 seconds after an open circuit occurs in the secondary The device resets within 2 seconds after the control switch is turned off and re energized and cannot be tripped by switching the load circuits or other transients Regulators include an overcurrent protective device that opens the primary switch when the output current exceeds the 100 percent current 6 6 A or 20 A by 5 percent The device operates within 5 seconds after an overcurrent of 5 percent and within 1 second after an overcurrent of 25 percent The device resets within 2 seconds after the control switch is turned off and re energized The overcurrent protection cannot be activated by a momentary 0 25 second overcurrent caused by switching the load circuits and other transients Input voltage is single phase 60 Hz ac Regulators o
48. The other L 828 CCRs 4 7 5 10 20 30 kW 6 6 A 20 A and 50 70kW may differ in size and appearance Figure 3 1 828 CCR 4 30kW 6 6 A 1 Ammeter shown or Digital Power Meter 2 Rotary Switch The L 828 CCRs are designed to Supply three or five precision output current levels 6 6 20 A maximum to power airport series lighting circuits on runways and taxiways e Accurately regulate the output current to within 1 of the adjustable nominal levels from no load to full load and with input voltage variations of 5 to 10 of nominal Maintain the nominal output current levels even when 30 percent of the isolation transformers in the series lighting circuit supplied by the regulator have open secondaries 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 L 829 CCR 2 10 L 829 CCR See Figure 4 This subsection describes the L 829 CCR The L 829 uses a URC to provide regulator and control functions It also uses the Advanced Control Equipment ACE or ACE2 for control and monitoring functions NOTE Figure 4 shows a L 829 15 kW 6 6 A CCR The other L 829 CCRs 4 7 5 10 20 30 kW 6 6 A 20 A amp 50 70kW may differ in size and appearance Figure 4 L 829 CCR with ACE2 Q Q m 2 1 ACE2 F
49. applicable Not applicable Not applicable Not applicable AWG 3 0 Increased 1 wire size to comply with small conductor limits in NEC 240 4 D It is recommended that the circuit breaker on the input power supply lines have a rating of 125 of the CCR s input current as given in Table 4 unless local codes require a different rating technique Refer to the CCR s nameplate for the kW rating and input voltage to determine the actual input current from Table 4 If no standard size circuit breaker exists at the 12595 value use the next larger standard size circuit breaker NOTE The currents listed in Table 4 represent actual input currents assuming the worst case limits of AC 150 5345 10 for power factor efficiency and number of required lamps out Table 4 CCR Input Voltage and Current for the CCR Power Ratings song 208 Vac 220 Vac 240 Vac 347 Vac 480 Vac 4 kW 27A 26A 24A 16A 12A 7 5 kW 51A 48A 44A 31A 22A 10 kw 68A 65A 59A 41A 30A 15 kW 97A 92A 84A 58A 42A 20 kw 129A 122A 112A 78A 56A 30 kw 190A 179 A 164A 114A 82A 50 kW Not applicable Not applicable Not applicable Not applicable 136A 70 kW Not applicable Not applicable Not applicable Not applicable 188A 15 2010 ADB Airfield Solutions All Rights Reserved CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D 2 18 Specifications Specifications 6 9 11
50. for which such products are made ADB Airfield Solutions will correct by repair or replacement at its option equipment or parts which fail because of mechanical electrical or physical defects provided that the goods have been properly handled and stored prior to installation properly installed and properly operated after installation and provided further that Buyer gives ADB Airfield Solutions written notice of such defects after delivery of the goods to Buyer Refer to the Safety section for more information on Material Handling Precautions and Storage precautions that must be followed ADB Airfield Solutions reserves the right to examine goods upon which a claim is made Said goods must be presented in the same condition as when the defect therein was discovered ADB Airfield Solutions furthers reserves the right to require the return of such goods to establish any claim ADB Airfield Solutions obligation under this guarantee is limited to making repair or replacement within a reasonable time after receipt of such written notice and does not include any other costs such as the cost of removal of defective part installation of repaired product labor or consequential damages of any kind the exclusive remedy being to require such new parts to be furnished ADB Airfield Solutions liability under no circumstances will exceed the contract price of goods claimed to be defective Any returns under this guarantee are to be on a transportation charges
51. lbs 3492 72A0306 1 8 2 HARTING CONN S 48 in Ibs 205 609 Sous 68 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Wiring Schematics Figure 47 Powerpack 5 30kW 43A2616 page 2 of 2 REV S 8 B SUPPLY TX LEAD COLORS ALL REGULATORS 300 SERIES WIRES TANK LOOP 600V 105 C NOTES Dies 23 og coLons 100 SERIES WIRES PRIMARY 4 MIRE NUMBER EASSIGNED AT THE CREATION OF E 45 dm VAC INPUT _ m POWER 600V 105 C USTD REGULATORS UCCF 2004 REGULATORS 2 WIRE SIZES EIE ae 502 WHT tu ae 083 28 WHTIBRN 100 105 PRIMARY POWER SEE TABLE 253 PERS F3 ae ORG POWER 480 V POWER ALL V s POWER ALL V s 200 210 HIGH VOLTAGE 12AWG 25KV 150C 89A0086 1
52. prepaid basis For products not manufactured by but sold by ADB Airfield Solutions warranty is limited to that extended by the original manufacturer This is ADB Airfield Solutions sole guarantee and warranty with respect to the goods there are no express warranties or warranties of fitness for any particular purpose or any implied warranties of fitness for any particular purpose or any implied warranties other than those made expressly herein All such warranties being expressly disclaimed Trademarks General notice other product names used here are for identification purposes only and may be trademarks of their respective companies Proprietary Information This information carrier contains proprietary information which shall not be used for other purposes than those for which it has been released nor be reproduced or disclosed to third parties without the prior written consent of ADB Airfield Solutions No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical photocopy recording or otherwise without the prior written permission of ADB Airfield Solutions No patent liability is assumed with respect to the use of the information contained herein Neither is any liability assumed for damages resulting from the use of the information contained herein ADB Airfield Solutions shall not be liable to the purchaser of this product or third parties for damages losses
53. signals in accordance with the desired output current setting Detects an overcurrent or open circuit and switches the constant current regulator off When in Remote mode enables the CCI to provide 120 Vac at 50 W The CCI is the Remote power control source Figure 6 Universal Regulator Controller URC S 5 Lad 2 12 1 L 829 Advanced See Figure 4 and Figure 7 The L 829 ACE or ACE2 control and monitoring unit Control Equipment ACE consists of an integrated control unit that is interfaced to each CCR either internally or within or ACE2 a small external enclosure The ACE printed circuit boards are mounted inside a small and rugged environmental enclosure that is directly attached to the door of the L 829 CCR The ACE consists of microprocessor based module s that processes communication control commands input output interface and failsafe functionality for controlled elements in the airfield lighting vault Figure 7 2 Control Board For more information about the ACE see e Advanced Control Equipment ACE manual 9640287 or the Advanced Control Equipment ACE2 manual 96A0357 Programming manual 9640348 2010 ADB Airfield Solutions All Rights Reserved 13 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC L 828 L 829 CCR Monitoring Options 2 13 L 828 L 829 CCR Monitoring Options 2 13 1 Opti
54. the CCR to prevent damage to the PCB that is located on the front Left side of the enclosure If output input and remote control wiring must enter from the left side of the enclosure then wiring must be then routed through conduit where it passes the PCB area See Figure 10 2010 ADB Airfield Solutions All Rights Reserved 21 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Installation 22 6 9 11 To install wiring perform the following procedure 1 Verify the input supply voltage corresponds to the voltage rating on the nameplate of the regulator 2 Make sure the front panel rotary selector switch is set to the OFF position 3 Ground the regulator by making an adequate ground wire AWG 6 or larger connection to the external earth ground lug on the regulator 4 An appropriate disconnect type cutout or circuit breaker shall be provided outside the regulator for the input power supply lines 5 Short circuit the output terminals TB2 1 TB2 2 using 8 AWG minimum wire to avoid lamp destruction in case of excessive current output 6 Referto Table 3 for the recommended input wire Connect the power supply lines from the disconnect switch or main circuit breaker to the CCR input fuse block F1 F2 or terminal block TB3 Tighten all connections Figure 10 Wiring on Right Side of CCR 1 1 Front of C
55. top screws on the assembly plate and tighten all four until the arrestors are secure Connect the wires for 100 402 101 403 802 and 803 and tighten retaining screws Close the CCR front door by tightening the 3 door screws Restore the SCO to the ON position Restore primary power to the CCR at the breaker panel Turn the CCR local switch to the REM position Turn CCR local switch to the OFF position Remove and lock out tag out primary power to the CCR at the breaker panel Lock out tag out the SCO in the maintenance position Remove the side panel of the CCR by removing the 8 mounting screws Be careful as you will also need to disconnect the ground wire attached from the frame to the panel Figure 34 Output Lightning Arrestors 8 9 E 7 4 Loosen the 11 16 inch wire retaining nuts for 200 201 203 ST1 5 2 and 202 and disconnect Remove the 4 10 x 32 pan head screws and retain until later Replace the Input Lightning Arrestor assembly Replace and tighten the screws on the assembly plate Connect the wires for 200 201 203 ST1 ST2 and 202 and tighten retaining nuts Connect the ground wire from the frame to the side panel 10 Put the side panel back on the CCR with the 8 screws 11 Restore the SCO to the ON position 12 Restore primary power to the CCR at the breaker panel 13 Turn the CCR local switch to the REM position 56 2010 ADB Airfield Solutions All Rights Reserved 96A0408
56. 0 3 15 5 16 1 12 1 12 7 10 0 10 6 8 2 8 8 The regulator maintains the output current within the limits of Table 8 while powering any load between no load or short circuit and full load For regulators 10 kW or larger the regulation is maintained over the full range of environmental conditions specified in this section and for the input voltages specified in Table 4 For regulators less than 10 kW the regulation is provided at nominal input voltage for all brightness steps 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 2 18 4 Regulation 2 18 5 Environmental Operating Conditions 2 18 6 Protection Devices 2 18 6 1 Open Circuit Protection 2 18 6 2 Overcurrent Protection 2 18 7 Input Voltage 2 18 7 1 Built In True rms Reading Ammeter L 828 only 2 18 7 2 Rating and Input Voltage 2 18 8 Temperature Rise CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Specifications Refer to Table 8 for output current limits Current regulation is obtained under the conditions listed in Environmental Operating Conditions The L 828 CCRs are designed for indoor use only in an area with adequate ventilation for cooling the constant current regulator The environmental operating conditions include temperature range relative humidity and altitude Table 9 Environmental Operating Conditions Temperature Range
57. 2 35 070 35 0710 8 4 8 4 8 4 6 2 4 30kW 35A072 35A073 35A072 35A073 35A072 35A073 35A071 35A072 35A070 35A0709 7 3 7 3 7 3 5 1 3 50kW N A N A N A N A N A N A N A N A 35A0605 70kW N A N A N A N A N A N A N A N A N A 35A0604 Table 29 Power Core List Power Core List 35A0604 70kW High Efficiency Power Transformer 480V 20A 35A0605 50kW High Efficiency Power Transformer 480V 20A 35A0703 30kW High Efficiency Power Transformer 480V 6 6A 35A0704 20kW High Efficiency Power Transformer 480V 6 6A 35A0705 15kW High Efficiency Power Transformer 480V 6 6A 35A0706 10kW High Efficiency Power Transformer 480V 6 6A 35A0707 7 5kW High Efficiency Power Transformer 480V 6 6A 35A0708 4kW High Efficiency Power Transformer 480V 6 6A 35A0709 30kW High Efficiency Power Transformer 480V 20A 35A0710 20kW High Efficiency Power Transformer 480V 20A 35A0711 15kW High Efficiency Power Transformer 480V 20A 35A0712 10kW High Efficiency Power Transformer 480V 20A 35A0715 30kW High Efficiency Power Transformer 480 347V 6 6A 2010 ADB Airfield Solutions All Rights Reserved 47 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Troubleshooting 6 9 11 35A0716 20kW High Efficiency Power Transformer 480 347 6 6A 35A0717 15kW High Efficiency Power Transformer 480 347V 6 6A 35A0718 10kW High Effic
58. 2 6 2 6 6 2 6 2 6 2 6 2 6 2 6 2 CCF6615 325A SHOWN BUILD 10KW AND 7 5KW CCR S BY USING THIS DRAWING AND CONFIGURING THE PARTS BELOW FOR 20A REGULATORS CONFIGURE THE FOLLOWING 7 5 amp 10KW NOT APPLICABLE 1 POWER CORE SEE CORE LIST 2 SURGE ARRESTOR 15KW 6 6 94A0433 6 15KW 20A 94A0433 3 10KW 6 6 94A0433 3 3 CURRENT SENSING TRANSFORMER 3540528 ON ALL 20A 4 AMMETER KIT SEE 44 7050 REPLACEMENT ITEMS FOR 7 5KW 208 480V SEE SHEET 3 REPLACEMENT ITEMS FOR 10KW 240 480V OED COPY ES 6 6 21212 a a 5 3 a E a a E initialed m RED ink below indicates authorized copy DESCRIPTION DESCRIPTION 2 SZ 5 SIEISISISIS 8535535325 ADB 3 31 313 331313 313131313 3133 31313 3 3 31313 313 3 3 31318313 ADB Airfield Solutions PO BOX 30829 Tel 614 861 1304 27 SEECORELIST pwn TSAN 2068W FRO iji 1 1 1 27 SEECORELIST 20 80V FERRO 1 1 1 1 1 1 1 t osoecio 977 Gahanna Parkway Fax 614 864 2069 10 44A7032 07 CAP PLT ASSY 7 5 KW IXT CCR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10 44A7032 10 CAP PLT ASSY 10 KWIXT CCR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2964 SEEECO DIR 23NOVI0 Columbus Ohio 43230 12 44A7069 320 7 5 PLT ASSEM 6 6A 208 480V SIG SRS 1
