ADB CCF Ferroresonant L-828 User manual

Signature Series™

CCF (Ferroresonant) L-828 /

L-829

Constant Current Regulator

with Universal Regulator Controller

(URC)

Air-Cooled, 4-70kW, 6.6A / 20A

ETL Certified to FAA Specification

AC 150/5345-10F

Document No. 96A0288

Issued: January 21, 2007

Rev. U: May 28, 2010

Ferroresonant L-828/L-829 CCR Record of Changes

 2009 ADB Airfield Solutions, Incorporated

96A0288T

Page

Rev

Description

EC No.

Checked

Approved

Date

A

Released manual.

00819

JG

WT

01/25/02

2-9, 3-2,

6-2, 7-5,

7-6, 7-9,

8-2 thru 8-

5

B

Added subsection Input Power Breaker Sizing

and added note on circuit breaker rating in

reference to Table 2-5. Changed Table 2-5.

Added contactors (53A0412-40 and 53A0412-

90) to parts list and to Figure 7-2 (Part 1 of 2).

Deleted part 72A0096 from Figure 7-2. Added

new wiring schematics in Figure 8-2 for

SMR/SMI options. Updated wiring schematics

in Figure 8-1. Added warning about putting

conduit wiring on right side of CCR. Added

Table 2-5 on input current. Removed SMI and

SMR from L-828/L-829 CCR Optional Parts.

00862

JY

WT

04/15/02

6-6, 6-7,

7-8

C

Added troubleshooting problem and new

wiring procedure in Section 6, Added part

number 44A6178 to Figure 7-3.

00891

JR

WT

05/17/02

2-9, 7-2,

7-9, 8-1

thru 8-4

D

Added stacking kit 94A0355 to Table 2-4

(Optional Equipment) and to L-828/L-829

Optional Parts. Updated Fig. 8-1 wiring

schematic. Deleted Figure 8-2 because Figures

8-1 and 8-2 were combined. Updated ordering

code in Figure 7-1.

00997

JG

WT

01/6/03

2-3, 2-8

thru 2-10,

2-13, 3-4

thru 3-7

E

Added procedure for stacking CCRs using

stacking kit 94A0355. Deleted references to

2400 Vac CCRs. Updated Tables 2-3,

2-5, and 2-12. Deleted Table 2-6. Updated

Figure 2-3.

01017

MH

WT

02/4/03

2-3, 2-15,

3-8, 4-3,

4-4, 7-3,

8-1

F

Added information on SGRS style Powerpack

CCRs

CS

WT

04/12/04

2-8,2-9,3-

2,4-4,7-

3,7-4

G

Corrected AWG sizes in Table 2-2, 2-3.

Warning Note on with Figure 3-1, reworded

Step 3Output Current Adjustments

01264

WT

5/7/04

All

H

Added 50/ 70KW and Powerpacks

01312

WT

9/13/04

Cover

I

Corrected Title Page of Manual

N/A

WT

9/22/04

All

J

Added detailed info about 50/70Kw

01414

WT

WT/JG/JR

6/3/05

4-8 thru 4-

12, 3-4

K

Added Digital Power Meter

Added I/O Table 3-4

01443

01364

WT

JR

9/8/05

Record of Changes

Ferroresonant L-828/L-829 CCR Record of Changes

 2009 ADB Airfield Solutions, Incorporated

96A0288T

Page

Rev

Description

EC No.

