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

CCF (Ferroresonant) L-828 /
L-829 Constant Current
Regulator with Universal
Regulator Controller (URC)
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)
96A0288 Rev. W
6/9/11
Disclaimer
Disclaimer
Table of
Contents
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
Safety
Products of ADB Airfield Solutions manufacturer are guaranteed against mechanical, electrical, and physical defects
(excluding lamps) for a period of one year from the date of installation or a maximum of 18 months from date of
shipment and are guaranteed to be merchantable and fit for the ordinary purposes for which such products are made.
ADB Airfield Solutions will correct by repair or replacement, at its option, equipment or parts which fail because of
mechanical, electrical or physical defects, provided that the goods have been properly handled and stored prior to
installation, properly installed and properly operated after installation, and provided further that Buyer gives ADB
Airfield Solutions written notice of such defects after delivery of the goods to Buyer. Refer to the Safety section for
more information on Material Handling Precautions and Storage precautions that must be followed.
ADB Airfield Solutions reserves the right to examine goods upon which a claim is made. Said goods must be
presented in the same condition as when the defect therein was discovered. ADB Airfield Solutions furthers reserves
the right to require the return of such goods to establish any claim.
ADB Airfield Solutions’ obligation under this guarantee is limited to making repair or replacement within a reasonable
time after receipt of such written notice and does not include any other costs such as the cost of removal of defective
part, installation of repaired product, labor or consequential damages of any kind, the exclusive remedy being to
require such new parts to be furnished.
ADB Airfield Solutions’ liability under no circumstances will exceed the contract price of goods claimed to be defective.
Any returns under this guarantee are to be on a transportation charges 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.
Introduction Installation
Trademarks
General notice: other product names used here are for identification purposes only and may be trademarks of their
respective companies.
Proprietary Information
Operation
Parts
This information carrier contains proprietary information, which shall not be used for other purposes than those for
which it has been released, nor be reproduced or disclosed to third parties without the prior written consent of ADB
Airfield Solutions.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means,
mechanical, photocopy, recording, or otherwise, without the prior written permission of ADB Airfield Solutions. No
patent liability is assumed with respect to the use of the information contained herein. Neither is any liability assumed
for damages resulting from the use of the information contained herein.
ADB Airfield Solutions shall not be liable to the purchaser of this product or third parties for damages, losses, 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.
Schematics
ii
© 2010 ADB 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)
TOC
Disclaimer
TABLE OF CONTENTS
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC) ... i
1.0: Safety ................................................................................................................... 1
Safety
Table of
Contents
1.1 :To use this equipment safely: .............................................................................. 1
1.1.1 :Additional Reference Materials: .................................................................. 1
1.1.2 :Qualified Personnel ..................................................................................... 1
1.1.3 :Intended Use ............................................................................................... 1
1.1.4 :Storage ........................................................................................................ 1
1.1.4.1 :Operation ............................................................................................ 2
1.1.4.2 :Material Handling Precautions ............................................................ 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 Regulators .................................................. 2
2.0: Introduction ......................................................................................................... 3
© 2010 ADB Airfield Solutions All Rights Reserved
Schematics
Parts
Operation
Installation Introduction
TOC
2.1 :About this manual ................................................................................................ 3
2.1.1 :How to work with the manual ....................................................................... 3
2.1.2 :Record of changes ...................................................................................... 3
2.2 :Product Introduction ............................................................................................. 4
2.3 :Compliance with Standards ................................................................................. 4
2.4 :Features ............................................................................................................... 4
2.5 :Electrical Supply ................................................................................................... 5
2.5.1 :Remote Control ........................................................................................... 5
2.5.2 :Total Harmonic Distortion* (THD) ................................................................ 5
2.5.3 :Theory of Operation Introduction ................................................................. 5
2.6 :ACE2 Unit ............................................................................................................ 5
2.7 :Environmental Operating Conditions ................................................................... 6
2.7.1 :Monitoring Option ........................................................................................ 6
2.7.2 :Application Notes ......................................................................................... 7
2.8 :Theory of Operation ............................................................................................. 8
2.8.1 :Power Circuit ............................................................................................... 8
2.8.2 :Output Measurement ................................................................................... 8
2.8.3 :Universal Regulator Controller (URC) ......................................................... 8
2.8.3.1 :URC PCB Inputs/Outputs ................................................................... 8
2.8.4 :Output Current Monitor Circuitry .................................................................. 9
2.8.5 :Local Control Position Detection ................................................................. 9
2.8.6 :Contactor Drive ............................................................................................ 9
2.8.7 :Remote Control Position Detection ............................................................. 9
2.8.8 :Fault Protection ......................................................................................... 10
2.9 :L-828 CCR ......................................................................................................... 11
2.10 :L-829 CCR ....................................................................................................... 12
2.11 :SGRS Powerpack™ ......................................................................................... 13
2.12 :Universal Regulator Controller ......................................................................... 14
2.12.1 :L-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 Interface ....................................................... 15
2.13.3 :Optional Scanning Monitor Ready ........................................................... 15
2.14 :Optional Series Cutout Type SCO ................................................................... 15
2.15 :L-828 CCRs (4-70 kW 6.6 A/ 20 A): Required Equipment ............................... 15
2.16 :Input Wire Size ................................................................................................. 16
2.17 :Input Power Breaker Sizing .............................................................................. 16
2.18 :Specifications ................................................................................................... 17
2.18.1 :Efficiency ................................................................................................. 17
2.18.2 :Reactive Loading ..................................................................................... 17
2.18.3 :Resistive Loading .................................................................................... 17
iii
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
TOC
96A0288 Rev. W
6/9/11
Disclaimer
2.18.4 :Regulation ................................................................................................18
2.18.5 :Environmental Operating Conditions .......................................................18
2.18.6 :Protection Devices ...................................................................................18
2.18.6.1 :Open-Circuit Protection................................................................... 18
2.18.6.2 :Overcurrent Protection .................................................................... 18
2.18.7 :Input Voltage ............................................................................................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 Rise ....................................................................................18
2.19 :Dimensions and Weights ..................................................................................19
Table of
Contents
3.0: Installation .........................................................................................................21
Safety
3.1 :Unpacking ..........................................................................................................21
3.2 :Installation ..........................................................................................................21
3.2.1 :Wiring Connections and Startup ................................................................21
3.3 :Stacking CCR’s (Optional) ..................................................................................24
3.4 :SGRS Style Powerpacks (Optional) ...................................................................27
3.5 :Frames ...............................................................................................................28
Introduction Installation
TOC
4.0: Operation ...........................................................................................................29
Operation
4.1 :Introduction .........................................................................................................29
4.2 :CCR Control Procedures ....................................................................................29
4.2.1 :Local Control ..............................................................................................29
4.2.2 :Remote Control ..........................................................................................30
4.3 :CCR Door Interlock (Optional ) ...........................................................................30
4.4 :CCR Shutdown Procedure ................................................................................30
4.5 :CCR Adjustment Procedures .............................................................................31
4.5.1 :Output Current Adjustment ........................................................................31
4.5.2 :Overcurrent Adjustment .............................................................................32
4.6 :SCO Cutout Working Positions ..........................................................................33
4.7 :Application Notes ...............................................................................................35
4.8 :Digital Power Meter Calibration (optional) ..........................................................36
4.8.1 :Display .......................................................................................................36
4.8.2 :Function Buttons ........................................................................................36
4.8.3 :DPM Displays ............................................................................................36
4.8.4 :Calibration Procedure ................................................................................37
Parts
5.0: Maintenance and Repair ...................................................................................41
Schematics
5.1 :Introduction .........................................................................................................41
5.2 :Maintenance Schedule .......................................................................................41
5.2.1 :Short-Circuit Test .......................................................................................42
5.2.2 :Open-Circuit Test .......................................................................................42
5.3 :Troubleshooting ..................................................................................................43
5.3.1 :Preliminary Troubleshooting ......................................................................43
5.3.2 :Troubleshooting Fuses ..............................................................................44
5.3.3 :L-828 General Troubleshooting .................................................................50
5.4 :Additional L-829 General Troubleshooting Procedures ......................................51
5.5 :Feedback Wiring Modification Procedure ...........................................................52
5.6 :Component Replacement Procedures ...............................................................52
5.6.1 :Removing and Replacing URC PCB .........................................................52
5.6.2 :Removing and Replacing Dual SCR Module Assembly ............................53
5.6.3 :Removing and Replacing Contactor ..........................................................54
5.6.4 :Removing and Replacing Input Lightning Arrestors (front of Component Mounting
Plate) ...................................................................................................................55
5.6.5 :Removing and Replacing Output Lightning Arrestors (front of Component Mounting
Plate) ...................................................................................................................55
6.0: Parts ...................................................................................................................57
iv
© 2010 ADB 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)
TOC
Disclaimer
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: Schematics ........................................................................................................ 63
74
Schematics
Parts
Operation
Installation Introduction
TOC
Safety
Table of
Contents
Document Date (12/2010)
© 2010 ADB Airfield Solutions All Rights Reserved
v
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
TOC
96A0288 Rev. W
6/9/11
Disclaimer
Table of
Contents
Safety
Introduction Installation
TOC
Operation
Parts
Schematics
vi
© 2010 ADB Airfield Solutions All Rights Reserved
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Safety
1.0 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.
1.1 To use this
equipment safely:
Disclaimer
96A0288 Rev. W
6/9/11
WARNING
•
•
•
•
•
1.1.2 Qualified Personnel
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 the company operating this equipment to ensure that its personnel meet
these requirements.
Always use required personal protective equipment (PPE) and follow safe electrical work practices.
Safety
Installation Introduction
Safety
1.1.1 Additional Reference
Materials:
Table of
Contents
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. All wiring
must meet local codes.
• Route electrical wiring along a protected path. Make sure they will not be damaged by moving
equipment.
• Protect components from damage, wear, and harsh environment conditions.
• Allow ample room 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.
Operation
NFPA 70B, Electrical Equipment Maintenance.
NFPA 70E, Electrical Safety Requirements for Employee Workplaces.
ANSI/NFPA 79, Electrical Standards for Metalworking Machine Tools.
OSHA 29 CFR, Part 1910, Occupational Health and Safety Standards.
National and local electrical codes and standards.
Parts
1.1.3 Intended Use
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.
Schematics
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.
1.1.4 Storage
CAUTION
If equipment is to be stored prior to installation, it must be protected from the weather and kept free of
condensation and dust.
Failure to follow this instruction can result in injury or equipment damage.
© 2010 ADB Airfield Solutions All Rights Reserved
1
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
To use this equipment safely:
96A0288 Rev. W
6/9/11
Disclaimer
1.1.4.1 Operation
WARNING
Table of
Contents
• 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 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.
• Use this 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.
Safety
Introduction Installation
To use this
equipment
safely:
1.1.4.2 Material Handling
Precautions
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.
Operation
1.1.4.3 Action in the Event of a
System or Component
Malfunction
WARNING
• Do not operate a system that contains malfunctioning components. If a component malfunctions, turn
the system OFF immediately.
• Disconnect and lock out electrical power.
• Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component
according to instructions provided in its manual.
Parts
1.1.4.4 Maintenance and Repair
WARNING
Schematics
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.
• Use only 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.
• Do not attempt 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.
1.1.4.5 Operation of
Overloaded Regulators
WARNING
• Operation of a Regulator while overloaded at any step may result in equipment failure or equipment
damage.
2
© 2010 ADB Airfield Solutions All Rights Reserved
2.0 Introduction
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator
2.1 About this manual
The manual shows the information necessary to:
•
•
•
2.1.1 How to work with the
manual
Disclaimer
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Introduction
Install
Carry Out Maintenance
Carry Out Troubleshooting on the CCF (Ferroresonant) L-828 / L-829 Constant Current
Regulator.
Table of
Contents
96A0288 Rev. W
6/9/11
1. Familiarize yourself with the structure and content.
2. Carry out the actions completely and in the given sequence.
2.1.2 Record of changes
A
Released manual.
00819
JG
WT
01/25/02
3-1, 2-16,
2-17, 7-2,
7.4 to 710
L
Added lifting instructions and CCR
weight table, and updated the parts
list tables, and Fig 7-3
01471
WT
WT/JG
10/21/05
All
M
Correct rev level to match PDM
N/A
WT
WT
10/21/05
Pg 2-3, 25, 2-10, 213, 5-2
N
Corrected callouts Fig 2-3, Table 21, Table 2-9, Table 5-1, Removed
Fig 8-3
01635
BB/JR
WT
6/21/06
8-1, 8-2,
8-3, 8-4,
8-5
O
Revised notes on pg 8-1 and revised
schematics Fig 8-1 thru 8-5
01759
WT/BE
WT
6/12/07
P
Added references to ACE2 manual
96A0357 and updated weights and
dimensions. Added references to
VR7 & VR8 input lightning arrestors
and updated parts list. Corrected list
of figures.
01875
JC
JC
1/7/08
7-5
Q
Corrected part 44A6178 to show as
3-step rotary switch, added part
44A6178-5 as 5-step rotary switch in
Fig 7-3
01893
JC
JC
1/18/08
ALL
R
Updated Name
JM
JM
5/29/09
2-15, 3-6,
7-2, 7-3
S
Reference ECO 2200. Changed size
of 10KW 240/480 VAC CCF to
medium frame
JC
JC
6/25/09
All
T
ADB update
ER
GM
12/17/09
6-9
U
SCO update
JC
JR
05/28/10
All
V
Updated entire manual,
Diagrams/Schematics
2306
JG
JC
3/03/11
All
W
Updated parts, diagrams,
schematics and drawings
3285
JC
JG
06/09/11
2-2, 2-3,
2-5, 2-15,
4-3, 6-7,
6-9, 8-1
02349
X
Y
© 2010 ADB Airfield Solutions All Rights Reserved
3
Safety
DATE
Installation Introduction
EC NO. CHECKED APPROVED
Operation
DESCRIPTION
Parts
REV
Schematics
PAGE
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Product Introduction
Disclaimer
2.2 Product
Introduction
96A0288 Rev. W
6/9/11
WARNING
Read the instructions in their entirety before starting installation.
Table of
Contents
This section describes the ADB Airfield Solutions Signature Series Ferroresonant, L-828/L829, constant current regulators (CCRs). These CCRs are manufactured according FAA
specification AC 150/5345-10 (latest edition).
2.3 Compliance with
Standards
FAA
L-828/L-829 AC 150/5345-10 (Current Edition) ETL Certified
ICAO
Safety
Aerodrome Design Manual Part 5, para. 3.2.1.4 to 3.2.1.6
Military
UFC 3-535-01; NAVAIR 51-50AAA-2
Introduction Installation
Uses
Supplies three or five precision output levels to power series lighting circuits on airport
runways and taxiways.
2.4 Features
Operation
Advanced CCR architecture combines the performance advantages of both saturable
reactor and Ferroresonant technologies. Produces minimal EMI, high efficiency, and near
unity power factor for AC 150/5345-10 test conditions, exceeding FAA and military
requirements for power factor and efficiency. Unique CCR design has excellent input
power factor and efficiency at all intensity steps and lower loads.
•
Does not exceed the conducted power line emission limits given in Table 4 of AC
150/5345-10 (latest edition) with testing as specified by the Federal Communications
Commision (FCC) in the Code of Federal Regulations (CFR) Title 47, Subpart B, Section
15.107b. Does not exceed the radiated emission limits given in Table 5 of AC 150/ 5345-10
with testing as specified in the Code of Federal Regulations (CFR) Title 47, Subpart B,
Section 15.109b.
•
Optional integrated ACETM 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 10%), Remote/Local status, and incorrect output current.
•
•
No input turn on in-rush current surge.
•
Available in two classes and styles:
Class 1 = 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.
Parts
•
Schematics
4
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.
Industrial powder coat finish.
Input lightning protection and output lightning protection included.
© 2010 ADB Airfield Solutions All Rights Reserved
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Electrical Supply
Disclaimer
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 and 70kW
120V AC, 60Hz or +48V DC, ±10%
2.5.2 Total Harmonic
Distortion* (THD)
Current THD: 10% maximum in highest step
Safety
Voltage THD: 1.9% maximum in all steps
* Tested with 100% resistive load according to FAA AC150/5345-10 (Latest Edition).
2.5.3 Theory of Operation
Introduction
Ferroresonant circuitry and a solid-state control system accurately regulate the output current
to within the FAA-allowable range from no load to full load and with input voltage variations of
-5% to +10% of nominal.
For more theory of operation see: “Theory of Operation” on page 8.
2.6 ACE2 Unit
The ACE2TM 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
Schematics
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 & Monitoring System (ALCMS) by
simply adding redundant communication wires. See ADB ACE2 catalog sheet 2084 for
additional information.
Installation Introduction
2.5.1 Remote Control
Table of
Contents
NOTE: Efficiency
90% minimum for 4 to 20kW
92% minimum for 30kW
93% minimum for 50kW
94% minimum for 70kW
Operation
2.5 Electrical Supply
Parts
96A0288 Rev. W
6/9/11
© 2010 ADB Airfield Solutions All Rights Reserved
5
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Environmental Operating Conditions
Disclaimer
2.7 Environmental
Operating Conditions
2.7.1 Monitoring Option
•
•
•
96A0288 Rev. W
6/9/11
Temperature: -40°C to +55°C (-40°F to +131°F)
Humidity: 10 to 95%
Altitude: 0 to 6,600 ft (2,000 m)
See Figure 1.
Figure 1:
CCF Ordering Codes
Table of
Contents
Ordering Code
CCFXXXX-XXXX
Amperage
66 = 6.6A output
20 = 20A output
Safety
Size
04 = 4kW, 6.6A only
07 = 7.5kW, 6.6A only
10 = 10kW, 6.6A only
15 = 15kW
20 = 20kW
30 = 30kW
50 = 50kW, 20A only
70 = 70kW, 20A only
Introduction Installation
Output Range
3 = 3-step without Series Cutout1
4 = 3-step with Series Cutout1
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
Operation
Monitoring Options (See Application Notes)
0
1
2
3
4
= None (Standard L-828)
= ALCMS Scanning Monitor Interface
= ALCMS Scanning Monitor Ready
= L-829 Monitoring (ACE)
= Insulation Resistance Monitoring System
(IRMS) Ready
5 = L-829 Monitoring (ACE) and IRMS
6 = L-828 with Digital Power Meter
Parts
Schematics
CCR Input/Output Monitoring
0 = No optional CCR input or output circuit
monitoring 2
A = With L-829 or IRMS monitoring; without
optional input CCR monitoring3
G= With L-829 or IRMS monitoring; with optional
input CCR monitoring3
Footnotes
Notes
• A ferroresonant CCR is preferred for airports that
• A ferroresonant CCR is preferred for airports that require low
require low output harmonic content (EMI) or that have
output harmonic content (EMI) or that have varying loads, such
varying loads, such as Runway Guard Lights using
as
Runway Guard
Lights using incandescent
incandescent
(tungsten-halogen)
lamps, L-849(tungsten-halogen)
REILs
lamps,
L-849 fREILs
usingorxenon
flash
lamps,
or Runway Status
using xenon
ash lamps,
Runway
Status
Lights
Lights
(RWSL)
(RWSL)
•• Runway
(tungstenRunwayGuard
GuardLights
Lightsusing
usingincandescent
incandescent
(tungstenhalogen)
halogen) lamps should be powered with ferroresonant
lamps should be powered with ferroresonant type CCRs and not
with thyristor type CCRs
eld
canisoffer
a non-ETL
Certif
ed Style
Class Solutions can
1.Solutions
3-step, 20A
not standard
FAA
operation.
ADB1,Airfield
offer afor
non-ETL
Certified
Class 2orCCR
forneeds.
dedicated 5.5A sign
2 CCR
dedicated
5.5AStyle
sign1,circuits
other
circuitscontact
or otherthe
needs.
contact the ADB
Please
ADBPlease
Sales Department
for Sales
more Department for
more details.
details.
22. Used only with Monitoring Options 0, 1, 2, and 6.
Used only with Monitoring Options 0, 1, 2, and 6.
3. Used only with Monitoring Options 3 and 5.
3
Used only with Monitoring Options 3 and 5.
6
© 2010 ADB Airfield Solutions All Rights Reserved
L-828 supplied with analog ammeter
1 ALCMS Scanning Monitor Interface (SMI)
The SMI option adds Primary Power and Remote/Local monitoring relays. Dry relay Interface
contacts are connected to a dedicated terminal block for each monitored point. Typical
application: connecting ADB L-828 CCR to ALCMS or L-827 that is manufactured by others.
Note that this option does not provide dedicated output current or voltage transformers.
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 (ACETM)
Disclaimer
0 None Standard
Table of
Contents
2.7.2 Application Notes
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Environmental Operating Conditions
Safety
96A0288 Rev. W
6/9/11
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
•
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.
•
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
Schematics
This option replaces the analog ammeter with a Digital Power Meter. The Digital Power Meter
is used on L-828 CCRs to indicate True RMS output current, voltage, VA, and watts. It can
also be set to activate an alarm if there is a 10% or 15% drop in the load (Low VA).
Parts
If application is for connection to ADB L-890 ALCMS: Add a “/A” to end of Ordering Code.
The ACE unit will then be programmed to provide monitoring data via dual redundant
communication links. If application is for a stand-alone L-829 CCR: Ordering Code is not
changed. The ACE unit is programmed to activate a dry contact closure if a fault is present.
The fault alarm can then be connected to any external monitoring system.
Operation
Installation Introduction
Includes FAA L-829 monitoring equipment.
© 2010 ADB Airfield Solutions All Rights Reserved
7
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Theory of Operation
96A0288 Rev. W
6/9/11
Disclaimer
2.8 Theory of
Operation
This subsection describes the L-828 CCR theory of operation.
2.8.1 Power Circuit
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.
Table of
Contents
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.
Safety
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.
2.8.2 Output Measurement
Introduction Installation
The output current flows through the high voltage current transformer T5. T5 provides
feedback to the URC board on the actual current output to the airfield series circuit.
A second current transformer, T2, provides current to a true-rms-reading ammeter mounted
onto the front panel to indicate output current.
2.8.3 Universal Regulator
Controller (URC)
See Figure 6. This subsection describes the board level circuitry found on the universal
regulator controller.
Figure 2:
L-828 CCR Power Circuit Block Diagram
T1
C1 - Cx
T5
T2
Input
Voltage
Output
Current
Operation
SCRs
RMS Current
Meter
URC
Controller
Parts
Schematics
2.8.3.1 URC PCB
Inputs/Outputs
8
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.
•
•
•
•
•
•
A current proportional to the output current from a current transformer (T5).
Remote control signals from a remote control terminal block located in the L-828 chassis
(120Vac/48Vdc) (TB1).
Phase angle reference voltage derived from the input voltage.
24 Vac center tapped supply voltage from T4.
The URC provides the outputs listed below.
A contact to complete the input contactor K1 coil circuit.
A contact to enable the Remote CCI voltage at TB1.
© 2010 ADB Airfield Solutions All Rights Reserved
•
Gate drive signals to the SCR block used to regulate the output current.