59. 300 311 TANK LOOP amp CAPS 2 AWG 600V 105C 8940199 9 300 303 2 RUNS AS SHOWN 9 55 3 E 400 409 MEDIUM CURRENT 12AWG 600V 105C 89A0185 9 017 PERE C 500 562 STD CONTROL 18AWG 600 89A0182 9 BRIAN POWER oS O 600 604 HIGH VOLTAGE 8AWG 7 5 8940202 600 105 C Eo Tele alok OBSOLETE USE 200 SERIES WIRE 1 z u 700 701 INPUT POWER 2 0 AWG 600 105C 89A0231 ene 800 806 GROUND 12AWG 600 GN YL 89A163 5 89A0201 9 904 906 GROUND 18AWG 600V GN YL 89A0163 7 70 kw 2 0 AWG 5 1000 1004 GROUND 4 AWG 600V 105 GN YL 8940233 a 1100 GROUND 6 AWG 600V 105 GN YL 89A0168 5 86 E 395 1 RELATED DOCUMENTS 2282 5 216 2010 ADB Airfield Solutions All Rights Reserved 71 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Wiring Schematics 6 9 11 72 2010 ADB Airfield Solutions All Rights Reserved CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC User Manual Registered office ADB Airfield Solutions LLC 977 Gahanna Parkway Columbus OH 43230 USA Phone 1 614 8611 304 Fax 1 614 8642 069 Other addresses ADB Airfield Solutions Ltd 5500 North Service Road Suite 1108 Burlington Ontario L7L 6W6 Canada Phone 1 905 331 6887 Fax 1 905 331 9389 ADB Airfield Technol
60. 36 x 29 x 30 in 556 480 514 600 91 4 x 73 7 x 76 2 cm 91 4 x 73 7 x 76 2 cm 252 2 217 7 233 1 272 2 WRN 36 x 29 x 30 in 36 x 29 x 30 in 783 749 770 826 91 4 x 73 7 x 76 2 cm 91 4 x 73 7 x 76 2 cm 355 2 339 7 349 3 374 7 ISRN 36 x 29 x 30 in 36 x 29 x 30 in 960 872 826 906 91 4 x 73 7 x 76 2 cm 91 4 x 73 7 x 76 2 cm 435 4 395 5 374 7 411 40 x 33 x 34 in 40 x 33 x 34 in 20kW 1290 1150 1187 1097 101 6 x 83 8 x 86 4 101 6 x 83 8 x 86 4 585 4 521 6 538 4 497 6 cm cm or 40 x 33 x 34 in 40 x 33 x 34 in 1410 1350 1381 1302 101 6 x 83 8 x 86 4 101 6 x 83 8 x 86 4 639 6 612 3 626 4 590 60 cm cm 50kw2 NA 70 x 33 x 34 in NA NA NA NA 2150 975 2 5 177 8 83 8 86 4 2400 7OkW cm NA NA NA NA 1088 6 1 Based on Input Voltage 2 50kW and 70kW CCRs are only available on 480V input Figure 8 1 4 SE D go EOR H Front View Y 18 Ferroresonant CCR Dimensions Typical of 4 30 kW Top View 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 2010 ADB Airfield Solutions All Rights Reserved CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Dimensions Figure 9 Ferroresonant CCR Dimensions Typical of 50 70 kW SSI
61. 4 CORE T1 4 30KW 480V 8 8 8 5 si cle ant ce lca NM i amp g 25 USED INSULATE CCF 2004 CORE 8 104 WTOVR1 a 8 8 o 9 gt lc 99 18 z a uj S a X 4e STA 104 225 2 E s E g g C CC TOTO 2840028 SCR 7 5 30KW 5 al al gf 4 4 TO VR2 W O CVM L x3 SNUBBER ASSY gt sas L x3 FOR 2840011 4KW SEE PG 2 TB 1 W 44A6149 K FOR PREVIOUS SCR COLOR CODING SEE PG 2 21915 vy c1 5 STEP WIRING Jalal a p WIRBSCLOSS x2 1 2 SIC c C2 3 STEP CONN S IN s 59 ojona 802 210 8048 0537 FAN x A xj gt 105 io o Z i NV 4 C H 8 8047 2 a COMP PANEL Ty i2 8 x T T H3 GND LUG BOLT 88 828882 8 8 8 8048 0 539 28 Z ON BACK SIDE 90 000002020 2 FAN NEUTRAL 22420 1000 100 oc NOTE 14 C E L 301 H2 SC HARTING GND PIN E 5 H4 Y ale ARSD E OIG DANT CE TN TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER 808 r Lc RAK CONNECTION AREA w CHASIS GND AS LISTED ON COMPONENT LABEL 4456 4 0 H4 72A0017 TERM BLK 35 in lbs ELO EN SEE 43A2616 5070 FOR 50 70KW WIRING 72A0071 TERM BLK 50 in
62. 425 COO 30 00 PORZOSEIS FROM DPN NOTES C 44022 2 a 1 SEE SHEET 2 FOR BOM ISOMETRIC VIEW L 829 AND Za 2 DPM DOOR SHOWN PLACES 27 CONFIGURED 5 FOR 10KW AND 7 5KW REGULATORS 2900 SEE SHEET 3 FOR 7 5KW CORE LOADING 5 2 51 OPTION IS ADDED AT COMPONENT PLATE LEVEL O 5 3 SMI OPTION IS ADDED AT COMPONENT PLATE LEVEL 4 SMR OPTION IS ADDED AT COMPONENT PLATE LEVEL 5 DIGITAL POWER METER OPTION IS ADDED AT THE s 85595405 58148 COMPONENT PLATE LEVEL i e 4 TJ T lo EB 6 ALEGIBLE COPY OF 43A3736 WIRING SCHEMATIC IS TO BE PERMANENTLY MOUNTED IN AN UNOBSTRUCTED PLACE INSIDE i mo J Tei THE CONTROL CABINET E wn TE FII PLACES 4 L lo CONTROLLED COPY S Unauthorized duplication of this document in whole or part is prohibited Initialed in RED ink below indicates authorized copy
63. 531 228 DA 252 Leni C 2 EON IG an 10AWG ES 400 409 MEDIUM CURRENT 12AWG 600V 1060 88 01856 981 dh 409 RE E 485 299 894019319 SROI 500 547 STD CONTROL 18AWG 600V 89A0182 9 FEE 80 x C 28 7 5 kW 10AWG 75 8AWG 7 5 8AWG 600 HIGH VOLTAGE 8AWG 7 5 SIL 8940202 BLKBLK 13 em 89A0195 9 89A0196 9 89A0196 9 OBSOLETE USE 200 SERIES WIRE 700 701 PRIMARY POWER 6AWG 600V 105C 89A0230 M no mE 10 kW 10AWG 10 kW 8AWG 10 kW 8AWG 800 806 GROUND 12AWG 600V GRN YEL 89 163 5 i Ge 3 89A0195 9 89A0196 9 89A0196 9 900 905 GROUND 18AWG 600V GRN YEL 89A0163 7 H STE TED TO vo oR RED mus ANC JERN SANG 15 KW 6AWG 1000 01 GROUND 6AWG 600V GRN YEL 89A0168 5 1 4 480 0 2 89A0195 9 89A0199 9 89A0197 9 i F4 T4 B B gt 502 WHIBRN RED se 20 KW 222 20KW 20kW TBB 43A2550 WIRING DIAGRAM ACE1 TO URCII 1 PCB uo 8 F3 43A3128 WIRING DIAGRAM ACE2 TO URCII 1 PCB i B 2 508 T 30 kW 6AWG 30 kW 2AWG 30kW TBD 43A2616 5070 WIRING DIAGRAM SGRS 50 amp 70KW E sd 8 E 55 _ 8 WHEBLK VIGET 508 89A01 97 9 89A01 99 9 44 6293 FERRO SGRS WIRE HARNESS 4 30KW 6 6 20 5 3 3 94 0368 1 POWER WIRE FERRO SGRS 4KW 212 8 8 amp 59 BLK C 94A0368 2 POWER WIRE KIT FERRO SGRS 7 5 amp 10KW H 5 94A0368 3 POWER WIRE KIT FERRO SGRS
64. 55 589 m 1 2 SEE PG 2 FOR DOOR CLOSED INDICATOR WIRING a 5 jg 22 ge B ese 1 i 3 DOOR SWITCH 8624 SC26 4 IA wsc P TE 900 1 85 2 8 50601 538 li 55 o 501 pie Cu x2 ANALOG Bt e k 1 VR1 I SC1 2 801 WW METER Flo jue pz 353058 818 203 203 Lt 35A0539 546 REV C SAME COLORS LG INDUCTOR L OPTION T9 AX NO GND REQD HTN 2 HV SC2 3 8 1 208 240 VAC INPUT SEE PG 2 FOR PREVIOUS REV S L 828 42 T6 3 4 i pA 7 5 6 6A 3530493 VR2 amp RESP 502A BLK TA ey 506 TO STAB CONN L 3540528 HE HH NOTE 14 DPM OPTION E 5 REDIBLK GRNIVEL 532 221 2 FI 2 5 P gt f 5 5 A NOTE 14 5 5 51 15 5 6 C vio s BRN so DIGITAL PWR METER 54438225 EJ OPTION SHC 509 8 28 3c 528 VM 24 B i 1248 E RED C mu 531 ads 7 NOTE 8 3 155222535 4 20 WIRING ROTARY SWITCH Bk do Hindi A Pee CONNECTION PI P2 pee SHE 88 20 283344 5 F5 250V SLO BLO 47 0119 814 13 211 514 13 211 BAAS S T9 OPTIONAL SCO WIRING I 509 510 C 8 5 0308 i NOTE 4 5 7 d Y Y 20 6 6A i 5 8 TO IRMS i 451 524 d 5 e 579 1 4 UN KEYED MATING CONN W
65. 89A0196 9 89A0196 9 89A0196 9 89A0196 9 300 303 TANK LOOP SEE TABLE OFg 1 zee 400 409 MEDIUM CURRENT 12AWG 600V 105 C 89A0185 9 82 k 25 15 kW 4AWG 6AWG 6 AWG 6 AWG Ec Hd 89 0198 9 89 0197 9 89A0197 9 89A0197 9 500 535 STD CONTROL 18AWG 600V 105 C 8940182 9 4 8 800 804 GROUND 12AWG 600V GN YL 89A163 5 2 ase 20 kw 1 0 AWG 2 AWG 2 AWG 6 AWG 22 2 3 2 2 900 905 GROUND 18AWG 600V GN YL 89A0163 7 30 kW 1 0 AWG 2 AWG 2 AWG 6 AWG 3 SEE BILL OF MATERIALS FOR NUMBER OF MOV s OR SURGE 433 88 0 89A0201 9 89A0199 9 89A0198 9 89A0197 9 SUPPRESSORS IN EACH LEG H E H Bi iiis n 300 SERIES WIRES 10 0 4 USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK iB EHE TANK LOOP POWER SBEH 8 8 600V 105 C akw 10AWG 2 2 5 IF A JUMPER WIRE IS REQUIRED FOR ANY CORE LEAD USE HIGH a 89 0195 9 VOLTAGE 89A0086 1 WIRE 7 5kW 10AWG 6 GROUNDING NOTES hii NOTE USES 44A6035 1 PCB WITH 89A0195 9 GND EACH PANEL TO THE FRAME 5 ge inui JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG s B 33255 10 kw 6 AWG 2 82542945 FIRMWARE 90A0041D 7 USES POWER WIRE KIT 94A0561 XXXX 1 14132283 15 6AWG 89A0197 9 5 20 kW 2AWG u 89 0199 9 25 DIGITAL POWER METER OPTION 30kW 2AWG 2 e 89A0199 9 aa z 216 a OUTPUT NOTE 8 le OUTPUT CONNECTIONS g 1 6 TERMINAL BLOCKS SCR PART
66. A 15 20 30 50 70 kW CHF XXXX Other parts CHF XXXX Other parts 44A7075 1 URC PC Assembly IRMS LI Board Option 44A6397 44A6178 Rotary Switch 3 Step 44A6178 5 Rotary Switch 5 Step 1475 92 030 Table 35 CHF XXXX Current Curre SCO Series Circuit Cutout Option nt Voltage Monitor Assembly CVM Voltage Monitor Assembly CVM Option 44A6326 10 Current Voltage Monitor Assembly 6 6A 44A6326 11 Table 36 CHF XXXX Ammeter Current Voltage Monitor Assembly 20A Ammeters 52A0099 Analog Ammeter 6 6A 52A0098 Analog Ammeter 20A Note Refer to ACE M anuals for Optional L 829 Monitoring and Control Table 37 44A6107 1 CCF XXXX Capacitor Plate 30kW 6 6A and 20 20kW 6 6A 208 480V 44A6107 2 44A6107 2 20kW 20A 208 480V 44A6107 3 15kW 6 6A and 20A 208 480V 44A6108 3 10kW 208 480V 44A6108 1 7 5kW 208V 44A6217 4kW 208 480V 44A6392 07 7 5kW 220 480V 44A6483 09 2010 ADB Airfield Solutions All Rights Reserved 10kW and 30kW 2400V 49 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Troubleshooting 44 6483 13 6 9 11 50kW 20A 480V 44A6483 18 20kW 2400V 44A6483 26 50 50 kW 20A and 70kW 20A 480V 2010 ADB Airfield Solutions All Right
67. A 49A0097 70kW N A N A N A N A 49A0097 49A0081 Fuse Block 10 30A 600V 49A0082 Fuse Block 31 60A 600V 49A0085 Fuse Block 61 100A 600V 49A0097 Fuse Block 100 200A 250V 72A0091 Fuse Block 2P 30A 250V 72A0098 Fuse Block 31 60A 250V 72A0099 Fuse Block 100 200A 250V Table 23 L 828 L 829 Step Down T4 Transformer Fuses and F4 Fuses F3 and F4 on the L 828 L 829 CCRs protect transformer T4 which supplies 110 Vac and 24 Vac to the universal regulator control card Transformer T3 Fuses F3 and F4 Ratings CHF XXXX T4 Fuses F3 F4 SIZE 208 V 220 V 240 V 347 V 480 V 4kW 47A0113 47A0113 47A0113 47A0113 47A0108 7 5kW 47A0113 47A0113 47A0113 47A0113 4740108 10kW 47A0113 47A0113 47A0113 47A0113 4740108 15kW 4740187 47A0187 4740187 4740187 4740187 20kW 4740187 4740187 4740187 4740187 4740187 30kW 4740187 4740187 4740187 4740187 4740187 50kW N A N A N A N A 47A0187 70kW N A N A N A N A 47A0187 47A0108 Fuse 1A 500V 47A0113 Fuse 2A 250V 47A0187 Fuse 3A 500V 49A0084 Fuse Holder double 4 20 30 kW Table 24 1 829 Power Supply Transformer Fuse F5 ACE Power Supply Fuse Universal regulator power supply transformer fuse F5 protects the remote control circuitry on the URC Fuse F6 protects the 120 Vac power supply to the ACE Fuses F5 and F6 Ratings CHF XXXX ACE Fuses F5 F6 47A0119 Fuse 5A 250V 47A0061 Fuse Block single 2010 ADB Airfield Solutio
68. A0070 47A0193 47A0091 10kW 47A0094 47A0071 47A0071 47A0088 47A0085 15kW 47A0099 47A0096 47A0096 47A0217 47A0088 20kW 47A0072 47A0072 47A0099 47A0097 47A0087 30kW 47A0102 47A0101 47A0101 47A0106 47A0097 50kW N A N A N A N A 47A0106 70kW N A N A N A N A 47A0141 4740069 Fuse 25A 250V Time Delay 4740070 Fuse 45A 250V 4740071 Fuse 60A 250V 47A0072 Fuse 125A 250V 4740085 Fuse 30A 600V 4740087 Fuse 60A 600V 4740088 Fuse 50A 600V 4740090 Fuse 12A 600V 4740091 Fuse 25A 600V 4740092 Fuse 30A 250V 4740093 Fuse 50A 250V 4740094 Fuse 70A 250V 4740096 Fuse 80A 250V 4740097 Fuse 90A 600V 4740099 Fuse 110A 250V 47A0101 Fuse 175A 250V 47A0102 Fuse 200A 250V 47 0106 Fuse 125A 600V 47A0120 Fuse 2400V 47A0141 Fuse 200A 600V Table 22 Input Fuse Blocks CHF XXXX INPUT FUSE BLOCK Item 11 SIZE 208 V 220 V 240 V 347 V 480 V 4kW 72A0091 72A0091 72A0091 49A0081 49A0081 7 5kW 72A0098 72A0098 72A0098 49A0081 49A0081 10kW 72A0091 72A0098 72A0098 49A0082 49A0081 15kW 72A0091 49A0091 49A0091 49A0085 49A0082 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 CHF XXXX INPUT FUSE BLOCK Item 11 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Troubleshooting SIZE 208 V 220 V 240 V 347 V 480 V 20kW 72A0099 7240099 72A0099 49A0085 49A0082 30kW 72A0099 72A0099 72A0099 49A0097 49A0085 50kW N A N A N A N
69. AS USED d Sm m x 208 9955 8 L 59 o SC3 PIN 1 RED STRIPE IS ON THE LEFT SIDE HV SC1 SC3 8 Zo g uuu E gt 16 SAME FOR ROTARY SWITCH CONN a sn ge amp IF KEYED MATING CONN IS USED Ey SED K 20 90 26 HV SC2 T4 347 VAC INPUT PIN 1 RED STRIPE IS ON THE RIGHT SIDE 61 669 4 T4 SAME FOR ROTARY SWITCH CONN CVM VR2 NOTE 11 9 In oS o BLK GRY 506 1 2072 pont 8 5 2 i GRN YEL 532 f 2 2 DANGER T1 5 8 2 503 1 oF 44 A6035 1 LETHAL VOLTAGE GND FRAME USING a io JUMPER ALWAYS USED ARE PRESENT i 6AWG G Y WIRE 2 E 518 8 8 BLK BRN 508 3 STEP 5 URC II PCB ASSY S 6 5 8 a 2 2 JUMPER 6 a 8 ole 509 5 5 5 2 8 8 i NOTE 1 ol 526 _ CONTROL 1 ASSEMBLY NOTES REB WINDINGS 508 gt 1 ADD APPROPRIATE JUMPER WHERE REQUIRED ONLY 1 JUMPER REQ D FORA ag xg amp 6 6A 5 STEP TIE ALL JUMPERS INTO CABLE HARNESS SO CONNECTOR HAS og 2 u o ee ae Ne TO BE PULLED FROM PCB WHEN REPLACING PCB E a g w Q COMPONENT PANEL 2 USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK T4 480 VAC INPUT 2 3 ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING gt of
70. BLY 447069 334 7 5 COMP PLT ASSEM 6 6A 208 480V SIG SRS 1 E 1 44A7047 334 10 COMP PLT ASSEM 6 6A 208 480V SIG SRS 5 1 E E 1 MATOS 488873 SIM GAFFNEY Ss E 4417069335 75 KIA COMP PLT ASSEM 66A 208 480V SIG SRS E 3 2101 25 E 5 F 44A7047 335 10KVA COMP PLT ASSEM 6 6A 208 480V SIG SRS 1 1 1 1 1 1 1 11 15 203 26 94 0433 3 SURGE ARR KIT SIG SRS REGULATOR a a 3 11 11111211 26 94404333 SURGE ARR KIT SIG SRS REGULATOR 3KV 11111111111111111 11 11 1111111 1 Information contained on this drawing is to be used expressly in 94 0561 3 XXX PWRWIRING KIT CHF 7 5KW XXXV 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 94405671 3 PWRWIRING KIT CHF 10KW XXXV W ACE 1 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 accord with purpose for which it was submitted Any disclosure 6615 11 57 22 2010 ADB Airfield Solutions All Rights Reserved 61 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Parts and Mechanical Drawings 6 9 11 Figure 40 CHF 7 10 15 kW CHF6615 XXXX 5 husm SAPANG STRAP 475 SUB ASSE 18 5 0015 33 12 13 HX NUT Unauthorized duplication of this document in whole or part is prohibited Initialed in RED ink below indicates authorized copy ADB Airfield Solutions P