Checked

Approved

Date

3-1, 2-16,

2-17, 7-2,

7.4 to 7-10

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

10/21/05

Pg 2-3, 2-

5, 2-10, 2-

13, 5-2

N

Corrected callouts Fig 2-3, Table 2-1, 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

2-2, 2-3,

2-5, 2-15,

4-3, 6-7,

6-9, 8-1

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

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

1/18/08

ALL

R

Updated Name

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

02349

JC

6/25/09

All

T

ADB update

ER

GM

12/17/09

6-9

U

MCO update

JC

JR

05/28/10

Ferroresonant L-828/L-829 CCR Table of Contents

 2009 ADB Airfield Solutions, Incorporated

96A0288T i

Section 1 Safety......................................................................................... 1-1

1. Introduction ........................................................................................... 1-1

2. Safety Symbols ...................................................................................... 1-1

3. Qualified Personnel ............................................................................... 1-2

4. Intended Use ......................................................................................... 1-3

5. Installation ............................................................................................. 1-3

6. Operation ............................................................................................... 1-4

7. Action in the Event of a System or Component Malfunction ............... 1-5

8. Maintenance and Repair ........................................................................ 1-5

Section 2 Description ................................................................................ 2-1

1. Introduction ........................................................................................... 2-1

2. L-828 CCR ............................................................................................ 2-1

3. L-829 CCR ............................................................................................ 2-2

4. SGRS Powerpack™ .............................................................................. 2-3

Universal Regulator Controller ......................................................... 2-4

L-829 Advanced Control Equipment (ACE™ or ACE2) ............... 2-5

5. L-828/L-829 CCR Monitoring Options ................................................ 2-6

Optional Insulation Resistance Monitoring System .......................... 2-6

Optional Scanning Monitor Interface ................................................ 2-6

Optional Scanning Monitor Ready .................................................... 2-6

Optional Series Cutout Type SCO ..................................................... 2-6

6. Theory of Operation .............................................................................. 2-7

Power Circuit ..................................................................................... 2-7

Output Measurement ......................................................................... 2-7

Universal Regulator Controller ......................................................... 2-7

7. Ferroresonant L-828 CCRs (4-70 kW 6.6 A/20 A): Required Equipment

................................................................................................................... 2-9

8. Input Power Breaker Sizing ................................................................ 2-10

9. Specifications ...................................................................................... 2-11

Ratings ............................................................................................. 2-11

Style ................................................................................................. 2-11

Power Factor .................................................................................... 2-11

Efficiency ........................................................................................ 2-11

Reactive Loading ............................................................................. 2-12

Resistive Loading ............................................................................ 2-12

Regulation ....................................................................................... 2-12

Environmental Operating Conditions .............................................. 2-13

Protection Devices ........................................................................... 2-13

Input Voltage ................................................................................... 2-14

Built-In True RMS-Reading Ammeter ............................................ 2-14

Input Wire Size ................................................................................ 2-14

Rating and Input Voltage ................................................................. 2-14

Temperature Rise ............................................................................ 2-14

Approximate Weight - pounds (kg) ................................................. 2-15

CCR Dimensions – inches (centimeters) ......................................... 2-15

Section 3 Installation ................................................................................. 3-1

1. Introduction ........................................................................................... 3-1

2. Unpacking ............................................................................................. 3-1

3. Installation ............................................................................................. 3-1

Wiring Connections and Startup ........................................................ 3-1

4. Stacking CCR’s (Optional) ................................................................... 3-5

5. SGRS Style Powerpacks (Optional) ...................................................... 3-8

Section 4 Operation ................................................................................... 4-1

1. Introduction ........................................................................................... 4-1

2. CCR Control Procedures ....................................................................... 4-1

Local Control ..................................................................................... 4-1

Ferroresonant L-828/L-829 CCR Table of Contents

 2009 ADB Airfield Solutions, Incorporated

96A0288T ii

Remote Control ................................................................................. 4-2

3. CCR Door Interlock (Optional) ............................................................. 4-3

4. CCR Shutdown Procedure .................................................................... 4-3

5. CCR Adjustment Procedures ................................................................ 4-4

Output Current Adjustment ............................................................... 4-4

Output Current Adjustment (cont.) .................................................... 4-5

Overcurrent Adjustment .................................................................... 4-6

6. S1 Cutout Type SCO Working Positions .............................................. 4-6

7. Digital Power Meter Calibration ........................................................... 4-8

Section 5 Maintenance .............................................................................. 5-1

1. Introduction ........................................................................................... 5-1

2. Maintenance Schedule........................................................................... 5-2

Short-Circuit Test .............................................................................. 5-3

