Document
Revision
June 25, 2012
2501
F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
Serial Number 300 and Higher
Cooper Industries
Crouse-Hinds Division
Crouse-Hinds Airport
Lighting
1200 Kennedy Road
Windsor, CT 06095
Copyright © 2012 Cooper Technologies Company
For Parts or Technical Service Call (860) 683-4300
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
1
Configuration Record
The following information is specific to the equipment describes as shipped from the factory and
should be retained. It should be provided when contacting the factory about this equipment for
any reason.
Constant Current Regulator, FAA Type
Manufacturer’s Part Number
Serial Number
Date of Manufacture
Factory Installed Options
Option/Part Number
Description
ii
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
2
Revisions
Revision
Number
A
B
Issue/Reissue
Letter Number
A205-33
A206-176
C
D
A206-243
A207-034
E
A207-120
F
A212-134
Description
Initial Issue
Cover page, added copyright; Figure 1,
revised V option description & deleted
options S & M and added options S2, S3,
M2 & M3; 6.2.3.2, added input fuse info
and Warning & notice sections; 7.1.5.3,
F2 was 1A Slo-Blo; Figure 11 & 11b,
34031 F2 was 1A Slo-Blo; 10.1, item 11,
deleted F2 and added items 12 & 13;
Figure 8, P/N 10047-2789 was 100472787 and added P/N 10047-2937
6.2.3.1 spec 150/5345-10F was -10E
Figure 1, deleted option S3 & M3; title
page, revised copyright to 2007
Revised revision on all pages to read E,
no other changes
Title page, updated copyright; Figures 2,
3 & 7, updated door latch pictorial &
P/N, was 10037-831
iii
Checked
3-25-05
6/26/06
Approved
TB
PG
7/11/06
2/12/07
PG
PG
2/12/07
PG
6/25/12
PG
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
3
Limited Product Warranty
THE FOLLOWING WARRANTY IS EXCLUSIVE AN IN LIEU OF ALL OTHER WARRANTIES,
WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF
LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR
PURPOSE.
Crouse-Hinds Airport Lighting Products (the “Company”) warrants each original Buyer of Products
Manufactured by the Company that such Products are, at the time of delivery to the Buyer free of material
and workmanship defects, provided that no warranty is made with respect to:
(a) any Product which has been repaired or altered in such a way, in Company’s judgement, as to affect
the Product adversely;
(b) any Product which has in Company’s judgment, been subject to negligence, accident or improper
storage ;
(c) any Product which has not been operated and maintained in accordance with normal practice and in
conformity with recommendations and published specifications of company; and,
(d) any Products, component parts or accessories manufactured by others but supplied by Company
(any claims should be submitted directly to the manufacturer thereof).
Crouse-Hinds Airport Lighting Products’ obligation under this warranty is limited to use reasonable efforts to
repair or, at its option, replace, during normal business hours at any authorized service facility of Company,
any Products which in its judgement proved not to be as warranted within the applicable warranty period.
All cost of transportation of Products claimed not to be as warranted and of repaired or replacement Products
to or from such service facility shall be borne by Purchaser. Company may require the return of any Product
claimed not to be as warranted to one of its facilities as designed by Company, transportation prepaid by
Purchaser, to establish a claim under this warranty. The cost of labor for installing a repaired or replacement
product shall be borne by Purchaser. Replacement parts provided warranty period of the Products upon
which they are installed to the same extent as if such parts were original components thereof. Warranty
services provided under the Agreement do not assure uninterrupted operations of Products; Company does
not assume any liability for damages caused by any delays involving warranty service. The warranty period
for the Products is 24 months from date of shipment or 12 months from date of first use whichever occurs
first.
iv
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
4
Safety Notices
This equipment is normally used or connected to circuits that may employ voltages which
are dangerous and may be fatal if accidentally contacted by operating or maintenance
personnel. Extreme caution should be exercised when working with this equipment.
While practical safety precautions have been incorporated in this equipment, the following
rules must be strictly observed:
4.1
KEEP AWAY FROM LIVE CIRCUITS
Operating and maintenance personnel must at all times observe all safety regulations. DO
NOT PERFORM MAINTENANCE ON INTERNAL COMPONENTS FOR RELAMP WITH POWER ON.
4.2
STORED ENGERGY
Ensure capacitors are discharged before working on equipment
4.3
RESUSCITATION
Maintenance personnel should familiarize themselves with the technique for resuscitation
found in widely published manuals of first aid instruction.
v
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
4.4
SAFETY SYMBOLS
DANGER:
DANGER
The hazard or unsafe practice will result in severe injury or death.
WARNING:
WARNING
The hazard or unsafe practice could result in severe injury or death.
CAUTION:
CAUTION
The hazard or unsafe practice could result in minor injury or death.
NOTICE:
NOTICE
Possibly dangerous situation, goods might be damaged.