The system output current is sensed by a current transformer (T5) whose secondary is
connected to J8-3 and J8-4 on the URC board. This current signal is passed through a 15ohm 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
Position Detection
Local control position detection is accomplished by using a rotary switch mounted on the front
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
Position Detection
When the local control signal to the micro-controller indicates “remote” the remote control
circuitry is active. Relay K1 on the URC board closes, providing 120VAC to the CCI
connection on TB2. The remote control inputs incorporate surge suppression and are
optically isolated from the rest of the PCB.
Schematics
Parts
Operation
Installation Introduction
Safety
2.8.4 Output Current
Monitor Circuitry
Disclaimer
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Theory of Operation
Table of
Contents
96A0288 Rev. W
6/9/11
© 2010 ADB Airfield Solutions All Rights Reserved
9
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Theory of Operation
Disclaimer
2.8.8 Fault Protection
96A0288 Rev. W
6/9/11
This subsection describes URC fault protection.
Overcurrent Protection
Table of
Contents
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
Safety
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.
Introduction Installation
Operation
Parts
Schematics
10
© 2010 ADB Airfield Solutions All Rights Reserved
2.9 L-828 CCR
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
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 shows 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.
L-828 CCR (4 -30kW/6.6 A)
Table of
Contents
Figure 3:
Disclaimer
96A0288 Rev. W
6/9/11
1
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.
•
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.
Schematics
Parts
•
Operation
1 Ammeter (shown) or Digital Power Meter
2 Rotary Switch
Installation Introduction
Safety
2
© 2010 ADB Airfield Solutions All Rights Reserved
11
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
L-829 CCR
Disclaimer
2.10 L-829 CCR
96A0288 Rev. W
6/9/11
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 & 50/70kW) may differ in size and appearance.
Table of
Contents
Figure 4:
L-829 CCR with ACE2
ADB
Safety
1
3
Introduction Installation
2
1 ACE2 Front Panel Display
2 L-829 CCR
3 Rotary Switch
Operation
Parts
Schematics
12
© 2010 ADB Airfield Solutions All Rights Reserved
2.11 SGRS
Powerpack™
This subsection describes the Switchgear Regulator Style Powerpack. The SGRS
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
Disclaimer
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
SGRS Powerpack™
Table of
Contents
96A0288 Rev. W
6/9/11
INPUT
1
2
VR 7,
F5
SCR
BLOCK
1
2
TB3
TB3
T4
INPUT
Installation Introduction
VR 7,8
Safety
2
UBBER
SNUBBER
TOP
7
4
6
URC PCB
TB1
F3-F4
8
5
2
ACE – 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
Schematics
1.
2.
3.
4.
5.
6.
7.
8.
Parts
Operation
K2
13
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Universal Regulator Controller
Disclaimer
2.12 Universal
Regulator Controller
96A0288 Rev. W
6/9/11
See Figure 6 below. The Universal Regulator Controller (URC) is a PC board that is designed
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.
Table of
Contents
•
•
•
Produces SCR drive signals in accordance with the desired output current setting.
Detects an overcurrent, or open circuit, and switches the constant current regulator off.
When in Remote mode, enables the CCI to provide 120 Vac at 50 W. The CCI is the
Remote power control source.
Figure 6:
Universal Regulator Controller (URC)
Safety
Introduction Installation
Operation
2.12.1 L-829 Advanced
Control Equipment (ACE
or ACE2)
Parts
See Figure 4 and Figure 7. The L-829 ACETM (or ACE2TM) control and monitoring unit
consists of an integrated control unit that is interfaced to each CCR either internally or within
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:
ACE2 Control and Monitor Boards
Control Board
Schematics
Monitor Board
(mounted on top of
control board)
For more information about the ACE, see:
14
•
Advanced Control Equipment (ACE) manual 96A0287 or the Advanced Control
Equipment (ACE2) manual 96A0357.
•
ACE Programming manual 96A0348.
© 2010 ADB Airfield Solutions All Rights Reserved
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
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.
2.13.2 Optional Scanning
Monitor Interface
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.
2.13.3 Optional Scanning
Monitor Ready
The scanning monitor ready includes the scanning monitor interface 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.
2.14 Optional Series
Cutout Type SCO
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.
2.15 L-828 CCRs (4-70
kW 6.6 A/ 20 A):
Required Equipment
Refer to Table 1 for required equipment that is supplied.
Table of
Contents
2.13.1 Optional Insulation
Resistance Monitoring
System
Safety
The L-829 CCR monitoring options include the Insulation Resistance Monitoring System
(IRMS), Scanning Monitor Interface (SMI), and Scanning Monitor Ready (SMR).
Installation Introduction
2.13 L-828/L-829 CCR
Monitoring Options
Disclaimer
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
L-828/L-829 CCR Monitoring Options
Operation
96A0288 Rev. W
6/9/11
Refer to Table 2 for required equipment that is not supplied.
Required Equipment Supplied
Description
Quantity
L-828/L-829 constant current regulator
As Req’d on Order
Instruction manual
1 per CCR on Order
Table 2:
Required Equipment Not Supplied
Description
Quantity
Input power wire. Refer to Table 3.
As required
Remote control wire, AWG 18 minimum, AWG 14 maximum
As required
Ground wire, AWG 8 minimum (6.6 A); AWG 6 minimum (20 A)
As required
Output load wire, AWG 6 minimum, 5000 Vac, L-824 type (6.6 A); AWG 8
minimum (20 A)
As required
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
Schematics
Table 1:
Parts
Refer to “Parts” on page 57 for ordering information.
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Input Wire Size
96A0288 Rev. W
6/9/11
Disclaimer
Description
2.16 Input Wire Size
Quantity
Ohmmeter
1
Mounting bolts, ½-13 x 1-1/2 in. long, ½ STD washers, and lockwashers
4
Table of
Contents
Table 3 refers to recommended input power supply wire size for each regulator power rating
dependent on the input voltage. This recommendation is based on 75°C rated copper wire
per NEC Table 310.16.
Table 3:
Recommended Input Wiring Rating
Safety
Power
Rating
208 Vac
220 Vac
240 Vac
347 Vac
480 Vac
2400 Vac
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*
Introduction Installation
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
Not
applicable
AWG 1/0
AWG 10
Not
applicable
AWG 3/0
AWG 8
50 kW
Not applicable Not applicable
Not
applicable
70 kW
Not applicable Not applicable
Not
applicable
*Increased 1 wire size to comply with small conductor limits in NEC 240.4.D.
NOTE: Wire to be rated for 5000 V for 2400 V CCRs.
2.17 Input Power
Breaker Sizing
Operation
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:
Parts
Schematics
16
CCR Input Voltage and Current for the CCR Power Ratings
Power
Rating
208 Vac
220 Vac
240 Vac
347 Vac
480 Vac
2400 Vac
4 kW
27 A
26 A
24 A
16 A
12 A
3A
7.5 kW
51 A
48 A
44 A
31 A
22 A
5A
10 kW
68 A
65 A
59 A
41 A
30 A
6A
15 kW
97 A
92 A
84 A
58 A
42 A
9A
20 kW
129 A
122 A
112 A
78 A
56 A
12 A
30 kW
190 A
179 A
164 A
114 A
82 A
17 A
136 A
28 A
188 A
38 A
50 kW
Not applicable Not applicable Not applicable
Not
applicable
70 kW
Not applicable Not applicable Not applicable
Not
applicable
© 2010 ADB Airfield Solutions All Rights Reserved
Table 5:
Class, Style and Power Ratings
Class
L-828/L-829
CCR Max
Output Current
1
6.6 A
2
20 A
1
3
4.8 A, 5.5 A, 6.6 A
5
2.8 A, 3.4 A, 4.1 A, 5.2 A, 6.6 A
2
5
8.5 A, 10.3 A, 12.4 A, 15.8 A, 20 15, 20, 30, 50 and
A
70 kW
4, 7.5, 10, 15, 20
and 30 kW
0.90 minimum
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.
Efficiency
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
Class
Style
1
1
1
2
2
2
Step
Nominal output amperes (A)
root mean square (RMS)
Allowable range
(A RMS)
B100
6.6
6.5 - 6.7
B30
5.5
5.4 - 5.6
B10
4.8
4.7 - 4.9
B5
6.6
6.5 - 6.7
B4
5.2
5.1 - 5.3
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
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
Installation Introduction
4 - 10 kW
Safety
Power Factor
CCR
2.18.3 Resistive Loading
Power Ratings
2
15 -70 kW
Table 7:
2.18.2 Reactive Loading
Nominal Output Current
Power Factor
CCR
2.18.1 Efficiency
Brightness
Steps
Operation
Table 6:
Style
Table of
Contents
This subsection provides specifications for L-828/L-829 CCR (4-70 kW 6.6 A/20 A).
Parts
2.18 Specifications
Disclaimer
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Specifications
Schematics
96A0288 Rev. W
6/9/11
17
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Specifications
96A0288 Rev. W
6/9/11
Disclaimer
2.18.4 Regulation
Refer to Table 8 for output current limits. Current regulation is obtained under the conditions
listed in Environmental Operating Conditions.
2.18.5 Environmental
Operating Conditions
The L-828 CCRs are designed for indoor use only in an area with adequate ventilation for
cooling the constant current regulator. The environmental operating conditions include
temperature range, relative humidity, and altitude.
Table of
Contents
Table 9:
Environmental Operating Conditions
Temperature Range
Safety
2.18.6 Protection Devices
Without monitoring
circuitry
With monitoring
circuitry
Relative Humidity
Altitude
-40 to +55 °C
(-40 to +131 °F)
0 to +55 °C
(-18 to +131 °F)
10 to 95% (noncondensing)
Sea level to 6,600 ft (2000
m)
L-828 CCRs have the following protection devices:
Introduction Installation
•
•
•
•
•
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.
Operation
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.
2.18.6.2 Overcurrent Protection
Regulators include an overcurrent protective device that opens the primary switch when the
output current exceeds the 100 percent current (6.6 A or 20 A) by 5 percent. The device
operates within 5 seconds after an overcurrent of 5 percent and within 1 second after an
overcurrent of 25 percent. The device resets within 2 seconds after the control switch is
turned off and re-energized. The overcurrent protection cannot be activated by a momentary
(0.25 second) overcurrent caused by switching the load circuits and other transients.
2.18.7 Input Voltage
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.
2.18.7.1 Built-In True-rmsReading Ammeter, L-828 only
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.
2.18.7.2 Rating and Input
Voltage
Table 10:
Parts
2.18.6.1 Open-Circuit
Protection
Schematics
2.18.8 Temperature Rise
18
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
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Dimensions and Weights
10kW
15kW
20kW
30kW
240/347/480 V
208 V
220 V
240 V
480 V
33 x 24 x 25 - in
83.8 x 61 x 63.5 - cm
83.8 x 61 x 63.5 - cm
36 x 29 x 30 - in
33 x 24 x 25 - in
91.4 x 73.7 x 76.2 - cm
83.8 x 61 x 63.5 - cm
36 x 29 x 30 - in
33 x 24 x 25 - in
91.4 x 73.7 x 76.2 - cm
83.8 x 61 x 63.5 - cm
40 x 33 x 34 - in
36 x 29 x 30 - in
960
872
826
906
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
101.6 x 83.8 x 86.4 - cm
101.6 x 83.8 x 86.4 - cm
1290
(585.4)
1150
(521.6)
1187
(538.4)
1097
(497.6)
40 x 33 x 34 - in
40 x 33 x 34 - in
1410
1350
1381
1302
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)
NA
NA
NA
2150
(975.2)
2400
(1088.6)
NA
NA
NA
2400
(1088.6)
2400
(1088.6)
NA
70kW2
NA
70 x 33 x 34 - in
177.8 x 83.8 x 86.4 - cm
434
427
467
502
(196.9)
(193.7)
(211.8)
(227.7)
556
480
514
600
(252.2)
(217.7)
(233.1)
(272.2)
783
749
770
826
(355.2
(339.7)
(349.3)
(374.7)
2400 V
33 x 24 x 25 - in
50kw2
Disclaimer
208/220 V
Weight - lb (kg)
2150 (975.2)
2150 (975.2)
2150 (975.2)
2150 (975.2)
2150 (975.2)
2150 (975.2)
1. Based on Input Voltage
2. 50kW and 70kW CCRs are only available on 480V input
3. 2400 Vac units are same dimensions as the 50/70 kW units
Ferroresonant CCR Dimensions – Typical of 4-30 kW
Operation
Figure 8:
Parts
W
Schematics
D
H
Top View
Front View
© 2010 ADB Airfield Solutions All Rights Reserved
Table of
Contents
Size
7.5kW
Dimensions and Weight
Dimensions (H x W x D)1 , 3
CCR
4kW
Table 11:
Safety
2.19 Dimensions and
Weights
Installation Introduction
96A0288 Rev. W
6/9/11
19
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Dimensions and Weights
Disclaimer
Figure 9:
96A0288 Rev. W
6/9/11
Ferroresonant CCR Dimensions – Typical of 50-70 kW
Table of
Contents
D
Safety
H
Introduction Installation
Top View
Operation
W
Parts
Schematics
20
© 2010 ADB Airfield Solutions All Rights Reserved
This section provides instructions for installing L-828/L-829 constant current regulators
(CCRs) (4-70kW/6.6 A/20 A). Refer to the airport project plans and specifications for the
specific installation instructions.
3.1 Unpacking
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.
3.2 Installation
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.
3.2.1 Wiring Connections
and Startup
WARNING
Read installation instructions in their entirety before starting installation.
• Installation and operation of the CCR should be performed by personnel qualified to work on high
voltage equipment. The high voltage involved with the unit makes it potentially dangerous and may be
lethal if contacted by operating personnel.
• Place wiring for output, input, and remote control only on the right side of 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
Table of
Contents
Safety
• Refer to the FAA Advisory Circular AC 150/5340-26, Maintenance of Airport Visual Aids Facilities, for
instructions on safety precautions.
• Observe all safety regulations. To avoid injuries, always disconnect power before making any wiring
connections or touching any parts.
• Become familiar with the general 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 PCB is static-sensitive. Must be grounded when handling PCB.
• 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.
Installation Introduction
Installation
WARNING
Read installation instructions in their entirety before starting installation.
Operation
L-828 / L-829 CCR Installation
Parts
3.0 Installation
Disclaimer
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Installation
Schematics
96A0288 Rev. W
6/9/11
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Installation
96A0288 Rev. W
6/9/11
Disclaimer
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.
Table of
Contents
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.
Safety
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 input fuse block F1/F2 or
terminal block TB3. Tighten all connections.
Figure 10:
Wiring on Right Side of CCR
Introduction Installation
Installation
2
1
Operation
1. Front of CCR
2. Place Conduit and Wire on Right Side of CCR
Parts
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.
Schematics
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
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Installation
LOW (4.8 A)
CC
MEDIUM (5.5 A)
CC, B30
HIGH (6.6 A)
CC, B100
OFF
Not applicable
Remote 120 Vac Control Connections (5-Step/6.6 A)
For this remote intensity step…
Table 14:
Connect CCI to…
Table of
Contents
Table 13:
Disclaimer
Remote 120 Vac Control Connections (3-Step/6.6 A)
For this remote intensity step…
Connect CCI to…
2.8 A
CC
3.4 A
CC, B2
4.1 A
CC, B3
5.2 A
CC, B4
6.6 A
CC, B5
OFF
Not applicable
Safety
Table 12:
Installation Introduction
Installation
96A0288 Rev. W
6/9/11
Remote 120 Vac Control Connections (5-Step/20 A)
For this remote intensity step…
Connect CCI to…
8.5 A
CC
10.3 A
CC, B2
12.4 A
CC, B3
15.8 A
CC, B4
20 A
CC, B5
OFF
Nothing
CAUTION
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.
Table 15:
Input/Output Connections
CCR Size
Input Location
4 thru 30kW with SCO
CCF 20kW/208 V
Top of each Fuse Block front of
component plate right hand side
Terminal Block (black)
CCF 4, 7.5, 10 kW
Output Location
Bottom of SCO
CCF 30kW/208 V
Front of component plate right hand
side
N/A
© 2010 ADB Airfield Solutions All Rights Reserved
Schematics
15. Connect the 6.6 A or 20 A series lighting circuit to the output terminals/ bushings and
tighten all connections.
Parts
Operation
12. Make sure wiring connections are tight and no wires are shorting across each other.
Lightning Arrestors (VR1 and VR2)
on Back of component plate
Lightning Arrestors (VR1 and VR2)
on Back of component plate
Lightning Arrestors (VR1 and VR2)
on Back of component plate
23
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Stacking CCR’s (Optional)
Disclaimer
CCR Size
Input Location
96A0288 Rev. W
6/9/11
Output Location
Terminal Block (white)
CCF 15,20,30 kW
Table of
Contents
CCF 50, 70 kW
3.3 Stacking CCR’s
(Optional)
Front of component plate right hand
side Top of each Fuse Block front of
component plate right hand side
Lightning Arrestors (VR1 and VR2)
on Back of component plate
Top of each Fuse Block – front of
component plate top right side
Lightning Arrestors (VR1 and VR2)
on Back of component plate
CAUTION
Read installation instructions in their entirety before starting installation.
Safety
• 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:
Introduction Installation
Stacking
CCR’s (Optional)
1. Remove the four ½ x 3−3/4 HILTI anchor bolts with 4 nuts and lock washers for anchoring
the CCRs to concrete, and the four 1/2−13 x ¾ hex head bolts and ½ split lock washers
from the stacking kit (Part Number 94A0475/XX).
2. See Figure 11 for anchor bolt template. Use the four ½ 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
A
Operation
D
B
Parts
Schematics
C
Table 16:
24
Bolt patterns for the 3 CCR sizes
CCR
A
B
C
D
24.75 in
Small
22.50 in
23.50 in
23.75 in
Medium
27.50 in
28.50 in
28.75 in
29.75 in
Large
31.50 in
32.50 in
32.75 in
33.75 in
© 2010 ADB Airfield Solutions All Rights Reserved
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Stacking CCR’s (Optional)
Figure 12:
Location of Bolts for Stacking CCRs
Disclaimer
96A0288 Rev. W
6/9/11
1
Operation
Installation Introduction
Stacking
CCR’s (Optional)
Safety
Table of
Contents
1
2
Schematics
Parts
1. Hex Head Bolts and Split Lock washers
2. ½ x 3−3/4 inch HILTI Anchor Bolt Location
© 2010 ADB Airfield Solutions All Rights Reserved
25
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Stacking CCR’s (Optional)
96A0288 Rev. W
6/9/11
Disclaimer
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 CCR
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
Table of
Contents
3
Safety
1
Introduction Installation
Stacking
CCR’s (Optional)
2
1. Stacking Bolt
2. Bottom CCR Anchored to Concrete
3. Top CCR
Operation
Parts
Schematics
26
© 2010 ADB Airfield Solutions All Rights Reserved
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
SGRS Style Powerpacks (Optional)
3.4 SGRS Style
Powerpacks
(Optional)
Disclaimer
96A0288 Rev. W
6/9/11
CAUTION
Read installation instructions in their entirety before starting installation.
Powerpack Installation in SGRS
Safety
Figure 14:
Table of
Contents
• 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.
Operation
Installation Introduction
SGRS Style
Powerpacks (Op-
1
Schematics
Parts
2
1. Upper Bay Powerpack
2. Lower Bay Powerpack
© 2010 ADB Airfield Solutions All Rights Reserved
27
Parts
Schematics
SOUTHCO SCREW RETAINER,
12-6-1
44A6055
DOOR ASSEMBLY
44A6054
FRAME WELDMENT
SOUTHCO
CLIP-ON RECEPTICAL
12-11-050-27
(3 PLACES)
SEE MODEL FOR OBROUND
LOCATION DETAILS
(32) #10-32 X .75 LONG
TAPTITE SCREW
PAN HEAD, PHILLIPS
(32) #10 NYLON WASHER
(8) PER PANEL, (2) SIDE, (1) TOP, (1) REAR
60A2637
SIDE FILLER
SIDE AND BACK PANELS TO BE
FABRICATED
FROM 5052 ALUMINUM .062 THICK
Figure 15:
REV D CHANGES INCLUDE
DOOR MACHINING
SEE 44A6055-A FLAT LAYER
FOR SPECIFIC DETAIL
INSTALL "PEM" BSO-632-20
FROM FAR SIDE 2 PLACES
(ADDED ON REV D)
60A2636
REAR FILLER
3.5 Frames
1/4-20 X 1/2 LG.
COPPER COATED
WELD STUD TYP
8 PLACES
Operation
SOUTHCO CAPTIVE SCREW
12-13-505-11
(5) #10-32 X .38 LONG
TAPTITE SCREW
PAN HEAD, PHILLIPS
FOR HINGE
Introduction Installation
Frames
FABRICATE HINGE FROM
MCM / CARR #15665A215
Safety
28
60A2638
TOP FILLER
Table of
Contents
60A2639 REV. B
VERTICAL ANGLE
Disclaimer
60A2637
SIDE FILER
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Frames
96A0288 Rev. W
6/9/11
Large Frame Assembly
© 2010 ADB 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)
Operation
Disclaimer
4.0 Operation
WARNING
Read the instructions in their entirety before starting installation.
Contents are static-sensitive. Must be grounded when handling PCB.
4.1 Introduction
Table of
Contents
Operation of a Regulator while overloaded at any step may result in equipment
failure or equipment damage.
This section provides the operational procedures listed below for the L-828/L-829 constant
current regulator (CCR) (4-70 kW/6.6 A or 20 A).
— CCR control procedures
— CCR adjustment procedures
— SCO Cutout working positions
4.2 CCR Control
Procedures
This subsection describes the regulator operations in local and remote controls.
4.2.1 Local Control
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.
Switch (3-Step/5-Step)
5-Step Switch Assembly
3-Step Switch Assembly
Output Current from Rotary Switch (3-Step/6.6A)
If you set the rotary switch to the
following...
B10
Table 18:
The result is...
4.8 A current output
B30
5.5 A current output
B100
6.6 A current output
Output Current from Rotary Switch (5-Step/6.6 A)
If you set the rotary switch to the
following...
© 2010 ADB Airfield Solutions All Rights Reserved
Schematics
Table 17:
Parts
Operation
Figure 16:
Installation Introduction
Operation
Safety
— CCR shutdown procedures
The result is...
B1
2.8 A current output
B2
3.4 A current output
B3
4.1 A current output
B4
5.2 A current output
B5
6.6 A current output
29
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
CCR Door Interlock (Optional )
Disclaimer
Table 19:
Output Current from Rotary Switch (5-Step/20 A)
If you set the rotary switch to the
following...
Table of
Contents
4.2.2 Remote Control
96A0288 Rev. W
6/9/11
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
Safety
If...
Then...
Introduction Installation
CCR Door
Interlock
(Optional )
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
setting energized by remote 120 Vac or 48 Vdc control signals.
regulator
4.3 CCR Door
Interlock (Optional )
Switch is set to OFF
Remote control signals will not operate the regulator; that is, turn the
regulator on to a particular brightness setting or turn the regulator off.