Open-Circuit Test .............................................................................. 5-3

Section 6 Troubleshooting ........................................................................ 6-1

1. Introduction ........................................................................................... 6-1

2. Preliminary Troubleshooting ................................................................. 6-2

3. Troubleshooting Fuses .......................................................................... 6-3

L-828/L-829 Input Power Fuses F1 and F2 ....................................... 6-3

L-828 / L-829 Step-Down T4 Transformer Fuses F3 and F4 ............ 6-3

L-829 Power Supply Transformer Fuse F5 and ACE Power Supply

Fuse F6 .............................................................................................. 6-4

4. L-828 General Troubleshooting Procedures ......................................... 6-5

5. L-829 General Troubleshooting Procedures ......................................... 6-9

6. Feedback Wiring Modification Procedure ............................................ 6-9

Section 7 Parts ........................................................................................... 7-1

1. Introduction ........................................................................................... 7-1

2. Using the Illustrated Parts List .............................................................. 7-1

3. L-828/L-829 CCR (4-70 kW/6.6 A/20 A) Part Ordering Code ............. 7-2

4. SGRS Powerpack CCR (4-70 kW/6.6 A) Part Ordering Code ............. 7-3

5. L-828/L-829 CCR General Assembly (4-70kW Parts List ................... 7-4

L-828/L-829 CCR Optional Parts .................................................... 7-11

6. Universal Regulator Controller Parts List ........................................... 7-11

7. Recommended Spare Parts .................................................................. 7-11

Section 8 Wiring Schematics .................................................................... 8-1

1. Introduction ........................................................................................... 8-1

2. Wiring Schematics ................................................................................ 8-1

Ferroresonant L-828/L-829 CCR Table of Contents

 2009 ADB Airfield Solutions, Incorporated

96A0288T iii

Figure 2-1 L-828 CCR (4 -30kW/6.6 A) ............................................................... 2-1

Figure 2-2 L-829 CCR with ACE2 ........................................................................ 2-2

Figure 2-3 SGRS Powerpack with ACE or ACE2 ................................................. 2-3

Figure 2-4 Universal Regulator Controller (URC) ................................................. 2-4

Figure 2-5 L-828 CCR Power Circuit Block Diagram ........................................... 2-7

Figure 3-1 Wiring on Right Side of CCR .............................................................. 3-2

Figure 3-2 Location of Bolts for Stacking CCRs ................................................... 3-6

Figure 3-3 Stacking Bolt ........................................................................................ 3-7

Figure 3-4 Powerpack Installation in SGRS .......................................................... 3-8

Figure 4-1 Switch (3-Step/5-Step) ......................................................................... 4-1

Figure 4-2 SGRS Powerpack with ACE or ACE2 ................................................. 4-3

Figure 4-3 Output Current Clamp .......................................................................... 4-4

Figure 4-4 R40 (URC Board)................................................................................. 4-5

Figure 4-5 Handle Orientations .............................................................................. 4-6

Figure 4-6 S1 Cutout Operation Position ............................................................... 4-6

Figure 4-7 S1 Cutout Maintenance Position .......................................................... 4-7

Figure 4-8 S1 Cutout Test and Measure Position ................................................... 4-7

Figure 4-9 Meter Display ....................................................................................... 4-8

Figure 4-10 Function Buttons ................................................................................ 4-8

Figure 4-11 Calibration Menu .............................................................................. 4-10

Figure 4-12 Irms High Step Calibration ............................................................... 4-11

Figure 4-13 Irms Low Step Calibration ............................................................... 4-11

Figure 4-14 Vrms Calibration .............................................................................. 4-11

Figure 4-15 Vrms High Step Loaded ................................................................... 4-12

Figure 4-16 Save Vrms Calibration ..................................................................... 4-12

Figure 7-1 L-828/L-829 Part Ordering Code ......................................................... 7-2

Figure 7-2 SGRS Powerpack Part Ordering Code ................................................. 7-3