IMPORTANT:
IMPORTANT
Helpful information.
vi
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
5
Table of Contents
Title Page ......................................................................................................................................... i
1.0 Configuration Record................................................................................................................ ii
2.0 Revisions .................................................................................................................................. iii
3.0 Limited Product Warranty ....................................................................................................... iv
4.0 Safety Notices ............................................................................................................................v
5.0 Table of Contents .................................................................................................................... vii
6.0 General Information ...................................................................................................................1
6.1 Introduction .........................................................................................................................1
6.2 Equipment Description .......................................................................................................1
6.3 Installation Requirements ...................................................................................................4
7.0 Technical Description ................................................................................................................6
7.1 Theory of Operation ...........................................................................................................6
8.0 Installation and Operation ..........................................................................................................9
8.1 Installation ..........................................................................................................................9
8.2 Operation ............................................................................................................................4
9.0 Maintenance .............................................................................................................................25
9.1 Periodic Maintenance .......................................................................................................25
9.2 Corrective Maintenance ...................................................................................................25
9.3 Problem Solving Guide ....................................................................................................26
10.0 Spare Parts List ......................................................................................................................42
10.1 Scope
Figures
Figure 1 – Catalog Number Breakdown ..........................................................................................5
Figure 2 - CCR Front View ..........................................................................................................15
Figure 3 – CCR right Side Exterior View ......................................................................................16
Figure 4 – CCR Right Side Interior View .....................................................................................17
Figure 5 – CCR Top View .............................................................................................................18
Figure 6 – CCR Rear View ............................................................................................................19
Figure 7 – CCR Stacking ...............................................................................................................20
Figure 8 – Main Transformer with Component Panel ...................................................................21
Figure 9 – CCR Interior Door ........................................................................................................22
Figure 10 – Remote Control Connections by Customer ................................................................23
Figure 11 – CCR Wiring Diagram .................................................................................................28
Figure 11a – CCR Wiring Diagram (Partial Expanded) ................................................................29
Figure 11b – CCR Wiring Diagram (Partial Expanded) ................................................................30
Figure 12 – 34031 S1 DIP Switch Configuration ..........................................................................31
vii
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
6
General Information
6.1
Introduction
6.1.1
Purpose
This instruction manual provides information for installing and maintaining FAA Type L-828
Constant Current Regulators manufactured by Crouse-Hinds Airport Lighting Products, Windsor,
Connecticut 06095, U.S.A.
6.1.2
Applicability
Only 4, 7.5, and 10kW regulators bearing Crouse-Hinds catalog number series 828x0F, serial
number 300 and higher are covered by this manual. Refer to Figure 1 for complete part number
information. Instructions for standard options are provided as supplements to this manual.
6.2
Equipment Description
6.2.1
Features
The Constant Current Regulator is a power supply designed for precision operation of airfield
lighting. The output current is regulated within +/-1% at any load and for line voltages from
+10% to –5% of nominal. The three or five discrete brightness steps conform to FAA standards.
The regulator may be controlled both locally and from a remote location.
Protective circuits are provided to sense an overcurrent or an open circuit in the series lighting
loop and shutdown the regulator. The front panel display alerts maintenance personnel to the
nature of the shutdown. The protective circuitry can be reset by setting the regulator control
switch to off for 1 second. Provided no fault condition remains, setting the control switch to the
desired brightness step will restore operation.
The regulator may be connected directly to an FAA approved load switching device. No regulator
malfunction or damage to the series lighting loop will occur.
6.2.2
Options
This regulator can be factory supplied with various options. See Figure 1 for a list of options.
1
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
6.2.3
Specification
6.2.3.1 FAA Classification
Specification:
Constant Current Regulator manufactured and qualified to FAA Advisory
Circular 150/5345-10F
Type:
L-828 Regulator
Class:
1 – 6.6 amperes output current
Style:
1 – 3 Brightness Steps: 4.8, 5.5, 6.6 amperes
2 – 5 Brightness Steps: 2.8, 3.4, 4.1, 5.2, 6.6 amperes
Ratings:
Sizes – 4kW, 7.5kW, 10kW
Voltages – 208VAC 50/60 Hz, 220VAC 50/60Hz, 240VAC 50/60Hz, 380VAC
50Hz, 480 VAC 60Hz
6.2.3.2 Electrical Characteristics
Primary Power:
Refer to Table 1 for ampacity information based on regulator size and
line voltage.
Remote Control Power:
(a) Internal Supply – 120VAC, Standard (Other voltages optional)
(b) External Supply – 120VAC, Standard (Other voltages optional)
Recommended Input Power Fuse Sizes (not provided)
CCR Input Voltage
CCR kW Rating
4kW
208 VAC
220 VAC
240 VAC
480 VAC
30A, 250V
25A, 250V
25A, 250V
12A, 250V
7.5kW
50A, 250V
50A, 250V
45A, 250V
25A, 250V
10kW
70A, 250v
70A, 250V
60A, 250V
30A, 250V
2
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
NOTICE:
Condition Limits
NOTICE
Total CCR load shall not exceed the rated load on the nameplate, at installation and
subsequent load changes.
WARNING:
WARNING
Running the CCR for long periods of time while overloaded may cause damage to
the regulator.
3
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
6.2.3.3 Physical Characteristics
Dimensions:
Refer to Outline Drawings, Figures 2 – 5
Weight
4 kW – 490 lbs.