No remote control connections
exist on terminal block TB1
(switch is set to REM)
The position REM becomes an additional OFF position; that is, the
regulator is de-energized.
The optional door interlock disables remote and local control of the CCR when the door is
opened. If the door is opened while the CCR is running, the CCR will shut OFF.
This is to protect personnel from coming into contact with high voltage electronics.
Operation
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.
Parts
4.4 CCR Shutdown
Procedure
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.
Schematics
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.
30
© 2010 ADB Airfield Solutions All Rights Reserved
This subsection provides regulator adjustment procedures.
NOTE: The regulator has been adjusted at the factory to provide the nominal output current
levels as given in Table 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.
4.5.1 Output Current
Adjustment
Safety
Never service the regulator when it is in protective shutdown mode, Remote
controls or power fluctuations can restart the regulator.
To adjust the output current, perform the following procedure:
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
FLUKE 87
TRUE RMS MULTIMETER
mA
MIN MAX
RANGE
HOLD H
)))))
REL
Hz
CCR
OUTPUT
Auto-Range
Button
Select mA
PEAK MIN MAX
)
))))
mV
Ω
mA
A ~
V
~
V
Operation
uA ~
OFF
mA uA
10A MAX
FUSED
COM
400mA MAX
FUSED
!
VΩ
1000V MAX
Current Clamp
To Airfield Lighting
Series Circuit
Parts
A
Schematics
Red Lead
mA
Black Lead
COM
NOTE: Make sure the meter is set on the AC current scale.
Because the output current waveform is not a true sine wave, the ammeter must be of the
true-rms (root mean squared) type. Field instruments such as clamp-on ammeters and
Simpson voltmeters will give erroneously low readings.
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
Table of
Contents
4.5 CCR Adjustment
Procedures
Disclaimer
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
CCR Adjustment Procedures
Installation Introduction
CCR Adjustment Procedures
96A0288 Rev. W
6/9/11
31
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
CCR Adjustment Procedures
96A0288 Rev. W
6/9/11
Disclaimer
3. See Figure 18. Carefully adjust R40 on the universal regulator controller board until the
desired current is measured on the meter.
WARNING
Read the instructions in their entirety before starting installation.
Table of
Contents
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
Safety
Introduction Installation
CCR Adjustment Procedures
Operation
Parts
Schematics
4.5.2 Overcurrent
Adjustment
32
No adjustment is necessary.
© 2010 ADB Airfield Solutions All Rights Reserved
4.6 SCO Cutout
Working Positions
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
SCO Cutout Working Positions
See Figure 19 and Figure 20. The SCO cutout can be plugged in three orientations. For
additional information on the SCO cutout, refer to manual 96A0294, SCO Cutout.
SCO Cutout Handle Orientations
In the operation position, the regulator is connected to the series circuit, and the microswitch
is activated.
NOTE: An activated microswitch means that the normally open contact is closed and that the
normally closed contact is open. For interlocking with the CCR, only the normally open
contact is used. When the cover is removed, the microswitch is not activated. When the
microswitch is not activated local and remote control is disabled.
Figure 20:
SCO Cutout Operation Position
Microswitch
NO
Operation
NC
Parts
Series Circuit
Regulator
Ground
Schematics
See Figure 21. In the maintenance position, the regulator and the series circuit are both
shorted and grounded. The microswitch is not activated.
© 2010 ADB Airfield Solutions All Rights Reserved
Installation Introduction
SCO Cutout
Working Positions
Safety
Table of
Contents
Figure 19:
Disclaimer
96A0288 Rev. W
6/9/11
33
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
SCO Cutout Working Positions
Disclaimer
Figure 21:
96A0288 Rev. W
6/9/11
SCO Cutout Maintenance Position
NO
Microswitch
NC
Table of
Contents
Series Circuit
Regulator
Safety
Ground
You can determine the current orientation by observing the cutoff corner of the handle.
Introduction Installation
SCO Cutout
Working Positions
See Figure 22. In the test and measure position, the insulation resistance of the series circuit
can be measured. The regulator operation can be tested under short-circuited output
conditions.
In the test and measure position, the regulator is shorted and grounded; the series circuit is
shorted and connected to the measurement socket. The microswitch is activated.
Figure 22:
SCO Cutout Test and Measure Position
NO
Microswitch
NC
Operation
Series Circuit
Regulator
Measurement Socket
Parts
Ground
Schematics
34
© 2010 ADB Airfield Solutions All Rights Reserved
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Application Notes
2
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 I/II ALCMS
scanning monitoring system.
Includes FAA L-829 monitoring equipment.
•
3
L-829 Monitoring (ACETM)
•
4
If application is for connection to ADB L-890 ALCMS: Add a “/A”
to end of Ordering Code. The ACE unit will then be programmed
to provide monitoring data via dual-redundant communication
links.
If application is for a stand-alone L-829 CCR: Ordering Code is
not changed. The ACE unit is programmed to activate a dry
contact closure if a fault is present. The fault alarm can then be
connected to any external monitoring system.
Insulation Resistance
This option adds an IRMS board in the CCR. Application:
Monitoring System (IRMS)
connection to externally mounted ADB ACE unit.
Ready
Includes FAA L-829 and IRMS equipment.
•
5
L-828 with Digital Power
Meter
•
This option replaces the analog ammeter with a Digital Power
Meter. The Digital Power Meter is used on L-828 CCRs to
indicate True RMS output current, voltage, VA, and watts. It
can also be set to activate an alarm if there is a 10% or 15%
drop in the load
(Low VA).
Schematics
6
L-829 Monitoring (ACE)
and IRMS
If application is for connection to ADB L-890 ALCMS: Add a “/A”
to end of Ordering Code. The ACE unit will then be programmed
to provide monitoring data via dual-redundant communication
links.
If application is for a stand-alone L-829 CCR with Insulation
Resistance Monitoring: Ordering Code is not changed. The ACE
unit is programmed to activate a dry contact closure if a fault is
present. The fault alarm can then be connected to any external
monitoring system.
Table of
Contents
1
Application
Safety
0
Description
Installation Introduction
Application
Notes
Monitoring
Option
Disclaimer
Refer to “Monitoring Option” on page 6 and Figure 1.
Operation
4.7 Application Notes
Parts
96A0288 Rev. W
6/9/11
© 2010 ADB Airfield Solutions All Rights Reserved
35
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Digital Power Meter Calibration (optional)
96A0288 Rev. W
6/9/11
Disclaimer
4.8 Digital Power
Meter Calibration
(optional)
Figure 23:
Meter Display
4.8.2 Function Buttons
Figure 24:
Function Buttons
Table of
Contents
4.8.1 Display
Safety
Introduction Installation
Digital Power Meter Calibration
Scroll Up
Scroll Down
Enter (Save)
4.8.3 DPM Displays
Figure 25:
DPM Displays
Operation
Parts
Schematics
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
4.8.4 Calibration
Procedure
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Digital Power Meter Calibration (optional)
NOTE: The following is needed to calibrate the DPM:
Disclaimer
96A0288 Rev. W
6/9/11
— 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.
WARNING
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.
Table of
Contents
— Ability to apply a field load or equivalent resistive load to CCR.
Proceed as follows to calibrate the DPM
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.
NOTE: TIP: At each calibration step, wait until the thousands digit has settled before
proceeding.
Parts
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.
Schematics
•
•
NOTE: If the CCR output needs to be adjusted follow the procedure in “CCR Adjustment
Procedures” on page 31.
•
Wait until the Icnt and V Cnt values settle and select the ENTER button.
© 2010 ADB Airfield Solutions All Rights Reserved
Installation Introduction
Digital Power Meter Calibration
Calibration Menu
Operation
Figure 26:
Safety
1. Depress and hold the top SCROLL button and the bottom ENTER button
simultaneously for 3 seconds (See Figure 24) to enter the calibration menu.
37
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Digital Power Meter Calibration (optional)
Disclaimer
Figure 27:
96A0288 Rev. W
6/9/11
Irms High Step Calibration
Table of
Contents
Safety
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.
Introduction Installation
Digital Power Meter Calibration
Figure 28:
Irms Low Step Calibration
Voltage Calibration
Operation
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
Parts
Schematics
A. Vrms – High Step Loaded
WARNING
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
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Digital Power Meter Calibration (optional)
Vrms High Step Loaded
Disclaimer
Figure 30:
Table of
Contents
96A0288 Rev. W
6/9/11
B. Vrms - Off
Save Vrms Calibration
Schematics
Parts
Operation
Installation Introduction
Digital Power Meter Calibration
Figure 31:
Safety
Follow the prompts to turn off the CCR. When the Cnt has settled press the ENTER button.
(Cnt may not go to zero)
© 2010 ADB Airfield Solutions All Rights Reserved
39
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Digital Power Meter Calibration (optional)
96A0288 Rev. W
6/9/11
Disclaimer
Table of
Contents
Safety
Introduction Installation
Digital Power Meter Calibration
Operation
Parts
Schematics
40
© 2010 ADB Airfield Solutions All Rights Reserved
Only personnel authorized to work on high-voltage equipment should perform
maintenance on the regulator.
Operate regulator under local control (using rotary switch) when performing
maintenance tasks on the regulator. This will prevent the regulator from
accidentally being turned on and causing serious injury or death. De-energize
regulator by turning rotary switch to OFF, and remove input power to regulator by
turning off disconnect switch or main circuit breaker before opening access door
to service regulator.
This section provides preventive maintenance for L-828 /L-829 constant current regulators
(CCRs) (4-70 kW 6.6 A or 20 A).
5.2 Maintenance
Schedule
To keep the L-828/L-829 CCRs operating efficiently, follow a preventive maintenance
schedule.Refer to Table 21.
Table 21:
Interval
Daily
L-828/L-829 CCR (4-70 kW/6.6 A/20 A) Maintenance
Maintenance Task
Action
Check all control equipment for
proper operation.
Check local and remote control (if used) on each
brightness step.
Check input voltage.
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.
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.
Monthly
Replace contacts that are excessively burned or
pitted.
Check relays, wiring and
insulation.
Make sure input and output connections are tight and
that no damaged wires or damaged insulation exists.
Annually
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.
Refer to Open-Circuit Test in this section.
Unschedul
Check load on regulator.
ed
© 2010 ADB Airfield Solutions All Rights Reserved
Operate the local control switch to check for proper
operation of relays and contactors.
At installation and subsequent load changes make
sure that the output rms-voltage times the output truerms current does not exceed the rated load on the
nameplate of the regulator.
41
Disclaimer
Operation
5.1 Introduction
Installation Introduction
Maintenance and
Repair
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.
Table of
Contents
WARNING
Read the instructions in their entirety before starting installation.
Safety
This section provides maintenance and repair instructions for the L-828 and L-829 CCF Aircooled CCRs.
Maintenance
5.0 Maintenance
and Repair
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Maintenance and Repair
Schematics
96A0288 Rev. W
6/9/11
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Maintenance Schedule
96A0288 Rev. W
6/9/11
Disclaimer
5.2.1 Short-Circuit Test
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.
Table of
Contents
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.
Safety
2. Remove leads from output terminals and bushings. Use AWG 8 or larger wire to short
output bushings.
Introduction Installation
Maintenance
Schedule
3. Energize the regulator and turn the rotary selector switch to the lowest brightness step (1)
and then to the remaining brightness steps. Check the output current on the ammeter at
each step.
NOTE: The output current should be within the tolerance given in 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.
5. Turn off disconnect switch or main circuit breaker to remove input power to regulator.
6. Disconnect the shorting jumper and reconnect output cables.
Operation
7. Close input-power disconnect switch or main circuit breaker.
5.2.2 Open-Circuit Test
WARNING
Read the instructions in their entirety before starting installation.
Maintenance
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.
Schematics
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.
2. Disconnect cables from the output terminals and bushings.
3. Turn on input power to the regulator.
4. Turn the rotary switch to the lowest brightness position (1). The open-circuit protective
device should automatically de-energize the regulator in less than 2 seconds.
5. Turn the rotary switch to OFF. The open-circuit protective device should reset.
6. Turn the rotary switch to position 1. The regulator should turn on and then de-energize in
less than 2 seconds.
7. If regulator operation is satisfactory, turn rotary switch to OFF, and turn off disconnect
switch or main circuit breaker before reconnecting the load.
8. After the load has been reconnected, turn on input power to the regulator.
42
© 2010 ADB Airfield Solutions All Rights Reserved
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Troubleshooting
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.
The following is a check list of initial steps to perform.
•
•
•
•
•
•
•
•
Visually examine all areas of the CCR. Do burnt or loose connections/parts exist?
•
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.
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.
© 2010 ADB Airfield Solutions All Rights Reserved
43
Operation
Is the input voltage present and within +10 to –5% of nominal?
Maintenance
5.3.1 Preliminary
Troubleshooting
Safety
Only personnel authorized to work on high-voltage equipment should perform
maintenance on the regulator.
Installation Introduction
Troubleshooting
WARNING
Read the instructions in their entirety before starting installation.
Table of
Contents
Disclaimer
5.3 Troubleshooting
Schematics
96A0288 Rev. W
6/9/11
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Troubleshooting
Disclaimer
5.3.2 Troubleshooting
Fuses
96A0288 Rev. W
6/9/11
This subsection provides information for troubleshooting 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 power fuses F1 and F2
on the L-828 and L-829 CCRs. Input Power Fuses, F1 and F2, per CCR Input Voltage and
CCR kW Rating
Table of
Contents
CCF/XXXX INPUT FUSES (F1, F2)
Safety
Introduction Installation
Troubleshooting
Operation
Maintenance
Schematics
44
SIZE
208 V
220 V
240 V
480 V
4kW
47A0092
47A0069
47A0069
47A0090
7.5kW
47A0093
47A0093
47A0070
47A0091
10kW
47A0094
47A0071
47A0071
47A0085
15kW
47A0099
47A0096
47A0096
47A0088
20kW
47A0072
47A0072
47A0099
47A0087
30kW
47A0102
47A0101
47A0101
47A0097
50kW
N/A
N/A
N/A
47A0106
70kW
N/A
N/A
N/A
47A0141
47A0069
Fuse 25A 250V Time Delay
47A0070
Fuse 45A 250V
47A0071
Fuse 60A 250V
47A0072
Fuse 125A 250V
47A0085
Fuse 30A 600V
47A0087
Fuse 60A 600V
47A0088
Fuse 50A 600V
47A0090
Fuse 12A 600V
47A0091
Fuse 25A 600V
47A0092
Fuse 30A 250V
47A0093
Fuse 50A 250V
47A0094
Fuse 70A 250V
47A0096
Fuse 80A 250V
47A0097
Fuse 90A 600V
47A0099
Fuse 110A 250V
47A0101
Fuse 175A 250V
47A0102
Fuse 200A 250V
47A0106
Fuse 125A 600V
47A0141
Fuse 200A 600V
2400 V
For 2400V
applications a
fuse or breaker
should be
provided
external to the
CCR
© 2010 ADB Airfield Solutions All Rights Reserved
CCF/XXXX Input Fuse Blocks
SIZE
208 V
220 V
240 V
480 V
4kW
72A0091
72A0091
72A0091
49A0081
72A0098
72A0098
72A0098
49A0081
10kW
72A0091
72A0098
72A0098
49A0081
15kW
72A0091
49A0091
49A0091
49A0082
20kW
72A0099
72A0099
72A0099
49A0082
30kW
72A0099
72A0099
72A0099
49A0085
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
For 2400V
applications a
fuse or breaker
should be
provided
external to the
CCR
Safety
7.5kW
2400 V
Table of
Contents
Table 23:
Disclaimer
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Troubleshooting
Table 24:
L-828 / L-829 Step-Down T4 Transformer Fuses F3 and F4
Fuses F3 and F4 on the L-828/L-829 CCRs protect transformer T4, which supplies 110 Vac
and 24 Vac to the universal regulator control card. Transformer T3 Fuses F3 and F4 Ratings
Installation Introduction
Troubleshooting
96A0288 Rev. W
6/9/11
220 V
240 V
480 V
4kW
47A0113
47A0113
47A0113
47A0108
7.5kW
47A0113
47A0113
47A0113
47A0108
10kW
47A0113
47A0113
47A0113
47A0108
15kW
47A0187
47A0187
47A0187
47A0187
20kW
47A0187
47A0187
47A0187
47A0187
30kW
47A0187
47A0187
47A0187
47A0187
50kW
N/A
N/A
N/A
47A0187
70kW
N/A
N/A
N/A
47A0187
47A0108
Fuse 1A 500V
47A0113
Fuse 2A 250V
47A0187
Fuse 3A 500V
49A0084
Fuse Holder (double) (4, 20 - 30 kW)
© 2010 ADB Airfield Solutions All Rights Reserved
2400 V
Maintenance
208 V
47A0113
Schematics
SIZE
Operation
CCF/XXXX T4 Fuses (F3, F4)
45
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Troubleshooting
96A0288 Rev. W
6/9/11
Disclaimer
Table 25:
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
Table of
Contents
47A0119
Fuse .5A 250V
47A0061
Fuse Block (single)
Table 26:
CCF/XXXX Current Transformer T2
SIZE
6.6A
20A
Safety
Introduction Installation
Troubleshooting
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:
Operation
Maintenance
Schematics
46
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 60 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
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Troubleshooting
240 V
480 V
2400 V
4kW
28A0045
28A0045
28A0045
28A0045
28A0037
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:
Table of
Contents
220 V
Safety
208 V
Disclaimer
CCF/XXXX Dual SCR Block (SCR)
SIZE
CCF/XXXX Power Transformer T1 (Core)
SIZE
208 V
6.6A
208 V
20A
220 V
6.6A
220 V
20A
240 V
6.6A
240 V
20A
480 V
6.6A
480 V
20A
2400 V
6.6A
2400 V
20A
4kW
35A0559
N/A
35A0623
N/A
35A0512
N/A
35A0512
N/A
N/A
N/A
7.5kW
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
35A0594
35A0515/1
N/A
N/A
20kW
35A0563
35A0566
35A0624
N/A
35A0516
35A0545
35A0516
35A0545
35C0161/1 35C0179/1
30kW
35A0564
35A0567
35A0625
N/A
35A0517
35A0544
35A0517
35A0544
35C0145/1 35C0187/1
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
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
Maintenance
Power Core List
Schematics
Table 30:
Installation Introduction
Troubleshooting
Table 28:
Operation
96A0288 Rev. W
6/9/11
47
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Troubleshooting
Disclaimer
Table of
Contents
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
35A0516
20kW Power Transformer, 240/480V, 6.6A
35A0517
30kW Power Transformer, 240/480V, 6.6A
Safety
Introduction Installation
Troubleshooting
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
Operation
Table 32:
CCF/XXXX Output Lightning Arrestor VR2, VR3, VR4, VR5
Maintenance
Schematics
SIZE
208 V
6.6A
208 V
20A
220 V
6.6A
220 V
20A
240 V
6.6A
240 V
20A
480 V
6.6A
480 V
20A
2400 V
6.6A
2400 V
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
32A0024
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 40kA 750V
Use Kit 94A0576
32A0026
Surge Arrestor 3kV
Use Kit 94A0433/3
32A0114
Surge Arrestor 6kV
32A0115
Surge Arrestor 3kV
48
96A0288 Rev. W
6/9/11
© 2010 ADB Airfield Solutions All Rights Reserved
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Troubleshooting
6.6A
35A0548
Transformer, Current Sensing, 6.6A to 66mA
20A
35A0528
Transformer, Current Sensing, 20A to 66mA
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)
CCF/XXXX 2400V/120V Power Transformer (T3)
35A0678
Table 36:
2400 V to 120 V Transformer (All Sizes)
CCF/XXXX Capacitor Plate
44A6107/1
30kW (6.6A and 20A)
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
44A6217
7.5kW 208 V
4kW 208 - 480 V
44A6392/07
7.5kW 220 - 480 V
44A6483/09
10kW and 30kW 2400 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
Table 38:
SCO Series Circuit Cutout (Option)
CCF/XXXX Circuit Voltage Monitor Assembly (CVM) (Option)
44A6326/10
Circuit Voltage Monitor Assembly (6.6A)
44A6326/11
Circuit Voltage Monitor Assembly (20A)
Table 39:
Safety
Table 35:
Table of
Contents
CCF/XXXX Power Transformer (T4)
35A0539
Installation Introduction
Troubleshooting
Table 34:
Disclaimer
CCF/XXXX Current Sensing Transformer (T5)
Part
Description
Operation
SIZE
Maintenance
Table 33:
Schematics
96A0288 Rev. W
6/9/11
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
Disclaimer
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.
Table of
Contents
Since high open-circuit voltages may result by opening the primary of a series lighting circuit, only personnel authorized
to work on high-voltage equipment should be allowed to perform the open-circuit test.
Operating a regulator for long periods of time while seriously overloaded may cause the regulator to overheat.
Table 40:
Problem
Safety
1. Regulator not turning on
Possible Cause
Corrective Action
Introduction Installation
Troubleshooting
Main power supply off
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
Replace PCB.
Output circuit interrupted
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
Replace regulator controller.
Verify that SCR is triggering by replacing the PCB.
Operation
2. Regulator turns on but deenergizes suddenly
Overcurrent condition
Check feedback transformer T5 for damage and proper
connections. Polarity does not affect operation.
Compare input voltages across J8-4 to J8-3 with those
in “Output Current Monitor Circuitry” on page 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.
Maintenance
Check SCRs and wiring.
Replace SCR.
Refer to Problem #11 in this table.
Schematics
3. Output Current always 6.6
A/20 A or more
Universal regulator controller not calibrated
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
Refer to problem #2 in this table, Regulator turns on but
de-energizes suddenly.
Defective control board
If problem exists in Remote and local control, replace
universal regulator controller.
4. Output Current always 4.8 A or SCRs always conducting
less for 3-Step CCR or 2.8 A or
less for 5-Step CCR or 8.5 or less
on 20 A
Defective Ferroresonant resonant circuit
Verify SCR is triggering by replacing PCB. Check SCRs
and wiring for shorts in SCR circuitry.
Replace SCR.
(transformer or capacitor)
Visually inspect capacitors for damaged housing or wire
connections. Visually inspect transformer for damaged
coils, connections, and/or wiring.
CCR overload
Remove section of load.
Faulty capacitors will exhibit a bulging case.
5. More than 2 seconds required
for CCR to de-energize on open- Faulty overcurrent protection
circuit load
50
Replace URC PCB.
© 2010 ADB Airfield Solutions All Rights Reserved
Incorrect output current adjustment
Refer to “Output Current Adjustment” on page 31.
Faulty overcurrent protection
Replace URC PCB.
Incorrect output current adjustment
Refer to “Output Current Adjustment” on page 31. Refer
to Problem #11 in this table.
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:
Current meter not calibrated or faulty
•
•
Advanced Control Equipment (ACE) manual 96A0287 or
Advanced Control Equipment (ACE2) manual 96A0357 for
display calibration procedures.