Figure 7-3 CCF-828/L-829 CCR Component Mounting Plate Parts (Part 1 of 3) . 7-8

Table 2-1 Required Equipment Supplied ............................................................... 2-9

Table 2-2 Required Equipment Not Supplied ........................................................ 2-9

Table 2-3 Recommended Input Wiring Rating .................................................... 2-10

Table 2-4 CCR Input Current............................................................................... 2-10

Table 2-5 Class .................................................................................................... 2-11

Table 2-6 Style ..................................................................................................... 2-11

Table 2-7 Power Factor ........................................................................................ 2-11

Table 2-8 Efficiency ............................................................................................ 2-11

Table 2-9 Output Current ..................................................................................... 2-12

Table 2-10 Rating and Input Voltage ................................................................... 2-14

Table 2-11 L-828/L-829 CCR Weight ................................................................. 2-15

Table 2-12 L-828/L-829 CCR Dimensions .......................................................... 2-15

Table 3-1 Remote 120 Vac Control Connections (3-Step/6.6 A) ........................... 3-3

Table 3-2 Remote 120 Vac Control Connections (5-Step/6.6 A) ........................... 3-3

Table 3-3 Remote 120 Vac Control Connections (5-Step/20 A) ............................ 3-4

Table 4-1 Output Current from Rotary Switch (3-Step/6.6A) ................................ 4-2

Table 4-2 Output Current from Rotary Switch (5-Step/6.6 A) ............................... 4-2

Table 4-3 Output Current from Rotary Switch (5-Step/20 A) ................................ 4-2

Table 4-4 Remote Control ..................................................................................... 4-2

Table 5-1 L-828/L-829 CCR (4-70 kW/6.6 A/20 A) Maintenance ........................ 5-2

Table 6-1 Input Power Fuses, F1 and F2, per CCR Input Voltage and CCR kW

Rating ............................................................................................................. 6-3

Table 6-2 Transformer T3 Fuses F3 and F4 Ratings .............................................. 6-3

Table 6-3 Fuses F5 and F6 Ratings ........................................................................ 6-4

Table 7-1 L-828/L-829 CCR (4-70 kW/6.6A & 20 A) Part Numbers ................... 7-2

Table 7-2 SGRS Powerpack (4-70 kW/6.6 A) Part Numbers ................................ 7-3

WARRANTY FOR GOODS AND SERVICES: Seller warrants, to

the extent to which any of the same may be applicable, that (a) on the

date of shipment the goods are of the kind and quality described herein

and are free of non-conformities in workmanship and material, (b) the

List of Figures

List of Tables

Warranties

Ferroresonant L-828/L-829 CCR Table of Contents

 2009 ADB Airfield Solutions, Incorporated

96A0288T iv

engineering services performed by it will be performed in accordance

with generally accepted professional standards, (c) any specialized

tools, equipment and instruments for the use of which a charge is made

to the Buyer shall be adequate for the work to be performed and (d) any

replacement or other parts furnished by it or any work done by it on the

Buyer’s equipment or both shall be free of defects in workmanship and

materials. This warranty does not apply to goods delivered by Seller

but manufactured by others.

Buyer's exclusive remedy for any failure of the goods or services to

conform to any of the applicable warranties shall be to have Seller re-

perform services, repair or replace (at Seller's option) the

nonconforming item and any affected part of the goods provided by

Seller. Seller’s obligation to re-perform services or to repair or replace

goods shall be in effect for a period of one (1) year from initial

operation of the goods or completion of Services but not more than

eighteen (18) months from Seller’s shipment of the goods. Seller shall

correct any failure to conform to any of the applicable foregoing

warranties of which it is notified in writing within that period of time

specified.