71. CC B100 OFF Not applicable Table 13 Remote 120 Vac Control Connections 5 Step 6 6 For this remote intensity step Connect CCI to 2 8A 3 4A CC B2 4 1A CC B3 5 2A CC B4 6 6A CC B5 OFF Not applicable Table 14 Remote 120 Vac Control Connections 5 Step 20 A For this remote intensity step Connect CCI to 85 10 3A CC B2 12 4 A CC B3 15 8 A CC B4 20 A CC B5 OFF Nothing 12 Make sure wiring connections are tight and no wires are shorting across each other CAUTION A Read installation instructions in their entirety before starting installation Incorrect wiring can damage regulator Double check all connections 13 Energize regulator and set rotary selector switch to REM Operate the CCR by remote control and verify correct current levels are obtained on all brightness steps 14 Turn rotary selector switch to OFF and de energize regulator disengage disconnect switch or main circuit breaker Remove short circuit link between output terminals TB 2 1 and TB2 2 15 Connect the 6 6 A or 20 A series lighting circuit to the output terminals bushings and tighten all connections Table 15 Input Output Connections CCR Size Input Location Output Location 4 thru 30kW with SCO Bottom of SCO Top of each Fuse Block front of 7 component plate right hand side Lightning Arrestors VR1 and VR2 CHF 30kW 208 V on Back o
72. CR 2 Place Conduit and Wire on Right Side of CCR 7 Engage main circuit breaker or disconnect switch to energize the regulator 8 Turn front panel rotary selector switch to all brightness steps and verify that current values on the panel ammeter correspond to those in Table 8 for each brightness step 9 Disengage the main current breaker or disconnect switch to de energize the regulator 10 Turn the rotary selector switch to OFF 11 Connect remote control lines if required to remote control terminal block TB1 Use AWG 18 300 V wire or larger for 120 Vac signals See Wiring Schematics on page 65 for remote control connections NOTE If the ADB Airfield Solutions Advanced Control Equipment ACE is used with the Ferroresonant L 828 CCR refer to the Advanced Control Equipment manual 96A0245 or Advanced Control Equipment 2 ACE2 manual 96A0357 for wiring connections to remote control Table 12 through Table 14 provide the necessary connections for remote control Terminal B1 B10 does not need to be wired Brightness step B1 B10 occurs when the regulator is switched on Table 12 Remote 120 Vac Control Connections 3 Step 6 6 For this remote intensity step Connect CCI to LOW 4 8 A CC 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Installation MEDIUM 5 5 A CC B30 HIGH 6 6 A
73. Conditions 2 17 2 18 6 Protection Devices 2444044 0010 17 2 18 6 1 Open Circuit 17 2 18 6 2 Overcurrent 17 2 187 Inp ut Voltage nete UOS 17 2 18 7 1 Built In True rms Reading Ammeter L 828 only 17 2 18 7 2 Rating and Input Voltage 17 2 18 8 Temperature RISC c o cro ecce eni nates 17 2 19 Diirenslons enm ettet epp Pe iati eq tees 18 3 0 Installation eee 21 zUrnipacking mode enge ieedeituedieeelhiane 21 3 2 Install tlOri Ree 21 3 2 1 Wiring Connections and 21 3 3 Stacking CCR s Optional 24 3 4 SGRS Style Powerpacks Optional 27 S Se Frame S ass 28 4 0 29 4 1 o be 29 4 2 CCR Control 2 0 0 aeaiee 29 4 2 1 Eocal Gornittol aos iue ER oi Bed eie 29 4 22 Remote Control er EUER AR 30 4 3 CCR Door Interlock 2 40 2 24 30 4 4 CCR Shutdown Procedure 2 30 4 5 CCR Adjustment Procedures
74. EE 9 2 8 7 Remote Control Position Detection 2 4 4 0040 1 9 2 8 8 Fault Protection eedem nee ere er Riiie 9 29 L828 COR 5 e etude edite edet aima um edite 10 210 1 829 CGU e iR IN GITARRE ME 11 2 1 SGRS Powerpack soa de been tege td de d 11 2 12 Universal Regulator Controller sseeeenees 13 2 12 1 L 829 Advanced Control Equipment ACE or ACE2 13 2 13 L 828 L 829 CCR Monitoring Options 14 2 13 1 Optional Insulation Resistance Monitoring System 14 2 13 2 Optional Scanning Monitor Interface 14 2 13 3 Optional Scanning Monitor 14 2 14 Optional Series Cutout Type SCO sese 14 2 15 L 828 CCRs 4 70 kW 6 6 A 20 A Required Equipment 14 2 16 input Wire Size tea e oat ie e qan er tee eee 15 2 17 Input Power Breaker 15 2 18 Specifications o eeu acid ta 16 2 18 T ie HE eun eU est ces 16 2010 ADB Airfield Solutions All Rights Reserved iii CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D TOC 6 9 11 2 18 2 Reactive Loading 2 18 3 Resistive Loading 2 18 4 Regulation eU eet HD ber et OE p ER ER RARR 2 18 5 Environmental Operating
75. Hegulator turns on but de energizes suddenly If problem exists in Remote and local control replace universal regulator controller SCRs always conducting Verify SCR is triggering by replacing PCB Check SCRs and wiring for shorts in SCR circuitry Replace SCR snubber assembly Replace SCR Defective Ferroresonant resonant circuit transformer or capacitor Visually inspect capacitors for damaged housing or wire connections Visually inspect transformer for damaged coils connections and or wiring Faulty capacitors will exhibit a bulging case CCR overload Faulty overcurrent protection 2010 ADB Airfield Solutions All Rights Reserved Remove section of load Replace URC PCB 51 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Additional L 829 General Troubleshooting Procedures Problem 6 Short lamp life and or high output current reading on panel ammeter 7 Regulator not indicating proper current 8 Regulator operates by the local control switch but not by Remote control Possible Cause Incorrect output current adjustment 96A0408 Rev D 6 9 11 Corrective Action Refer to Output Current Adjustment on page 31 Faulty overcurrent protection Incorrect output current adjustment Replace URC PCB Refer to Output Current Adjustment in the Operation section Refer to Problem 11 in this table Cur
76. ION DETAIL DFW CCF6630 535A DFW REGULATORS TO CONFIGURED AS FOLLOWS o DRIVE ACE 1 KIT 94 0342 0 OVERLAY 44 6106 AND ACE HARNESS 44A6139 2 ACE1 IN THE MRP BOM INTERFACE _ DRIVE 94A0485 IN THE MRP BOM DRIVE 44A6032 DFW HINGED TOP ENCLOSURE PANEL ASSEMBLY 44 35 DFW N THE MRP BOM tar z s m OE 25 o Ve 30KW 347 480V SHOWN SEE CHART ON SHEET2 Sees il MS c L 828 eZ ONLY a 4 1 9 CONFIGURE F66 FOR 6 6A o e F20 FOR 20A CONTROLLED COPY Unauthorized duplication of this document in whole or parts prohibited initialed in RED ink below indicates authorized INTIAL amp DATE di ADB Information contained on this drawing is to be used egre in ADB Airfield Solutions lt d 76 Lo INSTALL DFW J INTERFACE 94A0485 IN THIS LOCATION accord with purpose for which it was submitted Any disclosure d P 0 BOX 30829 Tel 61 inr 1304 977 Gahanna Paray zd 614 864 2069 SEE NOTE 7 of this information is strictly prohibited except as ADB Airfield w Solutions jhe iting Copyright 2009 a d e m at erwise agree in writing Copyrig CHF6630 XXXX B
77. LTAGE SEE NOTE 6 35A0528 IF 20 REGULATOR 5 2 Li 000 T 1144 CONFIGURE FOR 3 STEP 5 STEP Ste Ch Ore 6 PLACES THIS SIDE E ao 5 8 B i 5 amp NOTES OUT 5 QUE 19 153 STEP WITH 51 CUTOUT NOTE 2 OWS 5 5 STEP WITHOUT T 4PLACES gt 6 5ST 60 amp 20 15 LI CONFIGS ONLY 2 8 NOTE da 4 L 828 DOOR SECTION B B SCALE 1 4 SECTION 3300 CONFIGURE FOR 8 NOTES 3 STEP 5 STEP 34 00 1 SEE SHEET 2 FOR BOM ISOMETRIC VIEW AND DPM DETAIL REF 2 S1 AND DIGITAL POWER METER OPTIONS ARE ADDED AT COMPONENT PLATE LEVEL Ya DRIVE 94340341 FOR 51 DRIVE 9440425 FOR DPM is BPLACES 2027 Dc DED SMI amp SMR OPTIONS ARE AD T COMP PLT LEVEL O Q DRIVE BHASIN FOR 20A FOR SMR DRIVE 94A0335P FOR SMI ALEGIBL 3736 WIRING SCHEMATIC IS TO BE PERMANENT Y MOUNTED IN AN UNOBSTRUCTED PLACE INSIDE THE TROL CABINET PANELS ARE HIDDEN FROM VIEW FOR CLARITY SEE 44A7045 X FOR INSTALLAT
78. Mutual Road and Rivonia Boulevard South Rivonia 2128 South Africa Phone 27 11 234 6768 Fax 27 11 234 6739 The information contained in this document is subject to change without notice ADB reserves the right to make changes and improvements to its products and assumes no responsibility for making these modifications on any equipment previously sold 96A0408 2010 ADB Airfield Solutions All Rights Reserved Document Date 12 2010
79. OP SIDE amp LEFT SIDE OF PCB TO CONNECT TO J3 m 40 FASTONTERM 10 IF A JUMPER IS NEEDED FOR ANY CORE LEAD USE HIGH VOLTAGE 89A0086 1 WIRE L828 TO TB1 NEU A CONNECTIONS app rancoro F 70 10 SEE BILL OF MATERIALS FOR NUMBER OF MOV S OR SURGE SUPPRESSORS IN EA _ SEE WIRING DIAGRAMS 5 1 SCR a8 alls PUR 43A2550 FOR ACE1 28A0028 5 8 6 E 43A3128 FOR ACE2 F6 250 SLO BLO 47A0119 3 XOOOO 252 lo dz COPPER BAR JUMPER 2 CONTROLLED COPY TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER AS LISTED ON COMPONENT LABEL 4 g itt eon ann tpat s pi hes n RED ho nso 8 72 0017 TERM BLK 35 in Ib s PREVIOUS 2840028 i APPROVED BY DATE 7240071 TERM BLK 50 in Ib s COLOR CODING 514 RED ADB Airfield Solutions 44A6504 1 WIRE HARNESS 50 70 515 WHT gt gt 977 Gahanna Parkway Columbus Ohio 43230 44A6504 2 WIRE HARNESS CCF 50 70 W ACE l sl s 2 2 5 Telephone 614 861 1304 Fax 614 864 2069 wo io O 94A0338 X48X POWER WIRE KIT FERRO CCR DRAWING THLE TB1 41 16 WIRING DIAGRAM 1 828 W URC 43A2550 WIRING DIAGRAM ACE1 TO URCII 1 PCB age A 3040 PRODUCTION RELEASE marn 50 amp 70KW FERRO CHF o 512 WHT X 43A3128 WIRING DIAGRAM ACE2 TO URCII 1 PCB am 5 STEP WIRING m cn ium i
80. PONENT PLATE LEVEL 9440425 3300 4 CONTROLLED COPY Unauthorized duplication of this document in whole or parts prohibited A Initialed in RED ink below indicates authorized copy Ig1 Lej BEN INTAL amp DHE ADB 9 9 9 0500510290598 5 oD F ADB Airfield Solutions PO BOX30829 Tel 614 861 1304 977 Gahanna Parkway Fax 614 864 2069 Columbus Ohio 43230 C 2866 DR DRAWING TLE 8 2964 SEE 22 DR mem CONSTANT CUBIENT REGULATOR 4KW SIGNATURE SERIES 1 828 SHOWN Xis 10 PLACES 51 PRODUCTION RELEASE JEG 99 480 VOLT 66 AMP 1 917 REVISION DESCRIPTION mv 1 828 1 829 LEVEL NUMBER VEN cu FNAL ASSEMBLY 1200 4343736 JM GAFFNEY O4AUGIO Em 7 Information contained on this drawing is to be used expressly in purpose for which if ila Any of this information is strictly prohibited except as ADB Solutions Inc may otherwise agree in writing Copyright 2009 ADB Airfield Salton ee CHF6604 C 58 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Parts and Mechanical Drawings Figure 37 4 kW CHF6604 XXXX PART NUMBER DESCRIPTION CORE LIST 35A0708 PWR TX IXT 4KW 480V 6 64 350720 PWRTX IXT 4KW 347 480V 6 6A a 350732 PWRTX IXT 4KW 208 220 240V
81. R 51 50AAA 2 Uses Supplies three or five precision output levels to power series lighting circuits on airport runways and taxiways e Advanced CCR architecture combines the performance advantages of both saturable reactor and Ferroresonant technologies Produces minimal EMI high efficiency and near unity power factor for AC 150 5345 10 test conditions exceeding FAA and military requirements for power factor and efficiency Unique CCR design has excellent input power factor and efficiency at all intensity steps and lower loads Does not exceed the conducted power line emission limits given in Table 4 of AC 150 5345 10 latest edition with testing as specified by the Federal Communications Commision FCC in the Code of Federal Regulations CFR Title 47 Subpart B Section 15 107b Does not exceed the radiated emission limits given in Table 5 of AC 150 5345 10 with testing as specified in the Code of Federal Regulations CFR Title 47 Subpart B Section 15 109b Optional integrated ACE unit provides state of the art remote control and L 829 monitoring capability Unique cycle mode allows display of True RMS current and voltage VA watts lamps out and series circuit insulation resistance value to be alternately displayed A visual indication is also provided for all other FAA monitored parameters including open circuit overcurrent loss of input power loss of input voltage low VA drop in load VA of 1096 Remote Local stat
82. ROUND 18AWG 600V GN YL 89A0163 7 1 RED STRIPE IS ON THE RIGHT SIDE SAME FOR ROTARY SWITCH CONN 304 amp 305 203 212 i i f 100 SERIES WIRES PRIMARY POWER NOT YET APPROVED FOR 70KW 38 42 3e awe 44A7075 1 PCB 600V 105 C dons 1 3 201 3 aH 15 USE FIRMWARE 90A0083D POWER OPTIONAL 7OKW Cord 81 CONROE 1 or higher U9 50kW 1 0 AWG 28 SCO 103 57 WINDING A ji 89A0201 9 5 1 300 amp 301 523 6 ASSEMBLY NOTES KP 145 9bR True alee neice 1 WIRE NO S REASSIGNED AT THE CREATION OF THIS DOC 1307 8 308 515 10 4 w ASSY NOTE 7 29 9 29 88 2 GROUND TO FOOT OF TRANSFORMER ren TAS g o 3 ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING NE 2 4 i m 2 WIRE 691 MUST BE TIED TO BLU WIRE NOT TO ANOTHER GND 9D m 5 CAUTION INPUT SIDE FEEDBACK a B 221078 6 DELETED 501 501A f4 TE 5 7 ADD APPROPRIATE JUMPER WHERE REQ D TIE ALL JUMPERS INTO CABLE A 0 HARNESS SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB MALEPASTON 8 GROUNDING NOTES 11213 12 34 56 1 2 3 4 5 6 7 8 TERM GND EACH PANEL TO THE FRAME e o m Fn JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG 800 303 2IRUNS EACHAS SHOWN 5 al 3 Sy 85 5 REPLACE FORK TERM 9 ROUTE THESE WIRES ALONG T
83. Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Parts and Mechanical Drawings 6 0 Parts and Figure 35 Ordering Codes Mechanical Ordering Code CHFXXXX XXXX Drawi ngs Amperage T 66 6 6A output 20 20A output Size 04 4kW 6 6A only 07 7 5kW 6 6A only 10 10kW 6 6A only 15 15kW 20 20kW 30 30kW 50 50kW 20A only 70 70kW 20A only Output Range 3 3 step without Series Cutout 4 3 step with Series Cutout 5 5 step without Series Cutout 6 5 step with Series Cutout Input Voltage 1 208 4 30kW only 2 240 4 30kW only 3 480 4 347 4 30kW only 5 220 4 30kW only Monitoring Options See Application Notes 0 None Standard L 828 1 ALCMS Scanning Monitor Interface 2 ALCMS Scanning Monitor Ready 3 L 829 Monitoring ACE 4 Insulation Resistance Monitoring System IRMS Ready 5 L 829 Monitoring ACE and IRMS 6 L 828 with Digital Power Meter CCR Input Output Monitoring 0 No optional CCR input or output circuit monitoring A With L 829 or IRMS monitoring without optional input CCR monitoring G With L 829 or IRMS monitoring with optional input CCR monitoring Notes Aferroresonant CCR is preferred for airports that require low output harmonic content EMI or that have varying loads such as Runway Guard Lights using incandescent tungsten halogen lam