Refer to Problem #11 in this table.
Blown fuse
8. Regulator operates by the local
control switch but not by Remote
control
Loose or broken Remote control wires
Incorrect wire connections
9. Ammeter on CCR oscillates
and loud noise occurs
Set the rotary switch to REM.
Installation Introduction
Additional
L-829 General Trouble-
The rotary switch on the input module not set to
REM
Check fuse F5.
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.
Refer to Table 12 through Table 14.
Check connections at SCR module. Replace URC
PCB.
SCR drive not working properly
Refer to Problem #11 in this table.
Regulator load too large
Operation
Either reduce the load or replace the regulator with a
larger kW CCR.
10. Output current not able to be
adjusted up to 6.6 A/20 A
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.
11. 5-Step regulator (in Steps 1 or
2) emitting loud hum, not
Light inductive load (for example, signs)
indicating proper current, and
operating erratically
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.
5.4 Additional L-829
General
Troubleshooting
Procedures
For additional L-829 CCR general troubleshooting procedures,
refer to the Troubleshooting section in manuals:
•
•
96A0287, Advanced Control Equipment (ACE™) or
96A0357, Advanced Control Equipment (ACE2™).
© 2010 ADB Airfield Solutions All Rights Reserved
Table of
Contents
7. Regulator not indicating proper
current
Corrective Action
Safety
6. Short lamp life and/or high
output current reading on panel
ammeter
Possible Cause
51
Maintenance
Problem
Disclaimer
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Additional L-829 General Troubleshooting Procedures
Schematics
96A0288 Rev. W
6/9/11
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Feedback Wiring Modification Procedure
Disclaimer
5.5 Feedback Wiring
Modification
Procedure
96A0288 Rev. W
6/9/11
WARNING
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.
Table of
Contents
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:
1. On the URC board, find connector J8.
Safety
2. Remove wires on pins 1 and 2, and insulate wire ends..
3. Remove jumper wire from pin 2 to 5.
4. Add a jumper wire (18-22 AWG) from pin 1 to 7.
5. Add a jumper wire (18-22 AWG) from pin 2 to 8.
Introduction Installation
Feedback
Wiring Modification Pro-
6.
Disconnect the field circuit from the regulator and short the regulator's output.
7. 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.
8. 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.
9. Remove input power from the regulator. Remove the output short circuit. Reconnect the
field circuit.
10. Apply input power to the regulator. Verify all steps output the correct current level.
Modification complete.
Operation
5.6 Component
Replacement
Procedures
5.6.1 Removing and
Replacing URC PCB
1. Turn CCR local switch to the OFF position.
Figure 32:
URC PCB
Maintenance
Schematics
2. Remove and lock out/tag out primary power to the CCR at the breaker panel.
3. Lock out/tag out the SCO in the maintenance position.
4. Loosen the door latch screws and open the CCR door.
5. Unplug green connectors J8, J1, J2, J3, J4, and J5 from the PCB.
6. 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.
52
© 2010 ADB Airfield Solutions All Rights Reserved
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
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.
Table of
Contents
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.
Disclaimer
96A0288 Rev. W
6/9/11
10. Plug in 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.
See drawing 43A2522 in “Schematics” on page 63.
Figure 33:
Dual SCR Module Assembly
Installation Introduction
Component
Replacement Proce-
5.6.2 Removing and
Replacing Dual SCR
Module Assembly
Safety
14. Turn the CCR local switch to the REM position.
Operation
#10 Split Lock Washer (2 or 4 each)
and
¼-20 X 1/2 Hex Head Screw (2 or 4 each)
1. Turn CCR local switch to the OFF position.
Maintenance
2. Remove and lock out/tag out primary power to the CCR at the breaker panel.
3. Lock out/tag out the SCO in the maintenance position.
4. Open the CCR front door by loosening the 3 door screws.
Schematics
5. 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.
6. 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 prior 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.
© 2010 ADB Airfield Solutions All Rights Reserved
53
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Component Replacement Procedures
96A0288 Rev. W
6/9/11
Disclaimer
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.
5.6.3 Removing and
Replacing Contactor
1. Turn CCR local switch to the OFF position.
Figure 34:
CCR Power Contactor
Table of
Contents
Contactor
#401/102
#400/103
Safety
Retaining Screw
Introduction Installation
Component
Replacement ProceOperation
#104
#105
#501
#531
2. Label the wires.
Maintenance
3. Remove and lock out/tag out primary power to the CCR at the breaker panel.
4. Lock out/tag out the SCO in the maintenance position.
5. Open the CCR front door by loosening the 3 door screws.
Schematics
6. Loosen the wire retaining lugs for 102, 103, 104 and 105 and disconnect. See
43A2522.dwg in “Schematics” on page 63.
7. Label any wires not labeled prior to disconnecting them.
8. 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.
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.
54
© 2010 ADB Airfield Solutions All Rights Reserved
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Component Replacement Procedures
1. Turn CCR local switch to the OFF position.
Disclaimer
5.6.4 Removing and
Replacing Input Lightning
Arrestors (front of
Component Mounting
Plate)
2. Remove and lock out/tag out primary power to the CCR at the breaker panel.
3. Lock out/tag out the SCO in the maintenance position.
4. Open the CCR front door by loosening the 3 door screws.
5. Loosen the wire retaining screws for 100, 402, 101, 403, 802 and 803 and disconnect.
See 43A2522.dwg in “Schematics” on page 63.
6. Remove the top two of (4) #10 x 32 pan-head screws and loosen the bottom two screws
until the arrestors are free.
7. Replace the Input Lightning Arrestor assembly. Replace the two top screws on the
assembly plate and tighten all four until the arrestors are secure.
Table of
Contents
96A0288 Rev. W
6/9/11
Safety
8. Connect the wires for 100, 402, 101, 403, 802 and 803 and tighten retaining screws.
9. Close the CCR front door by tightening the 3 door screws.
10. Restore the SCO to the ON position.
11. Restore primary power to the CCR at the breaker panel.
5.6.5 Removing and
Replacing Output
Lightning Arrestors (front
of Component Mounting
Plate)
Installation Introduction
Component
Replacement Proce-
12. Turn the CCR local switch to the REM position.
1. Turn CCR local switch to the OFF position.
2. Remove and lock out/tag out primary power to the CCR at the breaker panel.
3. Lock out/tag out the SCO in the maintenance position.
4. 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.
Output Lightning Arrestors
Schematics
Maintenance
Operation
Figure 35:
5. Loosen the 11/16-inch wire retaining nuts for 200, 201, 203, ST1, ST2 and 202 and
disconnect.
6. Remove the (4) #10 x 32 pan-head screws and retain until later.
7. Replace the Input Lightning Arrestor assembly. Replace and tighten the screws on the
assembly plate.
8. Connect the wires for 200, 201, 203, ST1, ST2 and 202 and tighten retaining nuts.
9. Connect the ground wire from the frame to the side panel.
10. Put the side panel back on the CCR with the 8 screws.
11. Restore the SCO to the ON position.
12. Restore primary power to the CCR at the breaker panel.
13. Turn the CCR local switch to the REM position.
© 2010 ADB Airfield Solutions All Rights Reserved
55
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Component Replacement Procedures
96A0288 Rev. W
6/9/11
Disclaimer
Table of
Contents
Safety
Introduction Installation
Component
Replacement ProceOperation
Maintenance
Schematics
56
© 2010 ADB Airfield Solutions All Rights Reserved
96A0288
Document Date (12/2010)
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Parts
6.0 Parts
See Figure 37
6.1 L-828/L-829 CCR (4-70 kW/6.6 A/20 A) Part Ordering Code
Table 42:
See Figure 36
kW Rating
Output
Part Number
4 KW
6.6 A
PPF6604-X3XX
PPSF6604-X3XX
7.5 KW
6.6 A
PPF6607-X3XX
PPSF6607-X3XX
Table 41:
L-828/L-829 CCR (4-70 kW/6.6A & 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
6.6 A
CCF6615-X2XX
CCF6615-X3XX
20 kW
6.6 A
CCF6620-X2XX
CCF6620-X3XX
30 kW
6.6 A
CCF6630-X2XX
CCF6630-X3XX
15 kW
20 A
CCF2015-X2XX
CCF2015-X3XX
20 kW
20 A
CCF2020-X2XX
CCF2020-X3XX
30 kW
20 A
CCF2030-X2XX
CCF2030-X3XX
50Kw
20A
N/A
CCF2050-53XX
70kW
20A
N/A
CCF2070-53XX
Figure 36:
10 KW
15 KW
20 KW
30 KW
CCFXX XX - X
X
X
6.6 A
PPF6610-X3XX
PPSF6610-X3XX
6.6 A
PPF6615-X3XX
PPSF6615-X3XX
20A
PPF2015-X3XX
PPSF2015-X3XX
6.6 A
PPF2020-X3XX
PPSF2020-X3XX
20A
PPF6620-X3XX
PPSF6620-X3XX
6.6 A
PPF2030-X3XX
PPSF2030-X3XX
20A
PPF6630-X3XX
PPSF6630-X3XX
20A
PPF2050-X3XX
PPSF2050-X3XX
30 KW
20A
PPF2070-X3XX
PPSF2070-X3XX
SGRS Powerpack Part Ordering Code
PPF6630-X 3 5 X
PPSF6630-X 3 5 X
X
FIELD CIRCUITS MONITORED
0 = No field circuit monitoring
A = Field circuit monitoring
G = Field circuit monitoring,with input
CCRmonitoring
OUTPUT RANGE (Note 4)
AMPERAGE
66 = 6.6 amp (4-30kW)
20 = 20 amp (15-70kW)
MONIT ORING OPTIONS
0 = None
1= ALCS ScanningMonitor Interface
2 = ALCS Scanning Monitoring Ready
3 = L-829ACE Monitoring
4 = IRMS Only
5 = L-829Monitoring – ACE and IRMS
6 = L-828 with Digital Power Meter
SIZE
04 = 4kW /6.6A Only
07 = 7.5kW /6.6A Only
10 = 10kW/ /6.6A Only
15 = 15kW
20 = 20kW
30 = 30kW
50 = 50kW /20A Only
70 = 70kW/ 20A Only
3 = 3 Step
4 = 3 Stepwith KIRK KEY
5 = 5 Step
6 = 5 Step with KIRK Key
INPUT
VOLTAGE
3 = 480
INPUT VOLTAGE
1 = 208 (4-30kW)
2 = 240 (4-30KW)
3 = 480 (4-70KW)
4 = 347
5 = 220 (4-30KW)
OUTPUTVOLTAGE
3 = 3 Stepwithout SCO Cutout
4 = 3 Stepwith SCOCutout
5 = 5 Stepwithout SCO Cutout
6 = 5 Stepwith SCOCutout
Fi
7 1 L 828/L 829 P
Od i
C d
© 2010 ADB Airfield Solutions All Rights Reserved
Part Number
Seismic Zone 4
50 KW
Figure 37:
L-828/L-829 Part Ordering Code
SGRS Powerpack (4-70 KW/6.6 A) Part Numbers
57
STAB CONNECTOR
CONNECTIONS
Blank = Vertical
H = Horizontal
MONIT ORING OPTIONS
0 = None
3 = L-829
4 = IRMS Only
5 = L-829andIRMS
6 = L-828with Digital M eter
PARTS
6.2 SGRS Powerpack CCR (4-70 kW/6.6 A) Part Ordering Code
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
2400 Vac CCF Parts and Diagrams
96A0288 Rev. W
6/9/11
Disclaimer
6.3 2400 Vac CCF Parts and Diagrams
Figure 38:
L-828 10KW 6.6A 2400V
PART
ITEM
NUMBER
NO.
1 35C0157-1
29
CCF6610 / X 9 X X
2
0 = L-828
14
DESCRIPTION
QTY.
Table of
Contents
PWR TX 10KW 2400V 6.6A AIR COOLED
1
2
42A0480
LABEL, "OUTPUT CURRENT" L-828
1
3
42A0525-X
LOCAL CONTROL LABEL, 3 OR 5 STEP (CONFIG.)
1
4
42B0269
LABEL L828
1
5
44A6178
PCB ASSY 34-PIN HDR/SW ADAPTOR
1
6
44A6483-09
CAP PLATE ASSEM., 50/70 AIR COOLED
1
7
44A6774
CONTACTOR/TRANSFORMERPLATE ASSY
1
8
44A6799
HARN ASSY, CCF, 2400V, 10-70KW
1
9
44A6852-X90
COMP PLT ASSEM., 15-50KW, 2400V, 6.6A L-828
1
A = L-829
NOTE 3
MONITORING OPTIONS:
6
3
0 = NONE
1 = SMI
4
2 = SMR
3 = L 829
4 = IRMS ONLY
5 = L 829 AND IRMS
6 = DIGITAL POWER METER
Safety
20
15
22
25
Introduction Installation
2400 Vac
CCF Parts
10
52A0098
AMMETER TRUE RMS 0-25
1
INPUT VOLTAGE:
11
60A2658-1
DISPLAY PANEL ANALOG URC CCR
1
9 = 2400
12
60A3129
CORE SUPPORT ANGLE, GLASTIC
2
OUTPUT RANGE:
13
60A4018
CABINET MOD., 2400V SIG SRS REGULATOR
1
3 = 3 STEP
14
61A0340
KNOB 3FLUTE 1/8"SHAFT ALUM BLK
1
15
64A0173-10
1/4-20 X 5/8 HX HD
16
64A0178-16
1/2-13 X 1 HX HD
8
17
64A0198-6
6-32 X 3/8 PAN HD PHIL
2
18
64A0947
EYEBOLT 1/2-13X1.5 1.19ID 2600
19
64A0981/12
1/4-20 X 3/4 FLT HD PHIL
20
64A0981/8
1/4-20 X 1/2 FLAT HD SCREW
10
21
65A0015/33
1/2-13 HX NUT
14
22
65A0347-4
1/4-20 SS NYLON INSERT NUT
38
23
66A0015/24
1/4 FLATWASHER
8
24
66A0015-33
1/2 FLATWASHER
22
25
66A0026/24
1/4 SPLIT LOCKWASHER
39
26
66A0026-33
1/2 SPLIT LOCKWASHER
14
27
72A0010
GROUND LUG
28
89A0209-24
RIBBON CABLE ASSY,34-POS W/CONNS,24"
1
29
91A0033
LBL L828 DANGER HIGH VOLTAGE
1
30
94A0502-10
PWR WIRE KIT CCF REG 10KW 2400V
1
31
66A0039-4
#6 EXT LOCKWASHER
2
4 = 3 STEP WITH S1
15
7
5 = 5 STEP
6 = 5 STEP WITH S1
SECTION D-D
SCALE 1 : 4
18
SECTION A-A
31
5
19
22
25
9
Operation
25
A
21
17
24
20
22
D
17
4
18
1
26
Parts
NOTES:
1) A LEGIBLE COPY OF 43A3403
WIRING SCHEMATICS IS TO BE
PERMANENTLY MOUNTED IN AN
UNOBSTRUCTED PLACE INSIDE
THE CONTROL CABINET.
D
11
12
10
7
2) CABINET ASSEMBLY PANELS ARE
HIDDEN FOR CLARITY.
A
24
26
21
16
19
25
22
23
Parts
3) REMOVE SET SCREW FROM 61A0340 KNOB.
APPLY LOCTITE 222. REPLACE SET SCREW
AND TIGHTEN.
1
CONTROLLED COPY
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
13
Schematics
INITIAL & DATE:
SECTION B-B
E
B
3052
SEE ECO - CHNG 35C0157 TO /1
CORRECTED COMP PLATE
DTR
2433
SEE ECO - ADDED NOTE 3
DTR
06JUL10
B
2589
DTR
26APR10
DTR
16AUG07
A
REV
LEVEL
SEE ECO
---ECO
NUMBER
INITIAL RELEASE
REVISION DESCRIPTION
DRAWN
BY
DRAWN BY:
D.T. RYAN
58
27
07OCT10
1856
C
ASSOCIATED DRAWINGS:
15
21JAN11
D
B
25
DTR
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.
ADB Airfield Solutions
P.O. BOX 30829
Tel. (614) 861-1304
977 Gahanna Parkway Fax. (614) 864-2069
Columbus, Ohio 43230
DRAWING TITLE:
CONSTANT CURRENT REGULATOR
L-828 10KW 6.6A 2400V
REV
DATE
DRAWN DATE:
16AUG07
SCALE:
SHEET NUMBER:
1:8
DRAWING NUMBER:
CCF6610-X900
1 OF 1
REV.
E
© 2010 ADB Airfield Solutions All Rights Reserved
96A0288 Rev. W
6/9/11
ITEM
NO.
1
5
28
2
13
CCF6620/ X 9 0 0
NOTE 3
0 = L-828
A = L-829
3
MONITORING OPTIONS:
4
PART NUMBER
DESCRIPTION
35C0161-1
Disclaimer
L-828 20KW 2400V 6.6A
QTY.
PWR TX 20KW 2400V 6.6A AIR COOLED
1
LABEL, "OUTPUT CURRENT" L-828
1
2
42A0480
3
42A0525-5
4
42B0269
5
44A6483-18
CAP PLATE ASSEM., (18 CAPS) 20KW 6.6A
1
6
44A6774
CONTACTOR/TRANSFORMERPLATE ASSY
1
7
44A6799
8
44A6852-X90
9
52A0098
ROTARY SWITCH LABEL 5 STEP FERRO
1
LABEL L828
1
HARN ASSY, CCF, 2400V, 10-70KW
Table of
Contents
Figure 39:
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
2400 Vac CCF Parts and Diagrams
1
0 = NONE
2 = SMR
3 = L 829
1
60A2658-1
5 = L 829 AND IRMS
11
60A3129
6 = DIGITAL POWER METER
12
60A4018
13
61A0340
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
17
64A0947
5 = 5 STEP
18
64A0981/8
6 = 5 STEP W/S1
19
64A0981/12
20
65A0015/33
21
65A0347-4
22
66A0015-33
23
66A0015/24
24
66A0026-33
1/2 SPLIT LOCKWASHER
14
25
66A0026/24
1/4 SPLIT LOCKWASHER
39
26
72A0010
27
89A0209-24
28
91A0033
29
94A0502-20
PWR WIRE KIT CCF REG 20KW 2400V
1
30
44A6178
PCB ASSY 34-PIN HDR/SW ADAPTOR
1
31
66A0039-4
4 = IRMS ONLY
L-828 DOOR
AMMETER TRUE RMS 0-25
10
DISPLAY PANEL ANALOG URC CCR
1
CORE SUPPORT ANGLE, GLASTIC
2
CABINET MOD., 2400V SIG SRS REGULATOR
Safety
1 = SMI
1
COMP PLT ASSEM., 15-50KW, 2400V, 6.6A L-828
1
KNOB 3FLUTE 1/8"SHAFT ALUM BLK
1
21
9 = 2400V
25
18
OUTPUT RANGE:
SECTION A-A
20
15
8
19
11
25
A
12
20
22
21
25
18
21
4
1/4-20 X 1/2 FLAT HD SCREW
10
1/4-20 X 3/4 FLT HD PHIL
10
1/2-13 HX NUT
14
1/4-20 SS NYLON INSERT NUT
38
1/2 FLATWASHER
22
1/4 FLATWASHER
8
GROUND LUG
1
RIBBON CABLE ASSY,34-POS W/CONNS,24"
1
LBL L828 DANGER HIGH VOLTAGE
1
C
#6 EXT LOCKWASHER
2
24
NOTES:
1. A LEGIBLE COPY OF 43A3403 WIRING SCHEMATIC
IS TO BE PERMANENTLY MOUNTED IN AN
UNOBSTRUCTED PLACE INSIDE THE CONTROL CABINET.
C
10
Parts
22
17
SECTION C-C
SCALE 1 : 4
EYEBOLT 1/2-13X1.5 1.19ID 2600
Operation
4 = 3STEP W/S1
14
24
2
3 = 3STEP
6
5
6-32 X 3/8 PAN HD PHIL
Installation Introduction
2400 Vac
CCF Parts
and Dia-
INPUT VOLTAGE:
14
9
A
16
Parts
2. CABINET ASSEMBLY PANELS ARE HIDDEN FOR CLARITY.
31
30
3. REMOVE SET SCREW FROM 61A0340 KNOB. APPLY LOCTITE 222.
REPLACE SET SCREW AND TIGHTEN.
1
21
23
25
14
CONTROLLED COPY
Schematics
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
INITIAL & DATE:
ADB Airfield Solutions
P.O. BOX 30829
Tel. (614) 861-1304
977 Gahanna Parkway Fax. (614) 864-2069
Columbus, Ohio 43230
SECTION B-B
D
3052
SEE ECO - CHNG 35C0161 TO /1
DTR
C
2433
SEE ECO - ADDED NOTE 3
DTR
06JUL10
B
2589
SEE ECO - HRDWR CHNGS
DTR
27APR10
DTR
20AUG07
A
B
REV
LEVEL
B
---ECO
NUMBER
ASSOCIATED DRAWINGS:
INITIAL RELEASE
REVISION DESCRIPTION
DRAWN
BY
DRAWN BY:
D.T. RYAN
25
© 2010 ADB Airfield Solutions All Rights Reserved
14
26
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.
21JAN11
DRAWING TITLE:
CONSTANT CURRENT REGULATOR
L-828 20KW 2400V 6.6A
REV
DATE
DRAWN DATE:
20AUG07
SCALE:
SHEET NUMBER:
1:8
DRAWING NUMBER:
CCF6620-X900
1 OF 1
REV.
D
59
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
2400 Vac CCF Parts and Diagrams
Disclaimer
Figure 40:
96A0288 Rev. W
6/9/11
L-828 20KW 2400V 20A
ITEM
NO.
1
DESCRIPTION
QTY.
35C0179-1
PWR TX 20KW 2400V 20A AIR COOLED
1
2
42A0480
LABEL, "OUTPUT CURRENT" L-828
3
42A0525-X
4
42B0269
5
44A6483-18
CAP PLATE ASSEM., (18 CAPS) 20KW 6.6A
1
1 = SMI
6
44A6772-690
COMP PLT ASSEM., 50KW, 480V, 20A L-828
1
2 = SMR
7
44A6774
8
44A6799
9
52A0098
5
28
CCF2020/ X 9 0 0
2
0 = L-828
13
A = L-829
Table of
Contents
NOTE 4
MONITORING OPTIONS:
PART NUMBER
1
LOCAL CONTROL LABEL, 3 OR 5 STEP (CONFIG.)