Repaired and replacement parts and repair services shall be warranted

for the remainder of the original period of notification set forth above,

but in no event less than 12 months from repair or replacement. In the

case of any other breach of the foregoing warranty, Seller shall furnish

engineering services or specialized tools, equipment and instruments, to

the same extent as on the original work. Buyer shall grant Seller access

to the goods or services at all reasonable times in order for Seller to

determine any nonconformity in the goods or services. It is understood

and agreed that, unless otherwise agreed to in writing by Seller, Seller

assumes no responsibility with respect to the suitability of the Buyer’s

equipment or any latent defects in the same. In no event shall Seller be

responsible for providing working access to the defect, including the

removal, disassembly, replacement or reinstallation of any equipment,

materials or structures to the extent necessary to permit Seller to

perform its warranty obligations, or transportation costs to and from the

Seller factory or repair facility, or for damage to equipment components

or parts resulting in whole or in part from improper maintenance or

operation or from their deteriorated condition. Seller shall have the

right of disposal of items replaced by it. If Seller is unable or unwilling

to repair or replace, or if repair or replacement does not remedy the

nonconformity, Seller and Buyer shall negotiate an equitable adjustment

in the contract price, which may include a full refund of the contract

price for the nonconforming goods or services. All warranty work shall

be performed in a single shift straight time basis Monday through

Friday. In the event the Buyer requires correction of warranty items on

an overtime schedule, the premium portion of such overtime shall be for

the Buyer’s account.

THIS IS SELLER’S SOLE GUARANTEE AND WARRANTY WITH

RESPECT TO THE GOODS AND SERVICES. THERE ARE NO

OTHER EXPRESS OR IMPLIED 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 ARE EXPRESSLY

DISCLAIMED.

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.

Disclaimers

Ferroresonant L-828/L-829 CCR Table of Contents

 2009 ADB Airfield Solutions, Incorporated

96A0288T v

Details and values given in this manual are average values and 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.

The information given does not release the buyer from making their own

experiments and tests.

Ferroresonant L-828/L-829 CCR Safety

 2009 ADB Airfield Solutions, Incorporated

96A0288T 1-1

Section 1

Safety

This section contains general safety instructions for using your 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. Note all

warnings and follow all instructions carefully. Failure to do so may result

in personal injury, death, or property damage.

To use this equipment safely,

• 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 remove

power prior to making any wire connections and touching any parts.

Refer to FAA Advisory Circular AC 150/5340-26.

• Read and become familiar with the general safety instructions

provided in this section of the manual before installing, operating,

maintaining, or repairing this equipment.

• Read and carefully follow the instructions given throughout this

manual for performing specific tasks and working with specific

equipment.

• Store this manual within easy reach of 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.

• Obtain and read Material Safety Data Sheets (MSDS) for all materials

used.

Become familiar with the safety symbols presented in this section. These

symbols will alert you to safety hazards and conditions that may result in

personal injury, death, or property and equipment damage.

1.

Introduction

2.

Safety Symbols

Ferroresonant L-828/L-829 CCR Safety

 2009 ADB Airfield Solutions, Incorporated

96A0288T 1-2

WARNING: Failure to observe this warning may result in

personal injury, death, or equipment damage.

WARNING: Risk of electrical shock. Failure to observe this

warning may result in personal injury, death, or equipment

damage.

WARNING: Disconnect equipment from line voltage. Failure

to observe this warning may result in personal injury, death, or

equipment damage.

WARNING: Wear safety goggles. Failure to observe may

result in serious injury.

CAUTION: Failure to observe may result in equipment

damage.

CAUTION: Contents are static-sensitive. Must be grounded

when handling PCBs.

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 see that its

personnel meet these requirements.

3. Qualified Personnel

Ferroresonant L-828/L-829 CCR Safety

 2009 ADB Airfield Solutions, Incorporated

96A0288T 1-3

WARNING: Use of this equipment in ways other than

described in this manual may result in personal injury, death, or

property and equipment damage. Use this equipment only as

described in this manual.

ADB Airfield Solutions cannot be responsible for injuries or damages

resulting from nonstandard, unintended applications of its equipment. This

equipment is designed and intended only for the purpose described in this

manual. Uses not described in this manual are considered unintended uses

and may result in serious personal injury, death, or property damage.