84. SSY 302 BNC 50001 3 8 5 ole i 8 2 8 8 POS STOP BLADE INSTALLATION gt 526 3g 5 REMOVE NUT 8 WASHERS TURN UPSIDE DOWN ze i AND TAP SHAFT TO REMOVE BLADES SHAFT al Eg ASSEMBIY NOTES 44 517 YEL M FLAT MUST BE IN THE POSITION SHOWN 8 2 ASSEMBLY NOTES 8 85 S338 19 518 BLU WHEN RE INSTALLING THE BLADES g wl g Sk 1 ADD 2 JUMPERS TO J5 AS SHOWN TIE JUMPERS INTO CABLE HARNESS a 415 CAUTION BLADES ARE VERY SMALL 5 z 5 E SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB Twisted 22awg wires STOP 5 5 8 2 GROUND TO FOOT OF TRANSFORMER AE rf ane BLADES 2 208 3 ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING o eTa 5 a 8 alg 4 WIRE 531 MUST BE TIED TO BLU WIRE NOT TO ANOTHER GND 12 TS 5 5 5 53 5 5 ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES EOR PREVIOUS SPR COLOR CODING SEERG 2 nK 23 1838 6 SNUBBER MAY BE SUPPLIED WITH SCR 8 88 93 8 7 REMOVED REV B CARS Ej 9 uw uw wo 8 GROUNDING NOTES sct3o pc 9 gt o GND EACH PANEL TO THE FRAME 1002 GNDIUC BOLT JUMPER INTERNAL GND LUG TO EXTERNAL 1000 ON BACK SIDE 1 3 STEP REG 5 STEP REG GND LUG BE PULLED FROM PCB 50120 1001 228 2 48 COMP PANEL 9 REFERENCE ASSY DWG 44 6292 2 FOR WIRE LUG ASSY 5 806 a 10 TORQUE SPEC S OF 53A0412 150 CONTACTOR 120
85. The output current flows through the high voltage current transformer T5 T5 provides feedback to the URC board on the actual current output to the airfield series circuit A second current transformer T2 provides current to a true rms reading ammeter mounted onto the front panel to indicate output current See Figure 6 This subsection describes the board level circuitry found on the universal regulator controller Figure 2 1 828 CCR Power Circuit Block Diagram C1 Ha 5 15 72 Input gt mi Voltage p 9 9 C urrent i SCRs i RMS Current 1 Meter URC as Controller RE LM gs 84 Local Control The URC receives the inputs listed below See Figure 6 in this section and Wiring Schematics on page 65 Local control signals from the front panel rotary switch Remote control signals from a remote control terminal block located in the L 828 chassis 120Vac 48Vdc TB1 A current proportional to the output current from a current transformer T5 Phase angle reference voltage derived from the input voltage 24 Vac center tapped supply voltage from T4 The URC provides the outputs listed below Acontact to complete the input contactor K1 coil circuit Acontact to enable the Remote CCI voltage at TB1 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 2 8 4 Output Current Monitor Circuitry 2 8 5 Loc
86. This subsection provides specifications for L 828 L 829 CCR 4 70 kW 6 6 A 20 A Table 5 Class Style and Power Ratings 1829 17329 Brightness Class CCR Max Style 9 Nominal Output Current Power Ratings Steps Output Current 686A 1 3 4 8 5 5 6 6 4 7 5 10 15 20 2 5 2 8 A 3 4 A 4 1 A 5 2 A 6 6 A and 30 kW 15 20 30 50 and 2 20 A 2 5 8 5 A 10 3 A 12 4 A 15 8 A 20 A 70 kW Table 6 Power Factor CCR Power Factor 4 10 kW 0 90 minimum 15 70 kW 0 95 minimum 2 18 1 Efficiency 2 18 2 Reactive Loading 2 18 3 Resistive Loading 16 The efficiency of the regulator operated with rated input voltage into a full load having unity power factor is not less than the value shown in Table 7 Table 7 Efficiency CCR Efficiency 4 20 kW 0 90 minimum 30 kW 0 92 minimum 50 kW 0 93 minimum 70 kW 0 94 minimum The CCR maintains the output current within the limits of Table 8 for all brightness steps when the load is connected via isolating transformers and the secondaries of 30 percent of the transformers become open circuited The load before opening the isolation transformer secondaries may be any value from half to full load For regulators less than 10 kW loaded as specified above the current remains below 6 8 amperes for the 100 percent brightness step Table 8 Output Current and Limits Nominal output amperes A Allowable range 188 Style Step root mean square RMS A RMS 19 7 2
87. ULATOR pun VOLTAGE 8 2964 SEE ECO METER KIT CHNG DIR 22NOVIO KW SIGNATURE SERIES 2 24 a PRODUCTION RELEASE 208 480 VOLT 6 6 AMP 3 480 828 L E di poii P pei pom pss JM GAFFNEY sur p OUTPUT RANGE 18 102 3 3 STEP WITHOUT 51 CUTOUT Information contained on this drawing is to be used expressly in 4 3 STEP WITH 51 CUTOUT NOTE 2 accord with purpose for which it was submitted Any disclosure 5 5 STEP 51 CUTOUT ofthis information is strictly prohibited except as ADB Airfield 6 5 STEP WITHS1 CUTOUT NOTE 2 my terns agree in writing Copyright 2010 CH F6604 XXXX 2010 ADB Airfield Solutions All Rights Reserved 59 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Parts and Mechanical Drawings 6 9 11 Figure 38 CHF 7 10 15 kW CHF6615 XXXX CHF6615 XXXX HIGH EFFICIENCY FERRO 2 CIRCUITS MONITORED NO INPUT MONITORING NO FIELD CIRCUIT MONITORING NO INPUT MONITORING 1 FIELD CIRCUIT MONITORED NO INPUT MONITORING 2 FIELD CIRCUITS MONITORED NO INPUT MONITORING 3 FIELD CIRCUITS MONITORED NO INPUT MONITORING 4 FIELD CIRCUITS MONITORED NO INPUT MONITORING 5 FIELD CIRCUITS MONITORED NO INPUT MONITORING 6 FIELD CIRCUITS MONITORED INPUT MONITORING PLUS 1 FIELD CIRCUIT MONITORED INPUT MONITORING PLUS 2 FIELD CIRCUIT MONITORED INPUT MONITORING PLUS 3 FIELD CIRCUIT MONITORED
88. WR TX 208 220 240V 6 6A 9 44A6508 1110 ACE II INTERNAL ASSY LCD DISPLAY W LOM 1 1 1 4d 1 1 1 3540735 15KW IXT PWR TX 208 220 240V 20A 00 10 44A7032 XX CAP PLT ASSY 10 15KW IXT 1411 111 111 1T 3 13 1 111 4 1 44A7045 M SHIPPING STRAP 10 15KW IXT SUB ASSE 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 44A7046 320 COMP PLATE ASSEM 15 KVA 240V 6 6A IXT d pem ems qam 12 44 7046 323 COMP PLT 15KW 3 55 L829 240V 6 6 5111 E Ae hl 12 44A7046 324 COMP PLT 15KW 3 55 L828 240V 6 6A IRMS ONLY i 22220165 2 5 S Be 12 44 7046 325 COMP PLT 15KW 3 55 L829 IRMS 240V 6 6A IRMS gt amp 28 1 jT 12 44 7046 326 COMP PLATE ASSEM 15 KVA 240V 6 6A L 828 W DPM amp om 81155 5 12 44 7046 330 COMP PLATE ASSEM 15 KVA 480V 6 6A IXT s 1158 15 11 d e de eet Qu 1829 DOOR 12 44 7046 331 COMP PLT 15KW 3 55 L828 480V 6 6A SMI ONLY 1 1 1 1 111 1 1 12 44A7046 332 COMP PLT 15KW 3 55 L828 480V 6 6A SMR T0 05017 2012 2112 2315 2382 AE Ee 12 44A7046 333 COMP PLT 15KW 3 55 L829 480V 6 6 IXT gt 2 11 ME bem a a fel 12 44A7046 334 COMP PLT 15KW 3 55 L828 480V 6 6A IRMS ONLY g Sv dm pm s 5415 caa 12 44A7046 335 COMP PLT 15KW 3 55 L829 IRMS 480V 6 6A 52111254 E il Be see Nee s j
89. acing Contactor 2 55 5 4 4 Removing and Replacing Input Lightning Arrestors front of Component Mounting Plate ied ee DRE REI GI ETHER RS ES 56 iv 2010 ADB Airfield Solutions All Rights Reserved CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D 6 9 11 Toc 5 4 5 Removing and Replacing Output Lightning Arrestors front of Component Mounting AEA E 56 6 0 Parts Mechanical 6 2 2 57 7 0 Wiring Schematics 248 28 22 eee e qtio eter ideae 65 74 Document Date 12 2010 9 a 2010 ADB Airfield Solutions All Rights Reserved CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D 6 9 11 TOC 5 5 7 vi 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 1 0 Safety 1 1 To use this equipment safely 1 1 1 Additional Reference Materials 1 1 2 Qualified Personnel 1 1 3 Intended Use 1 1 4 Storage Safety This section contains general safety instructions for installing and using ADB Airfield Solutions equipment Some safety instructions may not apply to the eq
90. ads from output terminals and bushings Use AWG 8 or larger wire to short output bushings 3 Energize the regulator and turn the rotary selector switch to the lowest brightness step 1 and then to the remaining brightness steps Check the output current on the ammeter at each step NOTE The output current should be within the tolerance given in Output Current and Limits on page 12 The panel meter is intended to indicate function Any calibrations should be performed with a calibrated true rms current meter 4 If the output current is not within the limits specified in Output Current and Limits on page 12 check the input voltage to the regulator The supply voltage should be within 5 to 10 of the nominal input voltage given on the regulator nameplate Refer to Adjustment Procedures in the Operation section 5 Turn off disconnect switch or main circuit breaker to remove input power to regulator 6 Disconnect the shorting jumper and reconnect output cables 7 Close input power disconnect switch or main circuit breaker WARNING Read the instructions in their entirety before starting installation Only personnel authorized to work on high voltage equipment should perform maintenance on the regulator Since high open circuit voltages may result by opening the primary of a series lighting circuit only personnel authorized to work on high voltage equipment should be allowed to perform the open circuit test To perform th
91. age Calibration At the calibration screen scroll to Vrms on the menu and press the ENTER button The next screen Figure 28 shows the last calibration voltage set points and internal A D numbers Select Y yes to enter the Vrms calibration Figure 28 Vrms Calibration 5 o 5 New Vrms Cal SP Low Cnt 8 SP Hi 3185 nt 114824 A Vrms High Step Loaded WARNING A Read the instructions in their entirety before starting installation Use proper safety procedures when adjusting the meter display Following screen prompts apply the field load or equivalent resistive load to the CCR at the high step Measure the Vrms at the CCR output terminals with the High Voltage probe Adjust the meter display to match the measured voltage Wait for the cnt number to settle this may take a couple minutes while the load heats up and then press the ENTER button 38 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Digital Power Meter Calibration optional Figure 29 Vrms High Step Loaded Rpplu Hi Step Loaded adjust value to match Vrms 3106 Cnt 1421 Wait until settled B Vrms Off Follow the prompts to turn off the CCR When the Cnt has settled press the ENTER button Cnt may not go to zero Figure 30 Save Vrms Calibration Save Vrms Cal
92. al Control Position Detection 2 8 6 Contactor Drive 2 8 7 Remote Control Position Detection 2 8 8 Fault Protection CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Theory of Operation Gate drive signals to the SCR block used to regulate the output current The system output current is sensed by a current transformer T5 whose secondary is connected to J8 3 and J8 4 on the URC board This current signal is passed through a 15 ohm shunt resistor R38 located on the URC board For the 6 6 amp regulator T5 provides 100 1 step down of the feedback current For 20 A regulators this ratio is 300 1 Output current steps 1 5 would correspond to voltage levels of 420 510 615 780 and 990 millivolts respectively Local control position detection is accomplished by using a rotary switch mounted on the front door of the CCR See Figure 3 The contactor drive circuit on the URC PCB pulls in the main contactor K2 by shorting points J4 2 to J4 4 When the local control signal to the micro controller indicates remote the remote control circuitry is active Relay K1 on the URC board closes providing 120VAC to the CCI connection on TB2 The remote control inputs incorporate surge suppression and are optically isolated from the rest of the PCB This subsection describes URC fault protection Overcurrent Protection The micro controller detects an over current condition by
93. amaged wires or damaged insulation exists Inspect housing for rust spots Clean and touch up rust spots with paint Inspect lightning arrestor connections Tighten any loose connections Replace charred or burnt wiring or broken arrestors Perform a short circuit test Refer to Short Circuit Test in this section Perform an open circuit test Check load on regulator Refer to Open Circuit Test in this section At installation and subsequent load changes make sure that the output rms voltage times the output true rms current does not exceed the rated load on the nameplate of the regulator 41 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Maintenance Schedule 5 1 1 Short Circuit Test 5 1 2 Open Circuit Test 42 6 9 11 WARNING Read the instructions in their entirety before starting installation Only personnel authorized to work on high voltage equipment should perform maintenance on the regulator Since high open circuit voltages may result by opening the primary of a series lighting circuit only personnel authorized to work on high voltage equipment should be allowed to perform the short circuit test To perform the short circuit test perform the following procedure 1 Remove input power to the regulator turn off disconnect switch or main circuit breaker and turn the rotary switch to OFF 2 Remove le
94. bled Figure 20 SCO Cutout Operation Position Microswitch NO NC Series Circuit Regulator Ground See Figure 21 In the maintenance position the regulator and the series circuit are both shorted and grounded The microswitch is not activated 2010 ADB Airfield Solutions All Rights Reserved 33 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D SCO Cutout Working Positions 34 6 9 11 Figure 21 SCO Cutout Maintenance Position NO Microswitch NC Series Circuit Regulator Ground You can determine the current orientation by observing the cutoff corner of the handle See Figure 22 In the test and measure position the insulation resistance of the series circuit can be measured The regulator operation can be tested under short circuited output conditions In the test and measure position the regulator is shorted and grounded the series circuit is shorted and connected to the measurement socket The microswitch is activated Figure 22 SCO Cutout Test and Measure Position NO Microswitch NC Regulator Series Circuit Measurement Socket Ground 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 4 7 Application Notes Monitoring Option Description CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Application Notes Application 0 None Standar