1
LABEL L828
1
0 = NONE
3
4
CONTACTOR/TRANSFORMERPLATE ASSY
1
3 = L 829
4 = IRMS ONLY
5 = L 829 AND IRMS
HARN ASSY, CCF, 2400V, 10-70KW
1
AMMETER TRUE RMS 0-25
1
6 = DIGITAL POWER METER
Safety
L-828 DOOR
INPUT VOLTAGE:
9 = 2400V
OUTPUT RANGE:
3 = 3STEP
Introduction Installation
2400 Vac
CCF Parts
14
18
21
Operation
17
22
20
15
60A4018
13
61A0340
2
CABINET MOD., 2400V SIG SRS REGULATOR
1
KNOB 3FLUTE 1/8"SHAFT ALUM BLK
1
64A0173-10
1/4-20 X 5/8 HX HD
25
64A0178-16
1/2-13 X 1 HX HD
8
6 = 5 STEP W/S1
16
64A0198-6
17
64A0947
18
64A0981/8
19
64A0981/12
20
65A0015/33
21
65A0347-4
22
66A0015-33
23
66A0015/24
24
66A0026-33
1/2 SPLIT LOCKWASHER
14
25
66A0026/24
1/4 SPLIT LOCKWASHER
39
26
72A0010
GROUND LUG
1
27
89A0209-24
28
91A0033
29
30
31
66A0039-4
SECTION C-C
SCALE 1 : 4
6
25
A
Parts
22
12
1
CORE SUPPORT ANGLE, GLASTIC
15
11
20
60A3129
14
18
24
11
DISPLAY PANEL ANALOG URC CCR
5 = 5 STEP
14
SECTION A-A
60A2658-1
4 = 3STEP W/S1
25
7
5
10
21
6-32 X 3/8 PAN HD PHIL
2
EYEBOLT 1/2-13X1.5 1.19ID 2600
4
1/4-20 X 1/2 FLAT HD SCREW
10
1/4-20 X 3/4 FLT HD PHIL
10
1/2-13 HX NUT
14
1/4-20 SS NYLON INSERT NUT
38
1/2 FLATWASHER
22
1/4 FLATWASHER
8
RIBBON CABLE ASSY,34-POS W/CONNS,24"
1
LBL L828 DANGER HIGH VOLTAGE
1
94A0502-20
PWR WIRE KIT CCF REG 20KW 2400V
1
44A6178
PCB ASSY 34-PIN HDR/SW ADAPTOR
C
1
#6 EXT LOCKWASHER
2
24
NOTES:
1. A LEGIBLE COPY OF 43A3403 WIRING SCHEMATIC
IS TO BE PERMANENTLY MOUNTED IN AN
UNOBSTRUCTED PLACE INSIDE THE CONTROL CABINET.
C
10
9
2.
CABINET ASSEMBLY PANELS ARE HIDDEN FOR CLARITY.
3.
3 STEP IS NOT AVAILABLE FOR 20A OUTPUT
A
Parts
31
16
30
4.
REMOVE SET SCREW FROM 61A0340 KNOB. APPLY LOCTITE 222.
REPLACE SET SCREW AND TIGHTEN.
1
21
23
25
CONTROLLED COPY
14
Schematics
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
INITIAL & DATE:
ADB Airfield Solutions
P.O. BOX 30829
Tel. (614) 861-1304
977 Gahanna Parkway Fax. (614) 864-2069
Columbus, Ohio 43230
SECTION B-B
B
D
3052
C
2433
B
2589
A
----
REV
LEVEL
B
ECO
NUMBER
ASSOCIATED DRAWINGS:
DTR
SEE ECO- CHNG 35C0179 TO /1
SEE ECO - ADD NOTE 4
SEE ECO - FH SCRW CHNG
INITIAL RELEASE
REVISION DESCRIPTION
D.T. RYAN
25
60
14
26
06JUL10
DTR
23APR10
DTR
21AUG07
DRAWN
BY
DRAWN BY:
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.
21JAN11
DTR
DRAWING TITLE:
CONSTANT CURRENT REGULATOR
L-828 20KW 2400V 20A
REV
DATE
DRAWN DATE:
21AUG07
SCALE:
SHEET NUMBER:
1:8
DRAWING NUMBER:
CCF2020-X900
1 OF 1
REV.
D
© 2010 ADB Airfield Solutions All Rights Reserved
96A0288 Rev. W
6/9/11
L-828 30KW 2400V 6.6A
ITEM
NO.
1
7
30
QTY.
1
LABEL, "OUTPUT CURRENT" L-828
1
42A0480
3
42A0525-X
4
42B0269
5
44A6178-X
6
44A6483-09
CAP PLATE ASSEM., 50/70 AIR COOLED
1
7
44A6483-18
CAP PLATE ASSEM., (18 CAPS) 20KW 6.6A
1
3 = L 829
8
44A6774
CONTACTOR/TRANSFORMERPLATE ASSY
1
4 = IRMS ONLY
9
44A6799
HARN ASSY, CCF, 2400V, 10-70KW
1
0 = L-828
15
DESCRIPTION
PWR TX 30KW 2400V 6.6A AIR COOLED
2
CCF6630/ X 9 0 0
2
PART NUMBER
35C0154-1
A = L-829
Disclaimer
Figure 41:
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
2400 Vac CCF Parts and Diagrams
1
LOCAL CONTROL LABEL, 3 OR 5 STEP (CONFIG.)
LABEL L828
1
NOTE 3
PCB ASSY 34-PIN HDR/SW ADAPTOR 3(5)-STEP
Table of
Contents
1
MONITORING OPTIONS:
3
0 = NONE
4
1 = SMI
2 = SMR
5 = L 829 AND IRMS
6 = DIGITAL POWER METER
INPUT VOLTAGE:
10
44A6852-X90
11
52A0098
1
12
60A2658-1
13
60A3129
14
60A4018
15
61A0340
16
64A0173-10
1/4-20 X 5/8 HX HD
31
17
64A0178-16
1/2-13 X 1 HX HD
8
18
64A0198-6
19
64A0947
20
64A0981/8
21
64A0981/12
1/4-20 X 3/4 FLT HD PHIL
10
22
65A0347-4
1/4-20 SS NYLON INSERT NUT
44
23
65A0015/33
1/2-13 HX NUT
14
24
66A0015-33
1/2 FLATWASHER
22
25
66A0015/24
1/4 FLATWASHER
26
66A0026-33
1/2 SPLIT LOCKWASHER
14
27
66A0026/24
1/4 SPLIT LOCKWASHER
45
28
72A0010
29
89A0209-24
30
91A0033
31
94A0502-30
32
66A0039-4
COMP PLT ASSEM., 15-50KW, 2400V, 6.6A L-828
AMMETER TRUE RMS 0-25
Safety
L-828 DOOR
1
DISPLAY PANEL ANALOG URC CCR
1
CORE SUPPORT ANGLE, GLASTIC
2
9 = 2400V
20
16
22
OUTPUT RANGE:
27
CABINET MOD., 2400V SIG SRS REGULATOR
1
5 = 5 STEP
6 = 5 STEP W/S1
16
26
24
23
17
19
10
13
27
A
14
23
24
22
2
4
1/4-20 X 1/2 FLAT HD SCREW
10
8
C
20
26
GROUND LUG
1
RIBBON CABLE ASSY,34-POS W/CONNS,24"
1
LBL L828 DANGER HIGH VOLTAGE
1
PWR WIRE KIT CCF REG 30KW 2400V
1
#6 EXT LOCKWASHER
2
NOTES:
1. A LEGIBLE COPY OF 43A3403 WIRING SCHEMATIC
IS TO BE PERMANENTLY MOUNTED IN AN
UNOBSTRUCTED PLACE INSIDE THE CONTROL CABINET.
C
12
6-32 X 3/8 PAN HD PHIL
EYEBOLT 1/2-13X1.5 1.19ID 2600
Parts
SECTION A-A
SECTION C-C
SCALE 1 : 4
1
Operation
4 = 3STEP W/S1
8
7
KNOB 3FLUTE 1/8"SHAFT ALUM BLK
Installation Introduction
2400 Vac
CCF Parts
and Dia-
3 = 3STEP
11
A
18
Parts
2. CABINET ASSEMBLY PANELS ARE HIDDEN FOR CLARITY.
32
5
3. REMOVE SET SCREW FROM 61A0340 KNOB. APPLY LOCTITE 222.
REPLACE SET SCREW AND TIGHTEN.
22
25
27
16
CONTROLLED COPY
1
Schematics
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
INITIAL & DATE:
ADB Airfield Solutions
P.O. BOX 30829
Tel. (614) 861-1304
977 Gahanna Parkway Fax. (614) 864-2069
Columbus, Ohio 43230
SECTION B-B
D
3052
C
2433
B
2589
A
B
REV
LEVEL
B
---ECO
NUMBER
ASSOCIATED DRAWINGS:
DTR
SEE ECO - CHNG 35C0145 TO -1
SEE ECO - ADD NOTE 3
SEE ECO - HRDWR CHANGES
INITIAL RELEASE
REVISION DESCRIPTION
D.T. RYAN
27
© 2010 ADB Airfield Solutions All Rights Reserved
16
28
06JUL10
DTR
27APR10
DTR
20AUG07
DRAWN
BY
DRAWN BY:
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.
21JAN11
DTR
DRAWING TITLE:
CONSTANT CURRENT REGULATOR
L-828 30KW 2400V 6.6A
REV
DATE
DRAWN DATE:
20AUG07
SCALE:
SHEET NUMBER:
1:8
DRAWING NUMBER:
CCF6630-X900
1 OF 1
REV.
D
61
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
2400 Vac CCF Parts and Diagrams
96A0288 Rev. W
6/9/11
Disclaimer
Table of
Contents
Safety
Introduction Installation
2400 Vac
CCF Parts
Operation
Parts
Parts
Schematics
62
© 2010 ADB 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)
Schematics
CONTROL
WINDINGS
PREVIOUS IRMS W/RES WIRING
FERRO/ACE WIRE HARNESS, SM. & MED./LG. FRAME
94A0338/XXXX
POWER WIRE KIT, FERRO CCR
43A2550
WIRING DIAGRAM, ACE1 TO URCII/1 PCB
43A3128
WIRING DIAGRAM, ACE2 TO URCII/1 PCB
DOC. NO.
5 STEP WIRING
(3 STEP CONN'S IN ( )'s)
904-IRMS
535-ACE PS
903-ACE PS
534-ACE PS
528 - IRMS
727 - KS4
539 - DPM T8
F5
TB1-N
TB1-GND
804
200
551
905
550
533
516
519
518
520
N/C
521
511
517
TB1
PREVIOUS "MOLDED" STYLE CVM WIRING
F6
(SEE PG. 2 WIRE NO.S)
529
530
PCFS
PCFS
FERRO WIRE HARNESS, SM. & MED./LG. FRAME
44A6139/1-/2
N/C
N/C
FOR PREVIOUS SCR WIRING
F6
XCP
N
GND
44A6136/1-/2
527
528
904
Use wrench to hold RES when
attaching wires
TO: J2
COLOR CODE, SEE PG. 2
J7 -1
-2
-3
200
PUR
G2
J3
804
28A0045 SCR ASSY: 4KW
ORG
G1
1
S1
S2
CCI
CC
B1 (B10)
B2 (B30)
B3 (B100)
B4
B5
NEU
72A0071 TERM. BLK.: 50 in-lb.s
K2
2
IRMS
H2
72A0017 TERM. BLK.: 35 in-lb.s
YEL
BLU
TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKER - AS
LISTED ON COMPONENT LABEL.
K1
3
526 - T4
PUR
ORG
G1
K1
K2
G2
726 - KS3
YEL
724 - KS2
BLU
301
SCR 28A0028, 7.5 - 30KW,
208-480V
300
COPPER BAR JUMPER
TB1-L2
© 2010 ADB Airfield Solutions All Rights Reserved
600
CVM
ACE Potted CVM/IRMS Options
Use wrench to hold RES when
attaching wires
(T2/T3 and meter not used)
(200 W/O IRMS; 201 W/IRMS)
DESCRIPTION
RELATED DOCUMENTS
OPTIONS
VARIATIONS
Table of
Contents
Safety
Installation Introduction
Schematics
REV
DATE
26MAY09
Operation
AA
REV.
B
C
Z
RED
Parts
ACE/CVM
CONNECTIONS
-SEE WIRING DIAGRAMS:
#43A3128 FOR ACE2
#43A2550 FOR ACE1
F6 = .5A, 250V, SLO-BLO (47A0119)
TO TB1-NEU
X4
A
ADB Airfield Solutions
977 Gahanna Parkway, Columbus, Ohio 43230
Telephone: 614-861-1304, Fax: 614-864-2069
8
509
305
300
12MAR07
7
BE
6
17DEC07
5
BE
4
18JUN08
3
SEE ECO-1947 (SCR COLOR CODE CHG)
2
521
1
519
6
520
5
BE
J1
4
DRAWING TITLE:
BLU
105
3
AIRFIELD LIGHTING COMPUTER SYSTEM
L-828 WURC, 4-30KW, 6.6 & 20AMP,
SIGNATURE SERIES FERRO CCF
WIRING DIAGRAM
1 OF 2
508
526
531
2
0
BRN
526
H1
X3
1
60
507
BLK
J2
3
516
511
2
X2
503
VIO
1
H2
517
X1
532
RED
J3
T1
105
518
GRN/YEL
506
ORG
RED/BLK
104
GRY
PUR
BLK
BLU
YEL
F3
T4
502
REV
LEVEL
J4
4
510
F4
501/501A
(T1) - 4-30 KW, 480V
REV
DATE
2
3
(T4) - 480 VAC INPUT
INITIAL & DATE:
ASSY. NOTE #1, PG.2
1
508
Parts
COM
532
MICROSWITCH
NC
NO
501B
507
506
6
CONTROL
WINDINGS
05SEP06
A
B
C
BE
305
300
44A6035/1
URC II PCB ASSY.
J5
REPLACE FORK TERM.
ON HARNESS W/FEM.
FASTON TERM.
70A0279
DRAWN
BY
526
531
4
5
3-STEP
JUMPER
ADD 72A0019
FORK TERM.
Schematics
ALWAYS USED
509
BLU
RED
2
3
H1
DANGER:
LETHAL VOLTAGES
ARE PRESENT
1
70A0596;
MALE FASTON
TERM.
REVISION DESCRIPTION
508
CVM
IF "KEYED" MATING CONN. IS USED,
PIN #1/RED STRIPE IS ON THE RIGHT SIDE
(SAME FOR ROTARY SWITCH CONN.).
70A0279 TERM.
(2 PLC.S)
ECO-01463
507
BRN
ST1
TO
AIRFIELD
V
VIO
ST2
ST1
REV
LEVEL
RED
BLK
H2
20 AMP
JUMPER
503
208
35A0308
(20:6.6A)
S2
ST4 ST3 ST2
1
X2
105
J8
S1
AB
X1
532
1
209
T1
506
2
OPTIONAL
SCO
501C (TO K2-A2)
GRY
GRN/YEL
3
ST1
BLK
RED/BLK
4
5
ST2
502
F3
104
6
ST3
T4
7
IF "UN-KEYED" MATING CONN. WAS USED,
PIN #1/RED STRIPE IS ON THE LEFT SIDE
(SAME FOR ROTARY SWITCH CONN.).
1
(T1) - 4-30 KW, 208V
(T4) - 347 VAC INPUT
8
J7
TO IRMS
TO DPM
J6
F4
1
DETAIL"A"
T9
501
538
2
ST4
WIRE #531 MUST BE TIED TO BLU
WIRE - NOT TO ANOTHER GND.
3
213
527
4
ST3
5
510
509
ST4
F5 =.5A, 250V, SLO-BLO (47A0119)
ATTACH TO FOOT OF T4
(2 PLACES)
P2
P1
H2
ROTARY SWITCH
CONNECTION
DRAWN
BY
20A CVM WIRING
526
531
BLU
RED
REVISION DESCRIPTION
509
AB
508
43A2522
BRN
ECO-2306: ADDED SCO MICROSWITCH WIRING BE
IF VARISTORS ARE PLATE
MOUNTED,
GND PLATE TO EARTH GND.
801
DRAWING NUMBER:
BLK
800
10 MAY 01
VR5
VR6
01SEP09
507
BAR
VIO
TITLEBLOCK UPDATE
524
525
503
RED
MICROSWITCH
WIRING - SEE
DETAIL "A"
BELOW
VR3
(NOTE 3, PG. 2: PROD. ONLY)
DIGITAL POWER METER
OPTION - SEE PG. 2
X2
LG. INDUCTOR (L)
532
GRN/YEL
524
VR4
CMS 29NOV06
X1
301
VR2
902
TITLEBLOCK UPDATE
F3
SM. INDUCTOR (L3)
(REV. I - SAME COLORS.
SEE PG. 2 FOR PREV. REV.S)
S2
S1
POS. CURRENT
FEEDBACK SENSOR
OPTION
(#53A0283)
6.6A = 35A0548
20A = 35A0528
-NO GND REQ'D
SEE ECO-1767.
RED/BLK
P2
X
401
35A0539/546
506
GRY
201
METER
OPTION
FB2
H1 (201)
T5
H1
P1
T2
W
BLK
CONTROL
WINDINGS
94A0463/X
502
A
B
C
BE
803
802
400
VR7 VR8
305
300
X2
X1
208/240 VAC INPUT
F4
T4
FB1
304
DRAWN DATE:
304
TO
AIRFIELD
DRAWN BY:
501A
209
SEE ECO-1860 (DPM & SNUBBER CHG'S)
COM
94A0358 KIT
203
ASSOCIATED DRAWINGS:
NO
2
OPTIONAL
SCO
OPT. DOOR-SW
501
203
501C
501B
SEE DETAIL"A"
208
501B
501C
1
VR1
204
Cx
X4
20A SHUNT POS. IS "MID"
(DO NOT USE SHUNT FOR 6.6A)
205
C2
TB2
206
SCO OPTION
A2 501/501C
531
402
403
89A0171
K2
ATTACH "OUTPUT" TAG - 2 PLC.S
202
207
103
A1
400
3
H1
525
40
X3
TB1-GND
804
550
6
X2
F5
TB1-NEU
904
551
401
5
C1
*INSULATORS REQ'D FOR
30KW, 6.6A CVM ONLY
DANGER:
LETHAL VOLTAGES
ARE PRESENT
H2 TO VR1 W/O CVM
NOTE 4
105
103
ST4 TO H2 W/6.6A CVM
H2 TO T9 W/20A CVM
527
528
H2 W/O CVM
101
H2
-1
-2
-3
200
4
T1
J5
ST1
3
X1
305
102
402
F2
2
105
104
J4
ST2
2
IRMS
J3
6.6A WIRING: SEE
BELOW FOR 20A
ST1
804
1
ST1
102
ST4 ST3 ST2
CVM
104
OUTPUT NOTE:
OUTPUT CONNECTIONS ON VR1
AND VR2 UNLESS TERMINAL
BLOCKS OR "SCO" IS USED.
200
SEE NOTE # 6
4-30 KW, 240V
F1
100
ST2
1
ST4
TB3
NOTE: LAND ALL CAP
BANK WIRES AS CLOSE
AS POSSIBLE TO THE
CENTER OF THE CAP BANK.
All information contained herein, including illustrations,
specifications, and dimensions, is believed to be reliable as of the
date of this publication, but is subject to change without notice.
ADB reserves the right to make changes and improvements to
its products and assumes no responsibility for these modifications.
Any disclosure of this information is strictly prohibited except as
ADB Airfield Solutions may otherwise agree to in writing.
Copyright © 2009 ADB Airfield Solutions.
CONTROLLED COPY
ST4 TO H2 W/6.6A CVM
FOR 30KW, 208V & 240V,
USE F1 & F2 FOR INPUT,
DO NOT USE TB3. LAND
402 & 403 ON 400-401
SIDE OF FUSE BLOCKS.
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
L-828 WURC, 4-30KW, 6.6 & 20AMP, 1 of 2
Y
Figure 42:
Disclaimer
7.0 Schematics
63
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Schematics
10 kW
8 AWG
89A0196/9
10 kW
8 AWG
89A0196/9
8 AWG
89A0196/9
8 AWG
89A0196/9
14 AWG
89A0184/9
15 kW
2 AWG
89A0199/9
15 kW
4 AWG
89A0198/9
6 AWG
89A0197/9
6 AWG
89A0197/9
10 AWG
89A0195/9
20 kW
2 AWG
89A0199/9
20 kW
1/0 AWG
89A0201/9
2 AWG
89A0199/9
2 AWG
89A0199/9
6 AWG
89A0197/9
30 kW
2 AWG
89A0199/9
30 kW
1/0 AWG
89A0201/9
2 AWG
89A0199/9
2 AWG
89A0199/9
6 AWG
89A0197/9
VR1(TB2-1)
IF VARISTORS ARE PLATE
MOUNTED,
GND PLATE TO EARTH GND.
S2
P1
S1
M2
VOLTAGE
146
760
P1 P2
754
757
756
751
WHITE
752
BLACK
753
751
754
RS5
RS3
RS2
753
762
756
752
750
755
757
DIGITAL POWER METER
44A6528
750
BLACK
1
2
3
4
5
6
>VOLTAGE
SHIELD
>CURRENT
SHIELD
902
724
72414
721
723
ATTACH TO FOOT OF T4
(2 PLACES)
KS2
120VAC
710
8
Parts
TO CC (TB1)
T4
506
72614
723
KS3
120VAC
725
720
7
13
719
532
Schematics
BRN
RED
507
VIO/WHT
508
BLK
VIO
725
TO N (TB1)
TO J4-4 ON PCB
727
719
13
727
728
14
4
8
KS4
120VAC
728
707
711
713
7
716
714
715
10
713
12
714
3
720
710
711
712
KS4
11
715
716
7
8
9
10
11
12
13
14
15
16
PRIMARY
> POWER
INTERNAL
> REMOTE
X2
X3
X4
X5
X6
C
H1
W
B
514-RED
C1
515-WHT
3
2
1
C2
Cx
64
REVISION DESCRIPTION
4
5
7
6
513-RED
17DEC07
12MAR07
BE
BE
CMS 29NOV06
18JUN08
302
COMMAND
> ON
>SAMPLING
LC
X
H2
H3
H4
H5
H6
SAMPLE
> GATE
VOLTS
208
220
230
240
250
CONNECT
X2 TO H2
X3 TO H3
X4 TO H4
X5 TO H5
X6 TO H6
Y
K
FB1
FB2
Z
J8-1
J8-2
H
(SMALL)
L SCR
(LARGE)
Y
300
J
PREVIOUS SCR WIRING:
SCR 28A0028, 7.5 - 30KW,
208-480V
301
G
4K
7K
5G
6G
DRAWING TITLE:
35A0539 COLORS SHOWN,
SEE 240V INPUT FOR 35A0546 COLORS
11
2
6
509
526
531
12
KS3
3
503
WHT/BLK
709
708
718
RED
RED/WHT
KS2
12
13
8
WHT/BRN
TBS4
4
4
(T4) - 480 VAC INPUT
512-WHT
W
709
726
COPPER BAR JUMPER
C
A
X1
303
712
F3
105
707
13
WIRE #531 MUST BE TIED TO VIO (OR RED)
WIRE - NOT TO ANOTHER GND.
502
12
(RED)
TO CCI (TB1)
F4
KS1
REV.