7.5kW – 581 lbs.
10kW – 711 lbs.
Mechanical:
The regulator has a vented steel enclosure painted blue. Upon opening the
door, locate K1 contactor to make input line connections. Output lighting
arrestors located on the right side of the door are used to make load
connections. The electronic control board is located on the interior of the door.
The remote control terminal block also plugs directly into the control board.
The CCR is designed to allow easy access to other customer serviceable parts.
The main transformer is an air-cooled ferroresonant type.
Environmental: Temperature:
6.3
-40 degrees C to +55 degrees C
(-40 degrees F to +131 degrees F)
Relative Humidity:
10 percent to 95 percent
Altitude:
Zero to 6,600 feet (2000 m)
Installation Requirements
The regulator is shipped from the factory complete and ready to install. The agency responsible
for installation must supply all necessary connectors, wire and conduit. The regulator is for indoor
use only. It must be floor mounted. If stacked, units need to be bolted together and bottom unit
must be bolted to the floor.
Caution – Exterior metal surfaces may exceed 120ºF
(49ºC) when regulator is operated at full power for more
than 10 hours.
4
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
EXAMPLE: 82860-F1-240-10-5 is a 10KW L-828 Regulator with 240V, 60 Hz input and 6.6A output. It has five
brightness steps.
Ordering Information
8 2 8
0 F -
-
-
-
FAA Type:
8 = L-828
Frequency:
5 = 50Hz
6 = 60 Hz
Regulator Type:
F = Ferroresonant
Input Voltage:
208 = 208 V, 50 or 60 Hz
220 = 220 V, 50 or 60 Hz
240 = 240 V, 50 or 60 Hz
380 = 380 V, 50 Hz
480 = 480 V, 60 Hz
Kilowatt Rating:
04 = 4kw
07 = 7.5kW
10 = 10kW
Output Brightness Steps:
* 1 = 1 Step (5.5A)
3 = 3 Step (4.8, 5.5 &6.6A)
5 = 5 Step (2.8, 3.4, 4.1, 5.2, &
6.6A)
* = 6.6A Output Units Only
Options:
B = Integral circuit breaker
S2 = Integral Model 2 S-1 cutout
C = Computer ready interface**
D = Digitrac™ computerized control and monitoring system (Includes option C)
M2 = Megatrac™ integral earth leakage detector (includes option S2)
V = 24, 48 & 60 VDC control voltage
Standard remote control voltage is 120 VAC, 50/60 Hz
** Potential & Current transformer included, circuit board with relay contacts for loss of input power and
local /remote control
Figure 1
Catalog Number Breakdown
5
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
7
Technical Description
7.1 Theory of Operation (Basic Regulator)
The information presented here applies to a standard model Constant Current Regulator (CCR).
Regulators supplied with options may have minor operating differences, but the basic operation is
the same for all units.
Many functions in the CCR are controlled by a custom programmed electronic circuit. This
device performs brightness step and digital display control, open circuit and over-current sensing,
and handles system fault conditions. Several optional features also use the programmed circuit to
reduce the amount of additional circuitry required. Each of the standard functions is discussed in
detail in the following paragraphs. Optional functions are discussed in Supplemental sections of
this manual.
7.1.1
Current Regulation
A power transformer in conjunction with a Solid State Relay (SSR) is used for current regulation.
This design provides precise control regardless of the load size or line voltage. For very low loads
or low brightness settings, the on-time of the SSR will be large. At increased loads or higher
brightness settings, the on-time will be lesser.
The SSR is controlled using closed-loop electronic feedback control. Load current is sensed by a
current transformer which generates an analog signal. The signal is processed by an electronic
circuit and compared to a predetermined reference. The result is a pulse width modulated control
signal. This control signal is applied to the coil of the SSR.
7.1.2
Brightness Control
Each brightness step has a specific digital reference value store in electronic memory. When the
desired step is selected by the rotary switch, the proper memory value is converted to an analog
signal. This signal is the reference used for comparison as discussed in paragraph 7.1.1. All
remote brightness connections are electrically isolated from the control electronics by optocouplers for transient protection.
6
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
7.1.3
Remote Control Operation
The regulator can operate remotely using external switches connected to the remote control
terminal block TB1. The exact wiring of these switches depends upon whether control power is
obtained from the regulator internal supply or from an external source.
The regulator turns on to brightness B1 (or B10 or ON) when control power is applied to terminal
CC and B1 (B10). To get a higher brightness, control power is applied to terminal B2, B3, B4 or
B5. (For three-step regulators, apply control power to B30 or B100, for one-step regulators, apply
control power to on). Only the terminal for the desired step and CC require control power. If two
or more steps are energized together, the regulator will operate at the highest brightness step
selected.
7.1.4
Digital Display
A multi-purpose Digital Display provides system operation data. Under normal conditions, the
display shows the output current being supplied by the CCR. Under power-up and the system
fault conditions, it displays specific CCR status data.