95. comparing the output current to a preset value If the output current exceeds this value the controller will shut the regulator down by removing drive to the input contactor This contactor will remain de energized until the controller is reset either by selecting the OFF position remotely or locally or cycling the input power off for a minimum of 2 seconds and then back on The control board will not recognize momentary over currents caused by load switching or other transient conditions Open Circuit Protection The micro controller detects an open circuit by the absence of current in the regulator output this will also detect an open or shorted current transformer If the output current is less than 1 5 amps the controller will shut the current regulator down within one second by removing drive to the input contactor This contactor will remain de energized until the controller is reset either by selecting the OFF position remotely or locally or cycling the input power off for a minimum of 2 seconds and then back on 2010 ADB Airfield Solutions All Rights Reserved 9 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D L 828 CCR 2 9 L 828 CCR 10 6 9 11 See Figure 3 This subsection describes the L 828 CCR The L 828 uses a Universal Regulator Controller URC to provide regulator and control functions NOTE Figure 3 shows a Ferroresonant 15 kW 6 6 A L 828 CCR
96. costs or expenses incurred by purchaser or third parties as a result of accident misuse or abuse of this product or unauthorized modifications repairs or alterations to this product ADB Airfield Solutions shall not be liable against any damages arising from the use of any options or parts other than those designated as approved products Copyright 2010 by ADB Airfield Solutions All rights reserved ii 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Toc TABLE OF CONTENTS CHF Ferroresonant L 828 L 829 Constant Current Regulator i 1 0 5 22 uode i te iut 1 1 1 To use this equipment safely 1 1 1 1 Additional Reference Materials 2 1 1 1 2 Qualified Personnel iie Linens teen ie deed eet 1 1 1 9 Intended USB niti ier bc RE ede eor toco 1 cie n 1 1 1 41 2 ente eet 2 1 1 4 2 Material Handling 2 1 1 4 3 Action in the Event of a System or Component Malfunction 2 1 1 4 4 Maintenance and 2 1 1 4 5 Operation of Overloaded 2 2 0 Introduction en EHE
97. current transformer CT and one potential transformer PT It also has resistor loads and a fuse in the potential transformer secondary Differential signals presenting the actual series circuit voltage and current are transmitted to the scanning monitor system two conductor shielded cables The series cutout Type SCO is often used at airports having a large number of series circuits to isolate the series circuit from the CCR during maintenance or testing operations It also allows manual measurement of resistance of the series circuit to ground without disconnecting the series cable The SCO cutout has a nominal working voltage of 5 kV and a nominal carrying current capacity of 20 amps AC For more information refer to the SCO Cutout manual 9640294 Refer to Table 1 for required equipment that is supplied Refer to Table 2 for required equipment that is not supplied Refer to Parts and Mechanical Drawings on page 57 for ordering information Table 1 Required Equipment Supplied Description Quantity L 828 L 829 constant current regulator As Req d on Order Instruction manual 1 per CCR on Order Table 2 Required Equipment Not Supplied Description Quantity Input power wire Refer to Table 3 As required Remote control wire AWG 18 minimum AWG 14 maximum As required Ground wire AWG 8 minimum 6 6 A AWG 6 minimum 20 A As required Output load wire AWG 6 minimum 5000 Vac L 824 type 6 6 A AWG 8 As
98. d L 828 supplied with analog ammeter ALCMS Scanning Monitor Interface SMI The SMI option adds Primary Power and Remote Local monitoring relays Dry relay contacts are connected to a dedicated terminal block for each monitored point Typical application connecting ADB L 828 CCR to ALCMS or L 827 that is manufactured by others Note that this option does not provide dedicated output current or voltage transformers ALCMS Scanning Monitor Ready SMR The SMR option adds several monitoring relays including Primary Power and Remote Local and also CCR output current and voltage transformers All monitored signals are connected to a dedicated terminal block Application only for connecting ADB L 828 CCR to ADB Gen ALCMS scanning monitoring system L 829 Monitoring ACE Includes FAA L 829 monitoring equipment If application is for connection to ADB L 890 ALCMS Add a A to end of Ordering Code The ACE unit will then be programmed to provide monitoring data via dual redundant communication links e If application is for a stand alone L 829 CCR Ordering Code is not changed The ACE unit is programmed to activate a dry contact closure if a fault is present The fault alarm can then be connected to any external monitoring system Insulation Resistance Monitoring System IRMS Ready This option adds an IRMS board in the CCR Application connection to externally mounted ADB ACE unit L 829 Monit
99. dance with the instruction manual If the CCR works in local but not Remote check the voltage on the Remote control lines Can the CCR be re energized by turning the rotary switch from OFF to Step B1 B10 Short the output of the CCR with an AWG 8 wire and turn on the CCR If the regulator operates normally the problem is probably load related If the CCR turns on and then shuts off after a few seconds and the ammeter has a high current reading the problem is overcurrent Adjust the output current accordingly If the output current is not adjustable replace the control board restart the regulator If the CCR still fails in overcurrent replace the SCR and restart 2010 ADB Airfield Solutions All Rights Reserved 43 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Troubleshooting 5 2 2 Troubleshooting Fuses 44 This subsection provides information for troubleshooting fuses L 828 L 829 Input Power Fuses F1 and F2 Table 21 96A0408 Rev D 6 9 11 Amp rating as a function of input voltage and CCR kW rating for input power fuses F1 and F2 on the L 828 and L 829 CCRs Input Power Fuses F1 and F2 per CCR Input Voltage and CCR kW Rating CHF XXXX INPUT FUSES F1 F2 SIZE 208 V 220 V 240 V 347 V 480 V 4kW 47A0092 47A0069 47A0069 47 0191 47A0090 7 5kW 47A0093 47A0093 47
100. e open circuit test perform the following procedure 1 Remove input power to regulator turn off disconnect switch or main circuit breaker and turn the rotary switch to OFF 2 Disconnect cables from the output terminals and bushings 3 Turn on input power to the regulator 4 Turn the rotary switch to the lowest brightness position 1 The open circuit protective device should automatically de energize the regulator in less than 2 seconds 5 Turn the rotary switch to OFF The open circuit protective device should reset 6 Turn the rotary switch to position 1 The regulator should turn on and then de energize in less than 2 seconds 7 lf regulator operation is satisfactory turn rotary switch to OFF and turn off disconnect switch or main circuit breaker before reconnecting the load 8 After the load has been reconnected turn on input power to the regulator 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 5 2 Troubleshooting Troubleshooting WARNING Read the instructions in their entirety before starting installation Only personnel authorized to work on high voltage equipment should perform maintenance on the regulator Allow only qualified personnel to perform the following tasks Observe and follow the safety instructions in this document and all other related documentation Since
101. evert to the default setting of A rms 36 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Digital Power Meter Calibration optional 4 8 4 Calibration NOTE The following is needed to calibrate the DPM Procedure Calibrated true rms AC multimeter with current clamp High Voltage probe capable of reading 5 000V true rms Ability to apply a shorted load to CCR Ability to apply a field load or equivalent resistive load to CCR WARNING A Read the instructions in their entirety before starting installation The CCR must be operating during calibration Risk of electrical shock Failure to observe this warning may result in personal injury death or equipment damage Proceed as follows to calibrate the DPM 1 Depress and hold the top SCROLL button and the bottom ENTER button simultaneously for 3 seconds See Figure 24 to enter the calibration menu Figure 25 Calibration Menu Menu The SCROLL buttons are used to select items on the calibration menu Scroll to the desired selection and then press the ENTER button See the following steps to calibrate the DPM Current Calibration During calibration you will be asked to wait until displayed cnt values settle These cnt values are internal A D values as measured by the power meter s microprocessor These values wi
102. f component plate CHF 4 7 5 10 kW side Terminal Block black Front of component plate right hand Lightning Arrestors VR1 and VR2 on Back of component plate N A Lightning Arrestors VR1 and VR2 on Back of component plate Terminal Block white Front of component plate right hand side Top of each Fuse Block front of component plate right hand side CHF 15 20 30 kW Lightning Arrestors VR1 and VR2 on Back of component plate CHF 50 70 kW Top of each Fuse Block front of Lightning Arrestors VR1 and VR2 component plate top right side 2010 ADB Airfield Solutions All Rights Reserved on Back of component plate 23 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Stacking CCR s Optional 3 3 Stacking CCR s 6 9 11 Optional CAUTION A Read installation instructions in their entirety before starting installation Before stacking CCRs larger than 10 kW or stacking more than 2 CCRs contact the ADB Airfield Solutions Sales Department To stack CCRs perform the following procedure 1 Remove the four 1 2 x 3 3 4 HILTI anchor bolts with 4 nuts and lock washers for anchoring the CCRs to concrete and the four 1 2 13 3 4 hex head bolts and split lock washers from the stacking kit Part Number 94A0355 2 See Table 11 for anchor bolt template Use the four 3 75 Lg HILTI anchor bolts with
103. for maintenance panel accessibility and cover removal Protect components from damage wear and harsh environment conditions Allow ample room for maintenance panel accessibility and cover removal Protect equipment with safety devices as specified by applicable safety regulations If safety devices must be removed for installation install them immediately after the work is completed and check them for proper functioning prior to returning power to the circuit NFPA 70B Electrical Equipment Maintenance NFPA 70E Electrical Safety Requirements for Employee Workplaces ANSI NFPA 78 Electrical Standards for Metalworking Machine Tools OSHA 29 CFR Part 1910 Occupational Health and Safety Standards National and local electrical codes and standards The term qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe operation maintenance and repair Qualified personnel are physically capable of performing the required tasks familiar with all relevant safety rules and regulations and have been trained to safely install operate maintain and repair the equipment It is the responsibility of tne company operating this equipment to ensure that its personnel meet these requirements Always use required personal protective equipment PPE and follow safe electrical work practices WARNING Using this equipment in ways other than described in this manual may result in per
104. hest step Voltage THD 1 9 maximum in all steps Tested with 100 resistive load according to FAA AC150 5345 10 Latest Edition Ferroresonant circuitry and a solid state control system accurately regulate the output current to within the FAA allowable range from no load to full load and with input voltage variations of 596 to 41096 of nominal For more theory of operation see Theory of Operation on page 8 The ACE2 unit provides L 829 monitoring and optional megging or CCR input monitoring capability Each unit is installed locally at each CCR that requires remote control and or monitoring within the airfield lighting electrical vault Optional CCR input monitoring monitors the following CCR input current CCR input voltage CCR input volt amps VA CCR input power watts CCR input power factor CCR efficiency The ACE2 unit is also a component of ADB s distributed control and monitoring system Each unit can be easily connected to an Airport Lighting Control amp Monitoring System ALCMS by simply adding redundant communication wires See ADB ACE2 catalog sheet 2084 for additional information 2010 ADB Airfield Solutions All Rights Reserved 5 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Environmental Operating Conditions 6 9 11 2 7 Environmental Temperature 40 C to 55 C 40 F to 131 F Operating Conditio
105. high open circuit voltages may result by opening the primary of a series lighting circuit only personnel authorized to work on high voltage equipment should be allowed to perform the open circuit test De energize regulator by turning rotary switch S1 to OFF and remove input power to regulator by turning off disconnect switch or main circuit breaker Discharge capacitors and ground output terminals bushings by using a grounding rod prior to touching any parts If the regulator de energizes the output circuit could be interrupted by an overcurrent open circuit or undervoltage condition Before inspecting the output circuit Place rotary selector switch S1 in the OFF position and turn off disconnect switch or main circuit breaker Without this precaution a dip in the power line may reset the regulator and turn it on resulting in an output voltage of thousands of volts which can cause serious injury or death Contents are static sensitive Must be grounded when handling PCB Short the output terminals before switching the regulator on The wire should be AWG 8 or larger 5 2 1 Preliminary The following is a check list of initial steps to perform Troubleshooting Visually examine all areas of the CCR Do burnt or loose connections parts exist Is the input voltage present and within 10 to 596 of nominal Check all the fuses Are the wire harness connectors to the control board fully seated Have the PCBs been adjusted in accor
