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CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with

1. gt 89 IMPORTANT KEEP WIRES 100 s amp 300 s AWAY FROM CORE DE E H2 TO P1 FOR x og 8 2 IMPORTANT SEE NOTE 9 FOR TOEN ASR 3 1 CORE d 8 ast E ___ SC1 1 amp 2 INPUT WIRE LUG ASSEMBLY 4 BANKS E lt a SS NT T9 uu 55 SL 3 RANAS due zt T7 SIE o 218 ET A SEE NOTE 10 f uc tj SEE NOTE 3 8 35A0308 SEC E 08 8 Bi y Bi 5 201
2. ITEM NUMBER DESCRIPTION QTY NO 9 1 35 0154 1 PWR TX 30KW 2400V 6 6A AIR COOLED 1 PE E 2 42 0480 LABEL OUTPUT CURRENT L 828 1 3 42 0525 LOCAL CONTROL LABEL 3 OR 5 STEP CONFIG 1 ia 1 829 4 42B0269 LABEL L828 1 NOTE 3 4 5 44 6178 ASSY 34 HDR SW ADAPTOR 3 5 STEP 1 MONITORING OPTIONS 3 0 NONE 6 44A6483 09 CAP PLATE ASSEM 50 70 AIR COOLED 1 129M 44A6483 18 CAP PLATE ASSEM 18 CAPS 20KW 6 6A 1 2 SMR REN 8 44A6774 CONTACTOR TRANSFORMERPLATE ASSY 1 4 IRMS ONLY 9 44A6799 HARN ASSY CCF 2400V 10 70KW 1 P 5 L 829 AND IRMS L 828 DOOR EE 10 44A6852 X90 COMP PLT ASSEM 15 50KW 2400V 6 6A L 828
3. ITEM PART NUMBER DESCRIPTION QTY NO 1 35C0179 1 PWR TX 20KW 2400V 20A AIR COOLED 1 2 42A0480 LABEL OUTPUT CURRENT L 828 1 L_ 1 3 42 0525 LOCAL CONTROL LABEL 3 OR 5 STEP CONFIG 1 NOT 4 14280269 LABEL L828 1 FA 5 44A6483 18 PLATE ASSEM 18 CAPS 20KW 6 6A 1 1 5 6 44 6772 690 COMP PLT ASSEM 50KW 480V 20A L 828 1 2 8MK 7 44 6774 CONTACTOR TRANSFORMERPLATE 55 1 3 L829 AIS ONUS 8 4 6799 HARN ASSY CCF 2400V 10 70KW 1 5 1 829 AND IRMS 9 52A0098 AMMETER TRUE RMS 0 25 1 6 DIGITAL POWER METER 10 60A2658 1 DISPLAY PANEL ANALOG URC CCR 1 828 DOOR INPUT VOLTAGE 11 60A3129 CORE SUPPORT ANGLE GLASTIC 2 9 2400V 3 412 6044018 CABINET MOD
4. ITEM PART DESCRIPTION QTY NO NUMBER 8 1 35 0157 1 PWR TX 10KW 2400V 6 6A AIR COOLED 1 CCF6610 X9 XX 2 42A0480 LABEL OUTPUT CURRENT L 828 1 QN a 5 L E 0 1 828 42 0525 LOCAL CONTROL LABEL 3 OR 5 STEP CONFIG 1 So A L 829 NOTE 3 4 14280269 LABEL L828 1 MONITORING OPTIONS 5 446178 PCB ASSY 34 PIN HDR SW ADAPTOR 1 rus 0 NONE jean 6 4446483 09 CAP PLATE ASSEM 50 70 AIR COOLED 1 H C 6 2 SMR 4406774 CONTACTOR TRANSFORMERPLATE ASSY 1 4 3 L829 8 4406799 HARN ASSY CCF 2400V 10 70KW 1 4 IRMS ONLY 5 L 829 AND IRMS 9 44A6852 X90 COMP PLT ASSEM 15 50KW 2400V 6 6A L 828 1 i SENET ove METER 10 52 0098 AMMETER TRUE RMS 0 25 1 NFU VOLTAGE 11 60 2658 1 DISPLAY PANEL ANALOG URC CCR 1 90000 12 60 3129 CORE SUPPORT ANGLE GLASTIC 2 o DUTP TRANGE 13 60A4018 CABINET MOD 2400V SIG
5. E ALL REGULATORS 300 SERIES WIRES TANK LOOP 600V 105 C T 21 ases coins NER 100 SERIES WIRES PRIMARY 1 WIRE NUMBERS REASSIGNED AT THE CREATION OF E ii a 2 00 X QU POWER 600V 105 C USTD REGULATORS UCCF 2004 REGULATORS Bcc uis HE A GER WHT RED 506 Lu 7 osi 28 ol 5 f 1 100 105 PRIMARY POWER SEE TABLE ra ese F3 2 mer 55 ono POWER 480 POWER REEN S POWER ALL V s 200 210 HIGH VOLTAGE 12AWG 25KV 150C 89A0086 1 zi 3 8 memi C meo ms 2 oodd 2 E mE 400 400 2 600 105 8940185 9 8 a iH WHT VIOWHT 508 E i gt ef 5 WHTIBLKe 2 Cs 89 0195 9 89 0195 9 500 547 STD CONTROL 18AWG 600V 89 0182 9 5 E ae 8 E s 7 5 kW 10AWG 7 5 kW 8AWG 7 5 kW 8AWG 600 HIGH VOLTAGE 8AWG 7 5KV SIL 8940202 ser vio een 89A0195 9 89A0196 9 89A0196 9 OBSOLETE USE 200 SERIES WIRE 700 701 PRIMARY POWER 6AWG 60
6. ls NOTES H 1 WIRE NUMBERS REASSIGNED AT THE CREATION OF gt S 58 2 WIRE SIZES ae 98 DIGITAL POWER METER OPTION FERC noe WIRES 100 105 PRIMARY POWER SEE TABLE HE o 200 213 HIGH VOLTAGE 12AWG 25KV 150C 89A0086 1 88 r4 2 i GET az BEND _ 600v 105 C 100 SERIES WIRES PRIMARY POWER 600V 105 C 21 ou POWER AL POWER 208V 220 V 240 V 347V 480 V 400 409 MEDIUM CURRENT 12AWG 600V 105C 89A0185 9 EH OUTPUT NOTE 4kW 10 AWG 4kw 14 ANG 14 AWG 14 AWG 14 AWG 500 535 STD CONTROL 18AWG 600V 105C 89A0182 9 9 32 og OUTPUT CONNECTIONS 89A0195 9 89A0184 9 89A0184 9 89A0184 9 89A0184 9 600 HI VOLTAGE 8AWG 7 5KV 89A0202 i 75KW 8AWG 75KW 8AWG 8AWG 8AWG 14 AWG OBSOLETE USE 200 SERIES WIRE E 85 sco NSUSED sonore 82401848 707 728 SCANNING MONITOR INTERFACE 18AWG 600V 89A0182 9 8 i 25 537 210 14 D 10kW 8AWG 10kW 8
7. IMPORTANT KEEP WIRES 100 s amp 300 s AWAY FROM CORE Ae Recrions ON VR1 3x 50KW CORE BLOCKS OR SCO IS USED 70KW 480VAC 305 304 203 212 Ed 4 BANKS ymo a pao lC 521 A Em EL S Aae SUG ated IN PUT E m L2 io T Tem amp NA J4 15 2 528 TB1 NEU rg x f 11 CVM IRMS OUTIFIBER CABLE o GRY 8 13 904 _ TB1 GND 1 OIN 1 NOTE LAND 4 4 B3 Bare Bhi Co 213 mis esmomm caw PE pt 100 15732 102 BANK WIRESAS CLOSE A Wise 5 ee 522 T9 DANGER a 2 305 ASPOSSIBLETO THE r Tir LA CONTROL 350308 ETNE 25 4 21 E o o CENTER OF THE CAP H H 300 ie Go 823 pum 3 b ao ot 101 5 6 103 H a sw 187112 EVER DO NOT USE SHUNT FOR 665 V 8 VR1 IRFIELD 305 SAL K2 age ee o8 19 a 204 5 210 SCO OPTION DOOR SW 309 X SIN Ex 2 POS CURRENT 201 202 i 501 501C 5018 o sot No COM 5014 20 02 FEEDBACK SENSOR t 11 5 3
8. p E IMPORTANT SEE NOTE 12 FOR 2 SC1 1 8 2 INPUT WIRE LUG ASSEMBLY E STA TO H2 W 2 E So 4 30 KW 240V la B S 88 1 ACE CVM amp IRMS Options Ole og DPM OPTION 8 m TORQUE 5 6 NM 2 PLC S NOTE LAND ALL CAP EE 5 i i eee e T4 5 1 1 g heng i CL 6 6awirine SEE 17 PRIM As p AS POSSIBLE shes NOTE 10 ICVM OPTION CVM BELOW FOR 20 cu MN OB ELS CENTER OF THE CAP BANK SEE NOTE 13 S27 F5 350346 OR MEM 8 TB3 CB1 _ J4 J5 528 TB1 NEU 61A0317 30 j 2 29 700 ae DANGER cs imusour BER 8 4 Teens zs RET 1 Ojo IRMSAN FIBER CABLE BLU i O g 525 305 x Aes ER NOTE 14 18 11 52 35 5104 INSULATORS REQD FOR scs MY Y SC5 12 g EH 300 B UG cry _cvm4 30KW amp 9ACVM ONLY so pee m 5 ccu ws 85176105 SEE PG 2 FOR DOOR NOT CLOSED INDICATOR WIRING x x 2855 RENE Re g 858 i i i Am o L WH K2 DOOR SWITCH SC2 1 SC2
9. 2 p _ _ _ BEES N E 7 i gt E ol INPUT VR 7 BB p TB3 UBBER TOP 0 1 M 1 Ifo 4 1 Li dl 5 B LM pat E 3 p 4 e RYG PN a e WE OOo Qs 1 not shown see Figure 14 Item 1 Installed on inside front of SGRS door SGRS Powerpack Rotary Switch not Shown See Figure 4 Item 3 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 13 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Universal Regulator Controller 6 9 11 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 signal
10. Intialed in RED ink below indicates authorized copy INTIAL amp DATE ADB Airfield Solutions P O BOX 30829 Tel 614 861 1304 977 Gahanna Parkway 614 864 2069 Columbus Ohio 43230 p 3052 SEE CHNG 35C0161 TO 1 21JANt1 2433 SEE ECO ADDED NOTE 3 DTR o6JuL10 DRAWING TITLE CONSTANT CURRENT REGULATOR B 2569 SEE ECO HRDWR CHNGS DIR 27APRO L 828 20KW 2400V 6 6A A INITIAL RELEASE DTR 20aUGO7 REV Eco DRAWN REV Frei REVISION DESCRIPTION in TUNET D T RYAN 20AUG07 woe nerit Information contained on this drawing Is to be used expressly in accord with purpose for which it was submitted Any disclosure of this information is strictly prohibited except as ADB Airfield Solutions Inc may otherwise agree in writing Copyright 2009 ADB Airfield Solutions 10F1 CCF6620 X900 O 2010 ADB Airfield Solutions All Rights Reserved 59 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W 2400 Vac CCF Parts and Diagrams 6 9 11 Figure 40 L 828 20KW 2400V 20
11. 335 3 5 uaria aais 4 92vo9 u3ril4 uvad 969209 s30v1d HOS SarmiHd 5 ONOT BE X 26 014 S ITU dOL 8E92v09 aais 1 92v09 Installation ANSNGTIM 9 21 OOHLNOS AANSSSV 4000 9509 vb Lr S3oVld 8 GNLS qM Q31vo9 91 2 1 X 0c v l VLAD 21512385 HOS 1V 14 V SS09V Pr 33S DNINIHOVN HOOQ SONTONI SADNVHO a No axaav SOvid 230690 WOHd 02 29 0689 Ed TIVISNI g I S0S le M3U9S 3ALLd V9 ODHLNOS 912 99991 HHVO WOW 31VOIH8V3 STONV TYOLLHIA 8 6E92v09 2010 ADB Airfield Solutions All Rights Reserved 28 96A0288 Rev W 6 9 11 4 0 Operation 4 1 Introduction 4 2 CCR Control Procedures 4 2 1 Local Control CCF 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 sec
12. 1 ACE2 Front Panel Display 21 829 CCR 3 Rotary Switch 12 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 SGRS Powerpack 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 Figure 5 SGRS Powerpack with ACE or ACE2
13. 30829 Tel 614 861 1304 b Hi 977 Gahanna Parkway Fax 614 864 2069 SEGTION B B P 1 D sE Eco cme acora TOH mm age 0 mbus Ohio 43230 4 b 5 C 2433 SEE ADD NOTE 4 DIR osjui _ORAWNGTME E kl ol CONSTANT CURRENT REGULATOR M B 2589 SEE ECO FH SCRW CHNG 20KW 2400V 20 _ VA WITUREEASE AUG l ME LENA REVGION DESCRIPTION mw 7 mo m Information contained on this drawing is to be used expressly in e accord with purpose for which it was submitted Any disclosure of this infc tion is stricth hibited yt as ADB Airfield 5 2020 900 5 ADB Airfield Solutions 60 O 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 2400 Vac CCF Parts and Diagrams Figure 41 L 828 30KW 2400 6 6A
14. sese 31 4 5 2 Overcurrent Adjustment onnnnrnnnvnnnnvnnnvnnnnnnnnrensvrennrnnnvrrenrnnnnnnenrensnnnsnrnenen 32 4 6 SCO Cutout Working Positions 33 4 7 Application Notes ie ei p pere in pine aa eine ntact 35 4 8 Digital Power Meter Calibration optional 36 49 1 Display aars eet dett et teens 36 4 8 2 Function Buttons 3 435 st E e eco ede 36 48 3 DPME DISplays ua tatio ite t ote ten ro iier t moe de ede RERO 36 4 8 4 Calibration Procedure 37 5 0 Maintenance and 2 4 2 2 41 5 1 Introductiori nemen ee e Be 41 5 2 Maintenance Schedule sssessesseeeeeeeneennee nennen 41 5 2 1 42 5 2 2 Open Circuit Test arena 42 5 3 sTreublesliootlng 2 rone ce eid dn dee ees 43 5 3 1 Preliminary Troubleshooting ee 43 5 3 2 Troubleshooting Fuses eee 44 5 3 3 L 828 General Troubleshooting eene 50 5 4 Additional L 829 General Troubleshooting Procedures 51 5 5 Feedback Wiring Modification Procedure 2 52 5 6 Component Replacement Procedures 52 5 6 1 Removing and Replacing URC 52 5 6 2 Removing
15. 7 1 702 702 mc 304 203 V 4 703 i A L INPUT 4 B SEE DETAL A abt uu pe VE d 4 L RN 100 LA 104 5 H H 103 AK E 92 7 61 a REF 3 are sd 3 gt 203 I tH m __ 2 i i NEZ ds NOTE LANDALLCAP FIF 102 9 5 3 WINDNGS IW 7 ZU KJE BANK WIRES AS CLOSE Y 523 I Fold 187 C mm AIRFIELD Am N 105 Al AS POSSIBLE TO THE H 44 14 _ FON E ND 307 61 201 202 S 202 205 205 iw FJ CENTER OF THE CAP 309 308 PIC 9 2 t9 H o0 9 E BANK AAN T TES T 103 M 114 vacuum 2 T1 2 5 5 35 0528 TT VR8 g E 15 CONTACTOR SEE NOTE 10 als 2 gt 81 82 902 5 MICROSWITCH 8 CONTACTOR 8 METER 524 2 8 S WIRING SEE 7 8 sg NOTES 2 e NorE3 8 8 DETAIL A 107 i SEE NOTE 5 er IE 300 303 2 RUNS EACH AS SHOWN 120 VAC INPUT NOTE 2 o a F7 T4 Q DETAIL 106 VG 4 v 99 n BLK P GRY num cs JE TAIL NG II ue Ei 3 F6 p ROTARY SWITCH 3 SEV 8 204 OP SONE N E CONNECTION eig g 5 10r V 1 200 170 I 252 RED F8 _ 5 250V SLO BLO 47A0119 gt il S siis E TO Ne 1 4 ERN BRN A 508 514131211 817 651413 211 5 ool
16. 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 96A0288 Rev W CCF 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 highest 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 out
17. me B 5 d ASSY NOTE 1 PG 2 EE f 1 508 2 g n J4 3 als s SIS T4 480 VAC INPUT T1 4 30 KW 480V en FT GNI PE A J3 J2 n g R E 2 228 MN 502 BLK GRY 506 1 2 3 112 3 4 5 6 1 2 3 4 5 61 7 8 e z DIE E 2 RED BLK 3 532 x i 8 2 gt 2 5 SEE EE ACE CVM 5 S7 h p DIG rh ES CONNECTIONS ioo TO TB1 NEU SEE WIRING DIAGRAMS al a BLK Alec BRN 508 3 43A3128 FOR 2 3 2 5 43A2550 FOR ACE1 5155 E F6 5A 250V SLO BLO 4740119 S 5 z 8 DXO 8 2 COPPER BAR JUMPER PREVIOUS IRMS W RES WIRING B 8 9 8 527 5 gigi a ra FS ol EET a T SCR 28A0028 7 5 30KW EE B RS a 8 9 TB1 GND S S S al 208 480V 2 lg 2 285 3 9 EE ESI ao 2 2 FEST 8 g 804 804 a E B pur Olak O 59 i 8 gang 4454 ORG i i 0 ni ME 200 200 n gt x gt BE r Kid 28A0045 SCR ASSY 4KW PP a Use wrench to hold RES when mi ale 62 5 PIP attaching wires lt 5 Oa TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER AS a 5 Va ML PREVIOUS MOLDED STYLE CVM WIRING 3 LISTED ON COMPONENT LABEL gt oo o FED E 72A0017 TERM BLK 35 in Ib s puede lt 45 T af EE SEE PG 2 WIRE NO S 2 3 4 i Ib 5
18. 7 EN H nd 1 4 U U D 5 AS peu NG n H H PEER E 1 4 mE rao Li Y l gt Top View Front View 2010 ADB Airfield Solutions All Rights Reserved 19 20 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Dimensions and Weights Figure 9 od I Top View Ferroresonant CCR Dimensions Typical of 50 70 kW 96A0288 Rev W E 21004 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF 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
19. User Manual 96A0288 Retain for future use Rev W 6 8 11 ETL Certified to FAA Specification 150 5345 10 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Airfield Solutions CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W 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 ordin