Unintended uses may result from taking the following actions:

• Making changes to equipment that have not been 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 your ADB Airfield Solutions equipment

• Allowing unqualified personnel to perform any task

Read the installation section of all system component manuals before

installing your equipment. A thorough understanding of system

components and their requirements will help you install the system safely

and efficiently.

WARNING: Failure to follow these safety procedures can

result in personal injury or death.

• Allow only qualified personnel to install ADB Airfield Solutions and

auxiliary equipment. Use only approved equipment. Using

unapproved equipment in an approved system may void agency

approvals.

• Make sure all equipment is rated and approved for the environment in

which you are using it.

• Follow all instructions for installing components and accessories.

• Install all electrical connections to local code.

Safety Symbols

(contd.)

4. Intended Use

5. Installation

Ferroresonant L-828/L-829 CCR Safety

 2009 ADB Airfield Solutions, Incorporated

96A0288T 1-4

• 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 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.

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.

• 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.

Installation

(contd.)

6. Operation

Ferroresonant L-828/L-829 CCR Safety

 2009 ADB Airfield Solutions, Incorporated

96A0288T 1-5

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.

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.

• Always use safety devices when working on this equipment.

• Follow the recommended maintenance procedures in your equipment

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.

7. Action in the Event of a

System or Component

Malfunction

8. Maintenance and Repair

Ferroresonant L-828/L-829 CCR Description

 2009 ADB Airfield Solutions, Incorporated

96A0288T 2-1

Section 2

Description

This section describes the ADB Airfield Solutions Signature Series.

Ferroresonant, L-828/L-829, constant current regulators (CCRs). These

CCRs are manufactured according FAA specification AC 150/5345-10F.

NOTE: Signature Series is a trademark of ADB Airfield Solutions.

See Figure 2-1. This subsection describes the L-828 CCR. The L-828

uses a Universal Regulator Controller (URC) to provide regulator and

control functions.

NOTE: Figure 2-1 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.

Figure 2-1 L-828 CCR (4 -30kW/6.6 A)

1. Ammeter (shown) or Digital Power Meter

2. Rotary Switch

1.

Introduction

2. L-828 CCR

Ferroresonant L-828/L-829 CCR Description

 2009 ADB Airfield Solutions, Incorporated

96A0288T 2-2

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

See Figure 2-2. 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 2-2 shows a ferroresonant 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.

Figure 2-2 L-829 CCR with ACE2

1. ACE2 Front Panel Display

2. L-829 CCR

3. Rotary Switch

3. L-829 CCR

Ferroresonant L-828/L-829 CCR Description

 2009 ADB Airfield Solutions, Incorporated

96A0288T 2-3

See

Figure 2-3. 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 2-3 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.

2

VR 7,

UBBER

TB3

INPUT

1 2

TOP

1 2

TB3

TB1

K2

URC PCB

VR 7,8

SCR

BLOCK

F3-F4

T4

F5

SNUBBER

INPUT

Figure 2-3 SGRS Powerpack with ACE or ACE2

1. ACE – not shown see Fig

2-2, Item 1(Installed on

inside front of SGRS

door)

2. SGRS Powerpack 3. Rotary Switch – not

Shown See Fig 2-2,

Item 3 (Installed on

front of SGRS door)

4. Circuit Breaker

5. Series Circuit Stab

Connector

6. Input Power and control

wiring stab connector

7. URC Circuit Board 8. Roller Wheels

4.

SGRS Powerpack™

2

4

5

6

7

8

Ferroresonant L-828/L-829 CCR Description

 2009 ADB Airfield Solutions, Incorporated

96A0288T 2-4

See Figure 2-4 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 through-hole type

printed circuit board. The universal regulator controller PCB performs the

functions listed below.

• 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 2-4 Universal Regulator Controller (URC)

Universal Regulator

Controller

Ferroresonant L-828/L-829 CCR Description

 2009 ADB Airfield Solutions, Incorporated

96A0288T 2-5

See Figure 2-2 and picture below. The L-829 ACE (or ACE2) 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.