7.1.5
Protective System
7.1.5.1 Overcurrent Protection
Overcurrent protection is triggered by comparison of the value of the feedback signal to
predetermined limits. In the event of a minor overcurrent (between 5% and 25% above rated
output), the control system responds within 5 seconds. If a major overcurrent (greater than 25%
above rated output), occurs, the control system responds immediately. The response consists of
de-energizing the load by opening the main contactor and providing status data to the digital
display. To reset and re-energize the CCR, the rotary switch or remote brightness control switch
must be set to OFF for at least one second.
7.1.5.2 Open –Circuited Load Protection
This protection is triggered by comparison of the value of the feedback signal to a minimum
current level. If the current remains below 2 amps for about 2 seconds, the control system
performs the same shutdown sequence as for overcurrent protection.
7
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
7.1.5.3 Fuses
Fuse
Designator
F1
F2
F3
F4
F201
F202
Location
Purpose
34031 Circuit Board
Remote Control CC Fuse
34031 Circuit Board
Main DC Power Supply Fuse
34031 Circuit Board
Reference Voltage Fuse
34031 Circuit Board
Remote Control Neutral Fuse
34054 Interface Board
120 VAC Control Fuse
34054 Interface Board
120 VAC Option Fuse
See Spare Parts List for details in Section 10.
Size
1/8A Slo-Blo
2A Slo-Blo
1/8A Slo-Blo
1/8A Slo-Blo
1A Slo-Blo
1A Slo-Blo
7.1.5.4 Transient Protection
Protection against transients from lighting or other sources is provided. Lighting arrestor LA1
protects the regulator power lines. Arrestors LA2 and LA3 protect the regulator load lines.
Varistors are provided on the control system assembly to protect it from transients on the power
and control lines.
The lighting protection provided exceeds the requirements of the applicable Advisory Circular.
Lighting is a naturally occurring phenomenon that varies in intensity and frequency based upon
geographic location. Therefore, each installation should be evaluated to determine the need for
additional lighting protection.
7.1.6
System Status Information
The CCR Digital Display is used during power-up and fault conditions to provide data regarding
system status.
7.1.6.1 Power-Up
When power is applied to the CCR and when resetting from a latched fault mode, the control
electronics performs a series of internal checks. If these are completed without incident, the
control program number will be displayed for one second. The display will then begin to indicate
CCR output current. If any check is not successfully completed, the system will “lock-up” and not
allow the regulator to come on in any step. Cycle power to recover.
8
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
7.1.6.2 Fault Status Message
If the CCR control circuits detect an abnormal system shutdown, a message will automatically
scroll across the display. When two or more fault conditions exist, the most recent occurrence is
displayed. Messages are cleared when the system is reset or conditions return to normal. Refer to
the Operations Section 8.2 for information on specific messages.
8
Installation and Operation
WARNING
INSTALLATION, SERVICE, MAINTENANCE OR OPERATION SHOULD BE
PERFORMED BY QUALIFIED PERSONNEL ONLY.
8.1 Installation
The Constant Current Regulator is supplied ready for operation with all ordered options installed.
When properly connected, no electrical adjustment other than noted in this section should be
necessary before use.
8.1.1
Location
The regulator is designed for indoor locations meeting the environment specified in Section
6.2.3.3. The area should be clean and dry, protected from rain, snow, dust, etc., and have adequate
ventilation. The equipment should be accessible to qualified personnel only.
8.1.2
Installation Drawings
Typical details and dimensions are provided in Figures 2 thru 10.
9
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
8.1.3
Step Configuration
The CCR will be shipped configured the way it was ordered. Three steps are required if the
number of steps must be changed in the field.
1. Set switch S1 on the control board 34031 to the settings in Figure 12 corresponding to the
desired number of steps.
2. Change the rotary switch label plate as described in Figure 2. Order the correct plate if
required.
3. Change the number of rotary switch positions by removing the knob and switch. Be careful
not to loose the stop which is just behind the front panel. After removing the switch, change
the stop location as follows. Looking at the shaft find the location tab that sticks through the
front panel for alignment. Count that location as 1. Count clockwise from the location tab 7
positions for a 1-step regulator, 8 positions for a 3-step regulator, and 11 positions for a 5-step
regulator. Place the stop in that position and reinstall switch and knob
8.1.4
Recommended Installation and Maintenance Tools
The following tools are recommended for installation and maintenance.
1. True RMS amp meter. This must be a true RMS reading meter such as a Fluke 189 and a
Fluke 80I-600A or equivalent.
2. Vacuum cleaner for cleaning debris from installation and during regulator maintenance.
Avoid compress air since it can force debris into places where damage can occur.
3. Lock-out/Tag-out as required.
4. Tools to install conduit and cable to supply power to CCR.
5. Airfield wire and connector kits to make connections between CCR output and airfield circuit.
10
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
8.1.5
Power Requirements
Table 1 list the line current requirements for the different CCR power and voltage ratings. It is
recommended that the distribution circuit breaker or fuses be sized to carry 125% of the rated
circuit.
Table 1
Power Requirements
Rated Input
Voltage
208
220
240
380
480
8.1.6
4kW
21
20
18
12
9
Rated Input Current
(RMS Amperes)
7.5kW
10kW
40
53
38
50
34
46
22
29
17
23
Cable and Conduit
Do not locate line and load cables near sensitive control, radar, or communications lines. For
cable entrance locations, see Figure 5.