20. XO XO WHEN RE INSTALLING THE BLADES 2 g 8 1 ADD 2 JUMPERS 5 AS SHOWN TIE JUMPERS INTO CABLE HARNESS 415 DOC CAUTION BLADES ARE VERY SMALL 3 zx 58 SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB 1 Twisted 22awg wires eis u 2 gg 2 GROUND TO FOOT OF TRANSFORMER T 718519 ors BLADES 2 z 38 8g 22 3 ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING o UNE S za BE 4 WIRE 531 MUST BE TIED TO BLU WIRE NOT TO ANOTHER GND TACTA BTS S S al S 5 ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES SEER COLOR iss g 2 YS X 218 8 5 6 SNUBBER MAY BE SUPPLIED WITH SCR 8 OT pc di due o 9 7 REMOVED REV B Ev E 9 m uod 8 GROUNDING NOTES aie dS 4 9 4 D 5 a ol 88 GND EACH PANEL TO THE FRAME seid 1002 GNDIUGBOLT 7 JUMPER INTERNAL GND LUG TO EXTERNAL 7 1000 ON SAPE SIDE 3 5 REG 5 STEP REG GND LUG BE PULLED FROM PCB sc1 2 H m H 223 8 Ja COMP PANEL 9 REFERENCE ASSY DWG 44A6292 2 FOR WIRE LUG ASSY Ly 806 3 1228219 g 10 TORQUE SPEC S OF 53A0412 150 CONTACTOR 120 LB IN GRNIVELWIRE TS MOT 41444404 11 IF AJUMPER IS NEEDED FOR CORE LEAD USE AVAILABLE USE 89A0232 amp eg RUN UNDER CAP BANK x HIGH VOLTAGE 89A0086 1 WIRE WRAP WITH GREEN ELECTRICAL B 1 12 IF OUTPUT GOES THRU SGRS BAYS USE 40KV 89A0087 1 WIRE TAPEASSHOWN CHASIS GND CHASIS GND
21. Procedures NOTE The regulator has been adjusted at the factory to provide the nominal output current levels as given in Table 8 If the current level settings need to be adjusted read the following warning statement before proceeding WARNING 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 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 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 p Operation Current 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 reading
22. f 28 120VAC 220 X3TOH3 AE 1 texere io TO J4 4 ON PCB B 230 4 5 5 2 8 SEE 240V INPUT FOR 3540546 COLORS I 240 5 5 E 8 gt I 250 6 6 Fore N meaa aa 2 xr vo N 9542 LO LEEF EN z 2 2 lt tungen 27 Xo0OEO lt 10 64 O 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Schematics Figure 44 50 amp 70KW FERRO CCF 20 A 1 of 1
23. 600 gt 72A0071 TERM BLK 50 in Ib s Y FOR PREVIOUS SCR WIRING 57 1818281091212 8 i 8 8 E OF em og B 24 a 74 i otter ptions lt nr TB1 S ri lt N gt Use wrench to hold RES when 5889 555 aa attaching wires Toy ege Sor 44 6136 1 2 NOME 5 STEP WI RI NG tmm gt lal 1 ep e TBLA T2 T3 and meter not used 9 zt 44A6139 1 2 R IRE H SM amp MED LG FRAI 10121 94A0338 XXXX POWER WIRE KIT FERRO CCR 3 STEP CONN S IN 5 2 8 O O 2 200 W O IRMS 201 WIRMS 2 amp i W 43A2550 WIRING DIAGRAM ACE1 TO URCII 1 PCB p M o i 43A3128 WIRING DIAGRAM ACE2 TO URCII 1 PCB 43553 EN DOC NO DESCRIPTION gT 5 ga lt tESOr EM RELATED DOCUMENTS OPTIONS VARIATION 5522 19 2010 ADB Airfield Solutions All Rights Reserved 63 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Schematics 6 9 11 Figure 43 L 828 WURC 4 30KW 6 6 amp 20AMP 2 of 2
24. 2 CABINET ASSEMBLY PANELS ARE HIDDEN FOR CLARITY 3 DIG b 3 REMOVE SET SCREW FROM 61A0340 KNOB APPLY LOCTITE 222 1 b REPLACE SET SCREW AND TIGHTEN T EE E i J CONTROLLED COPY P 1 Se lo a 2 1 b j j 4 ADB Airfield Solutions 30829 Tel 614 861 1304 o b 977 Gahanna Parkway Fax 614 864 2069 SECTION B B 4 1 mm fauna 2047008 Ohio 4200 j 4 C 2433 SEE ADD NOTE 3 DTR Ph WwernE d lo ol lo CONSTANT CURRENT REGULATOR j k B 2588 SEE ECO HRDWR CHANGES DTR ET 30KW 2400V 66A d a 2 N 2 VE a INTIAL RELEASE DTR 2 g eee eee ee niens mus m 7 o Information contained on this drawing Is to be used expressly in accord with purpose for which it was submitted Any disclosure f this information is stricth hibited t as ADB Airfield arr X em ee GCF6630 x000 b ADB Airfield Solutions 2010 ADB Airfield Solutions All Rights Reserved 61 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W 2400 Vac CCF Parts and Diagrams 6 9 11 62 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Schemat
25. 28A0011 503 3 2 3 8 5 BLKBRN RED 507 BLU e COPPER BAR JUMPER FIRE VIOMHT 508 5 2 72214 512 WHT 2 Z Lwin 88 I E 707 wi al s og 2 P 59 _ 4 3 120vac 513 RED r x 8 8 s T g c x 3 8 o 53 2 D J s vio RED 514 RED 527 MU amp e f 3 5 g TO CCI TB1 lt HE TBS4 515 WHT 6 ET 5 2 MEDIEN Sd 27 2 s2ovac 707 7 PRIMARY ATTACH TO 13 POWER i d 5 2 PLACE g 9 WIRE 531 MUST BE TIED TO VIO OR RED INTERNAL o ol o F WIRE TO ANOTHER GND REMOTE za COMMAND PREVIOUS SCR WIRING 4 480 VAC INPUT TO CC TB1 725 gg gt ON F 1 SCR 28A0028 7 5 30KW ig pt2 WHTIBAN se p gt SAMPLING SMALL Js 208 480V D C Rewe 532 gt SAMPLE gt 503 pa GATE H3 C Y FB XP ern INC 77 sw CE L 5 gt FB2 8 22 24 WHT BLK VIOWHT 508 H5 Se 8 2 9 SCR 301 5 um H 2 pne AK P rek 4 5 i 5G 6G ES 526 VOLTS CONNECT N ux SE vo r TON TB1 27 A KSA 208 X2TOH2 4 22g
26. 6 6A output 20 20Ao0utput 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 7OkW 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 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 Footnotes 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 flash lamps or Runway Status Lights RWSL Runway Guard Lights using incandescent tungstenhalogen lamps should be powered with ferroresonant type CCRs and not with thyristor type CCRs 1 S step 20A is not standard FAA
27. CCR Dimensions H x W x D Weight Ib kg Size 208 220 V 240 347 480 V 208 V 220 V 240 V 480 V 2400 V 33x24x25 in 33 x 24 x 25 in 434 427 467 502 4kW 2150 975 2 83 8 x 61 x 63 5 cm 83 8 x 61x 63 5 cm 196 9 193 7 211 8 227 7 36 x 29 x 30 in 33 x 24 x 25 in 556 480 514 600 7 5kW 2150 975 2 91 4 x 73 7 x 76 2 cm 83 8 x 61 x 63 5 cm 252 2 217 7 233 1 272 2 36 x 29 x 30 in 33 x 24 x 25 783 749 770 826 10kW 2150 975 2 91 4 x 73 7 x 76 2 cm 83 8 x 61 x 63 5 cm 355 2 339 7 349 3 374 7 40 x 33 x 34 in 36 x 29 x 30 in 960 872 826 906 15kW 2150 975 2 101 6 x 83 8 x 86 4 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 1290 1150 1187 1097 20kW 2150 975 2 101 6 x 83 8 x 86 4 om 101 6 x 83 8 x 86 4 om 585 4 521 6 538 4 497 6 EE 40 x 33 x 34 in 40 x 33 x 34 in 1410 1350 1381 1302 30kW 2150 975 2 101 6 x 83 8 x 86 4 cm 101 6 x 83 8 x 86 4 cm 639 6 612 3 626 4 590 60 2150 2400 2 SOkw 70 x 33 x 34 in m NA 975 2 1088 6 2 177 8 x 83 8 x 86 4 cm 2400 2400 70kW NA NA NA NA 1088 6 1088 6 1 Based on Input Voltage 2 50kW and 70kW CCRs only available on 480V input 3 2400 Vac units are same dimensions as the 50 70 kW units Figure 8 Ferroresonant CCR Dimensions Typical of 4 30 kW T lO ec IN ye lt gt 1 7 1 1 SE OG pe
28. laSog aexeus z 13 FOR ICVM WIRING SEE DWG 44A6687 XXX GRIND PAINT OFF IN f 9 9 99 2 x 2 9 5 STEP WIRING 5 14 SEE SYSTEM PACKAGE FOR WIRING 44 6007 HARTING STAB CONNECTOR i USE EXT WASHER FIRST ig of NX ORGRIND PAINT OFF IN olv alal a v o go CONNECTION AREA 89 A S 38899 20 3d D e B D o xz 89 c 203 uo 3555 43A2616 WIRING DIAGRAM SGRS 4 30KW 6 6 amp 20A AE o 88 88888332 4446796 SGRS WIRE HARNESS 50 70KW WICCT ge a LO 94A0368 5 POWER WIRE KIT FERRO SGRS 50KW E o E f N NOTE 1 4 2 94A0368 6 POWER WIRE KIT FERRO SGRS 70KW 9 RS z 9 lt o DOC NO DESCRIPTION 2 2 2 ise RELATED DOCUMENTS 850z a pw 70 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Schematics Figure 50 Powerpack schematic 50 70 kW 2 of 2 POWER PAK WIRING FOR 94A0399 DOOR NOT CLOSED INDICATOR PREVIOUS MOLDED STYLE CVM WIRING CONTROLLED COPY y 977 Gahanna Parkway Columbus Ohio 43230 Telephone 614 861 1304 Fax 614 864 2069 4 600 2 x lt F6 ACE Potted CVM IRMS Options SC3 12 PPF STAB CONN SC3 11 PPF STAB CONN 529 7 a
29. 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 contents 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
30. 22 SCO Cutout Test and Measure Position NO Microswitch NC Series Circuit Regulator Measurement Socket Ground 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W 6 9 11 4 7 Application Notes Monitoring Option Description CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Application Notes Refer to Monitoring Option on page 6 and Figure 1 Application 0 None Standard 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 provi
31. 2400V SIG SRS REGULATOR 1 OUTPUT RANGE 18 61A0340 KNOB 3FLUTE 1 8 SHAFT ALUM BLK 1 SESSEL 14 64A0173 10 1 4 20 X 5 8 HX HD 25 4 3STEP W S1 or Gio BSBSTEP 15 64A0178 16 1 2 13 X 1 HX HD 8 j X 16 64 0198 6 6 32 X 3 8 PAN HD PHIL 2 gt 17 6440947 EYEBOLT 1 2 13X1 5 1 1910 2600 4 18 6440981 8 1 4 20 X 1 2 FLAT HD SCREW 10 19 64A0981 12 1 4 20 X 3 4 FLT HD PHIL 10 20 65A0015 33 1 2 13 HX NUT 14 o 21 65 0347 4 1 4 20 SS NYLON INSERT NUT 38 22 66A0015 33 1 2 FLATWASHER 22 23 66A0015 24 1 4 FLATWASHER 8 24 66 0026 33 1 2 SPLIT LOCKWASHER 14 25 66A0026 24 1 4 SPLIT LOCKWASHER 39 26 72 0010 GROUND LUG 1 SECTION C C SCALE 1 4 27 89A0209 24 RIBBON CABLE ASSY 34 POS W CONNS 24 1 SECTION A A 28 91 0033 LBL L828 DANGER HIGH VOLTAGE 1 29 94A0502 20 PWR WIRE KIT CCF REG 20KW 2400V 1 20 4446178 PCB ASSY 34 PIN HDR SW ADAPTOR 1 31 66 0039 4 6 EXT LOCKWASHER 2 pl NOTES 1 1 ALEGIBLE COPY OF 43A3403 WIRING SCHEMATIC J IS TO BE PERMANENTLY MOUNTED IN AN UNOBSTRUCTED PLACE INSIDE THE CONTROL CABINET 1 2 CABINET ASSEMBLY PANELS ARE HIDDEN FOR CLARITY 3 3 STEP IS NOT AVAILABLE FOR 20A OUTPUT 1 4 REMOVE SET SCREW FROM 61A0340 KNOB APPLY LOCTITE 222 1 REPLACE SET SCREW AND TIGHTEN G CEEA J CONTROLLED COPY 2 Unauthorized duplication ofthis document in whole or part is prohibited ie RED ink blow dentes 3 eee i ADB Airfield Solutions o lo
32. 333 8094 ADB Airfield Solutions Ltd 2nd Floor 3 Rivonia Village Cnr 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 96A0288 2010 ADB Airfield Solutions All Rights Reserved Document Date 12 2010
33. 4 thru 30kW with SCO Bottom of SCO Top of each Fuse Block front of GOF 20KW 208 V component plate right hand side Lightning Arrestors VR1 and VR2 CCF 30kW 208 V on Back of component plate Terminal Block black Lightning Arrestors VR1 and VR2 CCF 4 7 5 10 kW Front of component plate righthand Back of component plate side N A Lightning Arrestors VR1 and VR2 on Back of component plate 2010 ADB Airfield Solutions All Rights Reserved 23 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Stacking CCR s Optional 6 9 11 CCR Size Input Location Output Location Terminal Block white Front of component plate right hand Lightning Arrestors VR1 and VR2 side Top of each Fuse Block front of Back of component plate component plate right hand side Top of each Fuse Block front of Lightning Arrestors VR1 and VR2 component plate top right side on Back of component plate CCF 15 20 30 kW CCF 50 70 kW 3 3 Stacking CCR s 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 fou
34. 5 3 11 GROUND EACH PANEL TO THE FRAME 81 ge 514 RED 9 5 e siswHT gt lt XC Bile sm FOO 4 S rg 28A0037 X o o aol WIRE SIZES S e X c A 100 s PRIMARY POWER 8AWG 40KVDC 150C WHT 89 0087 1 XY 200 213 HIGH VOLTAGE 12AWG 25KV 150C WHT 89A0086 1 300 s TANK LOOP amp CAPS 2 AWG 600V 105C BLK 89A0199 9 300 303 2 RUNS EACH AS SHOWN prohibited ald n RED ink below ndicatesauthonied APPROVED BY DATE 500 s STD CONTROL 18AWG 600V WHT 89A0182 9 CONTROLLED COPY 700 S HIGH VOLTAGE 18AWG 15KV WHT 89A0280 22 2 Slo SIEMENS fia gt amp a 0 SIEMENS AIRFIELD SOLUTIONS INC 800 s GROUND 12AWG 600V GN YL 89A0163 5 EZ al sl ei SIEMENS AIRFIELD SOLUTIONS BC 900 s GROUND 18AWG 600V GN YL 89A0163 7 Telephone 614 861 1304 Fax 614 864 2069 DRAWWSTRE 446799 WIRE HARNESS CCF 2400V 10 70KW W O ACE TB1 oo i 2728 ADDEDSCOSWWIRING BE 20070 WIRING DIAGRAM L 828 W URC o e 8 8 2 A PRODUCTION RELEASE BE 21NOVO7 50KW FERRO CCF 2400V 5 STEP 94A0502 XX POWER WIRE KIT FERRO CCR 2400V TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER AS 5 STEP WIRING EXER eaaa Gm DOC NO DESCRIPTION LISTED ON COMPONENT LABEL us siae 20
35. 9 11 2 18 4 Regulation o ee 18 2 18 5 Environmental Operating Conditions 18 2 18 6 Protection 1 nter nnns 18 2 18 6 1 Open Circuit Protection sese 18 2 18 6 2 Overcurrent 18 2 187 Input Voltage e hs o eus 18 2 18 7 1 Built In True rms Reading Ammeter L 828 only 18 2 18 7 2 Rating and Input Voltage 18 2 18 8 Temperature 18 2 19 Dimensions and Weights 19 3 0 Installation 1 5n ene iens 21 Bil Unpacklng i5 aea e e e RE HEBR 21 3 2 Installation 1 i ee Ie da Re 21 3 2 1 Wiring Connections and Startup 2 21 3 3 Stacking CCR s Optional 24 3 4 SGRS Style Powerpacks Optional 27 dcin ge PT 28 4 0 Operation 2 eco Seno hae eina de re e coti ee 29 4 1 ilntroductlon s i Ea A 29 4 2 CCR Control 29 4 2 1 Local Control tan tec Pear eb E c d e c 29 4 2 2 Remote Control ERROR GERE EEG 30 4 3 CCR Door Interlock 30 4 4 CCR Shutdown Procedure 2 30 4 5 CCR Adjustment Procedures essere 31 4 5 1 Output Current Adjustment