ACE2 Control Board

For more information about the ACE, See:

Advanced Control Equipment (ACE) manual 96A0287 or the

Advanced Control Equipment (ACE2) manual 96A0357.

See manual 96A0348 for the ACE Programming Manual.

L-829 Advanced Control

Equipment (ACE™ or

ACE2)

Ferroresonant L-828/L-829 CCR Description

 2009 ADB Airfield Solutions, Incorporated

96A0288T 2-6

The L-829 CCR monitoring options include the Insulation Resistance

Monitoring System (IRMS), Scanning Monitor Interface (SMI), and

Scanning Monitor Ready (SMR).

The IRMS is used only on the L-829. It performs scheduled cable

insulation resistance measurements and can also perform manually

requested measurements. IRMS provides the ability for monitoring the

long-term degradation of the airfield series circuit cabling and showing the

results on the L-829 CCR front display panel.

WARNING: When servicing a regulator equipped with an

IRMS module, be sure that power to the IRMS is disconnected

before touching the IRMS board, or any of

the high voltage components or wires.

The scanning monitor interface is a relay assembly that can be mounted

internally to the front panel of the CCR. The relay assembly consists of

four relays and sockets. The relay assembly is used to generate feedback

signals concerning the CCRs operation to the Remote Multiplexer. The

relay assembly generates feed back for the following signals: Remote/local

status, commanded ON status, regulator running status, and primary power

status.

The scanning monitor ready includes the scanning monitor interface plus

one current transformer (CT) and one potential transformer (PT). It also

has resistor loads, and a fuse in the potential transformer secondary.

Differential signals presenting the actual series circuit voltage and current

are transmitted to the scanning monitor system two-conductor shielded

cables.

The series cutout Type SCO is often used at airports having a large number

of series circuits to isolate the series circuit from the CCR during

maintenance or testing operations. It also allows manual measurement of

resistance of the series circuit to ground without disconnecting the series

cable. The SCO cutout has a nominal working voltage of 5 kV and a

nominal carrying current capacity of 20 amps AC.

5.

L-828/L-829 CCR

Monitoring Options

Optional Insulation

Resistance Monitoring System

Optional Scanning Monitor

Interface

Optional Scanning Monitor

Ready

Optional Series Cutout Type

SCO

Ferroresonant L-828/L-829 CCR Description

 2009 ADB Airfield Solutions, Incorporated

96A0288T 2-7

This subsection describes the L-828 CCR theory of operation.

See Figure 2-5. A resonant network consisting of T1, C1, and the SCRs

draws from the input lines. This network is capable of drawing a limited

amount of power. It can be routed to one of two places. The first is the

output leads to the airfield. The second is a resonant tank comprised of C1

and part of T1.

As more power is allowed to flow into the resonant tank, less is available

to flow to the field. It is by regulating the current in this tank that the

SCRs regulate throughput current to the airfield. It is important to note

that the output of the regulator will be the smallest when the “SCRs” are

conducting 100% of the time. This is the opposite of what is seen in

simple SCR regulators where the SCRs are used to directly control the

output of the regulator.

NOTE: C1 is actually a bank of capacitors located near T1.

The components of the resonant network are designed to deliver an output

current slightly higher than 6.6 A/20 A for the minimum input voltage,

while the SCRs are fully off.

The output current flows through the high voltage current transformer T5.

T5 provides feedback to the URC board on the actual current output to the

airfield series circuit.

A second current transformer, T2, provides current to a true rms-reading

ammeter mounted onto the front panel to indicate output current.

See Figure 2-4. This subsection describes the board level circuitry found

on the universal regulator controller.

Figure 2-5 L-828 CCR Power Circuit Block Diagram

6. Theory of Operation

Power Circuit

Output Measurement

Universal Regulator

Controller

ADB CCF Ferroresonant L-828, CCF Ferroresonant L-829, Signature Series User manual

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