8.1.7
Installation Check List
Read these instructions before attempting installation.
1.
Improper installation can damage this regulator and may void the warranty! If the
equipment fails to perform properly at any step of this procedure, consult the
troubleshooting guide in Section 9. Call Crouse-Hinds Airport Lighting Products (860)
683-4300 if further information is required during installation.
2.
Instructions for each equipment option included should also be read before proceeding
with installation
3.
SUGGESTION:
completed.
To stay organized, make a check mark next to each step as it is
11
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
8.1.7.1 Mechanical Installation
1.
Unpack the Constant Current Regulator, and check for any shipping damage.
2.
For handling, a 2” forklift clearance is provided underneath the unit and 2 lifting lugs are
provided. The regulator should be in place before lifting.
3.
Refer to Figures 2 thru 7 for mechanical installation details. Adequate clearance should
be left around the regulator for accessing and cooling. Maintain 1-foot clearance
between cabinet and rear wall.
8.1.7.2 Power Wiring and Check out
1. Connect the ground conductor to the equipment ground terminal. It is located on the lower
right side toward the front of the regulator.
CAUTION: DO NOT CONNECT COUNTERPOISE SYSTEM TO THIS
TERMINAL.
2. Verify that the line voltage is the same as the regulator nameplate voltage rating. This is
very important. CONNECTION TO THE WRONG LINE VOLTAGE MAY VOID
THE WARRANTY.
3. See Figure 5 for conduit knockout locations.
4. Connect the line voltage source K1 contactor line side terminals. Torque lugs to 60in –
lbs. (6.78 N-m)
5. Connect the series lighting circuit to the output lighting arrestor, LA2 and LA3.
CAUTION: DO NOT MEGGER TEST THE SERIES LIGHTING LOAD
WHILE IT IS CONNECTED TO THE REGULAOR.
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
6. Before connecting remote control lines, check regulator operation using the rotary switch
on the front panel. Follow steps A-C below. NOTICE: The regulator is equipped with a
safety interlock switch so that when the door is opened, the regulator will de-energize. Be
sure that the interlock switch is in its normal operating position before operating.
A. Apply main power to the regulator
B. Operate the regulator at all brightness steps and check the load current levels are
correct. See regulator nameplate for load current levels.
IMPORTANT – ONLY A TRUE RMS INSTRUMENT CAN ACCURATELY
MEASURE THE REGULATOR OUTPUT EXTERNALLY.
OTHER
INSTRUMENTS WILL PROVIDE IMPROPER READINGS.
C. Shut off main power to the regulator.
8.1.7.3 Control Wiring and Checkout
1. Connect remote control lines to terminal block TB1 located on the 34031 Control Board
using the appropriate wiring diagram. Refer to Figures 9, 10, and 11. The regulator is
shipped configured for internally supplied remote control power. Jumpers E4 through E9
must be removed if external control power is used.
CAUTION: INCORRECT WIRING CAN CAUSE MALFUNCTION OR
DAMAGE TO THE CONTROL SYSTEM AND POSSIBLY VOID THE
EQUIPMENT WARRANTY. RECHECK THESE CONNECTIONS BEFORE
OPERATING.
2. Make final operation check using local and remote modes. Steps A-C below.
A. Apply main power to the regulator
B. Operate the regulator in the local mode at all brightness steps and check for the
correct current levels.
C. Operate the regulator in the Remote mode at all brightness steps and check for
correct current levels.
13
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
8.1.7.4 Final Installation Steps
1. Make any option related connections discussed in the option supplements.
2. Check that all cables and wiring are dressed within the cabinet. Reinstall all covers.
14
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
CONSTANT CURRENT REGULATOR
SINGLE PHASE
PowerTrac
IDENTIFICATION:
INPUT:
FAA L-829
A@
KW
Hz
KW @ 6.6A
BRIGHTNESS STEPS
OFF
Hz,
VOLTS,
OUTPUT:
REMOTE
TM
FAA L-828
VOLTS,
CONTROL:
3
5
OUTPUT CURRENT
4.8, 5.5, 6.6A
2.8, 3.4, 4.1, 5.2, 6.6A
1
PART NUMBER
2
LOCAL
CONTROL
SWITCH
SERIAL NUMBER
WINDSOR, CT U.S.A.
3
5
4
!
DANGER
HIGH VOLTAGE PRESENT INSIDE CABINET
WHEN THE REGULATOR IS ENERGIZED
Figure 2
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
Figure 3
16
Document 2501
Rev. F
C1
WARNING
DISCHARGE CAPACITORS
BEFORE HANDLING
Figure 4
17
TB3
CAP1
CAP2
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
INT
GND
Figure 5
18
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
Figure 6
19
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
Figure 7
20
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
K2
T3
T2
INPUT
GND
INPUT
RV1
E1
LA1
T4
TB2
K1
T5
E2
T6
T1
LA3
LA3 OUTPUT
LA2 OUTPUT
LA2
Figure 8
21
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
34031-1
TB1
N
CCI
CC
B1/B10/0N
B2/B30
B3/B100
B4
B5
B6
10
11
12
REMOTE
CONTROL
TERMINAL
BLOCK
DOOR
GND
Figure 9
22
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
Figure 10
23
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
8.2 Operation
Figure 2 shows the standard controls and indicators on the front control panel.