36. A current output B4 5 2 A current output B5 6 6 A current output 2010 Airfield Solutions Rights Reserved 29 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W CCR Door Interlock Optional 4 2 2 Remote Control 4 3 CCR Door Interlock Optional 4 4 CCR Shutdown Procedure 30 6 9 11 Table 19 Output Current from Rotary Switch 5 Step 20 A He dad d 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 20 for instructions on how to set up and use remote control Table 20 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 iS SEND OR 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 T
37. B AIRFIELD 2400 120V Mx NOTE 4 q T 0 i 205 g _ lt C 708 F5 54A 250V SLO BLO 47A0119 4 i had NOTE 5 2 509 up d 0 IF UN KEYED MATING CONN WAS USED 70 0279 TERM RED J BLU 532 5 PIN 1 RED STRIPE IS ON THE LEFT SIDE dJa eres AN 328 J6 SAME FOR ROTARY SWITCH 88 NOTE 2 e 70A0596 a IF KEYED MATING CONN IS USED ER PIN 1 RED STRIPE IS ON THE RIGHT SIDE R E SAME FOR ROTARY SWITCH ON HARNESS WEM 1 ADD 72A0019 gg FASTON TERM 2 i FORK TERM x 44A6035 1 elm ASSEMBLY NOTES 2145 1 SOME WIRE 5 REASSIGNED THE CREATION THIS DOC Jumpers sgg URC Il ASSY 2 GROUND TO FOOT OF TRANSFORMER ASSY NOTE 7 3 ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING 8 4 WIRE 703 MUST BE TIED TO BLU WIRE NOT TO ANOTHER GND 5 ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES 205 6 DELETED 2 J4 7 ADD JUMPERS AS SHOWN TIE ALL JUMPERS INTO CABLE HARNESS SO 3 CONNECTOR HAS PULLED FROM PCB WHEN REPLACING PCB 4 8 GROUNDING NOTES U 300 303 2 RUNS EACH AS SHOWN J3 J2 J1 GND EACH PANEL TO THE FRAME m 1 2 1 2 4 5 6 1 2 3 4 s5 6 7 8 JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG 5 oln a 9 IF A JUMPER IS NEEDED FOR ANY CORE LEAD USE HIGH VOLTAGE 5 2 5515588 89A0086 1 WIRE E E 8 BE 10 USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK
38. EEE i DIG FOR 28A0011 4KW SEE PG 2 TB1 alle Ww P BAANG149 K FOR PREVIOUS SCR COLOR CODING SEE PG 2 gge c1 aeiia 1 5 STEP WIRING al a p WIRBSCLOS amp i i x2 2 ol Llu 4t 3 STEP CONN S IN s 5 9o 8 m 8 8 8 2 215 TD pita 537 FAN X4 i i M SC4 6 105 op 9995 540 277 2 2 105 X Z i4 isl UN go SC4 7 I COMP PANEL 39 919955912 g a T H3 X 5165 GND LUG BOLT 88 88888383 15 Scis 038 5 2 ON BACK SIDE DO DANDADAD H2 2 j8 1 o 1000 1000 1 4 FAN NEUTRAL 5 8 SC HARTING GND PIN z 3 H4 Y USEIEXT WASHERIFIRST TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER eM CHASIS OND AS LISTED ON COMPONENT LABEL i 72A0017 TERM BLK 35 in lbs 5 a EN SEE 43A2616 5070 FOR 50 amp 70KW WIRING 72A0071 TERM BLK 50 in Ibs 5g 9 35 siai Emer og E EM 72A0306 1 8 2 HARTING CONN S 48 in lbs A 68 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Schematics Figure 48 PPF Powerpack schematic 4 30 kW 2 of 2
39. Np 22228523 WGINDUGTORE RE i L i VRS 22 3 503 RED BLK BHO 532 i o VRE Gi T IF VARISTORS ARE PLATE i 15 d L 833 MAS RED vio 507 s GND PLATE TO EARTH GND 5542128 BARI 82 2 20 CVM WIRING ERE Hu GE ETE ROTARY SWITCH 818 CONNECTION ses 8 8 8 28 ATTACH TO FOOT OF T4 509 r RES 250V SLO BLO 47A0119 5 4 3214 AA ER bd ER Alle V2 PLACES w TOIRMS A NT AIRFIELD TOI WIRE 531 MUST BE TIED TO BLU 58 TO DPM 1 4 UN KEYED MATING CONN WAS USED we 2 WIRE NOT TO ANOTHER GND SS PIN 1 RED STRIPE IS ON THE LEFT SIDE 4 ma 71080279 TERM E J6 SAME FOR ROTARY SWITCH CONN o dw 3 Pres z i 574 STXST ST oe 879 Gr 8 E 4 347 INPUT 11 4 30 KW 208V t IF KEYED MATING CONN IS USED 9 h eee a8 Fa T4 1 m ES PIN 1 RED STRIPE IS ON THE RIGHT SIDE M TERM 9 per a dv L de SAME FOR ROTARY SWITCH CONN m S ees DIE 1 LETHAL VOLTAGE Ero MEN 82 RED BLK GRN YEL 532 i 15 il 10 2 ARE PRESENT 70 0279 2B VE S Cuo ar Jm ME 44A6035 1 Ltd 8 i 4 x ooo URC II PCB ASSY s i 1 b i
40. Oi A DO NOT USE TB3 LAND i Oe me 402 amp 403 ON 400 401 Min prote SEE NOTE 6 s ul E f SIDE OF FUSE BLOCKS 6 6A WIRING SEE 1 57 F5 d aif 84 AS POSSIBLE TO THE 528 TB1 NEU 5 Oleg 598 CENTER OF THE CAP BANK BELOW FOR 20 ret g ATTACH OUTPUT TAG 2 PLC S Be g 2 TBS F1 105 TA STA TO H2 WI6 6A 2 z 5 H 8 59 1 400 21 1 1 2 104 i x H2 H2TO T9 W 20A CVM INSULATORS REQ D FOR 804 Li AE TB2 Ost 254 gt 9 7020 lt 305 HZ TO VR1 W O DANGER Ed 30KW 6 6A CVM ONLY M 202 208 032 pee 23 ata 7 L L x2 9 G 5 LETHAL VOLTAGE re L Tps ge k 52 p 5 165 NOTE ds ARE PRESENT B 5 288 101 103 gt L L f 3 VR1 ss 8 2 21 coon HH AN ERU i A i d 858 e SCOOPTION DOOR SW Qd old ME ES Ze e A2 sorsoic_is01c sotB p NO COM 501A 55 se 5 UB T5 i POS CURRENT E 5i 8 i 6 6A 35A0548 FEEDBACK SENSOR amp d 22228 li SEE DETAIL A 94A0358KIT WES n fanm MING SEE xi x2 c DE FB2 B 3 FERTH 208 240 VAC INPUT mee i g 8 p 35 0939 546 NVE AG SS ee i is ge F4 T4 REV 1 SAME COLORS b x DIGITAL POWER METER 112 NOTE 3 PG 2 PROD ONLY ESTE VR7 VR8 Am S02 GRY 506 SEE PG 2 FOR PREV REV S 35 Q Eu g NIS
41. Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Digital Power Meter Calibration optional Figure 30 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 31 Save Vrms Calibration Save Vrms Cal SP Low t SP Hi 1743 Cnt 49289 L ad e 2010 Airfield Solutions Rights Reserved 39 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W 6 9 11 Digital Power Meter Calibration optional O pej m 5 40 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W 6 9 11 5 0 Maintenance and Repair CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Maintenance and Repair This section provides maintenance and repair instructions for the L 828 and L 829 CCF 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 main
42. SRS REGULATOR 1 20 5 3 3 STEP 14 61A0340 KNOB 3FLUTE 1 8 SHAFT ALUM BLK 1 15 EE 4 3 STEP WITH S1 v9 15 64A0173 10 1 4 20 5 8 17 e 6 5 STEP WITH S1 16 6440178 16 1 2 13 X 1 HX HD 8 8 17 64A0198 6 6 32 X 3 8 PAN HD PHIL 2 E E g g 18 64A0947 EYEBOLT 1 2 13X1 5 1 1910 2600 4 S 19 64A0981 12 1 4 20 X 3 4 FLT HD PHIL 18 a 20 64A0981 8 1 4 20 X 1 2 FLAT HD SCREW 10 21 65A0015 33 1 2 13 HX NUT 14 p 22 65A0347 4 1 4 20 SS NYLON INSERT NUT 38 SECTION D D _ SCALE 1 4 23 66A0015 24 1 4 FLATWASHER 8 J 24 66A0015 33 1 2 FLATWASHER 22 le 25 66A0026 24 1 4 SPLIT LOCKWASHER 39 EE 26 66A0026 33 1 2 SPLIT LOCKWASHER 14 SECTION A A 27 72A0010 GROUND LUG 1 EYE i b 28 89A0209 24 RIBBON CABLE ASSY 34 POS W CONNS 24 1 29 91A0033 LBL L828 DANGER HIGH VOLTAGE 1 AH 30 94A0502 10 PWR WIRE KIT CCF REG 10KW 2400V 1 j 31 66A0039 4 6 EXT LOCKWASHER 2 le d P p NOTES x o d 1 ALEGIBLE COPY OF 43A3403 1 E WIRING SCHEMATICS IS TO BE 1 PERMANENTLY MOUNTED IN AN 1 eik UNOBSTRUCTED PLACE INSIDE ld sl THE CONTROL CABINET 4 fo 8 El x od Qu B 1 2 2 CABINET ASSEMBLY PANELS 1 ER d HIDDEN FOR CLARITY 4 Q 1 s 3 REMOVE SET SCREW FROM 6140340 KNOB 1 APPLY LOCTITE 222 REPLACE SET SCREW j s De d AND TIGHTEN 2 1 1 L k j CONTROLLED COPY 2
43. XX Ei Sco p 1 1 CONNECTION gi a 107 H1 So DIG xj 200 1 70 02 SAA DBO LO BUG 2 8 8 5 4 BLK BRN BRN HE 5 4 3 2 1 8 7 6 5 a 3 211 A goh 8 AIRFIELD 2400 120 5 4 1 27 us N 205 o nores 4 509 I p VA UN KEYED MATING CONN WAS USED 2 eres M fae RED BLU y 532 FS 25A 250v PIN 1 RED STRIPE IS ON THE LEFT SIDE a NOTE 42 H 5 SLO BLO 47A0119 J6 SAME FOR ROTARY SWITCH CONN 9 ge 70A0596 MALE FASTON 1 4 IF KEYED MATING CONN IS USED fi TERM PIN 1 RED STRIPE IS ON THE RIGHT SIDE SAME FOR ROTARY SWITCH CONN FORK ADD 72A0019 ON HARNESS W FEM i FORK TERM 3 FASTON TERM 44A6035 1 Torr ASSEMBLY NOTES J5 URC II PCB ASSY 1 SOME WIRE NO S REASSIGNED AT THE CREATION OF THIS DOC 2 GROUND TO FOOT OF TRANSFORMER Cw JUMPERS SEE 3 ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING ASSY NOTE 7 4 WIRE 703 MUST BE TIED TO BLU WIRE NOT TO ANOTHER GND 5 ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES 6 DELETED J4 7 ADD JUMPERS AS SHOWN TIE ALL JUMPERS INTO CABLE HARNESS SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB 8 GROUNDING NOTES J3 J2 J1 GND EACH PANEL TO THE FRAME 1 2 3 1 2 s 4 s5 e 1 2 3 4 5 6 7 8 JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG d E sssaz 9 IF A JUMPER IS NEEDED FOR ANY CORE LEAD US
44. and Replacing Dual SCR Module Assembly 53 5 6 3 Removing and Replacing Contactor 2 54 5 6 4 Removing and Replacing Input Lightning Arrestors front of Component Mounting Plate java ite ne E i IR INR 55 5 6 5 Removing and Replacing Output Lightning Arrestors front of Component Mounting Plate ouis iet Lebe tetti tute T mede er en 55 6 0 Parts aio RERO D EIU 57 iv 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Toc 6 1 L 828 L 829 CCR 4 70 kW 6 6 A 20 A Part Ordering Code 57 6 2 SGRS Powerpack CCR 4 70 kW 6 6 A Part Ordering Code 57 6 3 2400 Vac CCF Parts and Diagrams 58 7 0 Schematlics ak Aden tuti duse 63 Document Date 12 2010 74 7 fond o 2010 ADB Airfield Solutions All Rights Reserved CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W 6 9 11 TOC 5 3 7 vi 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF 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 Materi
45. 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 SCR drive not working properly Regulator load too large Light inductive load for example signs Refer to Table 12 through Table 14 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 regulator 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 Step 5 If it does not occur in highest step refer to Feedback Wiring Modification Procedure on page 52 to modify wiring For additional L 829 CCR general troubleshooting procedures refer to the Troubleshooting section in manuals e 96A0287 Advanced Control Equipment ACE or e 96A0357 Advanced Control Equipment ACE2 2010 ADB Airfield Solutions All Rights Reserved
46. 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 Used only with Monitoring Options 3 and 5 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W 6 9 11 2 7 2 Application Notes CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Environmental Operating Conditions 0 None Standard L 828 supplied with analog ammeter 1 ALCMS Scanning Monitor Interface SMl 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 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 Monitoring ACE Includes FAA L 829 monitoring equipment If application is for connection to ADB L 890 ALCMS Add
47. 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 A or less for 3 Step CCR or 2 8 A or less for 5 Step CCR or 8 5 or less on20A 5 More than 2 seconds required for CCR to de energize on open circuit load 50 Table 40 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 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 PCB Output circuit interrupted Replace 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 acro
48. 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 safety 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 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
49. 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 environments 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 R
50. switch added part 44A6178 5 as 5 step rotary switch in 01939 uC de 118 09 Fig 7 3 ALL R Updated Name JM JM 5 29 09 2 15 3 6 Reference ECO 2200 Changed size 7 2 7 3 S 1 240 480 VAC CCF to 02349 JC JC 6 25 09 medium frame All T update ER GM 12 7 09 6 9 U SCO update JC JR 05 28 10 All ig iS pdated entire 2306 JG JC 3 03 11 Diagrams Schematics All w Updated parts diagrams 3285 JC JG 06 09 11 schematics and drawings X Y 2010 ADB Airfield Solutions All Rights Reserved 3 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W 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 NAVAIR 51 50AAA 2 Uses Supplies three or five precision output levels to power series lighting circuits on airport runways and taxiways Advanced CCR architecture combines the performance advantages of both saturabl
51. 0 53XX Figure 36 L 828 L 829 Part Ordering Code CCFXX XX X X X X AMPERAGE 66 6 4 30kW 20 20 amp 15 70kW SIZE 04 4kW 6 6A Only 07 7 5KW 6 6A Only 10 10kW 6 6A Only 15 2 15kW 20 20kW 30 30kW 50 50kW 20A Only 70 70kW 20A Only 2010 ADB Airfield Solutions All Rights Reserved OUTPUTVOLTAGE FIELD CIRCUITS MONITORED 0 No field circuit monitoring A Field circuit monitoring Field circuit monitoring with input CCRmonitoring MONIT ORING OPTIONS 0 None 1 ALCS ScanningMonitor Interface 2 ALCS Sanning Monitoring Reag 3 L 829ACE Monitoring 4 IRMS Only 5 L 829Monitoring ACE ard IRMS 6 L 828 with Digital Powe Meter INPUT VOLTAGE 12208 4 30kW 2 240 4 30KW 3 480 4 70KW 4 2347 5 220 4 30KW 3 3 Sepwithout SCO Cutout 4 3 Sepwith SCOCutout 5 5 Sepwithout SCO Cutout 6 5 Sepwith SCOCutout Parts 57 6 2 SGRS Powerpack CCR 4 70 kW 6 6 A Part Ordering Code See Figure 37 Table 42 SGRS Powerpack 4 70 KW 6 6 A Part Numbers Part Number kW Rating Output Part Number Seismic Zane 4 4KW 6 6A PPF6604 X3XX PPSF6604 X3XX 7 5 KW 6 6A PPF6607 X3XX PPSF6607 X3XX 10 KW 6 6A PPF6610 X3XX PPSF6610 X3XX 6 6A PPF6615 X3XX PPSF6615 X3XX 1S KWY 20A PPF2015 X3XX PPSF2015 X3XX 6 6 A PPF2020 X3XX PPSF2020 X3XX 20 PPF6620 X3XX PPSF6620 X3XX 6 6A PPF2030 X3XX PPSF2030 X3XX 20 PPF6630 X3XX PP