106. iency Power Transformer 480 347V 6 6A 35A0719 7 5kW High Efficiency Power Transformer 480 347V 6 6A 35A0720 4kW High Efficiency Power Transformer 480 347V 6 6A 35A0721 30kW High Efficiency Power Transformer 480 347V 20A 35A0722 20kW High Efficiency Power Transformer 480 347V 20A 35A0723 15kW High Efficiency Power Transformer 480 347V 20A 35A0724 10kW High Efficiency Power Transformer 480 347V 20A 35A0727 30kW High Efficiency Power Transformer 208 220 240V 6 6A 35A0728 20kW High Efficiency Power Transformer 208 220 240V 6 6A 35A0729 15kW High Efficiency Power Transformer 208 220 240V 6 6A 35A0730 10kW High Efficiency Power Transformer 208 220 240V 6 6A 35A0731 7 5kW High Efficiency Power Transformer 208 220 240V 6 6A 35A0732 4kW High Efficiency Power Transformer 208 220 240V 6 6A 35A0733 30kW High Efficiency Power Transformer 208 220 240V 20A 35A0734 20kW High Efficiency Power Transformer 208 220 240V 20A 35A0735 15kW High Efficiency Power Transformer 208 220 240V 20A 35A0736 10kW High Efficiency Power Transformer 208 220 240V 20A Table 30 Input Lightning Arrestor VR7 VR8 CHF XXXX Input Lightning Arrestor VR7 VR8 32A0028 Input Power Lightning Assestor All sizes and input voltages Kit used is 94B001 1 Table 31 Output Lightning Arrestor CHF XXXX Output Lightning Arrestor VR2 VR3 VR4 VR5 208V 208V 220v 220v 240v 240V 347V 347V 480V 480V
107. in Remote check the Remote control signals Blown fuse Replace any blown fuse Check the input supply voltage and make sure that it is between 5 and 10 of the nominal value listed on the CCR nameplate Defective URC PCB Output circuit interrupted Replace URC PCB Apply a short to the regulator output Turn the regulator on If the regulator works correctly repair the lighting circuit Follow all safety precautions in this manual Defective printed circuit board Overcurrent condition Universal regulator controller not calibrated Replace regulator controller Verify that SCR is triggering by replacing the PCB Check feedback transformer T5 for damage and proper connections Polarity does not affect operation Compare input voltages across J8 4 to J8 3 with those in Output Current Monitor Circuitry on page 5 If the voltage at the terminals is correct for the selected step and the output is not correct and the difference cannot be corrected by calibrating the regulator as specified in Output Current Adjustment in the Operation section Check SCRs and wiring Replace SCR Refer to Problem 11 in this table With regulator set on Step B100 B5 adjust R40 until a current reading of 6 6 A or 20 A is measured Check remaining steps to verify the values from Output Current and Limits on page 12 Overcurrent condition Defective control board Refer to problem 2 in this table
108. iversal Regulator Controller URC 96A0408 Rev D Wiring Schematics 6 9 11 Figure 48 Powerpack 50 70kW 43A2616 5070 page 1 Of 2 gt IMPORTANT KEEP WIRES 100 s amp 300 s AWAY FROM CORE 8 28 IMPORTANT NOTE 9 FOR CORE
109. l ash lamps or Runway Status Lights RWSL 2 3 step 20A is not standard FAA operation ADB Airfield Solutions can offer a non ETL Certified Style 1 Class 2 CCR for dedicated 5 5A sign circuits or other needs Please contact the ADB Sales Department for more details 3 Used only with Monitoring Options 0 1 2 and 6 4 Used only with Monitoring Options 3 and 5 5 20A is only ETL Certified in 50kW and 70kW 2 7 2 Application Notes 0 None Standard L 828 supplied with analog ammeter 1 ALCMS Scanning Monitor Interface SMI The SMI option adds Primary Power and Remote Local monitoring relays Dry relay Interface contacts are connected to a dedicated terminal block for each monitored point Typical application connecting ADB L 828 CCR to ALCMS or L 827 that is manufactured by others Note that this option does not provide dedicated output current or voltage transformers 6 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Environmental Operating Conditions 2 ALCMS Scanning Monitor Ready SMR The SMR option adds several monitoring relays including Primary Power and Remote Local and also CCR output current and voltage transformers All monitored signals are connected to a dedicated terminal block Application only for connecting ADB L 828 CCR to older ADB Gen I II ALCMS scanning monitoring system 3 L 829
110. ll always vary slightly while the meter is measuring voltage and current They are displayed to give feedback that the load has settled and the meter is obtaining a steady reading Operation NOTE TIP At each calibration step wait until the thousands digit has settled before proceeding A Irms High Step 6 6 amps Using the SCROLL buttons select Irms and follow the prompts to calibrate the Irms Short the CCR output and then turn the CCR to the highest step Measure the CCR output current with a true rms current meter and adjust the current value on the meter display to match NOTE If the CCR output needs to be adjusted follow the procedure in CCR Adjustment Procedures on page 30 Wait until the and V Cnt values settle and select the ENTER button 2010 ADB Airfield Solutions All Rights Reserved 37 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Digital Power Meter Calibration optional 6 9 11 Figure 26 rms High Step Calibration Apply Hi Step Shorted adjust value to natch Irms 6 60 I Cnt 694295 Cnt 5 3621 antil settled UAM B Irms Low Step 2 8 amps Repeat the previous steps and follow the prompts for the Low CCR step C Press ENTER button to save Figure 27 rms Low Step Calibration Rpplu Lo Step Shorted adjust value to match Irms 2 81 I Cnt 291226 U Cnt 18987 until settled Volt
111. n their entirety before starting installation Dangerous voltages are present on the URC PCB It is strongly recommended that a nonconductive screwdriver be used during calibration to protect personnel and the PCB from accidental damage 2010 ADB Airfield Solutions All Rights Reserved 31 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D 6 9 11 CCR Adjustment Procedures Figure 18 R40 URC Board 5 o E 4 5 2 Overcurrent No adjustment is necessary Adjustment 32 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 SCO Cutout Working Positions 4 6 SCO Cutout See Figure 19 The SCO cutout can be plugged in three orientations For additional Working Positions information on the SCO cutout refer to manual 9640294 SCO Cutout Figure 19 Handle Orientations ON LL In the operation position the regulator is connected to the series circuit and the microswitch is activated NOTE An activated microswitch means that the normally open contact is closed and that the normally closed contact is open For interlocking with the CCR only the normally open contact is used When the cover is removed the microswitch is not activated When the microswitch is not activated local and remote control is disa
112. nd 20 AMP SIGNATURE SERIES l N NIM st 5 SCALES SHEET NUMBERS DESCRIPTION 3 STEP CONN S IN s 5 90 0 a d z 542 amp amp E EET NA T ms may otherwise agree in writing Copyright 2011 ADB Airfield Solutions lic RELATED DOCUMENTS 43A3736 5070 2010 ADB Airfield Solutions All Rights Reserved 67 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Wiring Schematics 6 9 11 Figure 46 Powerpack 5 30kW 43A2616 1 of 2
113. ns Humidity 10 to 95 Altitude 0 to 6 600 ft 2 000 m 2 7 1 Monitoring Option See Figure 1 Figure 1 CHF Ordeing Codes Ordering Code CHFXXXX XXXX Amperage BE 66 6 6A output 20 20A output Size 04 4kW 6 6A only 07 7 5kW 6 6A only 10 10kW 6 6A only 15 15kW 20 20kW 30 30kW 50 50kW 20A only 70 70kW 20 only 2 240 4 30kW only 3 480 Output Range E 3 3 step without Series Cutout e 4 3 step with Series Cutout 5 5 step without Series Cutout c 6 5 step with Series Cutout Input Voltage 1 208 4 30kW only 5 4 347 4 30 kW only 5 220 4 30kW only Monitoring Options See Application Notes 0 None Standard L 828 1 ALCMS Scanning Monitor Interface 2 ALCMS Scanning Monitor Ready 3 L 829 Monitoring ACE 4 Insulation Resistance Monitoring System IRMS Ready 5 L 829 Monitoring ACE and IRMS 6 L 828 with Digital Power Meter CCR Input Output Monitoring 0 No optional CCR input or output circuit monitoring With L 829 or IRMS monitoring without optional input CCR monitoring G With L 829 or IRMS monitoring with optional input CCR monitoring Footnotes 1 A Ferroresonant CCR is preferred for airports that require low output harmonic content EMI or that have varying loads such as Runway Guard Lights using incandescent tungsten halogen lamps L 849 REILs using xenon f
114. ns All Rights Reserved 45 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Troubleshooting 6 9 11 Table 25 Current Transformer T2 CHF XXXX Current Transformer T2 SIZE 6 6A 20A 4kW 35A0263 N A 7 5kW 35A0263 N A 10kW 35A0263 N A 15kW 35A0263 35A0308 20kW 35A0263 35A0308 30kW 35A0263 35A0308 50kW N A 35A0308 70kW N A 35A0308 35A0263 Current Transformer 6 6 6 6A Only required if analog current meter used 35A0308 Current Transformer 20 6 6A Only required if analog current meter used Table 26 CHF CCR Contactors CHF XXXX CONTACTORS SIZE 208 240 V 347 V 480 V 4kW 53A0412 25 53A0412 25 53A0412 25 7 5kW 53A0412 50 53A0412 40 53A0412 40 10kW 53A0412 60 53A0412 50 53A0412 40 15kW 53A0412 90 53A0412 75 53A0412 40 20kW 53A0412 120 53A0412 90 53A0412 50 30kW 53A0331 53A0412 150 53A0412 75 50kW N A N A 53A0412 150 70kW N A N A 53A0331 53A0331 Contactor 3P 200A 170A 120VAC Coil 53A0412 150 Contactor 2P 150 FLA 53A0412 25 Contactor 2P 25 FLA 53A0412 40 Contactor 2P 40 FLA 53A0412 50 Contactor 2P 50 FLA 53A0412 60 Contactor 2P 60 FLA 53A0412 75 Contactor 2P 75 FLA 53A0412 90 Contactor 2P 90 FLA 53A0431 Contactor 2P 160A 1501 3600V Table 27 Dual SCR Blocks CHF XXXX Dual SCR Block SCR SIZE 208 V 220 V 240 V 347 V 480 V 4kW 28A0056 28A0056 28A0056 28A0056 28A0056
115. ntents and their condition Note any exterior damage to the carton that might lead to detection of equipment damage If you note any damage to any equipment file a claim with the carrier immediately The carrier may need to inspect the equipment NOTE Take care to maintain the unit in an upright position when handling the regulator Recommend lifting for the 4 thru 70kW regulators is to use a forklift from underneath the CCR frame Lifting points four 3 4 inch ID eyebolts on the top corners of the CCR frame are provided per FAA specifications If lifting eye bolts are used use either a portable hoist and sling s or sling s attached from forks on forklift See Table 11 dimensions and weights before lifting WARNING Read installation instructions in their entirety before starting installation If lift points eyebolts are used lift straight up Side loading on the eyebolts may cause them to bend Place the regulator inside a well ventilated room with sufficient clearance for personnel to inspect and maintain the unit WARNING Read installation instructions in their entirety before starting installation Installation and operation of the CCR should be performed by personnel qualified to work on high voltage equipment The high voltage involved with the unit makes it potentially dangerous and may be lethal if contacted by operating personnel Place wiring for output input and remote control only on the right side of
116. ogies Ltd 01A Unit 9F LSH Plaza 8 Wangjing Jie Chaoyang District Beijing 100102 P R China Phone 86 10 8476 0106 Fax 86 10 8476 0090 ADBN V Dubai Silicon Oasis Wing D Office D 309 P O Box 341218 United Arab Emirates Phone 971 4372 4970 Fax 971 4372 4975 ADB 5 39 47 Boulevard Ornano 93200 Saint Denis ADB Airfield 977 Gahanna Pkwy Solutions USA Columbus Ohio 43230 USA Telephone 1 614 861 1304 Fax 1 614 864 2069 www adb airfieldsolutions com France Phone 33 1 4922 9250 ADB Fax 33 1 4922 9255 Unit 44 Business Innovation Centre Binley Business Park ADB Airfield Solutions GmbH amp Co KG Harry Weston Road Von der Tannstr 31 Coventry CV3 2TX 90439 N rnberg United kingdom Germany Phone 44 0 1455 883130 Phone 49 911 9239 1287 Fax 44 0 1455 883179 Fax 49 911 2852 582 ADB ADBN V Airfield Solutions Asia Pacific Regional HQ Leuvensesteenweg 585 Unit C 9 3 1 Level 9 Block C B 1930 Zaventem Mines Waterfront Business Park Belgium No 3 Jalan Tasik Phone 32 2 722 17 11 The Mines Resort City Fax 32 2 722 17 64 43300 Seri Kembangan Selangor info adb adb air com Malaysia www adb air com Phone 603 8941 4868 Fax 603 8942 4869 ADB Airfield Solutions Netherlands Prinses Beatrixlaan 614 Office D3 14 2595 BM Den Haag The Netherlands Phone 31 0 70 304 3611 Fax 31 0 70 333 8094 ADB Airfield Solutions Ltd 2nd Floor 3 Rivonia Village Cnr
117. on 1 1 4 2 Material Handling Precautions 1 1 4 3 Action in the Event of a System or Component Malfunction 1 1 4 4 Maintenance and Repair 1 1 4 5 Operation of Overloaded Regulators 6 9 11 A WARNING Only qualified personnel physically capable of operating the equipment and with no impairments their judgment or reaction times should operate this equipment Read all system component manuals before operating this equipment A thorough understanding of system components and their operation will help you operate the system safely and efficiently Before starting this equipment check all safety interlocks fire detection systems and protective devices such as panels and covers Make sure all devices are fully functional Do not operate the system if these devices are not working properly Do not deactivate or bypass automatic safety interlocks or locked out electrical disconnects or pneumatic valves Protect equipment with safety devices as specified by applicable safety regulations If safety devices must be removed for installation install them immediately after the work is completed and check them for proper functioning Route electrical wiring along a protected path Make sure they will not be damaged by moving equipment Never operate equipment with a known malfunction Do not attempt to operate or service electrical equipment if standing water is present Usethis equipment only in the en