8.2.1
Local Control Rotary Switch
The local control rotary switch in conjunction with the digital display acts as an interactive control
terminal for commanding the regulator into local brightness steps or to place it into remote control
mode.
8.2.2
Digital Display
During normal operation, the digital display functions as a True RMS ammeter, displaying the
regulator load current. During power-up, under system fault conditions the display performs other
functions. When these other functions are finished using the display, it automatically returns to
reading load current.
When power is initially applied to the regulator, the computer performs checks for valid operation.
If these checks are completed successfully, the display will read “P-X.X.”, where X.X is the
software program version number, for a period of 1 second. The normal display activity will
begin.
If the regulator should shut down due to system fault, a message will immediately begin to scroll
across the display to explain the reason for the shut down. See Section 9 for further information.
8.2.3
System Fault Display
If a regulator shutdown occurs, you can find out what happened by reading the display:
“HIGH LOAD CURRENT” – Overcurrent protection trip.
“LOOP” – Open Load protection trip.
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
9
Maintenance
WARNING
INSTALLATION, SERVICE, MAINTENANCE OR OPERATION SHOULD BE
PERFORMED BY QUALIFIED PERSONNEL ONLY.
9.1 Periodic Maintenance
The Constant Current Regulator should be inspected periodically as shown below:
Interval
Procedure
1. Remove main power from the regulator.
2. Open the front door
3. Check all wiring connection for loose connections and tighten as
necessary.
4. Check for broker or damaged wires and parts.
6 months
5. Remove dust build – up.
6. Inspect housing for rust or chipped paint. Clean and touch up with
paint as required.
7. Close door.
8. Restore primary power to the regulator. Operate the regulator at all
brightness steps, first by local control, then by remote control. Check
for proper load currents.
9.2 Corrective Maintenance
Corrective maintenance is required when the regulator does not work properly. This usually
requires the replacement of parts or subassemblies. The use of easily removable subassemblies
make repairs a simple task. The removal and replacement method should be obvious to qualified
personnel.
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
WARNING
VOLTAGES ABOVE 1000 VOLTS ARE PRESENT WHEN THE REGULATOR IS
OPERATING. DO NOT REPAIR OR SERVICE WITHOUT FIRST REMOVING
POWER FROM THE REGULATOR. THE USE OF LOCK-OUT DEVICES IS
RECOMMENDED.
ENERGY MAY BE STORED IN CAPACITORS. DISCHARGE CAPACITORS BEFORE
WORKING ON THEM.
REGULATORS WITH REMOTE CONTROL MAY HAVE POWER COMING ON THE
REMOTE CONTROL LINES EVEN WHEN THE CCR IS OFF.
AIRFIELD CIRCUITS MAY BE ENERGIZED BY OTHER SOURCES. CHECK FOR
VOLTAGE BETWEEN OUTPUT TERMINALS AND FROM OUTPUT TERMINALS TO
GROUND BEFORE WORKING ON AIRFIELD CIRCUIT.
The control assembly contains parts which can be replaced in the field by a service person. If
properly trained personnel are not available, replace the entire control assembly. Improper
removal and handling can cause damage to the equipment. Particular areas of concern are:
A. Remove power from the regulator before disconnecting the connector plugs from the control
board.
B. Note connections of terminal block connectors when replacing them back onto the control
board.
CAUTION: THE CIRCUIT CARDS WITHIN THE CONTROL ASSEMBLY
ARE STATIC SENSITIVE. DO NOT REMOVE OR HANDLE THEM
WITHOUTHT A STATIC CONTROL WRIST STRAP.
9.3 Problem Solving Guide
This guide will assist qualified airport maintenance personnel in locating and correcting equipment
failures. Problems associated with option functions are addressed in the specific option
Supplement. If further assistance is required, contact the Customer Service Department at CrouseHinds Airport Lighting Products, Windsor, Connecticut. (Reference Figure 11 Wiring Diagram)
26
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
9.3.1
Fault Isolation
The first step in fault isolation is the preliminary evaluation. Start by checking for disconnected
wires, switches in the wrong position, blown or missing fuses, etc. Determine if other equipment
on the same circuit is operating properly. Be sure that the equipment is being used properly by
checking the operation instructions. Finally, if the digital display is working, use the displayed
message to localize the problem.
If these checks do not pinpoint the problem, try operating the regulator with a short across the load
terminals. OPERATING INTO A SHORT WILL NOT HARM THE REGULATOR. This is
the best way to find out if the problem is with the regulator or the load circuit. Once these checks
have been made, refer to the checklist for further instructions.