52. 0 FLA 53A0412 75 Contactor 2P 75 FLA 53A0412 90 Contactor 2P 90 FLA 53A0431 Contactor 2P 160A 1501 3600V 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Troubleshooting Table 28 CCF XXXX Dual SCR Block SCR SIZE 208 V 220 V 240 V 480 V 2400 V 4kW 28A0045 28A0045 28A0045 28A0045 2840037 7 5kW 28A0028 28A0028 28A0028 28A0028 28A0037 10kW 28A0038 28A0038 28A0038 28A0038 28A0037 15kW 28A0028 28A0028 28A0028 28A0028 28A0037 20kW 28A0028 28A0028 28A0028 28A0028 28A0037 30kW 28A0028 28A0028 28A0028 28A0028 28A0037 50kW N A N A N A 28A0037 28A0037 70kW N A N A N A 28A0037 28A0037 28A0028 Dual SCR Module 7 5 15 20 30 kW 28A0037 Dual SCR Module 50 70 kW All 2400V regulators 28A0038 Dual SCR Module 10 kW 28A0045 Dual SCR Module 4 kW Table 29 Power Transformer T1 Core SIZE 208 V 208 V 220 V 220 V 240 V 240 V 480 V 480 V 2400 V 2400 V 6 6A 20A 6 6 20 6 6 20 6 6 20 6 6 20 4kW 35A0559 N A 35A0623 N A 35A0512 N A 35A0512 N A N A N A 7 5bkW 35A0560 N A 35A0673 N A 35A0592 N A 35A0592 N A N A N A 10kW 35A0561 N A 35A0641 N A 35A0593 N A 35A0593 N A 35C0157 1 N A 15kW 35A0562 35A0565 35A0634 N A 35A0594 35A0515 1 35A
53. 0 V 44A6483 13 50kW 20A 480 V 44A6483 18 20kW 2400V 44A6483 26 50 kW 20A and 70kW 20A 480 V Table 37 CCF XXXX Other parts 44A6035 1 URC PC Assembly 44A6397 IRMS LI Board Option 44A6178 Rotary Switch 3 Step 44A6178 5 Rotary Switch 5 Step 1475 92 030 SCO Series Circuit Cutout Option Table 38 CCF XXXX Circuit Voltage Monitor Assembly CVM Option 44A6326 10 Circuit Voltage Monitor Assembly 6 6A 44A6326 11 Circuit Voltage Monitor Assembly 20 Table 39 CCF XXXX Ammeter 52A0099 Analog Ammeter 6 6A 52A0098 Analog Ammeter 20A Note Refer to ACE Manuals for Optional L 829 Monitoring and Control 2010 ADB Airfield Solutions All Rights Reserved 49 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Troubleshooting 5 3 3 L 828 General Troubleshooting 96A0288 Rev W 6 9 11 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
54. 0594 35A0515 1 N A N A 20kW 35A0563 35A0566 35A0624 N A 35A0516 35A0545 35A0516 35A0545 35C0161 1 35 0179 1 30kW 35A0564 35A0567 35A0625 N A 35A0517 35A0544 35A0517 35A0544 35C0145 1 35 0187 1 50kW N A N A N A N A N A N A N A 35A0605 N A 35A0671 70kW N A N A N A N A N A N A N A 35A0604 N A N A Table 30 Power Core List Part Number Power Core 35A0559 4kW Power Transformer 208V 6 6A 35A0560 7 5kW Power Transformer 208V 6 6A 35A0561 10kW Power Transformer 208V 6 6A 35A0562 15kW Power Transformer 208V 6 6A 35A0563 20kW Power Transformer 208V 6 6A 35A0564 30kW Power Transformer 208V 6 6A 35A0565 15kW Power Transformer 208V 20A 35A0566 20kW Power Transformer 208V 20A 35A0567 30kW Power Transformer 208V 20A 35A0623 4kW Power Transformer 208V 6 6A 35A0673 7 5kW Power Transformer 220V 6 6A 35A0641 10kW Power Transformer 220V 6 6A 35A0634 15kW Power Transformer 220V 6 6A 35A0624 20kW Power Transformer 220V 6 6A 35A0625 30kW Power Transformer 220V 6 6A 2010 ADB Airfield Solutions All Rights Reserved 47 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Troubleshooting 6 9 11 Part Number Power Core 35A0512 4kW Power Transformer 240 480V 6 6A 35A0592 7 5kW Power Transformer 240 480V 6 6A 35A0593 10kW Power Transformer 240 480V 6 6A 35A0594 15kW Power Transformer 240 480V 6 6A 35A051
55. 0V 105C 89A0230 10KW T0AWG TORN SAWG BAWG 800 806 GROUND 12AWG 600V GRN YEL 89A163 5 i Los MM 89A0195 9 89A0196 9 89A0196 9 900 905 GROUND 18AWG 600V GRN YEL 89A0163 7 i WESS NOT TO ANOTHER GND 01 i 15 kW 10AWG 15 kW 2AWG 15 kW 6AWG 1000 01 GROUND 6AWG 600V GRN YEL 89A0168 5 4 480 VAC INPUT 02 89A0195 9 89A0199 9 89A0197 9 i i F4 T4 B i 8 Sh 14 sen ose 20 kW 22 20 kW ei M 2004 4342550 WIRING DIAGRAM TO URCII 1 F3 2 Creo 43A3128 WIRING DIAGRAM ACE2 TO URCII 1 PCB E SHE oos sm DIG Reo 7 sor 30 kW 6AWG 30 kW 2AWG 30kW TBD 43A2616 5070 WIRING DIAGRAM SGRS 50 amp 70KW als ES 1444244 gt WHT BLK VIOMHT 508 89A0197 9 89A0199 9 44A6293 FERRO SGRS WIRE HARNESS 4 30KW 6 6 amp 20A 2 5 9 3 s 94A0368 1 POWER WIRE KIT FERRO SGRS 4KW S amp vo 94A0368 2 POWER WIRE KIT FERRO SGRS 7 5 amp 10KW j 94A0368 3 POWER WIRE KIT FERRO SGRS 15KW 5 a SEE 43A2616 5070 FOR 50 amp 7OKW WIRING AOE SHOWER Wire TET DOC NO DESCRIPTION d 8 RELATED DOCUMENTS 85 a POWER PAK WIRING FOR 94A0399 DOOR NOT 2 E 5 CLOSED INDICATOR 8 8 5 PREVIOUS 5 W RES WIRING Us g g g 59 844045 IRMS IN FIBER CABLE BLU JA 527 F5 E 8 3 3 5 IRMS OUT FIBER CABLE O GRY IBS umm aem m E ul 8 SC3 12 PPF STAB CONN SC3 11 PPF
56. 1 11 52 0098 AMMETER TRUE RMS 0 25 1 e 8 INPUT VOLTAGE 12 x i ES 12 60A2658 1 DISPLAY PANEL ANALOG URC CCR 1 n 9 2400V 13 60 3129 CORE SUPPORT ANGLE GLASTIC 2 20 16 ow OUTPUT RANGE 14 60 4018 CABINET MOD 2400V SIG SRS REGULATOR 1 T 1 3 3STEP AM 15 6180340 KNOB 3FLUTE 1 8 SHAFT ALUM BLK 1 8 7 5 5STEP 16 64A0173 10 1 4 20 X 5 8 HX HD 81 Q 6 5 STEP W S1 Y 17 64A0178 16 1 2 13 X 1 HX HD 8 18 64A0198 6 6 32 X 3 8 PAN HD PHIL 2 19 64A0947 EYEBOLT 1 2 13X1 5 1 19ID 2600 4 20 64 0981 8 104 20 X 1 2 FLAT HD SCREW 10 21 64 0981 12 1 4 20 X 3 4 FLT HD PHIL 10 22 65 0347 4 114 20 SS NYLON INSERT NUT 44 IT 23 65A0015 33 1 2 13 HX NUT 14 21 24 66 0015 33 1 2 FLATWASHER 22 SECTION C C SCA E 25 66A0015 24 1 4 FLATWASHER 8 SECTION A A 26 66 0026 33 1 2 SPLIT LOCKWASHER 14 26 24 23 18 27 66 0026 24 1 4 SPLIT LOCKWASHER 45 gt t 28 72 0010 GROUND LUG 1 z PED AL OR ERES 29 89 0209 24 RIBBON CABLE ASSY 34 POS W CONNS 24 1 i 30 91A0033 LBL L828 DANGER HIGH VOLTAGE 1 b mE 31 94A0502 30 PWR WIRE KIT CCF REG 30KW 2400V 1 k d 32 6640039 4 6 EXT LOCKWASHER 2 j o P 1 J NOTES cc s b 1 ALEGIBLE COPY OF 43A3403 WIRING SCHEMATIC 7 y IS BE PERMANENTLY MOUNTED IN AN Jo e 3 m UNOBSTRUCTED PLACE INSIDE THE CONTROL CABINET j E gt 4 b A
57. 24 32A0026 32A0114 32A0114 50kW N A N A N A N A N A N A N A 32A0114 32A0114 32A0114 70kW N A N A N A N A N A N A N A 32A0114 32A0114 32A0114 32A0024 Surge Arrestor 6kV Use Kit 94A0433 6 32A0025 Surge Arrestor 40 750V Use Kit 94A0576 32A0026 Surge Arrestor 3kV Use Kit 94A0433 3 32A0114 Surge Arrestor 6kV 32A0115 Surge Arrestor 3kV 48 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Troubleshooting Table 33 CCF XXXX Current Sensing Transformer T5 SIZE Part Description 6 6A 35A0548 Transformer Current Sensing 6 6A to 66mA 20A 35A0528 Transformer Current Sensing 20A to 66mA Table 34 CCF XXXX Power Transformer T4 35A0539 240 347 480 to 120 24 5A 4 7 5 10 kW 35A0546 240 347 480 to 120 24 5A 15 20 30 50 70 kW 35A0679 120 to 120 24 5A All 2400V regulators Table 35 CCF XXXX 2400V 120V Power Transformer T3 35A0678 2400 V to 120 V Transformer All Sizes Table 36 CCF XXXX Capacitor Plate 44A6107 1 30kW 6 6A and 20 44A6107 2 20kW 6 6A 208 480 V 44A6107 2 20kW 20A 208 480 V 44A6107 3 15kW 6 6A and 20A 208 480 V 44A6108 3 10kW 208 480 V 44A6108 1 7 5kW 208 V 44A6217 4kW 208 480 V 44A6392 07 7 5kW 220 480 V 44A6483 09 10kW and 30kW 240
58. 3 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 accordance 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 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Troubleshooting 6 9 11 5 3 2 Troubleshooting This subsection provides information for troubleshooting fuses Fuses Table 22 L 828 L 829 Input Power Fuses F1 and F2 Amp rating as a function of input voltage and CCR kW rating for input pow
59. 40098 7240098 49A0081 For 2400V 10kW 72A0091 72A0098 72A0098 49A0081 applications a 15kW 72A0091 49A0091 49A0091 49A0082 2 snou 20kW 72A0099 72A0099 72A0099 49A0082 provided 30kW 72A0099 72A0099 72A0099 49A0085 external to the CCR 50kW N A N A N A 49A0097 70kW 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 49A0091 Fuse Block 61 100A 250V 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 24 1 828 L 829 Step Down T4 Transformer Fuses and F4 Fuses 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 CCF XXXX T4 Fuses F3 F4 SIZE 208 V 220 V 240 V 480 V 2400 V 4kW 4740113 4740113 4740113 4740108 7 5kW 47A0113 47A0113 47A0113 47A0108 10kW 47A0113 47A0113 47A0113 47A0108 15kW 47A0187 47A0187 47A0187 47A0187 47A0113 20kW 47A0187 47A0187 47A0187 47A0187 30kW 47 0187 47 0187 47 0187 47 0187 50kW N A N A N A 47A0187 7OkW N A N A N A 4740187 4740108 Fuse 1A 500V 47A0113 Fuse 2A 250V 47A0187 Fuse 3A 500V 49A0084 Fuse Holder double 4 20 30 kW 2010 ADB Airfield Solutions All Rights Reserved 45 CCF Ferroresonant L 828 L 829 Constant Current Regulator
60. 51 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Feedback Wiring Modification Procedure 6 9 11 5 5 Feedback Wiring Modification Procedure 5 6 Component Replacement Procedures 5 6 1 Removing and Replacing URC PCB 52 WARNING A Shut down the regulator and disconnect input power before performing the procedure below Failure to observe this warning may result in personal injury death or equipment damage NOTE After making this wiring modification the regulators maximum rated load will be reduced by approximately 15 To modify the wiring to correct problem 11 in the General Troubleshooting Procedures subsection perform the following procedure NC St PON T 10 1 On the URC board find connector J8 Remove wires on pins 1 and 2 and insulate wire ends Remove jumper wire from pin 2 to 5 Add a jumper wire 18 22 AWG from pin 1 to 7 Add a jumper wire 18 22 AWG from pin 2 to 8 Disconnect the field circuit from the regulator and short the regulator s output Apply input power to the regulator Turn the regulator to step B1 B10 and verify the output current is in the correct range for that step If so verify the remaining steps and proceed to Step 9 If the regulator shuts down for an over current condition remove input power from the regulator and swap the wires in J8 pins 1 and 2 Go back to Step 7 Remove input power from
61. 5A0528 OPTION 5 i 8 SEEDETAIL A 94A0358 50KW 4B0VAC 3 BANKS alg 5 T 3540308 Plo 253A0283 VR2 MICROSWITCH Eee 472220210 T2 i WIRING SEE 8 2 SEE NOTE 13 METER Y DETAIL A 3 U480 VAC INPUT NOTE OPTION st S2 302 VR4 VR3 SEE NOTE gt 8 12 Bk GRY 506 3 PROD ONLY As 524 RED BLK 3 532 F8 06 L 525 X 2 VR6 VR5 RED 507 250 47A0119 300 303 2 RUNS EACH AS SHOWN t BLK BRN 508 2c 509 NOTE 3 NOTE 5 2 ES ai 581 505 WIRE SIZES i NU ERE le Y 102 103 PRIMARY POWER SEE TABLE B NorE42 AT CONNECTION RUN 200 213 HIGH VOLTAGE 12AWG 25KV 150 89A0086 1 F7 75A 250V SLO BLO 470119 8 V8 S sis 508 504 300 311 TANK LOOP amp CAPS 2 AWG 600 105C 89 0199 9 NOTE 4 51413 2 1 8 716 51413 2 1 _ 3 J8 300 303 2 RUNS EACH AS SHOWN 2 5 5A 250V 810 810 47A0119 Ca IF UN KEYED MATING CONN WAS USED 400 403 MEDIUM CURRENT 12AWG 600V 105C 89A0185 9 PIN 1 RED STRIPE IS ON THE LEFT SIDE 527 __ TOIRMS J6 SAME FOR ROTARY SWITCH CONN 500 562 STD CONTROL 18AWG 600V 89A0182 9 800 803 GROUND 12AWG 600V GN YL 89A163 5 IF KEYED MATING CONN IS USED 900 905 GROUND 18AWG 600V GN YL 89A0163 7 PIN 1 RED STRIPE IS ON THE RIGHT SIDE pepe SAME FOR ROTARY SWITCH CONN 304 amp 305 203212 m 100 SERIES WIR
62. 6 20kW Power Transformer 240 480V 6 6A 35A0517 30kW Power Transformer 240 480V 6 6A 35A0515 1 15kW Power Transformer 240 480V 20A 35A0545 20kW Power Transformer 240 480V 20A 35A0544 30kW Power Transformer 240 480V 20A 35A0605 50kW Power Transformer 480V 20A 35A0604 70kW Power Transformer 480V 20A 35C0157 1 10kW Power Transformer 2400V 6 6A 35C0145 1 30kW Power Transformer 2400V 6 6A 35C0179 1 20kW Power Transformer 2400V 20A 35C0187 1 30kW Power Transformer 2400V 20A 35C0161 1 20kW Power Transformer 2400V 6 6A 35A0671 50kW Power Transformer 2400V 20A Table 31 CCF XXXX Input Lightning Surge Protection VR7 VR8 94B0011 Input Power Lightning Assestor All sizes and input voltages 208 480 MOV is 32A0028 94B0189 Input Power Lightning Surge Protection 2400V Regulators Table 32 CCF XXXX Output Lightning Arrestor VR2 VR3 VR5 SIZE 208 V 208 V 220 V 220 V 240 V 240 V 480 V 480 V 2400 V 2400 V 6 6A 20A 6 6A 20A 6 6A 20A 6 6A 20A 6 6A 20A 4kW 32A0025 N A 32A0025 N A 32A0025 N A 32A0025 N A 32A0114 32A0114 7 5kW 32A0115 N A 32A0115 N A 32A0115 N A 32A0115 N A 32A0114 32A0114 10kW 32A0114 N A 32A0114 N A 32A0114 N A 32A0114 N A 32A0114 32A0114 15kW 32A0024 32A0026 32A0024 32A0026 32A0024 32A0026 32A0024 32A0026 32A0114 32A0114 20kW 32A0024 32A0026 32A0024 32A0026 32A0024 32A0026 32A0024 32A0026 32A0114 32A0114 30kW 32A0024 32A0026 32A0024 32A0026 32A0024 32A0026 32A00