118. onal Insulation Resistance Monitoring System 2 13 2 Optional Scanning Monitor Interface 2 13 3 Optional Scanning Monitor Ready 2 14 Optional Series Cutout Type SCO 2 15 L 828 CCRs 4 70 kW 6 6 A 20 A Required Equipment 14 96A0408 Rev D 6 9 11 The L 829 CCR monitoring options include the Insulation Resistance Monitoring System IRMS Scanning Monitor Interface SMI and Scanning Monitor Ready SMR The IRMS is used only on the L 829 It performs scheduled cable insulation resistance measurements and can also perform manually requested measurements IRMS provides the ability for monitoring the long term degradation of the airfield series circuit cabling and showing the results on the L 829 CCR front display panel WARNING A When servicing a regulator equipped with an IRMS module be sure that power to the IRMS is disconnected before touching the IRMS board or any of the high voltage components or wires The scanning monitor interface is a relay assembly that can be mounted internally to the front panel of the CCR The relay assembly consists of four relays and sockets The relay assembly is used to generate feedback signals concerning the CCRs operation to the Remote Multiplexer The relay assembly generates feed back for the following signals Remote local status commanded ON status regulator running status and primary power status The scanning monitor ready includes the scanning monitor interface plus one
119. ons at the bottom of the contactor 13 Connect wires 400 and 401 to the top connectors of the contactor 14 Connect the wires for 102 103 104 and 105 and tighten retaining lugs 15 Close the CCR front door by tightening the 3 door screws 16 Restore the SCO to the ON position 17 Restore primary power to the CCR at the breaker panel 18 Turn the CCR local switch to the REM position 2010 ADB Airfield Solutions All Rights Reserved 55 Ej z S 8 8 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Component Replacement Procedures 5 4 4 Removing and 1 Replacing Input Lightning 2 Arrestors front of i Component Mounting 3 Plate 4 5 6 7 8 9 10 11 12 5 4 5 Removing and 1 Replacing Output 2 Lightning Arrestors front of Component Mounting 3 Plate 4 6 9 11 Turn CCR local switch to the OFF position Remove and lock out tag out primary power to the CCR at the breaker panel Lock out tag out the SCO in the maintenance position Open the CCR front door by loosening the 3 door screws Loosen the wire retaining screws for 100 402 101 403 802 and 803 and disconnect See Internal Wiring Schematic 43A2522 dwg in Wiring Schematics on page 65 Remove the top two of 4 10 x 32 pan head screws and loosen the bottom two screws until the arrestors are free Replace the Input Lightning Arrestor assembly Replace the two
120. or Unplug green connectors J8 J1 J2 J3 J4 and J5 from the PCB Disconnect the ribbon cable from J6 by pressing out on the tabs at both sides of the ribbon connection and pull the cable away from the board Remove the 4 screws at the 4 corners of the PCB Remove the ground wire from the top right corner Remove and label the ground wire from the top left corner of the PCB Mount the new PCB by replacing the 4 screws at the corners of the PCB including the ground wire on the top right corner Plug the ribbon cable back into J6 by pressing it in It is keyed and will only go in one way Also verify the tabs on the side have locked into place 10 Plug in all of the green connectors to the board J8 J1 J2 J3 J4 and J5 11 Close the CCR door and loosen the door latch screws 12 Restore the SCO to the ON position 13 Restore primary power to the CCR at the breaker panel 14 Turn the CCR local switch to the REM position See Internal Wiring Schematic 48A2522 dwg in Wiring Schematics on page 65 2010 ADB Airfield Solutions All Rights Reserved 53 5 El o CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Component Replacement Procedures 6 9 11 Figure 32 Dual SCR Module Assembly deseo Ncc 11 12 13 14 15 16 17 54 10 Split Lock Washer 2 4 each and 14 20 X 1 2 Hex Head Scre
121. oring ACE and IRMS Includes FAA L 829 and IRMS equipment If application is for connection to ADB L 890 ALCMS Add a A to end of Ordering Code The ACE unit will then be programmed to provide monitoring data via dual redundant communication links If application is for a stand alone L 829 CCR with Insulation Resistance Monitoring Ordering Code is not changed The ACE unit is programmed to activate a dry contact closure if a fault is present The fault alarm can then be connected to any external monitoring system 2010 ADB Airfield Solutions All Rights Reserved L 828 with Digital Power Meter This option replaces the analog ammeter with a Digital Power Meter The Digital Power Meter is used on L 828 CCRs to indicate True RMS output current voltage VA and watts It can also be set to activate an alarm if there is a 10 or 15 drop in the load Low VA 35 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Digital Power Meter Calibration optional 6 9 11 4 8 Digital Power Meter Calibration optional 4 8 1 Display Figure 23 Meter Display Function Buttons cobra 4 8 2 Function Buttons Figure 24 Function Buttons Scroll Up Scroll Down Enter Save 4 8 3 DPM Displays o 2 5 NOTE Scroll through displays using the Scroll Up and Scroll Down buttons After 30 seconds the display will r
122. perate as required see subsections Resistive Loading and Reactive Loading in this section when the input voltage is anywhere between 95 and 110 percent of the nominal value The regulator is designed to withstand momentary voltages up to 120 percent of nominal input voltage without shutting off or being damaged by such overvoltage so long as the duration of overvoltage excursions are not longer than 50 milliseconds and do not occur more than once per minute For the L 828 only a flush mounted true rms reading ammeter mounted on the front of the input module PCB indicates the output current The meter accuracy is 3 0 percent of the maximum output current Table 10 Rating and Input Voltage Rating Input Voltage 4 7 5 10 15 20 30 kW 208 480 Vac 5 to 10 50 70 kW 480 Vac 5 to 10 The temperature rise of the transforming portion of the regulator is in accordance with ANSI C57 12 91 for air cooled regulators 2010 ADB Airfield Solutions All Rights Reserved 17 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Dimensions 6 9 11 2 19 Dimensions Table 11 Dimensions and weights CCR Dimensions H x W x D Weight Ib kg Size 208 220V 240 347 480V 208V 220V 240V 347V 480V mo 33x24x25 in 33x24x25 in 434 427 467 502 83 8x61x63 5 cm 83 8 61 63 5 196 9 193 7 211 8 227 7 SERW 36 x 29 x 30 in
123. perly trained and familiar with ADB Airfield Solutions equipment are permitted to service this equipment Disconnect and lock out electrical power Always use safety devices when working on this equipment Follow the recommended maintenance procedures in the product manuals Do not service or adjust any equipment unless another person trained in first aid and CPR is present Connect all disconnected equipment ground cables and wires after servicing equipment Ground all conductive equipment Useonly approved ADB Airfield Solutions replacement parts Using unapproved parts or making unapproved modifications to equipment may void agency approvals and create safety hazards Check interlock systems periodically to ensure their effectiveness Donotattempt to service electrical equipment if standing water is present Use caution when servicing electrical equipment in a high humidity environment Use tools with insulated handles when working with electrical equipment A WARNING Operation of a Regulator while overloaded at any step may result in equipment failure or equipment damage 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 2 0 Introduction 2 1 About this manual 2 1 1 How to work with the manual 2 1 2 Record of changes Introduction CCF Ferroresonant L 828
124. pn COM 501A ce o essa a RD FEEDBACK SENSOR 5 8 SEEDETAL A 94A0358 KIT al 5 1 35A0308 rie AU 9 2 i T5 35A0528 21 5380283 VR2 a 4 5 SEENOTE 12 d luna 12 IAE ga v ur 480 VAC INPUT OPTION s 52 cas 4 D 8 524 BELOW r No 502 BLK 4 ory 506 a _ 8 ONLY Z 524 7 RED BLK 3 onu 532 F8 A 525 J VRB H 506 50 lt 17 7 EUN 220003 RED 507 2 300 303 2 RUNS EACH AS SHOWN 250V SLO BLO 47 0119 BK BRN 508 5A 250V FEEDBACK JUMPER NOTE 3 4 509 18AWG L NOTE 5 3 C 4 C 526 WIRE SIZES RED BLU 531 Eud 102 103 PRIMARY POWER SEE TABLE 5 note 2 02 77 74 CONNECTION S 200 213 HIGH VOLTAGE 12AWG 25KV 150C 89 0086 1 T 508 cu 00 LO BIO STaTsTzT HE Te TaT TaT E 300 311 TANK LOOP amp CAPS 2 AWG 600V 105C 89A0199 9 NOTE 4 JE 3 J8 E 300 303 2 RUNS EACH AS SHOWN 2 5A 250V SLO BLO 470119 2 1 4 IF UN KEYED MATING CONN WAS USED 400 403 MEDIUM CURRENT 12AWG 600V 105C 89 0185 9 E PIN 1 RED STRIPE IS ON THE LEFT SIDE 1 1 157 TOIRMS 8 Jg SAME FOR ROTARY SWITCH CONN 500 562 STD CONTROL 18AWG 600V 89A0182 9 7 800 803 GROUND 12AWG 600V GN YL 89A163 5 E 0 99 IF KEYED MATING CONN IS USED 900 905 G
125. ps L 849 REILs using xenon flash lamps or Runway Status Lights RWSL Runway Guard Lights using incandescent tungsten halogen lamps should be powered with ferroresonant type CCRs and not with thyristor type CCRs 8 step 20A is not standard FAA operation ADB Airfield Solutions can offer a non ETL Certified Style 1 Class 2 CCR for dedicated 5 5A sign circuits or other needs Please contact the ADB Sales Department for more details Used only with Monitoring Options 0 1 2 and 6 3 Used only with Monitoring Options 3 and 5 2010 ADB Airfield Solutions All Rights Reserved 57 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D Parts and Mechanical Drawings 6 9 11 Figure 36 CHF 4 kW CHF6604 XXXX 838 2299 FRAME 0 ZARTOAS XX FOR ASSEMBLY INSTRUCTION A Q jee o 0 fal 9 502 E LOS OPM i N FRAME LA HHel 5 5 iei 70 25 00 L TOS B M
126. r Controller URC 96A0408 Rev D Wiring Schematics 6 9 11 Figure 44 Ferroresonant L828 L829 4 30kW 6 6A 20A Internal Wiring Schematic 43A3736 2 of 2 A 100 SERIES WIRES PRIMARY POWER 600V 105 C WIRE amp ASSEMBLY NOTES H 88 nsa ac o TIONS i 2 12 1 ADD APPROPRIATE JUMPER WHERE REQUIRED NO JUMPER IS T xi 2 12 1 O28 28 POWER i 208 2200 200 SAIN 180 6 6A 5 STEP TIE ALL JUMPERS INTO CABLE HARNESS SO CONNECTOR Ol 53 A 4kw 12AWG 12 AWG 12 AWG 12 AWG HAS TO BE PULLED FROM PCB WHEN REPLACING PCB 33 89 0184 9 89 0184 9 89 0184 9 89 0184 9 218 4 E E t 75kW 8AWG 8AWG 8 AWG 8 AWG i0 10 2 WIRE SIZES 93 89A0196 9 89A0196 9 89A0196 9 89A0196 9 100 105 PRIMARY POWER SEE TABLE B E 8 z 2a SEE NOTE BELOW ican EANG AWG SANG SAG 200 213 HIGH VOLTAGE 12AWG 25KV 150 C 89A0086 1 ei HE
127. r may make a faint bouncing sound as the controller bounces against the upper control limits NOTE This problem can also be verified by shorting the output of the CCR and verifying output current can be adjusted correctly in each step Increase load on regulator If you cannot increase the load verify that you are dealing with the right problem by placing a current clamp on the output of the regulator and measuring the frequency of the output Investigate to see if the problem occurs in Highest Step For additional L 829 CCR general troubleshooting procedures refer to the Troubleshooting section in manuals 96A0287 Advanced Control Equipment ACE or 96A0357 Advanced Control Equipment ACE2 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 5 4 Component Replacement Procedures 5 4 1 Removing and Replacing URC PCB 5 4 2 Removing and Replacing Dual SCR Module Assembly CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 1 Component Replacement Procedures Turn CCR local switch to the OFF position Figure 31 URC PCB 2 5 c amp 9 e E L o o J6 A amp Remove and lock out tag out primary power to the CCR at the breaker panel Lock out tag out the SCO in the maintenance position Loosen the door latch screws and open the CCR do
128. regulator to position OFF Remove input power before servicing control circuitry Never service the regulator when it is in protective shutdown mode Remote controls or power fluctuations can restart the regulator 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 CCR Adjustment Procedures 4 5 1 Output Current To adjust the output current perform the following procedure Adjustment 1 Connect a clamp on true rms reading instrument such as a Fluke 87 multimeter with a current clamp around one of the output current leads See Figure 17 Figure 17 Output Current Clamp Auto Range Button Select mA Ciamp To Airfield Lighting Series Circuit Red Lead mA Black Lead COM NOTE Make sure the meter is set on the AC current scale Because the output current waveform is not a true sine wave the ammeter must be of the true rms root mean squared type Field instruments such as clamp on ammeters and Simpson voltmeters will give erroneously low readings Operation 2 Energize the regulator locally and set the rotary selector switch to the maximum brightness position B5 or B100 3 See Figure 18 Carefully adjust R40 on the universal regulator controller board until the desired current is measured on the meter WARNING A Read the instructions i
129. rent meter not calibrated or faulty The rotary switch on the input module not set to REM Turn the regulator to the top step 6 6 A 20 A Verify the current with a true rms current meter If the meter is not accurate adjust the meter with the screw on the front cover For systems equipped with ACE refer to Advanced Control Equipment ACE manual 96A0287 or Advanced Control Equipment ACE2 manual 96 0357 for display calibration procedures Refer to Problem 11 in this table Set the rotary switch to REM Blown fuse Check fuse F5 Loose or broken Remote control wires Check connections on Remote terminal block TB1 If 120 Vac Remote control signals are used use an AC voltmeter 300 Vac scale to verify correct signals are received at the CCR Incorrect wire connections Refer to Table 12 through Table 14 9 Ammeter on CCR oscillates and loud noise occurs 10 Output current not able to be adjusted up to 6 6 A 20 A 11 5 Step regulator in Steps 1 or 2 emitting loud hum not indicating proper current and operating erratically 5 3 Additional L 829 General Troubleshooting Procedures 52 SCR drive not working properly Regulator load too large Light inductive load for example signs Check connections at SCR module Replace URC PCB Refer to Problem 11 in this table Either reduce the load or replace the regulator with a larger kW CCR When overloaded the regulato