721
8
Z
VIO
(BLK)BLK
526
531
708
TITLEBLOCK UPDATE
KS1
120VAC
W
72214
SEE ECO-1767.
722
X
TO F5
SEE ECO-1860 (DPM & SNUBBER CHG'S)
(BRN)
509
Y
508
AIRFIELD LIGHTING COMPUTER SYSTEM
L-828 WURC, 4-30KW, 6.6 & 20AMP,
SIGNATURE SERIES FERRO CCF
WIRING DIAGRAM
2 OF 2
VIO/WHT
717
(WHT)
WHT/BLK
PREVIOUS 4KW SCR WIRING (28A0011)
- TEST AT 240V, THEN ADJUST TAPS TO SPEC'D VOLTAGE.
104
4
301
(BLU)
717
(BLK)BRN
300
507
503
514-RED
RED
- MULTI-TAP INPUT VOLTAGE SPEC'D BY SALES DEPT.
TERMINAL BLOCKS 11-16 NOT USED.
515-WHT
(ORG)
513-RED
532
RED/WHT
512-WHT
(BLU)
SEE ECO-1947 (SCR COLOR CODE CHG)
NOTE: FOR 94A0335/JFK SMI KIT: KS3 & KS4 NOT USED;
506
RED
718
Parts
F3
REFERENCE NOTES:
(XXX)
T4
(WHT)
WHT/BRN
303
502
35A0546 COLORS
302
240 VAC INPUT
F4
(T1): 7.5KW MULTITAP 35A0636
SMI & SMR OPTIONS
35A0539 COLORS
BE
REV'S A - H SUPPLY TX LEAD COLORS
ECO-01463
Operation
T8 = 5000V/50V
T7 = 6.6A/0.13A
RS1-4 = 180 OHM
RS5 = 500 OHM
AB
TB1
TBS4
WHITE
TITLEBLOCK UPDATE
RELAY/LOAD_SELECT
UCONNECTIONS TO DPM
1/2A
761
RS4
CLOSED @
FS1
S1 S2
TB3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
-
Raw V+
Raw VGND
GND
115VAC
115VAC
V Sig1
V Sig2
l Sig1
lSig2
Sig Amp
TB2
1
2
3
4
5
6
7
8
9
10
11
12
536
537
539 (TB1-NEU)
V
GND
538 (F5)
K1-COM
>.5A
K1-NO
K2-COM
2.8A (S1)
K2-NO
K3-COM
3.4A (S2) +V Out 1
K3-NO
-V Out 2
K4-COM
4.1A (S3) +l Out 3
K4-NO
-l Out 4
K5-COM
5.2A (S4)
GND 5
K5-NO
K6-COM
6.6A (S5)
K6-NO
K7-COM
LVA (LOW VA)
K7-NO
LOAD-SELECT-AC2
LOAD SELECT (120V)
LOAD-SELECT-AC1
H1(601)
611
T7
EARTH GND
120V
755
610
611
801
ASSEMBLY NOTES:
1) ADD APPROPRIATE JUMPER WHERE REQUIRED
(ONLY 1 JUMPER REQ'D FOR A 6.6A, 5-STEP).
TIE ALL JUMPERS INTO CABLE HARNESS SO
CONNECTOR HAS TO BE PULLED FROM PCB
WHEN REPLACING PCB.
2)
GROUNDING NOTES:
- GND EACH PANEL TO THE FRAME
- JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG
145
P2
REV
LEVEL
800
OPTIONAL VOLTMETER
T8
VR5
AB
205
Introduction Installation
Schematics
207
VR3
(NOTE 3, PG. 2: PROD. ONLY)
VR6
6. IF A JUMPER IS REQUIRED FOR ANY CORE LEAD,
USE HIGH VOLTAGE 89A0086/1 WIRE.
VR2(TB2-2)
43A2522
VR4
5. DELETED.
SMR OPTION
MICROSWITCH
WIRING - SEE
DETAIL "A",
PG.1
DRAWING NUMBER:
206
501C
VR2
4. USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK.
01SEP09
204
T6
209
BAR
2
DRAWN DATE:
203
3. SEE BILL OF MATERIALS FOR NUMBER OF MOV's OR
SURGE SUPPRESSORS IN EACH LEG.
10 MAY 01
203
TO
AIRFIELD
610
H1
6.6A = 35A0493
20A = 35A0528
208
VR1
200
H1
1
707-728: SCANNING MONITOR INTERFACE, 18AWG, 600V, 89A0182/9
750-758: SCANNING MONITOR READY, 22AWG 2 COND SHLD, 89A0126
760-762: SCANNING MONITOR READY, 18AWG, 600V, 89A0182/9
800-804: GROUND, 12AWG, 600V, GN/YL, 89A163/5.
900-905: GROUND, 18AWG, 600V, GN/YL, 89A0163/7.
DRAWN BY:
202
0
211
Safety
200
21
612
35A0346
TB2
OPTIONAL
SCO
ATTACH "OUTPUT" TAG - 2 PLC.S
H2
T7
600-: HI-VOLTAGE, 8AWG, 7.5KV, 89A0202:
OBSOLETE - USE "200" SERIES WIRE.
ADB Airfield Solutions
977 Gahanna Parkway, Columbus, Ohio 43230
Telephone: 614-861-1304, Fax: 614-864-2069
14 AWG
89A0184/9
REV
DATE
8 AWG
89A0196/9
26MAY09
8 AWG
89A0196/9
DRAWN
BY
8 AWG
89A0196/9
REVISION DESCRIPTION
7.5 kW
ECO-2306: ADDED SCO MICROSWITCH WIRING BE
8 AWG
89A0196/9
AA
7.5 kW
REV
LEVEL
14 AWG
89A0184/9
REV
DATE
14 AWG
89A0184/9
05SEP06
14 AWG
89A0184/9
BE
14 AWG
89A0184/9
PRIM.
211
536
480 V
347V
4 kW
BE
210
SEC.
240 V
220 V
10 AWG
89A0195/9
ASSOCIATED DRAWINGS:
537
208 V
POWER
4 kW
94A0463/X
H2
501B
Table of
Contents
OUTPUT NOTE:
OUTPUT CONNECTIONS
ON VR1AND VR2 UNLESS
TERMINAL BLOCKS OR
"SCO" IS USED.
100 SERIES WIRES - PRIMARY POWER - 600V - 105°C
ALL
DRAWN
BY
POWER
INITIAL & DATE:
DIGITAL POWER METER OPTION
2. WIRE SIZES:
100-105: PRIMARY POWER, SEE TABLE.
200-213: HIGH VOLTAGE, 12AWG, 25KV, 150C, 89A0086/1.
300-305: TANK LOOP, SEE TABLE.
400-409: MEDIUM CURRENT, 12AWG, 600V, 105C, 89A0185/9
500-535: STD CONTROL, 18AWG, 600V, 105C, 89A0182/9.
All information contained herein, including illustrations,
specifications, and dimensions, is believed to be reliable as of the
date of this publication, but is subject to change without notice.
ADB reserves the right to make changes and improvements to
its products and assumes no responsibility for these modifications.
Any disclosure of this information is strictly prohibited except as
ADB Airfield Solutions may otherwise agree to in writing.
Copyright © 2009 ADB Airfield Solutions.
300 SERIES WIRES
TANK LOOP
600V - 105°C
CONTROLLED COPY
NOTES:
1. WIRE NUMBERS REASSIGNED AT THE CREATION OF
THIS DOCUMENT.
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
L-828 WURC, 4-30KW, 6.6 & 20AMP, 2 of 2
RS1
Disclaimer
Figure 43:
96A0288 Rev. W
6/9/11
© 2010 ADB Airfield Solutions All Rights Reserved
96A0288 Rev. W
6/9/11
50 & 70KW FERRO CCF, 20 A, 1 of 1
Disclaimer
Figure 44:
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Schematics
IMPORTANT! KEEP WIRES (100's & 300's) AWAY FROM CORE!
401
F3
RED/BLK
GRN/YEL
T1
202
P2
201 (202)
POS. CURRENT
FEEDBACK SENSOR
OPTION
(#53A0283)
T5 - 35A0528
VR2
T2
S2
S1
SEE NOTE #5
532
506
VIO
507
BLK
BRN
508
902
524
VR4
BLU
526
531
524
525
F8 505
Table of
Contents
TO
AIRFIELD
MICROSWITCH
WIRING - SEE
DETAIL "A";
BELOW
VR3
(NOTE 12
- PROD. ONLY)
VR5
VR6
800
(300-303 = 2 RUNS EACH AS SHOWN)
(.5A, 250V, SLO-BLO; 47A0119)
210
OPTIONAL
SCO
201
35A0308 P1
506
503
2
VR1
501C
L
METER
OPTION
NOTE
#2
RED
204
211
207
11
50KW, 480VAC (3 BANKS)
- SEE NOTE 13
204
1
Safety
U480 VAC INPUT
T4 GRY
BLK
1&7
L1
6
20A SHUNT POS. IS "MID"
(DO NOT USE SHUNT FOR 6.6A)
209
502
309
(310)
501A
TB2
205
208
F4
COM
94A0358 KIT
ATTACH "OUTPUT" TAG - 2 PLC.S
206
NO
TB1-GND
804
550
OPT. DOOR-SW
501
F5
TB1-NEU
904
551
501B
SEE DETAIL"A"
527
528
Installation Introduction
Schematics
VR7 VR8
400
SCO OPTION
501/501C 501C
403
803
802
402
531
A2
301
307
308
-1
-2
-3
DANGER:
LETHAL VOLTAGES
ARE PRESENT
35A0308
(20:6.6A)
525
K2
J5
523
303
103
6
302
5
A1
GRY
BLU
200
0
40
T9
CONTROL
WINDINGS
IRMS-OUT(FIBER CABLE)
IRMS-IN (FIBER CABLE)
2
101
101
40
3
L4
CVM
213
522
8
9
J4
ST1
F2
102
103
300
SEE NOTE # 11
201
IRMS
J3
ST1
203
102
5
ST4 ST3 ST2
ST3
ST
4
L3
B1
S2
P2
4
804
2
3
L2
ST1
1
B2
B3
NOTE: LAND ALL CAP B4
BANK WIRES AS CLOSE
AS POSSIBLE TO THE
CENTER OF THE CAP
BANK.
1
40
203 (212)
3
ST2
100
402
304
ST3
100
ST4
F1
200
S1
P1
305
70KW, 480VAC
(4 BANKS)
INPUT
OUTPUT NOTE:
OUTPUT CONNECTIONS ON VR1
AND VR2 UNLESS TERMINAL
BLOCKS OR "SCO" IS USED.
ST4
212
50KW CORE
306
501B
(311)
801
509
NOTE #5
505
5
3
2
1
8
7
5
6
J7
1
J6
800-803: GROUND, 12AWG, 600V, GN/YL, 89A163/5.
1
L4
CONTROL
WINDING
T1
70 kW
2/0 AWG
89A0231
208
2
OPTIONAL
SCO
J4
4
1
2
3
J1
4
5
6
1
2
3
4
5
6
7
8
ACE/CVM
CONNECTIONS
-SEE WIRING DIAGRAMS:
#43A2550 FOR ACE1
#43A3128 FOR ACE2
F6 = .5A, 250V, SLO-BLO (47A0119)
TO TB1-NEU
K2
PUR
ORG
G2
303
302
ADD 72A0019
FORK TERM.
70A0596;
MALE FASTON
TERM.
REPLACE FORK TERM.
ON HARNESS W/FEM.
FASTON TERM.
70A0279
3
POWER WIRE KIT, FERRO CCR
WIRING DIAGRAM, ACE1 TO URCII/1 PCB
43A3128
WIRING DIAGRAM, ACE2 TO URCII/1 PCB
DOC. NO.
DESCRIPTION
RELATED DOCUMENTS
© 2010 ADB Airfield Solutions All Rights Reserved
TB1
512-WHT
513-RED
5 STEP WIRING
(3 STEP CONN'S IN ( )'s)
Parts
903-ACE PS
904-IRMS
535-ACE PS
550
905
551
516
519
518
520
521
517
N/C
N/C
F6
PCFS
PCFS
94A0338/X48X
43A2550
515-WHT
511
WIRE HARNESS, CCF 50/70, W/ACE
N/C
44A6504/2
S1
S2
CCI
CC
B1 (B10)
B2 (B30)
B3 (B100)
B4
B5
NEU
WIRE HARNESS, CCF 50/70, W/O ACE
534-ACE PS
APPROVED BY:
514-RED
44A6504/1
CONTROLLED COPY
Unauthorized duplication of this document in whole or part is prohibited. Initialed in
RED ink below indicatesauthorized copy.
DATE:
SIEMENS AIRFIELD SOLUTIONS, INC.
977 Gahanna Parkway, Columbus, Ohio 43230
Telephone: 614-861-1304, Fax: 614-864-2069
E
02306
ADDED SCO SWITCH WIRING
BE
27MAY09
D
01947
NEW SCR WIRE COLOR CODE BE
19JUN08
C
01767
VAR & ACE NOTE CHG.S
BE
14MAR07
DRAWING TITLE:
B
01463
TERM. BLK MARKING CHG.
BE
05SEP06
A
-----
PRODUCTION RELEASE
BE
18APR05
REV LEVEL
ECO NUMBER
DRAWN BY
REV
DATE
WIRING DIAGRAM, L-828 W/URC,
50 & 70KW FERRO CCF,
20 AMP, SIGNATURE SERIES
ASSOCIATED DRAWINGS:
REVISION DESCRIPTION
DRAWN BY:
DRAWN DATE:
BE
22FEB05
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
Siemens Airfield Solutions, Inc. may otherwise agree in writing. Copyright Ó 2001 Siemens
Airfield Solutions, Inc.
Schematics
PREVIOUS 28A0028
COLOR CODING:
533
72A0071 TERM. BLK.: 50 in-lb.s
XCP
N
GND
72A0017 TERM. BLK.: 35 in-lb.s
COPPER BAR JUMPER
526 - T4
TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKER - AS
LISTED ON COMPONENT LABEL.
528 - IRMS
YEL
K1
BLU
G1
2
J2
3
521
NOTE 10
526
511
(300-303 = 2 RUNS EACH AS SHOWN)
2
TO
AIRFIELD
70A0279 TERM.
(2 PLC.S)
501C - TO K2-A2
3
501/501A
J3
1
1/0 AWG
89A0201/9
209
518
L
DETAIL"A"
480V
50 kW
ASSY. NOTE #7
1
SCR #
28A0028
POWER
1
504
10
J5
6
NOTE 10
309 & 310
302
303
4
5
3-STEP
JUMPER
523
1&6
L1
5
44A6035/1
URC II PCB ASSY.
3
ALWAYS USED
519
307 & 308
8
7
301
ASSEMBLY NOTES:
1) WIRE NO.S REASSIGNED AT THE CREATION OF THIS DOC.
2) GROUND TO FOOT OF TRANSFORMER.
3) ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING.
4) WIRE #531 MUST BE TIED TO BLU WIRE - NOT TO ANOTHER GND.
5) ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES.
6) DELETED.
7) ADD APPROPRIATE JUMPER WHERE REQ'D (TIE ALL JUMPERS INTO CABLE
HARNESS SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB.
8) GROUNDING NOTES:
- GND EACH PANEL TO THE FRAME
- JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG.
9) ROUTE THESE WIRES ALONG TOP SIDE & LEFT SIDE OF PCB TO CONNECT TO J3.
10) IF A JUMPER IS NEEDED FOR ANY CORE LEAD, USE HIGH VOLTAGE 89A0086/1 WIRE.
11) SEE BILL OF MATERIALS FOR NUMBER OF MOV'S OR SURGE SUPPRESSORS IN EA. LEG.
12) USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK.
2
520
103
300 & 301
ALWAYS USED
522
300
70KW CORE
102
100 SERIES WIRES
PRIMARY POWER
600V - 105°C
1
4
L3
3 201
L2
Operation
203 (212)
2
900-905: GROUND, 18AWG, 600V, GN/YL, 89A0163/7.
516
306 & 311
500-562: STD CONTROL, 18AWG, 600V, 89A0182/9.
IF "KEYED" MATING CONN. IS USED,
PIN #1/RED STRIPE IS ON THE RIGHT SIDE
(SAME FOR ROTARY SWITCH CONN.).
1
304 & 305
(300-303 = 2 RUNS EACH AS SHOWN).
400-403: MEDIUM CURRENT, 12AWG, 600V, 105C, 89A0185/9.
Parts
TO IRMS
300-311: TANK LOOP & CAPS, 2 AWG, 600V, 105C, 89A0199/9,
IF "UN-KEYED" MATING CONN. WAS USED,
PIN #1/RED STRIPE IS ON THE LEFT SIDE
(SAME FOR ROTARY SWITCH CONN.).
PUR
ORG
527
200-213: HIGH VOLTAGE, 12AWG, 25KV, 150C, 89A0086/1.
1
COM
510
2
NC
NO
=.5A, 250V, SLO-BLO (47A0119)
BLU
YEL
F5
3
J8
510
509
4
501B
NOTE #4
4
501
504
MICROSWITCH
=.5A, 250V, SLO-BLO (47A0119)
532
F7
517
508
522
ROTARY SWITCH
CONNECTION
NOTE #2
WIRE SIZES:
102-103: PRIMARY POWER, SEE TABLE.
523
RED
507
NOTE #3
SCALE:
N/A
SHEET NUMBER:
DRAWING NUMBER:
43A2522/5070
1 OF 1
REV.
E
65
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Schematics
2400 Vac Schematic page 1 of 2
IMPORTANT! KEEP WIRES (100's & 300's) AWAY FROM CORE!
104
K2
101
105
105
103
702B
702
SEE DETAIL"A"
B2
(REF: 3 METAL JUMPERS)
10-30 KW, 2400V
305
T1
304
3
L2
VACUUM CONTACTOR
VR1
203
4
L3
B1
SEE NOTE # 9
5 201
103
NOTE: LAND ALL CAP
BANK WIRES AS CLOSE
AS POSSIBLE TO THE
CENTER OF THE CAP
BANK.
ATTACH "OUTPUT" TAG - 2 PLC.S
203
102
CONTROL
WINDINGS
523
201
1&7
L1
6
300
307
308
T2
11 L
T1
SEE NOTE 10
107
202
P1
205
205
202
P2
S2
S1
METER
301
NOTE 3
204
204
522
8
L4
9
902
524
TO
AIRFIELD
NOTE 3
6.6A = 35A0548
20A = 35A0528
(NO GND REQ'D)
T5
801
800
Safety
VR8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
702C
SCO
100
102
702 / 702C
703
OPTIONAL
VR7
104
Table of
Contents
2400V
INPUT
CAP BANK PLATE ASSY. # PER
KW SIZE:
10KW = 44A6483/09
20KW = 44A6483/18
30KW = 44A6483/09 &
44A6483/18
VR2
702C
SCO OPTION
MICROSWITCH
WIRING - SEE
DETAIL "A"
702B
106
525
Disclaimer
Figure 45:
96A0288 Rev. W
6/9/11
524
525
SEE NOTE #5
T3
701
701
F7
503
T4
BLK
JUMPER
BRN
BRN
F8
=.5A, 250V, SLO-BLO (47A0119)
508
5
509
RED
BLU
532
52
6
NOTE #2
3
2
1
8
7
6
5
1
510
F5
=.5A, 250V,
SLO-BLO (47A0119)
4
3
2
1
205
J8
J7
703
NOTE #5
4
9
NOTE 4
204
IF "UN-KEYED" MATING CONN. WAS USED,
PIN #1/RED STRIPE IS ON THE LEFT SIDE
(SAME FOR ROTARY SWITCH CONN.).
J6
1
IF "KEYED" MATING CONN. IS USED,
PIN #1/RED STRIPE IS ON THE RIGHT SIDE
(SAME FOR ROTARY SWITCH CONN.).
1
20 AMP JUMPER
2
3
ALWAYS USED 4
2
J4
4
4
5
6
7
8
521
3
518
2
519
1
520
6
516
5
WHT 512
4
RED 513
3
RED 514
511
2
514-RED
515-WHT
6
4
5
RED-513
Parts
7
WHT-512
300
Parts
WHT 515
1
526
2
J1
J2
3
510
2
517
J3
1
3
100's: PRIMARY POWER, 8AWG, 40KVDC, 150C, WHT, 89A0087/1.
SCR #
28A0037
COPPER BAR JUMPER
200-213: HIGH VOLTAGE, 12AWG, 25KV, 150C, WHT, 89A0086/1.
CONTROLLED COPY
300's: TANK LOOP & CAPS: 10KW = 8 AWG, 600V, 105C, BLK, 89A0196/9;
Unauthorized duplication of this document in whole or part is prohibited. Initialed in
RED ink below indicatesauthorized copy.
15-30KW = 2 AWG, 600V, 105C, BLK, 89A0199/9.
APPROVED BY:
POWER WIRE KIT, FERRO CCR, 2400V
DESCRIPTION
RELATED DOCUMENTS
66
TB1
WIRE HARNESS, CCF, 2400V, 10-70KW, W/O ACE
TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKER - AS
LISTED ON COMPONENT LABEL.
72A0017 TERM. BLK.: 35 in-lb.s
72A0071 TERM. BLK.: 50 in-lb.s
(5-STEP WIRING SHOWN)
(3-STEP CONNECTIONS IN ( )'s )
526
516
519
518
520
N/C
521
511
900's: GROUND, 18AWG, 600V, GN/YL, 89A0163/7.
517
N/C
800's: GROUND, 12AWG, 600V, GN/YL, 89A0163/5.
N/C
700'S: HIGH VOLTAGE, 18AWG, 15KV, WHT, 89A0280.
S1
S2
CCI
CC
B1 (B10)
B2 (B30)
B3 (B100)
B4
B5
NEU
Schematics
500's: STD CONTROL, 18AWG, 600V, WHT, 89A0182/9.
DOC. NO.
REPLACE FORK
TERM.
ON HARNESS W/FEM.
FASTON TERM.
70A0279
JUMPERS - SEE
ASSY. NOTE #7
6
3
702
WIRE SIZES:
94A0502/XX
70A0596;
MALE FASTON
TERM.
1
508
1
44A6799
TO
AIRFIELD
70A0279 TERM.
(2 PLC.S)
ADD 72A0019
FORK TERM.
44A6035/1
URC II PCB ASSY.
J5
5
3-STEP JUMPER
301
Operation
ASSEMBLY NOTES:
1) SOME WIRE NO.S REASSIGNED AT THE CREATION OF THIS DOC.
2) GROUND TO FOOT OF TRANSFORMER.
3) ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING.
4) WIRE #703 MUST BE TIED TO BLU WIRE - NOT TO ANOTHER GND.
5) ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES.
6) DELETED.
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:
- GND EACH PANEL TO THE FRAME
- JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG.
9) IF A JUMPER IS NEEDED FOR ANY CORE LEAD, USE HIGH VOLTAGE 89A0086/1 WIRE.
10) USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK.