63. 6 704 OW RS MM i Bi 3 583 NDUG L nes 3 3 z 2 504 536 I 535 501 S it x2 ANALOG Hii 201 5 S 7 VR1 8 Z 258 SC1 2 TT 8 301 UJ METER PRIS ps Soa 350528 8 8 203 203 HV SC2 x 4 35A0539 546 REV C SAME COLORS DUCT GI Y t O S 208 240 VAC SEE PG 2 FOR PREVIOUS REV S EG INDUCTOR L 828 T2 T6 y Men ge 52 902 3 F4 T4 5 io 66A 3640493 VR2 amp i HP 400 502A BLK GRY 508 TO STAB CONN hi QUAS AA DIG 14 X DPM OPTION 85553 RED BLK GRN YEL 532 227 l 5051 524 X 7 hamg SCST 525 NOTE 14 SC5 5 5 5 6 RED 507 A HE 3 BRN o 5 DIGITAL PWR METER 124822 X OPTION iH 855223 H 854259 Q NOTE 8 E 20A CVM WIRING 8 ROTARY SWITCH k B H EE 8 2 SIE CONNECTION sgg seg uo 1 P2 T9 B FEES 22582295 5 F5 SA 250V SLO BLO 47A0119 5 4 3 2 4 8 7 6 5 4 3 2 1 SA S OPTIONAL SCO WIRING s 5 5 5 APS 540308 9 NOTE 4 SX TOIRMS D S k oT 2 20 6 5 3 2 BE lt EE CD IF UN KEYED MATING CONN WAS USED d 2 l e S SS 508S PIN 1 RED STRIPE IS ON THE LEFT SIDE m HV SC1 z SC3 8 2 5 J6 SAME FOR ROTARY SWITCH CONN pp sn o Q zu mum age d 4404 ZO ELI ec E 2 203 209 T1 4 30 KW 20
64. 829 Constant Current Regulator with Universal Regulator Controller URC 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 96A0288 Rev W 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 The output current flows through the high voltage current transformer T5 T5 provides feedback to the URC board on the
65. 8V D t IF KEYED MATING CONN IS USED HV SC2 T4 VAC INEUT 2 SO ae PIN RED STRIPE IS ON THE RIGHT SIDE menn er S F4 T4 SAME FOR ROTARY SWITCH CONN CVM VR2 NOTE 11 8 Ir oS o BLK GRY 506 an AMD 1 1001 i E 216 JUMPER 2 ITT 8 amp 58 F3 RED BLK GRN YEL 532 DANGER 9 6 Ru nem 2 44A6035 1 LETHAL VOLTAGE GND TO FRAME USING a 503 PERRO ALWAYS USEI J5 i i Olg 1 io JUMPER ALWAYS USED URC II PCB ASSY ARE PRESENT 6AWG G Y WIRE 2 al eg BLK BRN 508 3sTEP 5 E 9 ben 3 2 98 sie JUMPER n 3 C w NOTE 1 S B 8 8 x 8 i 3c UE 1 ASSEMBLY NOTES 8 2 Gas RED BL sio 0 8 lt WINDINGS 508 17 1 ADD APPROPRIATE JUMPER WHERE REQUIRED ONLY 1 JUMPER REQD FORA gg 9 amp 8 amp 6 6A 5 STEP TIE ALL JUMPERS INTO CABLE HARNESS SO CONNECTOR HAS m BRE 501 F TO BE PULLED FROM PCB WHEN REPLACING PCB E us ug COMPONENT PANEL 2 USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK T4 480 VAC INPUT 32 n 3 ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING gt gt o 88 e ut cinch jr T1 4 30 KW 480V 172 3 772 3 4 5 6 7 8 4 WIRE 531 MUST BE TIED TO BLU WIRE NOT TO ANOTHER GND gu T4 FU 511 ale lo 5 ATTACH TO FOOT OF T4 eisio gs 502 _ GRY 56 104 5 55 bl 5 z 5 5 8 6 ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES 2 8 81815 f D
66. 9 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Introduction 2 0 Introduction CCF Ferroresonant L 828 L 829 Constant Current Regulator 2 1 About this manual manual shows the information necessary to e Install Carry Out Maintenance Carry Out Troubleshooting on the CCF Ferroresonant L 828 L 829 Constant Current Regulator 2 1 1 How to work with the 1 Familiarize yourself with the structure and content manual 2 Carry out the actions completely and in the given sequence 2 1 2 Record of changes PAGE REV DESCRIPTION EC NO CHECKED APPROVED DATE A Released manual 00819 JG WT 01 25 02 Added lifting instructions CCR Mo L weight table and updated the parts 01471 WT WT JG 10 21 05 7 4 to 7 f 10 list tables and Fig 7 3 All M Correct rev level to match N A WT WT 10 21 05 Pg 2 3 2 Corrected callouts Fig 2 3 Table 2 5 2 10 2 1 Table 2 9 Table 5 1 Removed 01635 BB JR WT 6 21 06 13 5 2 Fig 8 3 8 1 8 2 Revised notes on pg 8 1 and revised 8 3 8 4 nNoSS On pI 01759 WT BE WT 6 12 07 8 5 schematics Fig 8 1 thru 8 5 Added references to ACE2 manual 2 2 2 3 96A0357 and updated weights and 2 5 2 15 dimensions Added references to 4 3 6 7 2 VR7 amp VR8 input lightning arrestors 01875 Je 1 208 6 9 8 1 and updated parts list Corrected list of figures Corrected part 44A6178 to show as 3 step rotary
67. A SIGNATURE SERIES 20NOV07 AE AA FENGER 9 OE RELATED DOCUMENTS vr AMOaSOTO 2010 ADB Airfield Solutions All Rights Reserved 67 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Schematics 6 9 11 Figure 47 PPF Powerpack schematic 4 30 kW 1 of 2
68. AWG 8AWG 8AWG 14 AWG 3 i Re 35 89A0196 9 89A0196 9 89A0196 9 89A0196 9 89A0184 9 Eagan Sorte Misa Er Te er Bs t8 E 2 A 15 kW 2AWG 15 kW 4 AWG 6 AWG 6 AWG 10 AWG 2 2 d 88 8 oes ATTACH OUTPUT TAG 2 PLC S 89 0199 9 89 0198 9 89 0197 9 89 0197 9 89 0195 9 800 804 GROUND 12AWG 600V GN YL 89 163 5 252 7 ZokW DAWG sow SANG IANG S AWG 900 905 GROUND 18AWG 600V GN YL 89A0163 7 3 j o 4 89A0199 9 89A0201 9 89A0199 9 89A0199 9 89A0197 9 3 SEE BILL OF MATERIALS FOR NUMBER OF MOV s OR RAH 30kW 2AWG 30kW 1 0AWG 2AWG 2AWG 6 AWG SURGE SUPPRESSORS IN EACH LEG aiii 200 Q VR1 89A0199 9 89A0201 9 89A0199 9 89A0199 9 89A0197 9 98 4 USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK on N 203 _203 5 DELETED HG NTT prm 3 SMR OPTION 6 IF AJUMPER IS REQUIRED FOR ANY CORE LEAD Bii 35A 0528 BE Gnd MM USE HIGH VOLTAGE 89A0086 1 WIRE TEH H 7 VR2 TB2 2 l ib HE UA r 55 seg LL VR E VR1 TB2 1 Ex HI t 8 uz Seas es 8 6 eee ASSEMBLY NOTES 58 53252 9 Li B x TJADD APPROPRIATE JUMPER WHERE REQUIRED 3 e Q 1 MOUNTED ARE PLATE 2 VOLTAGE ONLY 1 JUMPER REQ D FOR A 6 6A 5 STEP 801 e 7 TIE ALL JUMPERS INTO CABLE HARNESS SO amp Slay i u 8 5 X CONNECT
69. B10 4 8 4 7 4 9 B5 6 6 6 5 6 7 B4 5 2 5 1 5 3 1 2 B3 4 1 4 0 4 2 B2 3 4 3 3 3 5 B1 2 8 2 7 2 9 B5 20 0 19 7 20 3 B4 12 8 15 5 16 1 2 2 B3 12 4 12 1 12 7 B2 10 3 10 0 10 6 B1 8 5 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 17 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Specifications 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 18 96A0288 Rev W 6 9 11 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 ope
70. CALE SHEET NUMBER 72A0017 TERM BLK 35 in Ib s 3 STEP CONNECTIONS IN INNE Noni RE LATE D D OC U M E NTS 720071 TERM BLK 50 in lb s 43A3403 66 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Schematics Figure 46 2400 Vac Schematic page 2 of 2 IMPORTANT KEEP WIRES 100 s amp 300 s AWAY FROM CORE 50KW CORE 50KW 3 BANKS 106 1 44A6483 26 CAP BANK eY 306 35 0671 ATTACH OUTPUT TAG 2 PLC S 2400V SCO OPTION 1 44 6483 13 CAP BANK ASSY 305
71. E HIGH VOLTAGE 89A0086 1 WIRE eg elie 10 USE INDIVIDUAL WIRES EACH CAPACITOR BANK 526 El 11 GROUND EACH PANEL TO THE FRAME g BEN I 718 scr 28A0037 r 4 5 o dys WIRE SIZES EE 100 s PRIMARY POWER 8AWG 40KVDC 150C WHT 89 0087 1 7 ME OG 200 213 HIGH VOLTAGE 12AWG 25KV 150C WHT 89A0086 1 COPPER BARSIUMPER 300 s TANK LOOP amp CAPS 10KW 8 AWG 600V 105C BLK 89 0196 9 CONTROLLED aa a 15 30KW 2 AWG 600V 105C BLK 89A0199 9 RED ney 500 s STD CONTROL 18AWG 600 WHT 89A0182 9 Jepsen one 7008 HIGH VOLTAGE 18AWG 15KV WHT 8940280 gg g SIEMENS 800 s GROUND 12AWG 600V GN YL 89A0163 5 zc ages OG Ne 900 s GROUND 18AWG 600V GN YL 89A0163 7 Telephone 614 001 1008 Fax 614 864 2008 5l el 3 2726 SEE ECO BE 14OCT10 DRAWING TITLE 44A6799 WIRE HARNESS CCF 2400V 10 70KW W O ACE TB1 mol flm 284 SEE EGO 26MAR09 WIRING DIAGRAM L 828 W URC z 2 nt 2 A PRODUCTION RELEASE BE 21Novo7 10 30KW FERRO CCF 2400V 6 6 94A0502 XX POWER WIRE KIT FERRO CCR 2400V TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER AS m p DOC NO DESCRIPTION LISTED ON COMPONENT LABEL 5 STEP WIRING SHOWN o ojojomm mimimiz andar amp 20A 3 5 STEP SIGNATURE SERIES 20 S
72. EDED FOR ANY CORE LEAD USE HIGH VOLTAGE 89A0086 1 WIRE SEE WIRING DIAGRAMS 8 11 SEE BILL OF MATERIALS FOR NUMBER OF MOV S OR SURGE SUPPRESSORS IN EA LEG SOR 218 PUR 43A2550 FOR ACE1 12 USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK 28A0028 8 or 8 3 gt lt 43 3128 FOR ACE2 r ST F6 5A 250V SLO BLO 47A0119 re KIEL MO zo lo Lap p g ee o ui 09 CONTROLLED COPY TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER AS COPPER BAR JUMPER iis LISTED ON COMPONENT LABEL n 8 5 8 Unsorted delen ots doeurment n whole or part ried lad 72A0017 TERM BLK 35 1 5 PREVIOUS 28A0028 d i EAT COLOR CODING T APPROVED DATE 72A0071 TERM BLK 50 in Ib s SIEMENS 514 RED 44A6504 1 WIRE HARNESS CCF 50 70 W O ACE 5 515 WHT F6 prep S zz z E 02306 ADDED SCO SWITCH WIRING 27MAYO9 Telephone 614 881 1304 Fac 614 864 2069 44A6504 2 WIRE HARNESS CCF 50 70 W ACE Ez a s 2 gt E D 01947 NEW SCR WIRE COLOR CODE BE 19JUNO8 94A0338 X48X POWER WIRE KIT FERRO CCR Eds bd TAAR C 01767 VAR amp ACENOTECHGS BE 14MARO7 5RAWNO TTIE TB 1 ME NE 01463 TERM BLK MARKING CHG BE osseP0s WIRING DIAGRAM L 828 W URC 43A2550 WIRING DIAGRAM ACE1 TO URCII 1 PCB 558 aes PRODUCTION RELEASE 184805 59 amp 70KW FERRO CCF elole poo 1 1 512 W
73. ES 2 lav 212 i i PI 5 cu used PRIMARY POWER DETAIL A 63 20 102 e 522 44 6035 1 POWER 4 OPTIONAL 70KW 8 50kW 1 0 AWG 208 103 7 3 WNDNG ager 5 URC II PCB ASSY 89A0201 9 F 1s SCO 1 300 amp 301 C 523 6 E TO ASSEMBLY NOTES 18812 pl open AIRFIELD 89A0231 8look 8 1 WIRE NO S REASSIGNED THE CREATION OF THIS DOC 3078 amp 308N 5 9 NOTE 10 9 99 88 2 GROUND TO FOOT OF TRANSFORMER E308 amp 310 504 T 3 ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING 2 E NE TERM 4 WIRE 531 MUST BE TIED TO BLU WIRE NOT TO ANOTHER GND sf L2 T4 3 Pics 5 ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES 303 L9 501 501A 6 DELETED i EEE gg 7 ADD APPROPRIATE JUMPER WHERE REQPD TIE ALL JUMPERS INTO CABLE 33 J2 n CI L HARNESS SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB 11213 11213121516171 5 8 GROUNDING NOTES T 5 m 5 Q GND EACH PANEL TO THE FRAME 900903 E RUNS EACH AS SHOWN NOTE 10 5 5 ju S 2522199 7 0 REPLACE FORK TERM JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG p mx ACE CVM ON HARNESS WFEM 9 ROUTE THESE WIRES ALONG TOP SIDE amp LEFT SIDE OF PCB TO CONNECT TO J3 526 TO TB1 NEU CONNECTIONS ADD72R0018 F T rotor 10 IF A JUMPER IS NE
74. HT nw REV LEVEL mace cow 5 43A3128 WIRING DIAGRAM ACE2 TO URCII 1 PCB oo 5 STEP WIRING slo mam 3 IS 20 AMP SIGNATURE SERIES OON o O O SORE SHEETRUUBER DOC NO DESCRIPTION 3 STEP CONN S IN S 5 9 o o m A miaz 20 aa poe E NA Tor Mrs toe e ese te Pda deme t RELATED DOCUMENTS EEE 43A2522 5070 E amp 2010 ADB Airfield Solutions All Rights Reserved 65 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Schematics 6 9 11 Figure 45 2400 Vac Schematic page 1 of 2 IMPORTANT KEEP WIRES 100 s amp 300 s AWAY FROM CORE 106 10 30 KW 2400V ATTACH OUTPUT TAG 2 PLC S SCO OPTION 10KW 44A6483 09 2400V VR7 70217026 imc mes 20KW 44A6483 18 EE T1 203 INPUT eC H skohe DU Tn OG VRI AX 2 5 1275 L3 2 H SEE NOTE 9 My 10 104 FE 5 B2 Bf malic 5 201 a E 97 6 H g REF 3 METAL HH _ 208 m S 241 lt XS VF Me V 41 103 lt 52 2O 81 8 LA 2 cC CO
75. IG LOGATE ON FRONT SIDE 3g xg WIRE 400 amp 401 TO TOP SIDE OF F3 amp F4 2 2 j GRNIVEL _532 OF PANEL gt TO TB1 NEU a ao 7 REMOVED REV U 508 Hd sog 8 SEE BILL OF MATERIALS FOR NUMBER OF MOV s OR SURGE SUPPRESSORS A z OU RED vio S07 T3 REQ D IN EACH LEG 8 uu 5 amp BLK BRN 508 8 9 GROUNDING NOTES DIG GND EACH PANEL TO THE FRAME 2 5s COPPER BAR JUMPER JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG 5 al 10 IF A JUMPER IS NEEDED FOR ANY CORE LEAD USE HIGH VOLTAGE 89A0086 1 WIRE 5 5 gla 11 IF OUTPUT GOES THRU SGRS BAYS USE 89 0087 1 3 ig RED BLU 531 CONTROL 512 BLU e ol Sk WINDINGS 2800 o 5 9 8 12 REFERENCE ASSY DWG 44 6292 1 FOR WIRE LUG ASSY S g 3 514 1 13 FOR ICVM WIRING SEE DWG 44A6687 XXX e 5 o 88 alo 14 SEE SYSTEM PACKAGE FOR WIRING OF 44A6007 X HARTING STAB CONNECTOR UB 3 8 amp Zl plz 6 7 r 1 T 5 A JJ o amp 3 E ug a 4 CCF 2004 CORE T1 4 30KW 480V gl x 8 28 a ge EEE i 2 z o NOTUSED INSULATE CCF 2004 CORE JE a8 WTOVR1 i B a Q i i a mH o i 5 i S a 2 2 STA CVM 994 EG E COMP PANEL s 5 E S C W 20A CVM L 2 28A0028 SCR 7 5 30KW 8825 8 SNUBBER ASSY gt TO VR2 W O CVM
76. NTROL NEZ TO 7 NOTE LANDALLCAP TT 9582 WINDINGS E AIRFIELD Ay m a lus 11 BANK WIRES AS CLOSE gt Go N f UN aN 37 Le s 2 AS POSSIBLE TO THE i L 300 C 187 ude m ge loos 0 00 m 221 i w menmeomeren CENTER OF THE 1 VI 561 15 66A 35 0548 Iw NOTES g C 15 BANK 308 sib Y C182 92 5 20A 35A0528 MICROSWITCH 8 16 METER 8 9 2 VR8 E 5 524 L NO GND REQD VR2 5 8 St WIRING SEE Z nores P T 1 KON EE RR DETAIL A 107 SEE NOTE 10 4 lt 2 524 525 X Eb 9 SEE NOTE 5 i F6 F7 2A 250V SB 120 VAC INPUT p F7 TA HER DETAIL A 106 S c 503 BLK GRY GRY a AE C 1 PIC OPTIONAL 1 1 C FG a E ROTARY SWITCH
77. Nai m 506 a ES So mse 59 21485 8 NOTE 2 e elg NOTE 4 ra 203 eg 25 HVSC2 818 Bs ROTARY SWITCH i VR2 H CONNECTION Bg BS 1100 NOTE 12 8818 5 5 4 312 1 8 716151413 2 1 FS 5A 250V SLO BLO 47A0119 3 B GND TO FRAME USING o B TOIRMS _ D IF UN KEYED MATING CONN WAS USED bid E Ki PIN 1 RED STRIPE IS ON THE LEFTSIDE D sos SC3 8 06 SAME FOR ROTARY SWITCH B 9 amp Dill IF KEYED MATING CONN IS USED E PIN 1 RED STRIPE IS ON THE RIGHT SIDE 9 r SNUBBER ASSY 70KW CORE SAME FOR ROTARY SWITCH CONN g 33 1 z z WHH 44 6149 2 44 6035 1 5 50 TO2 4 2 J5 URC II PCB ASSY i xat 1 JE 8 8 SC45 gt X 5 NOTE 1 Ld 561 FAN 805 104 S gt 08 E sca 0383 15 7 5 508 77 81815151 51 oT DE 1 amp 8 501 gt 5 E 3 2 d CHASIS GND 307 amp 308 14 4 EEG E09 J3 J2 J1 oos Ir FAN NEUTRAL Eiig FS DAE 11213141816 44A6178 SWITCH ADAPT PCB ASSY 1011 S J g st E ess ssa 302 t BNC 230001 3 55 8 8 8 8 8 3 POS STOP BLADE INSTALLATION a 526 EE 8 REMOVE NUT 8 WASHERS TURN UPSIDE DOWN al TOREN 2 AND TAP SHAFT TO REMOVE BLADES SHAFT a 3 se 517 YEL FLAT MUST IN THE POSITION SHOWN amp 5 ZJE ASSEMBLY NOTES 8 85 88 oj 518