130. required minimum 20 A Shorting jumper wire AWG 8 minimum As required Disconnect switch or main circuit breaker 1 Input lightning arrestors for input voltages greater than 480 Vac Mounted external to CCR NOTE lightning arrestors are standard on the power input for voltages As required 480 Vac and less for all new CCRs Voltmeter 60 Vdc full scale 1 Ammeter true rms reading 9 A maximum scale 1 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D 6 9 11 2 16 Input Wire Size 2 17 Input Power Breaker Sizing CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Input Wire Size Description Quantity Inductive type current probe 1 Ohmmeter Mounting bolts 92 13 x 1 1 2 in long STD washers and lockwashers 4 Table 3 refers to recommended input power supply wire size for each regulator power rating dependent on the input voltage This recommendation is based on 75 C rated copper wire per NEC Table 310 16 Table 3 Recommended Input Wiring Rating E 208 Vac 220 Vac 240 Vac 347 Vac 480 Vac 4 kW AWG 10 AWG 10 AWG 10 AWG 12 AWG 14 7 5 kW AWG 6 AWG 8 AWG 8 AWG 8 AWG 10 10 kw AWG 4 AWG 6 AWG 6 AWG 8 AWG 10 15 kw AWG 3 AWG 3 AWG 4 AWG 6 AWG 8 20 kW AWG 2 0 AWG 1 0 AWG 2 AWG 4 AWG 6 30 kW AWG 3 0 AWG 3 0 AWG 2 0 AWG 2 AWG 4 50 kW Not applicable Not applicable Not applicable Not applicable AWG 1 0 70 kW Not
131. ront Panel Display 21 829 CCR 3 Rotary Switch 2 11 SGRS This subsection describes the Switchgear Regulator Style Powerpack The SGRS Powerpack Powerpack operates similar to the stand alone type L 828 L 829 and uses a URC to provide regulator and control functions It also uses the Advanced Control Equipment ACE or ACE2 for control and monitoring functions The main difference is the CCR frame which is designed to insert into a SGRS line up NOTE Figure 5 shows a Ferroresonant L 829 30 kW 6 6 A CCR The other L 829 CCRs 4 7 5 10 15 20 KW 6 6 A 20 A and 50 70kW may differ in size and appearance 2010 ADB Airfield Solutions All Rights Reserved 11 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D SGRS Powerpack 12 6 9 11
132. s Reserved 96A0408 Rev D 6 9 11 5 2 3 L 828 General Troubleshooting CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Troubleshooting This subsection provides general troubleshooting procedures for the L 828 CCR WARNING Read the instructions in their entirety before starting installation Only personnel authorized to work on high voltage equipment should perform maintenance on the regulator Since high open circuit voltages may result by opening the primary of a series lighting circuit only personnel authorized to work on high voltage equipment should be allowed to perform the open circuit test Operating a regulator for long periods of time while seriously overloaded may cause the regulator to overheat Problem 1 Regulator not turning on 2 Regulator turns on but de energizes suddenly 3 Output Current always 6 6 A 20 A or more 4 Output Current always 4 8 Aor less for 3 Step CCR or 2 8 Aor less for 5 Step CCR or 8 5 less on 20 A 5 More than 2 seconds required for CCR to de energize on open circuit load Table 38 Possible Cause Main power supply off Corrective Action Verify presence of input voltage Switched off due to overcurrent Switch regulator off in local Wait for 2 seconds and check to see if the regulator now operates correctly Incorrect external wiring If the regulator works correctly in local but not
133. sonal injury death or property and equipment damage Use this equipment only as described in this manual ADB Airfield Solutions cannot be responsible for injuries or damages resulting from nonstandard unintended applications of its equipment This equipment is designed and intended only for the purpose described in this manual Uses not described in this manual are considered unintended uses and may result in serious personal injury death or property and equipment damage Unintended uses may result from taking the following actions Making changes to equipment that are not recommended or described in this manual or using parts that are not genuine ADB Airfield Solutions replacement parts Failing to make sure that auxiliary equipment complies with approval agency requirements local codes and all applicable safety standards Using materials or auxiliary equipment that are inappropriate or incompatible with ADB Airfield Solutions equipment Allowing unqualified personnel to perform any task CAUTION If equipment is to be stored prior to installation it must be protected from the weather and kept free of condensation and dust Failure to follow this instruction can result in injury or equipment damage 2010 ADB Airfield Solutions All Rights Reserved 1 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0408 Rev D To use this equipment safely 1 1 4 1 Operati
134. stment procedures SCO Cutout working positions This subsection describes the regulator operations in local and remote controls See Figure 16 Refer to Table 16 through Table 18 for output current when using local control The front panel rotary selector switch is used for regulator local control The rotary switch for the 3 step CCR has five positions the rotary switch for the 5 step has seven positions The regulator automatically maintains the output current within 1 of the nominal value for the brightness position selected Figure 16 Switch 3 Step 5 Step a REM per F REM pep N EN E B10 Bl z P B30 2 222 100 X B3 Local Control J C Local Control J C y 3 Step Switch Assembly 5 Step Switch Assembly Table 16 Output Current from Rotary Switch 3 Step 6 6A If you set the rotary switch to the The result is following B10 4 8 A current output B30 5 5 A current output B100 6 6 A current output Table 17 Output Current from Rotary Switch 5 Step 6 6 A If you set the rotary switch to the The result is following 1 2 8 A current output B2 3 4 A current output B3 4 1 A current output B4 5 2 A current output 5 6 6 A current output 2010 ADB Airfield Solutions All Rights Reserved 29 CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal
135. til either power to the regulator is cycled or the regulator is turned off with either the rotary switch or the remote controls This section provides preventive maintenance for L 828 L 829 constant current regulators CCRs 4 70 kW 6 6 A or 20 A 5 1 Maintenance Schedule To keep the Table 20 Interval Daily Monthly Annually Unscheduled 2010 ADB Airfield Solutions All Rights Reserved L 828 L 829 CCRs operating efficiently follow a preventive maintenance schedule Refer to Table 20 L 828 L 829 CCR 4 70 kW 6 6 A 20 A Maintenance Maintenance Task Check all control equipment for proper operation Check input voltage Action Check local and remote control if used on each brightness step If input voltage is not within 5 to 10 of the nominal value specified on the nameplate of the regulator notify power company to correct voltage Check and record output current on each brightness step Check relays wiring and insulation Use a true rms reading instrument Adjust current levels if out of tolerance Refer to Adjustment Procedures in the Operation section Refer to Output Current and Limits on page 12 for the current range for the 3 Step and 5 Step CCRs Replace contacts that are excessively burned or pitted Operate the local control switch to check for proper operation of relays and contactors Make sure input and output connections are tight and that no d
136. ty instructions in this section of the manual before installing operating maintaining or repairing this equipment Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment Make this manual available to personnel installing operating maintaining or repairing this equipment Follow all applicable safety procedures required by your company industry standards and government or other regulatory agencies URC PCB is static sensitive Must be grounded when handling Route electrical wiring along a protected path Make sure they will not be damaged by moving equipment Protect components from damage wear and harsh environment conditions Allow ample room for maintenance panel accessibility and cover removal Protect equipment with safety devices as specified by applicable safety regulations If safety devices must be removed for installation install them immediately after the work is completed and check them for proper functioning prior to returning power to the circuit This section provides instructions for installing L 828 L 829 constant current regulators CCRs 4 70kW 6 6 A 20 A Refer to the airport project plans and specifications for the specific installation instructions The equipment is shipped ready for installation Handle equipment very carefully to prevent component damage Unpack the carton upon receipt and check the co
137. uipment in this manual Task and equipment specific warnings are included in other sections of this manual where appropriate WARNING A Read installation instructions in their entirety before starting installation Refer to the FAA Advisory Circular AC 150 5340 26 Maintenance of Airport Visual Aids Facilities for instructions on safety precautions Observe all safety regulations To avoid injuries always disconnect power before making any wiring connections or touching any parts Refer to FAA Advisory Circular AC 150 5340 26 Become familiar with the general safety instructions in this section of the manual before installing operating maintaining or repairing this equipment Read carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment Make this manual available to personnel installing operating maintaining or repairing this equipment Follow all applicable safety procedures required by your company industry standards and government or other regulatory agencies Install all electrical connections to local code Use only electrical wire of sufficient gauge and insulation to handle the rated current demand All wiring must meet local codes Route electrical wiring along a protected path Make sure they will not be damaged by moving equipment Protect components from damage wear and harsh environment conditions Allow ample room
138. us and incorrect output current No input turn on in rush current surge To minimize the floor space required in a vault ADB 4 30kW regulators can be stacked using a stacking kit See Kits section for details Available in two classes and styles Class 1 2 6 6A maximum output current 4 30kW only Class 2 20A maximum output current 15 70kW only Style 1 3 Brightness Steps Style 2 5 Brightness Steps If input power loss occurs operation will resume within five seconds after restoration of input power Brightness Steps can be changed in the field between 3 and 5 Steps New label required Field upgradable from L 828 to L 829 with ACE unit Industrial powder coat finish Input lightning protection and output lightning protection included 2010 ADB Airfield Solutions All Rights Reserved 96A0408 Rev D CHF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 2 5 Electrical Supply 2 5 1 Remote Control 2 5 2 Total Harmonic Distortion THD 2 5 3 Theory of Operation Introduction 2 6 ACE2 Unit Electrical Supply Power Input 60Hz single phase available in 208 220 240 347and 480 Vac Power Factor 0 99 or more for 4 to 30kW 0 95 or more for 50 70kW NOTE Efficiency 90 minimum for 4 to 20kW 92 minimum for 30kW 93 minimum for 50kW 94 minimum for 70kW 120V AC 60Hz or 48V DC 10 Current THD 1096 maximum in hig
139. vironments for which it is rated Do not operate this equipment in humid flammable or explosive environments unless it has been rated for safe operation in these environments Never touch exposed electrical connections on equipment while the power is ON CAUTION This equipment may contain electrostatic sensitive devices Protect from electrostatic discharge Electronic modules and components should be touched only when this is unavoidable e g soldering replacement Before touching any component of the cabinet you should bring your body to the same potential as the cabinet by touching a conductive earthed part of the cabinet Electronic modules or components must not be brought in contact with highly insulating materials such as plastic sheets synthetic fiber clothing They must be laid down on conductive surfaces The tip of the soldering iron must be grounded Electronic modules and components must be stored and transported in conductive packing WARNING Do not operate a system that contains malfunctioning components If a component malfunctions turn the system OFF immediately Disconnect and lock out electrical power Allow only qualified personnel to make repairs Repair or replace the malfunctioning component according to instructions provided in its manual WARNING Allow only qualified personnel to perform maintenance troubleshooting and repair tasks Only persons who are pro
140. w 2 or 4 each Turn CCR local switch to the OFF position Remove and lock out tag out primary power to the CCR at the breaker panel Lock out tag out the SCO in the maintenance position Open the CCR front door by loosening the 3 door screws Remove wire 300 and the ground wire from the top lug of the SCR using a 11 16 inch socket note There are different versions of this SCR so hardware may vary Remove wire 301 from the bottom lug of the SCR using a 11 16 inch socket Pull the 4 colored gate wires from the bottom of the SCR Remove the SCR from the regulator by removing the 2 5 32 hex mounting screws Clean the heat sink surface with a dry rag The replacement SCR will arrive mounted to a rectangular metal plate Remove the SCR from the attached plate by removing the 2 5 32 mounting screws from the new SCR and the mounting it to the existing plate in the front of the regulator Place a thin layer of thermal paste on the heat sink prior to attaching the SCR Once the SCR is mounted in the CCR connect wire 300 and the ground wire to the top lug of the SCR Connect wire 301 to the bottom lug of the SCR Connect the colored gate wires according to the documentation supplied with the replacement SCR Different versions of the SCR require these gate wires to be connected in a different order refer to the documentation shipped with the replacement SCR Close all doors and replace all panels Restore the SCO to the

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