11) GROUND EACH PANEL TO THE FRAME.
OPTIONAL
SCO
COM
BLK
(2400/120V)
ROTARY SWITCH
CONNECTION
NC
NO
VIO
702B
GRN/YEL
RED
702
502
MICROSWITCH
F6
906
X1
700
522
H1
700
532
F1
523
RED/BLK
107
DETAIL"A"
GRY
GRY
702C - TO K2-1
X2
906
F2
H2
NOTE #2
VIO
106
120 VAC INPUT
50
Introduction Installation
Schematics
F6,F7 = 2A 250V SB
DATE:
SIEMENS AIRFIELD SOLUTIONS, INC.
977 Gahanna Parkway, Columbus, Ohio 43230
Telephone: 614-861-1304, Fax: 614-864-2069
BE
14OCT10
B
2144
SEE ECO
BE
26MAR09
A
C
-----
2726
PRODUCTION RELEASE
BE
21NOV07
REV LEVEL
ECO NUMBER
DRAWN BY
REV
DATE
ASSOCIATED DRAWINGS:
SEE ECO
REVISION DESCRIPTION
DRAWN BY:
DRAWN DATE:
BE
20NOV07
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 Siemens
Airfield Solutions, Inc. may otherwise agree in writing. Copyright Ó 2007 Siemens Airfield
Solutions.
DRAWING TITLE:
WIRING DIAGRAM, L-828 W/URC,
10-30KW FERRO CCF, 2400V, 6.6
& 20A, 3/5-STEP, SIGNATURE SERIES
SCALE:
SHEET NUMBER:
N/A
DRAWING NUMBER:
43A3403
1 OF 1
REV.
C
© 2010 ADB Airfield Solutions All Rights Reserved
96A0288 Rev. W
6/9/11
2400 Vac Schematic page 2 of 2
Disclaimer
Figure 46:
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Schematics
IMPORTANT! KEEP WIRES (100's & 300's) AWAY FROM CORE!
VACUUM
CONTACTOR
102
300
522
8
L4
9
201
202
P1
SEE NOTE 10
204
204
523
308
309
203
CONTROL
WINDINGS
1&7
L1
6
301
307
SEE NOTE # 9
11 L
T1
107
S2
S1
METER
NOTE 3
205
202
205
P2
T2 - 35A0308
T5 - 35A0528
902
524
VR2
NOTE 3
Table of
Contents
L3
5 201
103
NOTE: LAND ALL CAP
BANK WIRES AS CLOSE
AS POSSIBLE TO THE
CENTER OF THE CAP
BANK.
VR1
4
B1
TO
AIRFIELD
MICROSWITCH
WIRING - SEE
DETAIL "A"
Safety
B2
801
800
VR8
B3
524
525
SEE NOTE #5
Installation Introduction
Schematics
105
103
3
L2
SEE DETAIL"A"
SCO
105
203
OPTIONAL
K2
101
304
(REF: 3
METAL
JUMPERS)
ATTACH "OUTPUT" TAG - 2 PLC.S
305
702
702C
104
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
702B
702B
104
100
102
702C
303
VR7
SCO OPTION
702 / 702C
703
50KW CORE
(35A0671)
306
302
2400V
INPUT
50KW, (3 BANKS)
(1) 44A6483/26 CAP BANK ASSY.
(1) 44A6483/13 CAP BANK ASSY.
525
106
(300-303 = 2 RUNS EACH AS SHOWN)
T3
701
701
F7
503
BLK
T4
=.5A, 250V, SLO-BLO (47A0119)
508
5
9
509
BLU
NOTE #2
3
2
1
8
7
6
5
J7
703
RED
4
50
NOTE 4
F5
=.5A, 250V, SLO-BLO (47A0119)
532
J6
526
3
2
1
205
J8
IF "UN-KEYED" MATING CONN. WAS USED,
PIN #1/RED STRIPE IS ON THE LEFT SIDE
(SAME FOR ROTARY SWITCH CONN.).
1
510
4
1
2
3
ASSEMBLY NOTES:
4
1) SOME WIRE NO.S REASSIGNED AT THE CREATION OF THIS DOC.
2) GROUND TO FOOT OF TRANSFORMER.
3) ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING.
4) WIRE #703 MUST BE TIED TO BLU WIRE - NOT TO ANOTHER GND.
5) ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES.
6) DELETED.
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:
- GND EACH PANEL TO THE FRAME
- JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG.
9) IF A JUMPER IS NEEDED FOR ANY CORE LEAD, USE HIGH VOLTAGE
89A0086/1 WIRE.
10) USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK.
11) GROUND EACH PANEL TO THE FRAME.
70A0279 TERM.
(2 PLC.S)
IF "KEYED" MATING CONN. IS USED,
PIN #1/RED STRIPE IS ON THE RIGHT SIDE
(SAME FOR ROTARY SWITCH CONN.).
1
JUMPERS - SEE
ASSY. NOTE #7
5
6
ADD 72A0019
FORK TERM.
44A6035/1
URC II PCB ASSY.
J5
TO
AIRFIELD
70A0596;
MALE FASTON
TERM.
REPLACE FORK TERM.
ON HARNESS W/FEM.
FASTON TERM.
70A0279
1
2
3
J4
4
303
100's: PRIMARY POWER, 8AWG, 40KVDC, 150C, WHT, 89A0087/1.
4
5
6
7
Parts
3
8
521
2
518
1
519
6
520
5
516
WHT-515
4
6
4
5
WHT-512
SCR #
28A0037
Parts
7
3
WIRE SIZES:
3
514-RED
515-WHT
RED-513
302
300
301
2
2
RED-514
1
526
1
J1
J2
3
510
2
511
1
517
J3
U(300-303 = 2 RUNS EACH AS SHOWN)
RED-513
702
WHT-512
508
COPPER BAR JUMPER
200-213: HIGH VOLTAGE, 12AWG, 25KV, 150C, WHT, 89A0086/1.
CONTROLLED COPY
Schematics
NOTE #5
F8
Operation
BRN
OPTIONAL
SCO
COM
BRN
204
NC
NO
BLK
(2400/120V)
ROTARY SWITCH
CONNECTION
702B
VIO
702
GRN/YEL
RED
MICROSWITCH
502
906
F6
522
X1
700
532
H1
700
523
F1
DETAIL"A"
GRY
GRY
JUMPER
RED/BLK
107
NOTE #2
702C - TO K2-1
X2
906
F2
H2
VIO
106
120 VAC INPUT
300's: TANK LOOP & CAPS, 2 AWG, 600V, 105C, BLK, 89A0199/9,
Unauthorized duplication of this document in whole or part is
prohibited. Initialed in RED ink below indicatesauthorized copy.
(300-303 = 2 RUNS EACH AS SHOWN).
94A0502/XX
DOC. NO.
POWER WIRE KIT, FERRO CCR, 2400V
DESCRIPTION
RELATED DOCUMENTS
© 2010 ADB Airfield Solutions All Rights Reserved
72A0017 TERM. BLK.: 35 in-lb.s
72A0071 TERM. BLK.: 50 in-lb.s
(5 STEP WIRING)
526
516
519
518
521
520
511
TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKER - AS
LISTED ON COMPONENT LABEL.
517
N/C
TB1
WIRE HARNESS, CCF, 2400V, 10-70KW, W/O ACE
S1
S2
CCI
CC
B1
B2
B3
B4
B5
NEU
800's: GROUND, 12AWG, 600V, GN/YL, 89A0163/5.
900's: GROUND, 18AWG, 600V, GN/YL, 89A0163/7.
44A6799
N/C
700'S: HIGH VOLTAGE, 18AWG, 15KV, WHT, 89A0280.
N/C
APPROVED BY:
500's: STD CONTROL, 18AWG, 600V, WHT, 89A0182/9.
DATE:
SIEMENS AIRFIELD SOLUTIONS, INC.
977 Gahanna Parkway, Columbus, Ohio 43230
Telephone: 614-861-1304, Fax: 614-864-2069
DRAWING TITLE:
B
2726
ADDED SCO SW WIRING
BE
20OCT10
A
-----
PRODUCTION RELEASE
BE
21NOV07
REV
LEVEL
ECO
NUMBER
DRAWN
BY
REV
DATE
ASSOCIATED DRAWINGS:
REVISION DESCRIPTION
DRAWN BY:
DRAWN DATE:
BE
20NOV07
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 Siemens Airfield Solutions, Inc. may otherwise agree in writing. Copyright Ó 2007
Siemens Airfield Solutions.
WIRING DIAGRAM, L-828 W/URC,
50KW FERRO CCF, 2400V, 5-STEP,
20A, SIGNATURE SERIES
SCALE:
N/A
SHEET NUMBER:
DRAWING NUMBER:
43A3403/5070
1 OF 1
REV.
B
67
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Schematics
LOCATE ON FRONT SIDE
OF PANEL
H2
526
X4
105
509
526
531
305
300
104
7
8
521
6
520
5
519
516
4
517
3
513-YEL
CONTROL
WINDINGS
B
C
512-BLU
5
4
6
7
1
528
(T1): 4-30KW, 480V,
CCF-2004 CORE
2
FB2
H4
Y
G
L
301
Z
FB1
H2
SCR
(LARGE) H
FB2
H4
Y
J8-1
J8-2
Y
1000
1000
806
806
NS
SC3-9
518S
516S
520S
CHASIS GND.
SEE 43A2616/5070 FOR 50 & 70KW WIRING.
ADB Airfield Solutions
977 Gahanna Parkway, Columbus, Ohio 43230
Telephone: 614-861-1304, Fax: 614-864-2069
INITIAL & DATE:
REV
DATE
20AUG07
BE
DRAWN
BY
27SEP07
REV.
SC4-7
SC4-8
REVISION DESCRIPTION
805
538
539
FAN NEUTRAL
TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKERAS LISTED ON COMPONENT LABEL.
72A0017 TERM. BLK.: 35 in-lbs
72A0071 TERM. BLK.: 50 in-lbs
72A0306/1 & /2 HARTING CONN'S: 48 in-lbs
68
DRAWN DATE:
FAN
537
SC (HARTING GND. PIN)
USE EXT. WASHER FIRST
OR GRIND PAINT OFF IN
CONNECTION AREA.
02NOV07 06 AUG 01
TO2
SC4-6
540
(NOTE 14)
Q
905
516
518
519
520
521
N/C
519S
XCPS
SC3-10
COMP. PANEL
GND LUG BOLT
ON BACK SIDE
X
Z
J8-1
J8-2
W
H3
SC3-6
H1
300
SC3-7
Z
SNUBBER ASSY.
#44A6149
DRAWING TITLE:
FB1
302
H2
LC
(SMALL) J
Z
SC3-5
K
X
SC3-4
105
(COMP. PANEL)
TO IRMS
T
302
521S
W
C
X4
SC3-3
Cx
105
SC3-2
X2
SC3-1
X4
TB1
5 STEP WIRING
(3 STEP CONN'S IN ( )'s)
B
NOTE:LAND
ALL
CAP
BANK
WIRES
ASCLOSE
AS
POSSIBLE
TOTHECENTER
OFTHECAP
BANK.
C2
517
28A0028 SCR: 7.5 - 30KW
(FOR 28A0011 (4KW) SEE PG. 2)
(FOR PREVIOUS SCR COLOR CODING SEE PG. 2)
904
Schematics
C1
C
H3
C
X3
517S
L
A
K
B
X2
H1
104 X1
511
(ST4 TO "C" W/6.6A CVM)
("C" TO T9 W/20A CVM)
("C" TO VR2 W/O CVM)
N/C
W
A
511S
L X3
N/C
W TO VR1
X1
T
2
S1
S2
CCI
CC
B1 (B10)
B2 (B30)
B3 (B100)
B4
B5
NEU
XCP
N
GND
Parts
NOT USED, INSULATE
1
COPPER BAR JUMPER
A
3
(T1): 4-30KW, 240V, CCF-2004 CORE
6
TO IRMS
BLU
5
526 - T4
RED
508
J1
4
300
BRN
T3
H1
X3
301
Parts
BLK
TO TB1-NEU
3
5000:1
507
VIO
PUR 514
RED
2
PUR 514
ORG 515
X1
X2
1
YEL 513
105
532
GRN/YEL
503
510
511
T1
J2
3
BLU 512
RED/BLK
104
506
GRY
2
300
T4
BLK
1
ORG 515
F3
502
J3
(T1) - 4-30 KW, 480V
ECO-1818: ADDED SCO OPTION
4
518
501
BNC
COMPONENT PANEL
(T4) - 480 VAC INPUT
ASSEMBLY NOTES:
1) ADD APPROPRIATE JUMPER WHERE REQUIRED (ONLY 1 JUMPER REQ'D FOR A
6.6A, 5-STEP). TIE ALL JUMPERS INTO CABLE HARNESS SO CONNECTOR HAS
TO BE PULLED FROM PCB WHEN REPLACING PCB.
2) USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK.
3) ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING.
4) WIRE #531 MUST BE TIED TO BLU WIRE - NOT TO ANOTHER GND.
5) ATTACH TO FOOT OF T4.
6) ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES.
**WIRE 400 & 401 TO TOP SIDE OF F3 & F4.
7) REMOVED - REV. U.
8) SEE BILL OF MATERIALS FOR NUMBER OF MOV's OR SURGE SUPPRESSORS
REQ'D IN EACH LEG.
9) GROUNDING NOTES:
- GND EACH PANEL TO THE FRAME
- JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG.
10) IF A JUMPER IS NEEDED FOR ANY CORE LEAD, USE HIGH VOLTAGE 89A0086/1 WIRE.
11) IF OUTPUT GOES THRU SGRS BAYS, USE 89A0087/1.
12) REFERENCE ASSY. DWG. 44A6292/1 FOR WIRE LUG ASSY.
13) FOR ICVM WIRING - SEE DWG. # 44A6687-XXX.
14) SEE "SYSTEM PACKAGE" FOR WIRING OF 44A6007/X HARTING "STAB" CONNECTOR.
R
J4
REV
LEVEL
2
REV
DATE
508
21FEB06
1
CONTROL
WINDINGS
B
C
3
F4
ST2
NOTE 1
A
BE
305
300
539
Operation
BLU
RED
H2 W/O CVM
6
509
526
531
GND TO FRAME USING
6AWG G/Y WIRE
DRAWN
BY
44A6035/1
URC II PCB ASSY.
J5
REVISION DESCRIPTION
4
5
3 STEP
JUMPER
MOVED SC3-8 WIRE TO F5 (ECO-01546)
FERRO
JUMPER ALWAYS USED
H1
M
508
REV
LEVEL
507
BRN
DANGER:
LETHAL VOLTAGES
ARE PRESENT
V
VIO
3
43A2616
RED
BLK
2
HV-SC2
NOTE 11
1001
1
20 AMP
JUMPER
209
DRAWING NUMBER:
503
H2
X2
105
VR2
CVM
HV-SC1
SEE ECO's - 1832/1833.
X1
532
203
ST1
208
S
506
GRY
GRN/YEL
ST4 ST3 ST2
VR1
ST1
BLK
RED/BLK
T1
IF "KEYED" MATING CONN. IS USED,
PIN #1/RED STRIPE IS ON THE RIGHT SIDE
(SAME FOR ROTARY SWITCH CONN.).
ST2
502
104
202
ST1
ST3
T4
S2
ST2
ST4
F4
1
(T1) - 4-30 KW, 208V
S1
OPTIONAL SCO WIRING:
BE
J6
T9
35A0308
(20:6.6A)
DRAWN BY:
523
1
IF "UN-KEYED" MATING CONN. WAS USED,
PIN #1/RED STRIPE IS ON THE LEFT SIDE
(SAME FOR ROTARY SWITCH CONN.).
1
SC3-8
H2
2
300 SERIES TABLE CLARIFICATION
TO IRMS
3
T
4
J8
CMS 08AUG06
5
TITLEBLOCK UPDATE
6
O
7
12JUN08 BE
8
522
507
1
BE
508S
2
J7
SEE ECO's 1851, 1947 AND 1968
527
3
ST3
NOTE 4
4
NOTE 8
U
5
510
208
509
P2
P1
ST4
Introduction Installation
Schematics
F5 = .5A, 250V, SLO-BLO (47A0119)
NOTE 5
801
20A CVM WIRING
ROTARY SWITCH
CONNECTION
(T4) - 347 VAC INPUT
VR5
800
526
531
BLU
VR3
VR6
509
RED
F3
SC5-6
*DIGITAL PWR METER
OPTION
508
BRN
BLK
NOTE 6
NOTE 9
VR4
(NOTE 14) SC5-5
507
VIO
RED
20A = 35A0528
*DPM OPTION
29AUG06
503
524
HV-SC2
BE
532
VR2
6.6A = 35A0493
21APR06
(TO STAB CONN)
NOTE 14
SC5-1
524
SC5-7
525
506
GRY
GRN/YEL
203
UPDATED TERM. BLK. WIRING (ECO-1671)
F3
NOTE 5
T4
BLK
RED/BLK
203
H1(601)
T6
S2 902
BE
T2
HV-SC1
P
401
NOTE 8
502
6.6A = 35A0548
20A = 35A0528
NO GND REQ'D
REVISED DPM OPTION WIRING (ECO-01571)
P2
N
P1
VR1
ASSOCIATED DRAWINGS:
LG. INDUCTOR (L)
201
202
ST1
T5
H1
PG. 1 OF 2
ANALOG
METER
OPTION
(L-828)
X2
NOTE 11
200
V
803
Safety
F4
400
SC5-11
(FIBER CABLE)
S1
VR7 VR8
(NOTE 14)
SC5-12
804
13APR09
SM. INDUCTOR (L3)
X1
301
501
35A0346 OR
61A0317 (/30)
BAR
TO1
535
TB1-GND
*INSULATORS REQ'D FOR
30KW, 6.6A CVM ONLY
CVM-1
GRY
TB1-NEU
904
TITLEBLOCK UPDATE
536
35A0539/546; REV. C, SAME COLORS
(SEE PG. 2 FOR PREVIOUS REV.S)
208/240 VAC INPUT
802
SC2-1 SC2-6
COM1
CONTROL
WINDINGS
F5
528
20MAR07
NO1
X2
A
B
C
J5
BE
534
305
300
GRY
BLU
VAR & DPM UPDATES (ECO-1767)
DOOR SWITCH
534
X1
304
IRMS-OUT (FIBER CABLE)
(FIBER CABLE)
IRMS-IN
PRIM.
6.6 & 20A, 4-30KW
FERRO SGRS POWER PACK
WIRING DIAGRAM
A2
304
J4
DANGER:
LETHAL VOLTAGES
ARE PRESENT
SEC.
204
SC1-2
89A0171
SEE PG. 2 FOR "DOOR NOT CLOSED" INDICATOR WIRING
105
K2
A1
531
402
403
6
X4
527
205
400
3
4
X3
Cx
-1
-2
-3
206
40
3
5
C2
532
2
401
104
IRMS
J3
207
103
2
6.6A WIRING: SEE
BELOW FOR 20A
CVM
T7
OPTIONAL
SCO
101
402
1
ICVM OPTION:
SEE NOTE 13
522
102
NOTE 10
H1
ST1
506
701
CB1
100
X2
525
1
ST4 ST3 ST2
C1
*DPM OPTION
200
305
NOTE 2
ACE CVM & IRMS Options
H2
804
Table of
Contents
TB3
700
T1
X1
523
SC1-1
105
ST2
NOTE: LAND ALL CAP
BANK WIRES AS CLOSE
AS POSSIBLE TO THE
CENTER OF THE CAP BANK.
TORQUE = 5-6 NM (2 PLC.S)
ST1
104
BE
ST4 TO H2 W/ CVM
4-30 KW, 240V
All information contained herein, including illustrations,
specifications, and dimensions, is believed to be reliable as of the
date of this publication, but is subject to change without notice.
ADB reserves the right to make changes and improvements to
its products and assumes no responsibility for these modifications.
Any disclosure of this information is strictly prohibited except as
ADB Airfield Solutions may otherwise agree to in writing.
Copyright © 2009 ADB Airfield Solutions.
CONTROLLED COPY
IMPORTANT! SEE NOTE 12 FOR
SC1-1 & 2 INPUT WIRE LUG ASSEMBLY.
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
PPF Powerpack schematic 4-30 kW 1 of 2
ST4
Disclaimer
Figure 47:
96A0288 Rev. W
6/9/11
© 2010 ADB Airfield Solutions All Rights Reserved
96A0288 Rev. W
6/9/11
15 kW
2AWG
89A0199/9
15 kW
6AWG
89A0197/9
20 kW
6AWG
89A0197/9
20 kW
2AWG
89A0199/9
20kW
TBD
6AWG
89A0197/9
30 kW
2AWG
89A0199/9
30kW
WIRING DIAGRAM, SGRS 50 & 70KW
FERRO SGRS WIRE HARNESS, 4-30KW, 6.6 & 20A
509
94A0368/1
POWER WIRE KIT, FERRO SGRS, 4KW
526
531
94A0368/2
POWER WIRE KIT, FERRO SGRS, 7.5 & 10KW
94A0368/3
POWER WIRE KIT, FERRO SGRS, 15KW
94A0368/4
POWER WIRE KIT, FERRO SGRS, 20 & 30KW
DESCRIPTION
PREVIOUS "MOLDED" STYLE CVM WIRING
514
515
ADD WIRES 541 & 542.
1
0
60
ACE Potted CVM/IRMS Options
Use wrench to hold RES when
attaching wires
529
530
CVM
TB1-L2
(T2/T3 and meter not used)
GRY
CVM-1
200/201
Q
(FIBER CABLE)
T
2
600
H2
F6
3
REV.
PREVIOUS SCR WIRE COLOR CODING
Disclaimer
Schematics
536
NO1
4
5
7
6
CMS 08AUG06
513
Use wrench to hold RES when attaching wires
U
512
29AUG06
COM1
534
28A0011 SCR (4KW)
804
BE
NC DOOR SWITCH SC2-1
K2
A2
804
F5
TB1-N
TB1-GND
V
105
527
528
904
VAR & DPM UPDATES (ECO-1767)
SC3-11 (PPF STAB CONN.)
(NOTE 14)
J7 -1
-2
-3
300
A1
J3
BLU
531
400
6
IRMS
301
5
GRY
541
103
BLU
(FIBER CABLE)
0
20
542
SC3-12 (PPF STAB CONN.)
(NOTE 14)
(FIBER CABLE)
BLK
IRMS-IN
IRMS-OUT
20MAR07
PREVIOUS IRMS W/RES WIRING
BE
POWER PAK WIRING FOR 94A0399 "DOOR NOT
CLOSED" INDICATOR
TITLEBLOCK UPDATE
RELATED DOCUMENTS
ECO-1818: ADDED SCO OPTION
DOC. NO.
R
SEE 43A2616/5070 FOR 50 & 70KW WIRING.