78. OR HAS TO BE PULLED FROM PCB 2121 EE r gt l WHEN REPLACING PCB z ln EARTH ND Uem er al 2 GROUNDING NOTES 4188 el gi sce Ed 4 GND EACH PANEL TO THE FRAME z 49 M 89 A JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG 3 8 heka 5 Ul E TBS4 29425 226555 99898 gt seme als 20785 HE VER 4 f mae Hvo PIE 8 58238885 DIGITALPOWERMETER 3 E am 7 BE 05092 32 WHITE 2 CLOSED Gy 35824884 5 E 44A6528 f mage H gt CURRENT E 8 A LT step LSJ u 95959595959 595 lt 5 E 2 netavnoan seicce gt Tpit tose tie teeter S z UCONNECTIONS TO DPM Tee Te Te Teo To SES os ee T8 5000V 50V 9 8 B p 7 6 6A 0 13A i al 5 Jr RS1 4 180 OHM B S 5 500 OHM i E om WENNS d MMC NI debito PME 215 SIR EIES Fu REV S A SUPPLY TX LEAD COLORS 5 lt 8 E H 8 1 7 5KW MULTITAP 3500636 CE MONS eee ee a a im M REFERENCE NOTES alo NOTE FOR 94A0335 JFK SMI KIT amp KS4 NOT USED MULTI TAP INPUT VOLTAGE SPECD BY SALES DEPT g BIG TERMINAL BLOCKS 11 16 NOT USED TEST 240V THEN ADJUST TAPS TO SPEC D VOLTAGE PREVIOUS 4KW SCR WIRING
79. Options 2 13 1 Optional 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 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 by powering down the CCR 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 inte
80. R anchored to the concrete floor 5 Install the 4 hex head bolts and split lock washers See Figure 12 Item 1 and Figure 13 Item 1 Figure 13 Stacking Bolt 1 Stacking Bolt 2 Bottom CCR Anchored to Concrete 3 Top CCR 3 D r E D 26 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF 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 5 T 7 1 Upper Powerpack 2 Lower Powerpack 2010 ADB Airfield Solutions All Rights Reserved 27 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Frames 6 9 11 1 dOL 1 Sais 2 8 H3HSVM OH ze SdITliHd DNOTSL X ZE 0L Ze gt o 5 6 LL o i 23 o LL MOIHL 290 WNNINNTY 2505 Qaivoiuava 39 OL STANVd OVE 3015 6
81. RC Installation Table 12 Remote 120 Vac Control Connections 3 Step 6 6 For this remote intensity step Connect CCI to LOW 4 8 A CC MEDIUM 5 5 A CC B30 HIGH 6 6 A CC B100 OFF Not applicable Table 13 Remote 120 Vac Control Connections 5 Step 6 6 A For this remote intensity step Connect CCI to 28A CC 3 4A CC B2 41A 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 8 5A CC 10 3A CC B2 12 4A CC B3 15 8A CC B4 20A 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
82. RES de 8 C _ Use wrench to hold RES when ae MER 30 attaching wires E TB1 L2 e EE 5 55 QoS GRY T2 T3 and meter not used VMR men 2 j NO1 B La E BE P dud BE PREVIOUS IRMS W RES WIRING IRMS IN FIBER CABLE BLU Rms Y 5 FS IRMS OUT FIBER 3 9 SEND ESN 804 804 TORQUE SPEC S CONTACTOR FUSE BLOCK BREAKER AS SB LISTED ON COMPONENT LABEL 72A0017 TERM 35 in Ibs 72A0071 TERM BLK 50 in Ibs 72 0306 1 amp 2 HARTING CONN S 48 in lbs REVISION DESCRIPTION Use wrench to hold RES when attaching wires REV LEVEL PREVIOUS SCR WIRE COLOR CODING 513 RED DATE 20AUG07 2449 CTRL WIRE CONNEGORRECNON 090CT09 BE 18SEP07 W 2154 CHNGS FOR SHORTER GNDS DRAWN REV BY BAR 13APR09 BE 12JUN08 BE 21SEP07 WIRE SIZES 512 WHT 102 105 PRIMARY POWER SEE TABLE 514 01 8 3 200 206 HIGH VOLTAGE 12AWG 25KV 150C 89A0086 1 5 SG g S3 300 311 TANK LOOP amp CAPS 2 AWG 600V 105C 8940199 9 300 303 2 RUNS AS SHOWN 55 400 409 MEDIUM CURRENT 12AWG 600V 105 89A0185 9 ENG 00 562 STD CON
83. SF6630 X3XX 50 KW 20A PPF2050 X3XX PPSF2050 X3XX 30 KW 20A PPF2070 X3XX PPSF2070 X3XX Figure 37 SGRS Powerpack Part Ordering Code PPF6630 X 35 X PPSF6630 X 35 X OUTPUT RANGE Note 4 STAB CONNECTOR CONNECTIONS Blank Vertical Horizontal 3 3 Sep 4 3Stepwith KIRK KEY 5 5 6 5 Sep with KIRK Key INPUT VOLTAGE 3 480 MONIT ORING OPTIONS 0 None 3 L 829 4 IRMS Only 5 L 829andIRMS 6 L 828 with Digital Meter CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W 2400 Vac CCF Parts and Diagrams 6 9 11 6 3 2400 Vac CCF Parts and Diagrams Figure 38 1 828 10KW 6 6A 2400V
84. SSEM 15 50KW 2400V 6 6A L 828 1 9 52A0098 AMMETER TRUE RMS 0 25 1 10 60A2658 1 DISPLAY PANEL ANALOG URC CCR 1 11 60A3129 CORE SUPPORT ANGLE GLASTIC 2 12 60A4018 CABINET MOD 2400V SIG SRS REGULATOR 1 13 61A0340 KNOB 3FLUTE 1 8 SHAFT ALUM BLK 1 14 64A0173 10 1 4 20 X 5 8 HX HD 25 15 64A0178 16 1 2 13 X 1 HX HD 8 16 64A0198 6 6 32 X 3 8 PAN HD PHIL 2 17 64 0947 EYEBOLT 1 2 13 1 5 1 1910 2600 4 18 6440981 8 1 4 20 1 2 FLAT HD SCREW 10 19 64A0981 12 1 4 20 X 3 4 FLT HD PHIL 10 20 65A0015 33 1 2 13 HX NUT 14 21 65 0347 4 1 4 20 SS NYLON INSERT NUT 38 22 66A0015 33 1 2 FLATWASHER 22 23 66A0015 24 1 4 FLATWASHER 8 24 66A0026 33 1 2 SPLIT LOCKWASHER 14 25 66A0026 24 1 4 SPLIT LOCKWASHER 39 26 72A0010 GROUND LUG 1 27 89A0209 24 RIBBON CABLE ASSY 34 POS W CONNS 24 1 28 91A0033 LBL L828 DANGER HIGH VOLTAGE 1 29 94A0502 20 PWR WIRE KIT CCF REG 20KW 2400V 1 30 44A6178 PCB ASSY 34 PIN HDR SW ADAPTOR 1 31 66A0039 4 6 EXT LOCKWASHER 2 NOTES 1 ALEGIBLE COPY OF 43A3403 WIRING SCHEMATIC IS TO BE PERMANENTLY MOUNTED IN AN UNOBSTRUCTED PLACE INSIDE THE CONTROL CABINET 2 CABINET ASSEMBLY PANELS ARE HIDDEN FOR CLARITY 3 REMOVE SET SCREW FROM 61A0340 KNOB APPLY LOCTITE 222 REPLACE SET SCREW AND TIGHTEN CONTROLLED COPY Unauthorized duplication of this document in whole or part Is prohibited Sa ee se teh
85. STAB CONN s Pr 28A0011 SCR 4KW S 14 14 804 304 gt gt o Be Ss 512 SEEREN 3 103 50 6 105 5 513 4 5 8 i E 2 5 85 E A1 K2 Nc DOOR SWITCH SC2 1 Use wrench to hold RES when attaching wires 5 e m E b a 2 E 5 534 COMI 536 i 514 7 2 1 2 NO1 PREVIOUS MOLDED STYLE CVM WIRING x E 2L 515 6 zi 2 al ADD WIRES 541 amp 542 n m 8 2 RE 4 600 2 8 E F6 m S ACE Potted CVM IRMS Options 8 E E 5 Kg Use wrench to hold RES when a s w gt 530 Cv attaching wires E 3 9 5 TB1 L2 T2 T3 and meter not used S gi GRY Z 9 8 a 8 Bl 2 8 4 CVM 1 C N 200 201 BELE FIBER CABLE g 5 Egg ol alo z g PREVIOUS SCR WIRE COLOR CODING PO 513 RED 512 WHT 5 3 3 657 C 292 26 wu 4755 a S wx lt 00 BN BROS 5 Po gots PES 2010 ADB Airfield Solutions All Rights Reserved 69 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Schematics 6 9 11 Figure 49 PPF Powerpack schematic 50 70 kW 1 of 2
86. TROL 18AWG 600V 8940182 9 io 500 562 STD CONTROL 18 600V 89A0182 9 PRIMARY POWER S d 600 604 HIGH VOLTAGE 8AWG 7 5KV 89 0202 600V 105 C Ik o 2 ps n a Eg OBSOLETE USE 200 SERIES WIRE Sane pre zu e 700 701 INPUT POWER 2 0 AWG 600V 105C 89A0231 ERE ANG 800 806 GROUND 12AWG 600V GN YL 89A163 5 89A0201 9 904 906 GROUND 18AWG 600 GN YL 89A0163 7 70 kw 2 0 AWG 2 1000 1004 GROUND 4 AWG 600V 105 GN YL 8940233 89 0231 2 2 1100 GROUND 6 AWG 600V 105C GN YL 89A0168 5 29 ES 95 iD 588 e 43A2616 WIRING DIAGRAM SGRS 4 30KW 6 6 amp 20A 8 xo wore Mmm wets RW 94A0368 6 POWER WIRE KIT FERRO SGRS 70KW 9 gt 2 E lt DESCRIPTION Ew 8 RELATED DOCUMENTS a N 2010 ADB Airfield Solutions All Rights Reserved 71 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Schematics 6 9 11 72 2010 ADB Airfield Solutions All Rights Reserved CCF 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 C
87. The micro controller detects an over current condition by 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 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 L 828 CCR 2 9 L 828 CCR 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 sh
88. 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 1096 or 15 drop in the load Low VA 2010 ADB Airfield Solutions All Rights Reserved 7 CCF Ferroresonant L 828 L
89. 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 n C1 Cx 0 Ik T5 Te Input g Output Voltage TD Current L SCRs RMS Current Meter URC Controller 5 64 Local Control The URC receives the inputs listed below See Figure 6 in this section and Figure 42 in the Wiring Schematics section 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 e 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 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Theory of Operation Gate drive signals to the SCR block used to regulate the output
90. all of the green connectors to the board J8 J1 J2 J3 J4 and J5 11 Close the CCR door and tighten 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 5 6 2 Removing and See drawing 43A2522 in Schematics on page 63 Replacing Dual SCR Medus er Figure 33 Dual SCR Module Assembly 10 Split Lock Washer 2 or 4 each and 14 20 X 1 2 Hex Head Screw 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 7 Pull the 4 colored gate wires from the bottom of the SCR 8 Remove the SCR from the regulator by removing the 2 5 32 hex mounting screws Clean the heat sink surface with a dry rag 9 The replacement SCR will arrive mounted to a rectangular metal plate 10 Remove the SCR from the attached plate by removing the 2 5 32 hex 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 pri
91. als 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 equipment 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 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 Install all electrical connections to local code Use only electrical wire of sufficient gauge and insulation to handle the rated current demand A
92. anada Phone 1 905 331 6887 Fax 1 905 331 9389 ADB Airfield Technologies 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 N V S A 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
93. ary purposes 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 transporta
94. 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 operate 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 Contact ADB 2400 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 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Dimensions and Weights 2 19 Dimensions and Table 11 Dimensions and Weight Weights
95. current 2 8 4 Output Current The system output current is sensed by a current transformer T5 whose secondary is Monitor Circuitry 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 a 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 2 8 5 Local Control Local control position detection is accomplished by using a rotary switch mounted on the front Position Detection door of the CCR See Figure 3 2 8 6 Contactor Drive The contactor drive circuit on the URC PCB pulls in the main contactor K2 by shorting points J4 2 to J4 4 2 8 7 Remote Control When the local control signal to the micro controller indicates remote the remote control Position Detection 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 2010 ADB Airfield Solutions All Rights Reserved 9 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Theory of Operation 2 8 8 Fault Protection 10 6 9 11 This subsection describes URC fault protection Overcurrent Protection
96. de 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 Monitoring ACE and IRMS Includes FAA L 829 and IRMS equipment If application is for connection to 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 1596 drop in the load Low VA 35 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Re
97. e 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 status 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
98. ed minimum 20 A Shorting jumper wire AWG 8 minimum As required Disconnect switch or main circuit breaker 1 Voltmeter 60 Vdc full scale 1 Ammeter true rms reading 9 A maximum scale 1 Inductive type current probe 1 2010 ADB Airfield Solutions All Rights Reserved 15 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Input Wire Size 96A0288 Rev W 6 9 11 Description Quantity Ohmmeter Mounting bolts 12 13 x 1 1 2 in long V 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 2 16 Input Wire Size 2 17 Input Power Breaker Sizing 16 Table 3 Recommended Input Wiring Rating Fower 208 Vac 220 Vac 240Vac 347 Vac 480 Vac 2400 Vac Rating See note 4 kW AWG 10 AWG 10 AWG 10 AWG 12 AWG 14 AWG 14 7 5 kW AWG 6 AWG 8 AWG 8 AWG 8 AWG 10 AWG 14 10 kW AWG 4 AWG 6 AWG 6 AWG 8 AWG 10 AWG 14 15 kW AWG 3 AWG 3 AWG 4 AWG 6 AWG 8 AWG 14 20 kW AWG 2 0 AWG 1 0 AWG 2 AWG 4 AWG 6 AWG 14 30 kW AWG 3 0 AWG 3 0 AWG 2 0 AWG 2 AWG 4 AWG 12 50 kW Not applicable Not applicable applicable applicable AWG 1 0 AWG 10 Not Not 70 kw Not applicable Not applicable applicable applicable AWG 3 0 AWG 8 Increased 1 wire size to comply wit