27
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
Figure 11 – CCR Wiring Diagram See following pages for expanded view
28
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
29
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
30
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
Figure 12
31
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
9.3.1.2
DISPLAY MESSAGES AND WHAT THEY MEAN
DISPLAY MESSAGE
WHAT IT MEANS
‘P-X.X’ (where X.X is a number like 1.1)
This is the indication that all power up checks
are OK. The number is the program version.
This should appear for 1 second.
‘High Load Current’
The regulator has tripped off-line due to an over
current condition. See the section of protection
problems to fix.
‘LOOP’
The regulator has tripped off-line due to an
open circuit condition. Try operating the
regulator into a short circuit. If it doesn’t trip
again, check the field wiring for an open. If no
open is found, or the unit trips even with a short
circuit see the section on protection problems.
Display shows some other readable Message.
See the option supplement to find out what the
message means.
Display shows a bunch of funny things or
See the section on display problems.
garbage.
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
QUICK PROBLEM SOLVING CHECKLIST
SYMPTOM
1.
2.
System will not turn on.
3.
Control display OFF.
4.
System will not turn
Control display is ON.
on.
WHAT TO DO
Check power source turned on.
Check for 120 VAC across X1 and X2 on transformer T2. It
is probably bad.
Check F2. If good, see the section on power supply
problems.
Check door interlock switch.
1. If display reads ‘0.00’ see the section on local control
problem.
2. See the section on digital problems.
System will not turn off
1. See section on local control problems.
2. See section on remote control problems.
System turn on for 1 to 5
seconds, then trips out.
1. If display reads ‘LOOP’ or “High load current” see section
on protection problems.
2. See section on digital problems.
System works fine in Local but
1. See section on remote control problems.
does not work in remote.
1. Check for overload. Check for overload by shorting the
output terminals either with a shorting wire that will handle
the CCR output current or by pulling the S1 handle if
installed. If the regulator outputs appropriate step current in
Wrong current levels in any or
all steps, then the airfield circuit is probably overloading the
all steps.
CCR.
2. If problem is only in remote see section of remote control
problems.
3. Otherwise, see section on regulation problems.
Regulator works but display is
1. See section on display problems.
out or showing ‘funny’ data.
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
9.3.2
Detail Problem Solving Guide
On the next few pages are detailed problem solving guides. These guides make use of the digital
display and the indicators on the control box circuit card to speed repair.
9.3.2.1 Opening the CCR
CAUTION: TURN OFF MAIN POWER TO THE REGULATOR BEFORE
STARTING.
To open the regulator, turn the door latch to the left. Override the interlock switch by pulling the
interlock located in the top right corner of the unit. Turn on main power to the regulator to begin
trouble-shooting. DANGER: BE CAREFUL! THE CIRCUITS INSIDE AND AROUND
THE CABINET INTERIOR ARE ENERGIZED AND CONTAINED DANGEROUS
CURRENT LEVELS.
9.3.2.2 Circuit Card Indicators
Before doing any problem solving, take a few minutes to become familiar with the circuit card
indicators. They are provided as an aid in deciding what part or subassembly to change. Now go
to the detail checklist for the problem being addressed.
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
The following is a list of the indicators and their function:
Designator
DS1
Name
+5V
Description
Indicates +5V is available.
DS2
+12V
Indicates +12V is available.
DS3
-12V
Indicates –12V is available.
DS4
Unreg
Indicates unregulated power is available for 5V
and +/-12V regulators
DS5
Contactor
Indicates contactor is energized
DS6
Remote
Indicates rotary switch is in remote position.
DS7
Run
Indicates the CPU is running when on constantly.
There is a CPU problem if it is off or flashing.
DS8
Halt
Indicates the CPU is running when off
constantly. There is a CPU problem if it is off or
flashing.
DS9
Sync
Indicates the control is receiving a 60Hz signal
from the power transformer.
DS10
Feedback
Indicates the control is receiving a feedback
signal from the output current transformer.
The following LEDs indicate the associated relay is energized.
DS11
Relay1
Indicates the board is in remote mode.
DS12
Relay2
Indicates the CCR has input power.
DS13
Relay3
Indicates the CCR is outputting current.
DS14
Relay4
Indicates the CCR is outputting current in step 1.
DS15
Relay5
Indicates the CCR is outputting current in step 2.
DS16
Relay6
Indicates the CCR is outputting current in step 3.
DS17
Relay7
Indicates the CCR is outputting current in step 4.
DS18
Relay8
Indicates the CCR is outputting current in step 5.
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
POWER SUPPLY PROBLEM CHECKLIST
SYMPTON
All board indicators are OFF
1.
2.
3.
One power supply indicator is
OFF or it is very dim.
4.
1.
WHAT TO DO
Check fuse F2 to see if it has failed. If so, replace. If fuses
are okay, replace the 34031 board.
If the F2 fails again, replace the 34031 board.
If the indicators light, but the regulator still does not work
got to the next symptom.
Check door interlock switch.
Replace the 34031 Board
For further help contact Crouse-Hinds Airport Lighting Products.
CAUTION:
TURN OFF MAIN AND CONTROL POWER BEFORE
REMOVING OR INSTALLING CIRCUIT CARDS.