35A0539 COLORS SHOWN,
SEE 240V INPUT FOR 35A0546 COLORS
REV
LEVEL
44A6293
REV
DATE
43A2616/5070
21FEB06
TBD
BE
VIO
30 kW
DRAWN
BY
507
508
MOVED SC3-8 WIRE TO F5 (ECO-01546)
BLK
RED
VIO/WHT
WIRING DIAGRAM, ACE2 TO URCII/1 PCB
M
BRN
WHT/BLK
WIRING DIAGRAM, ACE1 TO URCII/1 PCB
43A3128
REV
LEVEL
503
43A2550
V
532
SEE ECO's - 1832/1833.
RED/WHT
300 SERIES TABLE CLARIFICATION
506
RED
S
T4
WHT/BRN
21APR06
F3
502
BE
F4
Table of
Contents
10AWG
89A0195/9
(T4) - 480 VAC INPUT
REVISED DPM OPTION WIRING (ECO-01571)
WIRE #531 MUST BE TIED TO VIO (OR RED)
WIRE - NOT TO ANOTHER GND.
Safety
15 kW
700-701: PRIMARY POWER, 6AWG, 600V, 105C, 89A0230.
800-806: GROUND, 12AWG, 600V, GRN/YEL, 89A163/5.
900-905: GROUND, 18AWG, 600V, GRN/YEL, 89A0163/7.
1000-01: GROUND, 6AWG, 600V, GRN/YEL, 89A0168/5.
Installation Introduction
Schematics
8AWG
89A0196/9
Operation
10 kW
Parts
8AWG
89A0196/9
Parts
10 kW
ADB Airfield Solutions
977 Gahanna Parkway, Columbus, Ohio 43230
Telephone: 614-861-1304, Fax: 614-864-2069
10AWG
89A0195/9
REV
DATE
10 kW
ATTACH TO FOOT OF T4
(2 PLACES)
20AUG07
600- HIGH VOLTAGE 8AWG, 7.5KV, SIL, 89A0202:
OBSOLETE - USE "200" SERIES WIRE.
BE
8AWG
89A0196/9
DRAWN
BY
7.5 kW
REVISION DESCRIPTION
8AWG
89A0196/9
REVISION DESCRIPTION
7.5 kW
INITIAL & DATE:
10AWG
89A0195/9
(RED)
TITLEBLOCK UPDATE
526
531
VIO
(BLK)BLK
All information contained herein, including illustrations,
specifications, and dimensions, is believed to be reliable as of the
date of this publication, but is subject to change without notice.
ADB reserves the right to make changes and improvements to
its products and assumes no responsibility for these modifications.
Any disclosure of this information is strictly prohibited except as
ADB Airfield Solutions may otherwise agree to in writing.
Copyright © 2009 ADB Airfield Solutions.
7.5 kW
509
27SEP07
10AWG
89A0195/9
02NOV07 06 AUG 01
4 kW
BE
10AWG
89A0195/9
BE
4 kW
ALL V's
N
(BRN)
POWER
O
508
ALL V's
CONTROLLED COPY
(BLU)
VIO/WHT
POWER
DRAWN DATE:
507
480 V
DRAWN BY:
(ORG)
RED
2. WIRE SIZES:
100-105: PRIMARY POWER, SEE TABLE.
200-210: HIGH VOLTAGE, 12AWG, 25KV, 150C, 89A0086/1.
300-305: TANK LOOP, SEE TABLE.
400-409: MEDIUM CURRENT, 12AWG, 600V, 105C, 89A0185/9.
500-547: STD CONTROL, 18AWG, 600V, 89A0182/9.
POWER
12JUN08 BE
(WHT)
WHT/BLK
UCCF-2004 REGULATORS
BE
532
RED/WHT
503
(BLK)BRN
USTD. REGULATORS
(BLU)
SEE ECO's 1851, 1947 AND 1968
506
RED
UPDATED TERM. BLK. WIRING (ECO-1671)
F3
(XXX)
(WHT)
WHT/BRN
P
502
T4
NOTES:
1. WIRE NUMBERS REASSIGNED AT THE CREATION OF
THIS DOCUMENT.
ASSOCIATED DRAWINGS:
35A0546 COLORS
240 VAC INPUT
F4
300 SERIES WIRES: TANK LOOP, 600V, 105°C
100 SERIES WIRES - PRIMARY
POWER, 600V, 105°C
35A0539 COLORS
13APR09
ALL REGULATORS
REV'S A & B - SUPPLY TX LEAD COLORS
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
PPF Powerpack schematic 4-30 kW 2 of 2
BAR
Figure 48:
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Schematics
513-RED
RED 514
© 2010 ADB Airfield Solutions All Rights Reserved
DRAWING TITLE:
3
43A2616
7
DRAWING NUMBER:
6
PG. 2 OF 2
4
6.6 & 20A, 4-30KW
FERRO SGRS POWER PACK
WIRING DIAGRAM
5
WHT 515
512-WHT
69
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Schematics
5
4
3
F5 = .5A, 250V, SLO-BLO (47A0119)
J6
12
1
2
5
552
8
6
NS
SC3-9
XCPS
SC3-10
539S
538S
SC3-6
SC3-7
6
TB1
(5 STEP WIRING)
43A2616
TO IRMS
SC3-5
537S
530S
7
ADB Airfield Solutions
977 Gahanna Parkway, Columbus, Ohio 43230
Telephone: 614-861-1304, Fax: 614-864-2069
5-STEP REG.
REV
DATE
09OCT09
REV
DATE
20AUG07
BE
905
539
538
537
530
N/C
529
4
5
9
904
USE EXT. WASHER FIRST
OR GRIND PAINT OFF IN
CONNECTION AREA.
SC3-3
CHASIS GND.
SC3-4
CHASIS GND.
SC3-1
GRIND PAINT OFF IN
CONNECTION AREA.
7
3
(COMP. PANEL)
RUN UNDER CAP BANK
529S
IF 4AWG GRN/YEL WIRE IS NOT
AVAILABLE, USE 89A0232 &
WRAP WITH GREEN ELECTRICAL
TAPE AS SHOWN.
806
533
1001
8
2
10
3-STEP REG.
533S
1001
COMP. PANEL
GND LUG BOLT
ON BACK SIDE
1
11
4
10
SC3-2
Schematics
1000
12
3
11
REV.
TO IRMS
(FOR PREVIOUS SCR COLOR CODING SEE PG. 2)
STOP
BLADES (2)
REVISION DESCRIPTION
Twisted 22awg. wires.
806
Parts
1002
1000
21SEP07
44A6178 SWITCH ADAPT. PCB ASSY.
POS./STOP BLADE INSTALLATION:
REMOVE NUT & WASHERS, TURN UPSIDE DOWN
AND TAP SHAFT TO REMOVE BLADES. SHAFT
"FLAT" MUST BE IN THE POSITION SHOWN
WHEN RE-INSTALLING THE BLADES.
CAUTION: BLADES ARE VERY SMALL!
519 ORG
520 PUR
DRAWN
BY
8
ECO-1818: ADDED SCO OPTION & PG. 2
7
Q
6
REV
LEVEL
5
W
4
44A6796
WIRING DIAGRAM, SGRS 4-30KW, 6.6 & 20A
SGRS WIRE HARNESS, 50/70KW W/CCT PCB
94A0368/5
POWER WIRE KIT, FERRO SGRS, 50KW
94A0368/6
POWER WIRE KIT, FERRO SGRS, 70KW
DOC. NO.
DESCRIPTION
RELATED DOCUMENTS
43A2616/5070
3
DRAWING NUMBER:
2
530
1
537
6
9
1002
5
J1
5
529
4
539
3
533
2
(NOTE 14)
70
INITIAL & DATE:
W
5
6
6
7
ECO-1832; ADD COMP. PLATE GND.
4
7
3
COPPER BAR JUMPER
TO TB1-NEU
1
526 - T4
2
3
517 YEL
518 BLU
303
302
301
300
1
2
PUR 520
ORG 519
5000:1
526
ASSEMBLY NOTES:
1) ADD 2 JUMPERS TO J5 AS SHOWN. TIE JUMPERS INTO CABLE HARNESS
SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB.
2) GROUND TO FOOT OF TRANSFORMER.
3) ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING.
4) WIRE #531 MUST BE TIED TO BLU WIRE - NOT TO ANOTHER GND.
5) ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES.
6) SNUBBER MAY BE SUPPLIED WITH SCR.
7) (REMOVED: REV. B)
8) GROUNDING NOTES:
SC1-3
- GND EACH PANEL TO THE FRAME
SC1-1
- JUMPER INTERNAL GND LUG TO EXTERNAL
SC1-2
GND LUG.BE PULLED FROM PCB
9) REFERENCE ASSY. DWG. 44A6292/2 FOR WIRE LUG ASSY.
10) TORQUE SPEC.'S OF #53A0412/150 CONTACTOR: 120 LB-IN.
11) IF A JUMPER IS NEEDED FOR ANY CORE LEAD, USE
HIGH VOLTAGE 89A0086/1 WIRE.
12) IF OUTPUT GOES THRU SGRS BAYS, USE 40KV 89A0087/1 WIRE.
13) FOR ICVM WIRING, SEE DWG. # 44A6687/XXX.
14) SEE "SYSTEM PACKAGE" FOR WIRING OF 44A6007/X HARTING "STAB" CONNECTOR.
J2
J3
1
BNC
8
BE
9
NOTE 11
T1
BE
906
526
527
532
J4
4
518
10 L
2
3
501
& 309
302
303
508
521
1&6
L1
5
538
CONTROL
WINDING
YEL 517
Parts
FAN NEUTRAL
307 & 308
1
BLU
CHASIS GND.
NOTE 1
6
540
105
300 & 301
8
L4
7
N/C
562
5
522
N/C
563
104
S1
S2
CCI
CC
B1
B2
B3
B4
B5
NEU
XCP
N
GND
SC4-8
562
SC4-7
FAN
805
J5
540S
561
L3
3 201
GND TO FRAME USING
6AWG G/Y WIRE
18SEP07
1
NOTE 12
1100
1
BE
560
4
540
SC4-6
3
2
44A6035/1
URC II PCB ASSY.
2
4
3
J8
1
H2
2
L2
4
IF "KEYED" MATING CONN. IS USED,
PIN #1/RED STRIPE IS ON THE RIGHT SIDE
(SAME FOR ROTARY SWITCH CONN.).
550
Operation
TO2
5
V
70KW CORE
306
305
304
6
HV-SC2
REV
LEVEL
SC3-8
1
SNUBBER ASSY.
#44A6149
7
IF "UN-KEYED" MATING CONN. WAS USED,
PIN #1/RED STRIPE IS ON THE LEFT SIDE
(SAME FOR ROTARY SWITCH CONN.).
1
TO IRMS
508S
8
J7
550
551
1
206
DRAWN
BY
203
VR2
ECO-1832: UPDATED FOR URCII/1 PCB
509
2
507
ROTARY SWITCH
CONNECTION
REVISION DESCRIPTION
906
NOTE #4
HV-SC1
ECO-2449: CTRL WIRE CONN. CORRECTION
VR1
NOTE #2
205
10 MAR 03
204
10OCT10
506
ECO-2154, CHNGS FOR SHORTER GNDS
526
531
S
BLU
R
RED
OPTIONAL SCO WIRING:
PG. 1 OF 2
Introduction Installation
Schematics
509
NOTE #5
SC5-6
DTR
SC5-5
508
All information contained herein, including illustrations,
specifications, and dimensions, is believed to be reliable as of the
date of this publication, but is subject to change without notice.
ADB reserves the right to make changes and improvements to
its products and assumes no responsibility for these modifications.
Any disclosure of this information is strictly prohibited except as
ADB Airfield Solutions may otherwise agree to in writing.
Copyright © 2009 ADB Airfield Solutions.
NOTE 14
*DIGITAL PWR METER
OPTION
12JUN08
BRN
35A0528
NO GND REQ'D
507
BE
BLK
*DPM OPTION
T2
532
SEE ECO's 1851, 1947 & 1968
VIO
HV-SC2
20A = 35A0528
201
506
NOTE #2
RED
203
VR2
CVM-1
(FIBER CABLE)
GRY
GRN/YEL
203
201
T6
GRY
503
NOTE #3
ACE CVM & IRMS OPTIONS:
T
RED/BLK
DANGER:
LETHAL VOLTAGES
ARE PRESENT
BE
501
ST1
13APR09
535
536
480 VAC INPUT
F4
T4
502
BLK
F3
401
COM1
NOTE 12
200
CVM
BE
400
NO1
534
T1
L
303
SC5-12
(COMP. PANEL)
TITLEBLOCK UPDATE
531
A2
50KW, 480VAC (3 BANKS)
TO1
NOTE 14
SC5-11
ST1
U
403
VR7 VR8
SC2-1 SC2-6
DOOR SW
ICVM OPTION:
SEE NOTE 13
ST3 ST2
TB1-GND
804
HV-SC1
VR1
DRAWN DATE:
11
ST4
NOTE 11
204
ASSOCIATED DRAWINGS:
6
307-308-309
J5
TB1-NEU
DRAWN BY:
307
ST1
L1
GRY
BLU
PRIM.
35A0346 OR
61A0317 (/30)
DRAWING TITLE:
402
0
40 A1
803
Safety
802
308
309
302
402
480 VAC INPUT
(310)
IRMS-OUT
(FIBER CABLE)
(FIBER CABLE)
IRMS-IN
SEC.
F5
50 & 70KW, 20A, 480VAC
SIESMIC FERRO SGRS POWER PACK
WIRING DIAGRAM
701
1&7
J4
-1 551
-2 552
-3 904
800
6 105
103
105
300 & 301
CONTROL
WINDINGS
T7
IRMS
527
5
701
BANK WIRES AS CLOSE
AS POSSIBLE TO THE
CENTER OF THE CAP
BANK.
ST2
804
4
8
L4
9
S2
J3
ST2
2 104
3
20A CVM WIRING
S1
ST3
1
5 201
104
ST4
SC1-2
102
402
1
40
B1
35A0308
(20:6.6A)
ST3
700
2
40
NOTE: LAND ALL CAP
B2
ST4
Table of
Contents
700
SC1-1
B3
B4
SEE NOTE #3
L3
200
T9
205
L2
K2
CB1
4
3
P2
P1
H2
305
304
304
801
5
30
OPTIONAL
SCO
6
30
(311)
SEE NOTE 10
*DPM OPTION
526
SC1-1 & 2 INPUT WIRE LUG ASSEMBLY.
ST2
H2 TO P1 FOR CVM
50KW CORE
306
70KW, 480VAC
(4 BANKS)
CONTROLLED COPY
IMPORTANT! KEEP WIRES (100's & 300's) AWAY FROM CORE!
IMPORTANT! SEE NOTE 9 FOR
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
PPF Powerpack schematic 50-70 kW 1 of 2
H2 (W/O CVM)
Disclaimer
Figure 49:
96A0288 Rev. W
6/9/11
© 2010 ADB Airfield Solutions All Rights Reserved
96A0288 Rev. W
6/9/11
44A6796
94A0368/5
94A0368/6
DOC. NO.
WIRING DIAGRAM, SGRS 4-30KW, 6.6 & 20A
FERRO SGRS WIRE HARNESS, 50 & 70KW SEISMIC
POWER WIRE KIT, FERRO SGRS, 50KW
POWER WIRE KIT, FERRO SGRS, 70KW
DESCRIPTION
RELATED DOCUMENTS
Disclaimer
Safety
Installation Introduction
Schematics
REV
DATE
09OCT09
DRAWN
BY
Operation
REVISION DESCRIPTION
Parts
REV
LEVEL
W
43A2616/5070
ECO-1832: UPDATED FOR URCII/1 PCB
REV.
R
ECO-1832; ADD COMP. PLATE GND.
S
SEE ECO's 1851, 1947 & 1968
TITLEBLOCK UPDATE
U
43A2616
PG. 2 OF 2
2/0 AWG
89A0231
50 & 70KW, 20A, 480VAC
SIESMIC FERRO SGRS POWER PACK
WIRING DIAGRAM
70 kW
7
DRAWING TITLE:
480V
1/0 AWG
89A0201/9
6
RED 514
POWER
50 kW
3
WHT 515
300-311: TANK LOOP & CAPS, 2 AWG, 600V, 105C, 89A0199/9 (300-303 = 2 RUNS AS SHOWN).
400-409: MEDIUM CURRENT, 12AWG, 600V, 105C, 89A0185/9.
100 SERIES WIRES
500-562: STD CONTROL, 18AWG, 600V, 89A0182/9.
PRIMARY POWER
600-604: HIGH VOLTAGE, 8AWG, 7.5KV, 89A0202:
600V - 105°C
OBSOLETE - USE "200" SERIES WIRE.
Parts
W
18SEP07
21SEP07
BE
BE
12JUN08
4
T
5
200-206: HIGH VOLTAGE, 12AWG, 25KV, 150C, 89A0086/1.
© 2010 ADB Airfield Solutions All Rights Reserved
13APR09
512-WHT
WIRE SIZES:
102-105: PRIMARY POWER, SEE TABLE.
700-701: INPUT POWER, 2/0 AWG, 600V, 105C, 89A0231.
800-806: GROUND, 12AWG, 600V, GN/YL, 89A163/5.
904-906: GROUND, 18AWG, 600V, GN/YL, 89A0163/7.
1000-1004: GROUND, 4 AWG, 600V, 105C, GN/YL, 89A0233.
1100: GROUND, 6 AWG, 600V, 105C, GN/YL, 89A0168/5.
BE
513-RED
BAR
PREVIOUS SCR WIRE COLOR CODING
Schematics
Use wrench to hold RES when attaching wires
REV
LEVEL
72A0071 TERM. BLK.: 50 in-lbs
72A0306/1 & /2 HARTING CONN'S: 48 in-lbs
REV
DATE
01OCT10
0
20
TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKER - AS
LISTED ON COMPONENT LABEL.
72A0017 TERM. BLK.: 35 in-lbs
TB1-GND
804
DRAWN
BY
804
F5
TB1-N
REVISION DESCRIPTION
J3
527
528
904
BE
GRY
J7 -1
-2
-3
DTR
(FIBER CABLE)
IRMS
ECO-2449: CTRL WIRE CONN. CORRECTION
BLU
ECO-2154, CHNGS FOR SHORTER GNDS
(FIBER CABLE)
V
IRMS-IN
IRMS-OUT
20AUG07
PREVIOUS IRMS W/RES WIRING
BE
ADD WIRES 541 & 542.
Table of
Contents
ADB Airfield Solutions
977 Gahanna Parkway, Columbus, Ohio 43230
Telephone: 614-861-1304, Fax: 614-864-2069
INITIAL & DATE:
60
536
NO1
ECO-1818: ADDED SCO OPTION & PG. 2
534
200/201
(FIBER CABLE)
Q
COM1
DRAWING NUMBER:
A2
CVM-1
SC2-1
10 MAR 03
K2
(T2/T3 and meter not used)
GRY
NC DOOR SWITCH
BE
105
CVM
DRAWN BY:
531
A1
6
530
TB1-L2
DRAWN DATE:
5
400
ACE Potted CVM/IRMS Options
Use wrench to hold RES when
attaching wires
529
541
542
103
0
H2
600
F6
All information contained herein, including illustrations,
specifications, and dimensions, is believed to be reliable as of the
date of this publication, but is subject to change without notice.
ADB reserves the right to make changes and improvements to
its products and assumes no responsibility for these modifications.
Any disclosure of this information is strictly prohibited except as
ADB Airfield Solutions may otherwise agree to in writing.
Copyright © 2009 ADB Airfield Solutions.
PREVIOUS "MOLDED" STYLE CVM WIRING
SC3-11 (PPF STAB CONN.)
(NOTE 14)
SC3-12 (PPF STAB CONN.)
(NOTE 14)
CONTROLLED COPY
POWER PAK WIRING FOR 94A0399
"DOOR NOT CLOSED" INDICATOR
Unauthorized duplication of this document in whole or part is prohibited.
Initialed in RED ink below indicates authorized copy.
PPF Powerpack schematic 50-70 kW 2 of 2
ASSOCIATED DRAWINGS:
Figure 50:
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Schematics
71
CCF (Ferroresonant) L-828 / L-829 Constant Current Regulator with Universal Regulator Controller (URC)
Schematics
96A0288 Rev. W
6/9/11
Disclaimer
Table of
Contents
Safety
Introduction Installation
Schematics
Operation
Parts
Parts
Schematics
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:
France
ADB Airfield Solutions LLC
Phone: +33 (1) 4922 9250
ADB
Fax: +33 (1) 4922 9255
Unit 44, Business Innovation Centre
977 Gahanna Parkway
Binley Business Park
Columbus, OH 43230
ADB Airfield Solutions GmbH & Co. KG
Harry Weston Road
USA
Von-der-Tannstr. 31
Coventry, CV3 2TX
Phone: +1 (614) 8611 304
90439 Nürnberg
United kingdom
Fax: +1 (614) 8642 069
Germany
Phone: +44 (0)1455 883130
Phone: +49 (911) 9239 1287
Fax: +44 (0)1455 883179
Fax:+49 (911) 2852 582
Other addresses:
ADB
ADB N.V.
Airfield Solutions
ADB Airfield Solutions Ltd.
Asia Pacific Regional HQ
Leuvensesteenweg 585
5500 North Service Road, Suite 1108
Unit C-9.3.1, Level 9, Block C
B-1930 Zaventem
Burlington, Ontario L7L 6W6
Mines Waterfront Business Park
Belgium
Canada
No. 3, Jalan Tasik
Phone: +32 (2) 722 17 11
Phone: +1 (905) 331 6887
The Mines Resort City
Fax: +32 (2) 722 17 64
Fax: +1 (905) 331 9389
43300 Seri Kembangan Selangor
[email protected]
Malaysia
www.adb-air.com
ADB Airfield Technologies Ltd.
Phone: +603 8941 4868
01A Unit, 9F, LSH Plaza
Fax: +603 8942 4869
8, Wangjing Jie
Chaoyang District
Beijing 100102
ADB Airfield Solutions Netherlands
P.R. China
Prinses Beatrixlaan 614
Phone: +86 10 8476 0106
Office D3.14
Fax: +86 10 8476 0090
2595 BM Den Haag
The Netherlands
ADB N.V.
Phone: +31 (0)70 304 3611
Dubai Silicon Oasis
Fax: +31 (0)70 333 8094
Wing D - Office D-309
P.O. Box 341218
ADB Airfield Solutions, Ltd.
United Arab Emirates
2nd Floor, 3 Rivonia Village
Phone: + 971 4372 4970
Cnr Mutual Road and Rivonia Boulevard
Fax: + 971 4372 4975
South
Rivonia 2128
ADB N.V./S.A.
South Africa
39/47 Boulevard Ornano
Phone: +27 (11)234 6768
93200 Saint-Denis
Fax: +27 (11)234 6739
ADB Airfield
Solutions USA
977 Gahanna Pkwy
Columbus, Ohio 43230 USA
Telephone: (+1 614-861-1304)
Fax: +1 614-864-2069
www.adb-airfieldsolutions.com
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)