99. epair 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 properly 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 96A0288 Rev W CCF Ferroresonant L 828 L 82
100. er Calibration optional 6 9 11 Figure 27 Irms High Step Calibration Apply Hi Step Shorted adjust value to natch Irms 6 60 I Cnt 694295 Cnt 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 28 Irms Low Step Calibration Rpplu Lo Step Shorted adjust value to match Irms 2 81 I Cnt 291226 U Cnt 19987 until settled Voltage Calibration At the calibration screen scroll to Vrms on the menu and press the ENTER button The next screen Figure 29 shows the last calibration voltage set points and internal A D numbers Select Y yes to enter the Vrms calibration Figure 29 Vrms Calibration 5 o 5 New Vims 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 96A0288
101. er 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 CCF XXXX INPUT FUSES F1 F2 SIZE 208 V 220 V 240 V 480 V 2400 V 47A0092 47A0069 47A0069 47A0090 7 5kW 47A0093 47A0093 47A0070 47A0091 For 2400V 10kW 47A0094 47A0071 47A0071 47 0085 applications a 15kW 47A0099 47A0096 47A0096 47A0088 ine snou 20kW 47A0072 47A0072 47A0099 47A0087 provided 3OKW 47A0102 47A0101 47A0101 47A0097 externalto the CCR 50kW N A N A N A 47A0106 70kW N A N A N A 47A0141 47A0069 Fuse 25A 250V Time Delay 47 0070 Fuse 45A 250V 4740071 Fuse 60A 250V 4740072 Fuse 125A 250V 47A0085 Fuse 30A 600V 4740087 Fuse 60A 600V 47A0088 Fuse 50A 600V 47A0090 Fuse 12A 600V 4740091 Fuse 25A 600V 4740092 Fuse 30A 250V 47A0093 Fuse 50A 250V 4740094 Fuse 70A 250V 47A0096 Fuse 80A 250V 4740097 Fuse 90A 600V 47A0099 Fuse 110A 250V 4740101 Fuse 175A 250V 4740102 Fuse 200A 250V 4740106 Fuse 125A 600V 4740141 Fuse 200A 600V 44 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Troubleshooting Table 23 CCF XXXX Input Fuse Blocks SIZE 208 V 220 V 240 V 480 V 2400 V 4kW 72A0091 72A0091 72A0091 49A0081 7 5kW 7240098 72
102. erform 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 Remove leads from output terminals and bushings Use AWG 8 or larger wire to short output bushings 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 Table 8 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 Table 8 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 Turn off disconnect switch or main circuit breaker to remove input power to regulator Disconnect the shorting jumper and reconnect output cables Close input power disconnect switch or main circuit breaker WARNING Read the instruct
103. es losses 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 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Toc TABLE OF CONTENTS CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC i 10 Safty x emere ed ht coed nee due es a 1 1 1 To use this equipment safely 1 1 1 1 Additional Reference Materials 2 1 1 1 2Qualitied Personnel uante incedere dt ete Aide cere ta 1 Aedes intended Use NR 1 je Eire 1 1 1 4 1 Operation Decet ete E 2 1 1 4 2 Material Handling Precautions en 2 1 1 4 3 Action in the Event of a System or Component Malfunction 2 1 1 4 4 Maintenance and Repair 2 1 1 4 5 Operation of Overloaded 2 2 0 Intr d ct 2 ine eb Uie e de trei tute 3 2 1 About this
104. eshooting 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 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
105. fe SECTION 5 SECTION SCALE 1 4 CCF6620 900 0 1 828 1 829 MONITORING OPTIONS 0 NONE 1 SMI 2 SMR 3 L829 4 IRMS ONLY 5 1 829 AND IRMS 6 DIGITAL POWER METER INPUT VOLTAGE 9 2400V OUTPUT RANGE 3 38 4 3STEP W S1 5 5STEP 6 5STEP 1 N L Sess TU ITEM PART NUMBER DESCRIPTION QTY E 35 0161 1 PWR TX 20KW 2400 6 6A AIR COOLED 1 2 42A0480 LABEL OUTPUT CURRENT L 828 1 3 42A0525 5 ROTARY SWITCH LABEL 5 STEP FERRO 1 4 42B0269 LABEL L828 1 5 44A6483 18 CAP PLATE ASSEM 18 CAPS 20KW 6 6A 1 6 44A6774 CONTACTOR TRANSFORMERPLATE ASSY 1 7 44A6799 HARN ASSY CCF 2400V 10 70KW 1 8 44A6852 X90 COMP PLT A
106. gulator Controller URC 96A0288 Rev W Digital Power Meter Calibration optional 6 9 11 4 8 Digital Power Meter Calibration optional 4 8 1 Display Figure 23 Meter Display 4 8 2 Function Buttons Figure 24 Function Buttons Scroll Up Scroll Down Enter Save 4 8 3 DPM Displays Figure 25 DPM Displays xe 5 5 0 00 kVA NOTE Scroll through displays using the Scroll Up and Scroll Down buttons After 30 seconds the display will revert to the default setting of A rms 36 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF 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 F
107. h ahead dapat ois document whole o para proi k ilo in RED ink below indicates authorized SECTION B B 5 5 ADB Airfield Solutions is E P O BOX 30829 Tel 614 861 1304 4 4 3052 ECO CHNG 35 0157 TO DTR avant 977 Gahanna Parkway Fax 614 864 2069 4 4 Columbus Ohio 43230 2 D 1856 CORRECTED COMP PLATE DTR 070CT10 BN c 2433 SEE ECO ADDED NOTE 3 DTR 06JUL10 DEUM NILES CONSTANT CURRENT REGULATOR 258 SEE ECO Die L 828 10KW 6 6A 2400V A INITIAL RELEASE DTR 16AUG07 m REVISION DESCRIPTION ERT IDEAE TDT RYAN MGAUGOT m ux eo 27 18 10F1 Information contained on this drawing is to be used expressly in accord with purpose for which it was submitted Any disclosure ff this inf i ricth hibited ADB Airfield Solutions Inc may otherwise agree in wing Copyright 2009 CCF6610 X900 E ADB Airfield Solutions 58 2010 ADB Airfield Solutions All Rights Reserved 96 0288 Rev W 6 9 11 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 2400 Vac CCF Parts and Diagrams Figure 39 L 828 20KW 2400V 6 6A 24 22 OS 20 15 D 11 L 828 DOOR SECTION A A oleo d
108. h small conductor limits in NEC 240 4 D NOTE Wire to be rated for 5000 V for 2400 V CCRs 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 125 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 Power 208 Vac 220 Vac 240 Vac 347 Vac 480Vac 2400 Vac Rating 4 kW 27 A 26 A 24 A 16A 12A 3A 7 5 kW 51A 48 A 44 A 31A 22 A 5A 10 kW 68 A 65A 59 A 41 30A 6A 15 kW 97A 92A 84A 58A 42A 9A 20 kW 129A 122A 112A 78A 56A 12A 30 kW 190A 179A 164A 114A 82A 17A Not 50 kW Not applicable Not applicable Not applicable applicable 136A 28 A Not 70 kW Not applicable Not applicable Not applicable applicable 188A 38 A 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 2 18 Specifications 2 18 1 Effic
109. he 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 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 NOTE Do Not use excessive force when pulling the plunger of the interlock switch or you will damage the switch 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 2010 ADB Airfield Solutions All Rights Reserved 96 0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 CCR Adjustment Procedures 4 5 CCR Adjustment This subsection provides regulator adjustment procedures
110. ics 7 0 Schematics Figure 42 L 828 WURC 4 30KW 6 6 amp 20AMP 1 of 2 H 8g gt 88 m e e e e e e m i RR OUTPUT NOTE 5 2 H i FOR 30KW 208V amp 240V f OUTPUT CONNECTIONS ON VR1 6 8 USE F1 amp F2 FOR INPUT peta et 802 iue eee eee y AND VR UNLESS TERMINAL
111. iency 2 18 2 Reactive Loading 2 18 3 Resistive Loading Specifications 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 828 1 829 Brightness Class CCR Max Style 9 Nominal Output Current Power Ratings Steps Output Current S 3 4 8 5 5 6 6 4 7 5 10 15 20 2 5 2 8 3 4 A 4 1 A 5 2 A 6 6 and 30 kW 8 5 A 10 3 A 12 4 A 15 8 A 20 15 20 30 50 and 2 20 2 5 70 kW Table 6 Power Factor CCR Power Factor 4 10 kW 0 90 minimum 15 70 kW 0 95 minimum 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 6 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 100 6 6 6 5 6 7 1 1 0 5 5 5 4 5 6
112. igure 24 to enter the calibration menu Figure 26 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 will 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 31 Wait until the lcnt and V Cnt values settle and select the ENTER button 2010 ADB Airfield Solutions All Rights Reserved 37 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Digital Power Met
113. input fuse block F1 F2 or terminal block TB3 Tighten all connections Figure 10 Wiring on Right Side of CCR Front of CCR 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 Schematics on page 63 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 22 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller U
114. ions 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 the 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 Disconnect cables from the output terminals and bushings Turn on input power to the regulator 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 Turn the rotary switch to OFF The open circuit protective device should reset Turn the rotary switch to position 1 The regulator should turn on and then de energize in less than 2 seconds If regulator operation is satisfactory turn rotary switch to OFF and turn off disconnect switch or main circuit breaker before reconnecting the load After the load has been reconnected turn on input power to the regulator 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 5 3 Troubleshooting Troubl
115. 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 personal 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 equipme
116. k 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 Table 8 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 damaged 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 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Maintenance Schedule 5 2 1 Short Circuit Test 5 2 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 p
117. ll 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 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
118. manual bte added benkene 3 2 1 1 How to work with the 3 2 1 2 ot changes D IR ERR instans 3 2 2 Product IN rOdUCHON ie Bid ides e ette ieee 4 2 3 Compliance with Standards eeccceceeeseceeeeeeeeeeeeeeeeeeaeeeaeeseeeeeaeeseeeseeesieeeeaeeeaes 4 2A dug R 4 2 5 Electrical Supply n eee eee LE E 5 2 5 1 Remote Control Lunn nesa uge 5 2 5 2 Total Harmonic Distortion THD reernnronnnnvrnrenvrnnrnvrnrrnnrnererrnnrrrrerrnnrnerrnnnne 5 2 5 3 Theory of Operation Introduction esee 5 2 6 SAGE2 Unit vassere eg ene tre reote mede 5 2 7 Environmental Operating Conditions seen 6 2 7 1 Monitoring Option i t Lee Rte OU rundes EORR 6 2 7 2 Application 7 2 8 Theory of Operation da puta del ea i 8 2 8 1 Power Circuit kan a i a 8 2 8 2 Output Measurement sviscerate 8 2 8 3 Universal Regulator Controller URC eene 8 2 8 3 1 URC Inputs OUtput 2 42 24 1 8 2 8 4 Output Current Monitor Circuitry senes 9 2 8 5 Local Control Position Detection 2 9 2 8 6 Contactor
119. mee ED DECR ea fe date ait 9 2 8 7 Remote Control Position Detection 2 2 444 44 9 2 8 8 Fault Protection ete tee E Rede iot 10 2 9 159285 CRI csi em E ete eet giten eH 11 2 10 L 829 GC RE ia eiie dene d ree o e RAD e edere 12 2 1 SGRS Powerpack RP AT 13 2 12 Universal Regulator Controller 22 14 2 12 1 11 829 Advanced Control Equipment ACE or ACE2 14 2 13 L 828 L 829 CCR Monitoring Options 15 2 13 1 Optional Insulation Resistance Monitoring System 15 2 13 2 Optional Scanning Monitor 15 2 13 3 Optional Scanning Monitor 2 15 2 14 Optional Series Cutout Type 15 2 15 L 828 CCRs 4 70 kW 6 6 A 20 A Required Equipment 15 2 16 Input Wire SI26 uns senaste HIR ERE 16 2 17 Input Power Breaker Sizing seen 16 2 18 SpecifiCations ie ut Re PE Bein 17 2 18 1 EfflClency eee eie ee a Pee tee 17 2 18 2 Reactive 22 17 2 18 3 Resistive Loading puste e rp Ree eie eile 17 2010 ADB Airfield Solutions All Rights Reserved iii CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W TOC 6
120. ning 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 Put the side panel back on the CCR with the 8 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 2010 ADB Airfield Solutions All Rights Reserved 55 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W 6 9 11 Component Replacement Procedures d 5 zi 5 D 3 56 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Document Date 12 2010 6 0 Parts CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 1 L 828 L 829 CCR 4 70 kW 6 6 A 20 A Part Ordering Code See Figure 36 Table 41 L 828 L 829 CCR 4 70 kW 6 6A amp 20 A Part Numbers kW Rating Output 240 V 480 V 4 kW 6 6 A CCF6604 X2XX CCF6604 X3XX 7 5 kW 6 6 A CCF6607 X2XX CCF6607 X3XX 10 kW 6 6 A CCF6610 X2XX CCF6610 X3XX 15 kw 6 6A CCF6615 X2XX CCF6615 X3XX 20 kW 6 6A CCF6620 X2XX CCF6620 X3XX 30 kW 6 6A CCF6630 X2XX CCF6630 X3XX 15 kW 20A CCF2015 X2XX CCF2015 X3XX 20 kW 20A CCF2020 X2XX CCF2020 X3XX 30 kW 20A CCF2030 X2XX CCF2030 X3XX 50Kw 20A N A CCF2050 53XX 70kW 20A N A CCF207
121. nt damage 2010 ADB Airfield Solutions All Rights Reserved 1 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W To use this equipment safely 1 1 4 1 Operation 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 in 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
122. or to attaching the SCR 11 Once the SCR is mounted in the CCR connect wire 300 and the ground wire to the top lug of the SCR 12 Connect wire 301 to the bottom lug of the SCR 13 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 14 Close all doors and replace all panels Ro I 8 2010 ADB Airfield Solutions All Rights Reserved 53 ED 5 2 El o CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Component Replacement Procedures 6 9 11 5 6 3 Removing and Replacing Contactor 54 15 Restore the SCO to the ON position 16 Restore primary power to the CCR at the breaker panel 17 Turn the CCR local switch to the REM position 1 Turn CCR local switch to the OFF position Figure 34 CCR Power Contactor Contactor P 401 102 f 400 103 Retaining Screw SIEMENS A2CF15AF 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 di
123. ows a Ferroresonant 15 kW 6 6 A L 828 CCR 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 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 A 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 11 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W L 829 CCR 6 9 11 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 1 829 CCR with ACE2 Q Q
124. pe r5 Qo Sy Io HV SC1 ER e 28 CB1 K2 NOTE LANDALLCAP gt pe Mog 5 ce j 20A CVM WIRING 1 meom J5 ET Te S zii 22 TN 102 M 2 104 BANK WIRES AS CLOSE ST Jp 59 9121 somrer FIBER CABLE o GRY 8 1 3 90 TBI GND Os 38 S aL g AS POSSIBLE TO THE 0009011 MENE FIBER GABLE o BLU NEMPE NOTE 1 3 E K a i O i i i 58 3s 3 4 CENTER OF THE CAP Lit i V TT s 804 ere 3E 25 7 S 69 E 0 NOTE12 1 iH oom r e ICVMOPTION cwm ibd Bee 480 VAC INPUT 402 A DOOR sw 36 3026 TO1 50KW 480VAC 3 BANKS 303 DN SEENOTE 13 1 8 403 2 1__ 1 535 501 DANGER 8 8 534 535 Le ETMALVOMTAGER ACE CVM amp IRMS OPTIONS HHE ARE PRESENT 203 203 5 HV SC2 H M ZEN 49 VACINPUT _ NN BE i i T4 FIBER CABLE 20 35A0528 3a BLK GRY 506 201 SS oprana 3 8 a 2C d 32283225 4 co REDIBLK 5 enveL 532 T A d 14 FT H NG 17 NOTE 2 35A0528 PU scs 5 5 5 6 NOTE 3 RED 507 NO GND REQD eee pcc iih 7 BLK llc BRN 508 DIGITAL PWR METER METER OPTIONAL SCO WIRING 52 38 509 EE 2 88322038 NOTE RS Je J fle
125. 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 43A2522 dwg in Schematics on page 63 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 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 35 Output Lightning Arrestors 8 9 10 11 12 13 8 8 5 BX Loosen the 11 16 inch wire retaining nuts for 200 201 203 ST1 ST2 and 202 and disconnect Remove the 4 10 x 32 pan head screws and retain until later Replace the Input Light
126. put 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 o 5 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W 6 9 11 Environmental Operating Conditions 2 7 Environmental Temperature 40 C to 55 C 40 F to 131 F Operating Conditions Humidity 10 to 95 Altitude 0 to 6 600 ft 2 000 m 2 7 1 Monitoring Option See Figure 1 Figure 1 CCF Ordering Codes Ordering Code CCFXXXX XXXX Amperage 66
127. r 1 2 13 x 34 hex head bolts and split lock washers from the stacking kit Part Number 94A0475 XX 2 See Figure 11 for anchor bolt template Use the four 1 x 3 75 Lg HILTI anchor bolts with 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 Table 16 Bolt patterns for the 3 CCR sizes CCR A B Small 22 50in 23 50 in 23 75in 24 75 in Medium 27 50 in 28 50 in 28 75 in 29 75 Large 31 50 in 32 50 in 32 75 33 75 in 24 2010 Airfield Solutions All Rights Reserved 96A0288 Rev W CCF 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 c D ES T 7 1 Hex Head Bolts and Split Lock washers 2 Ve x 3 3 4 inch HILTI Anchor Bolt Location 2010 Airfield Solutions Rights Reserved 25 96 0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Stacking CCR s Optional 3 Remove the 4 eye bolts from the anchored CCR 4 Stack the second CCR by positioning its 4 holes carefully on top of the holes of the CC
128. r not indicating proper current 8 Regulator operates by the local control switch but not by Remote control 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 4 Additional L 829 General Troubleshooting Procedures Possible Cause Incorrect output current adjustment CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC Additional L 829 General Troubleshooting Procedures 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 on page 31 Refer to Problem 11 in this table Current 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 e Advanced Control Equipment ACE2 manual 96A0357 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
129. rating conditions include temperature range relative humidity and altitude Table 9 Environmental Operating Conditions Temperature Range Relative Humidity Altitude Without monitoring circuitry 40 to 55 C 40 to 131 F With monitoring circuitry 0 to 55 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
130. rface plus one 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 NOTE For more information refer to the SCO Cutout manual 96A0294 Refer to Table 1 for required equipment that is supplied Refer to Table 2 for required equipment that is not supplied Refer to Parts 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 AWG 8 As requir
131. s 2 Energize the regulator locally and set the rotary selector switch to the maximum brightness position B5 or B100 2010 ADB Airfield Solutions All Rights Reserved 31 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 CCR Adjustment Procedures 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 in 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 NOTE By adjusting the R40 on the highest brightness step all other steps will be reclibrated Figure 18 R40 URC Board R40 5 o 5 4 5 2 Overcurrent No adjustment is necessary Adjustment 32 O 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF 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 and Figure 20 The SCO cutout can be plugged in three orientations For Working Positions additional information on the SCO cutout refer to manual 96A0294 SCO Cutout Figure 19 SCO Cutout Handle Orientations ON LL 8 In the operation posi
132. s 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 to provide 120 Vac at 50 W is the Remote power control source Figure 6 Universal Regulator Controller URC e 7 3 2 12 1 L 829 Advanced 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 and Monitor Boards Monitor Board mounted on top of control board Control Board HEN For more information about the ACE see Advanced Control Equipment ACE manual 96A0287 or the Advanced Control Equipment ACE2 manual 96A0357 ACE Programming manual 96A0348 14 2010 Airfield Solutions All Rights Reserved 96A0288 Rev W 6 9 11 CCF 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
133. sconnect See 43A2522 dwg in Schematics on page 63 Label any wires not labeled prior to disconnecting them Remove wires 400 and 401 from the top connectors of the contactor 9 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 ov Ro co M 12 Connect wires 531 and 501 to the contactor coil connections 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 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 5 6 4 Removing and Replacing Input Lightning Arrestors front of Component Mounting Plate 5 6 5 Removing and Replacing Output Lightning Arrestors front of Component Mounting Plate PON 8 9 10 11 12 1 2 3 4 Component Replacement Procedures Turn CCR local switch to the OFF position Remove and lock out tag out primary
134. ss J8 4 to J8 3 with those in Output Current Monitor Circuitry on page 9 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 on page 31 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 Table 8 Overcurrent condition Defective control board Refer to problem 2 in this table Regulator 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 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 Remove section of load Replace URC PCB 2010 ADB Airfield Solutions All Rights Reserved 96 0288 Rev W 6 9 11 Problem 6 Short lamp life and or high output current reading on panel ammeter 7 Regulato
135. tenance 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 until either power to the regulator is cycled or the regulator is turned off with either the rotary switch or the remote controls 5 1 Introduction CCRs 4 70 kW 6 6 A or 20 A 5 2 Maintenance Schedule Table 21 Interval Daily Monthly Annually Unschedul ed 2010 ADB Airfield Solutions All Rights Reserved This section provides preventive maintenance for L 828 L 829 constant current regulators To keep the L 828 L 829 CCRs operating efficiently follow a preventive maintenance schedule Refer to Table 21 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 Chec
136. the regulator Remove the output short circuit Reconnect the field circuit Apply input power to the regulator Verify all steps output the correct current level Modification complete Turn CCR local switch to the OFF position Figure 32 URC PCB eo Oe o m J1 er 2 e 17 2 3 526 4 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 door 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 2010 ADB Airfield Solutions All Rights Reserved 96A0288 Rev W CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 6 9 11 Component Replacement Procedures 7 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 8 Mount the new PCB by replacing the 4 screws at the corners of the PCB including the ground wire on the top right corner 9 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
137. tion 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 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 disabled 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 O 2010 ADB Airfield Solutions All Rights Reserved 33 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W SCO Cutout Working Positions 34 6 9 11 Figure 21 SCO Cutout Maintenance Position MO 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
138. tion charges 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 damag
139. tion 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 adjustment procedures SCO Cutout working positions This subsection describes the regulator operations in local and remote controls See Figure 16 Refer to Table 17 through Table 19 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 REM gep m ag AN B30 f N Be Z 2 AN ET B100 B3 ga po P C Local Control C Local Control 3 Step Switch Assembly 5 Step Switch Assembly Table 17 Output Current from Rotary Switch 3 Step 6 6A s ial rotary switch to the The result is B10 4 8 A current output B30 5 5 A current output B100 6 6 A current output Table 18 Output Current from Rotary Switch 5 Step 6 6 A If you set the rotary switch to the The result is following B1 2 8 A current output B2 3 4 A current output B3 4 1
140. 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 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 CCF Ferroresonant L 828 L 829 Constant Current Regulator with Universal Regulator Controller URC 96A0288 Rev W Installation 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 Refer to Table 3 for the recommended input wire Connect the power supply lines from the disconnect switch or main circuit breaker to the CCR
141. with Universal Regulator Controller URC Troubleshooting 46 Table 25 96A0288 Rev W 6 9 11 L 829 Power Supply Transformer Fuse F5 and ACE Power Supply Fuse F6 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 CCF XXXX ACE Fuses F5 F6 47A0119 Fuse 5A 250V 47A0061 Fuse Block single Table 26 CCF XXXX Current Transformer 2 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 27 CCF CCR Contactors SIZE 208 240 V 480 V 2400 V 4kW 53A0412 25 53A0412 25 53A0431 7 5kW 53A0412 50 53A0412 40 53A0431 10kW 53A0412 60 53A0412 40 53A0431 15kW 53A0412 90 53A0412 40 53A0431 20kW 53A0412 120 53A0412 50 53A0431 30kW 53A0331 53A0412 75 53A0431 50kW N A 53A0412 150 53A0431 70kW N A 53A0331 53A0431 53A0331 Contactor 3P 200A 170A 120VAC Coil 53A0412 120 Contactor 2P 120 FLA 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 6

CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with

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