PROTECTION PROBLEM CHECKLIST
WHAT TO DO
1. Observe feedback indicator on the control
board. If OFF, check current transformer
T3 for an open winding. If T3 is OK,
replace 34031 board.
2. While de-energized, check to see if K2
(Solid State Relay) SSR is shorted. If SSR
is shorted replace relay.
3. Ensure K1 contactor coil is getting power.
Display reads ‘HIGH LOAD CURRENT’
1. If regulator operates on lower steps but
currents are high, replace 34031 board.
2. If regulator trips right away, regardless of
step, replace 34031 board.
3. K2 SSR may be open.
Check coil
connections to K2 SSR. Replace K2 SSR if
necessary.
For further help contact Crouse-Hinds Airport Lighting Products.
SYMPTOMS
Display reads ‘LOOP;
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
CAUTION:
TURN OFF MAIN AND CONTROL POWER BEFORE
REMOVING OR INSTALLING CIRCUIT CARDS.
REGULATION PROBLEM CHECKLIST
SYMPTOM
All currents low.
WHAT TO DO
1. Check fuse F3 to see if control
winding fuse has blown. If okay,
replace 34031 board.
2. Check to see if K2 SSR is shorted.
3. Check connections to C1 capacitor
bank. Measure capacitance to verify
while CAP1 and CAP2 leads of power
transformer are disconnected:
4kw, 60Hz = 150uF
7.5kw, 60Hz = 250uF
10kw, 60Hz = 400uF
High steps OK, but low steps are high.
One-step high or low.
Low steps OK, but high steps are low.
Current fluctuates over a wide range.
1. Replace 34031 board
1. If in local and remote control replace
34031 board. See section on Remote
Control problems.
1. Run regulator in a short. If OK,
regulator is over-loaded.
2. Check connections to C1 capacitor
bank. Verify capacitance of C1
capacitor bank.
1. Observe +12V indicator. If it blinks,
then be sure area temperature is
below 130 degrees F. If it is OK,
replace the 34031 board.
For further help contact Crouse-Hinds Airport Lighting Products.
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Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
CAUTION:
TURN OFF MAIN AND CONTROL POWER BEFORE
REMOVING OR INSTALLING CIRCUIT CARDS.
LOCAL CONTROL PROBLEM CHECKLIST
SYMPTOMS
System will not turn on.
System will not turn off.
WHAT TO DO
1. Observe Contactor indicator.
It
should go on and off when
switching from off to a step. If it
doesn’t then replace 34031 board.
2. Check K1 coil for open. If open
replace K1. If OK replace 34031
board.
1. If system will not turn off when the
interlock switch is opened, K1 may
be welded closed.
2. Observe Contactor indicator. If on
all the time, replace 34031 board.
For further help contact Crouse-Hinds Airport Lighting Products.
38
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
CAUTION:
TURN OFF MAIN AND CONTROL POWER BEFORE
REMOVING OR INSTALLING CIRCUIT CARDS.
REMOTE CONTROL PROBLEM CHECKLIST
SYMPTOM
System will not turn on.
WHAT TO DO
1. Check in local control. If not OK,
see section on local control
problems.
2. Check remote supply and wiring. If
OK, replace 34031 board.
3. Check door interlock switch
System will not turn off.
1. Check for control lines longer than
10,000 feet in length.
Current fluctuates up or down.
1. Check for control lines longer than
10,000 feet in length.
For further help contact Crouse-Hinds Airport Lighting Products
39
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
CAUTION:
TURN OFF MAIN AND CONTROL POWER BEFORE
REMOVING OR INSTALLING CIRCUIT CARDS.
DIGITAL PROBLEM CHECKLIST
SYMPTOM
System will not turn on.
WHAT TO DO
1. Observe Run and Halt indicators. If
they are blinking, replace control
board. If the Run indicator is on all
the time, see the section on local
control problems.
For further help contact Crouse-Hinds Airport Lighting Products.
40
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
CAUTION:
TURN OFF MAIN AND CONTROL POWER BEFORE
REMOVING OR INSTALLING CIRCUIT CARDS.
DISPLAY PROBLEM CHECKLIST
SYMPTOM
Regulator runs but no display.
Regulator runs but Display shows wrong
current.
Regulator works but display is out or
showing “funny” data
WHAT TO DO
1. Check for a loose cable from the
display to the control board If OK
replace32752. Display Card.
1. Check S1 DIP switch settings on the
control board.
2. Replace 34031 board.
1. If display reads ‘P-.X.X.’ and does not
change, see the section on digital
problems.
2. Replace 34031 board.
For further help contact Crouse-Hinds Airport Lighting Products.
41
Document 2501
Rev. F
Instruction Manual
L-828 Constant Current Regulator
Series 828X0F
4kW, 7.5kW, 10kW, 6.6 Amperes
10
Spare Parts List
10.1 Scope
Parts that are option related are discussed in the respective Drawing for that Option.
RECOMMENDED SPARE PARTS
Item
Number
1
2
Reference
Designation
LA1
T2
3
K1
3
K1
4
K2 SSR
5
6
Capacitor
Bank
7
8
9
T3
LA2, LA3
10
F1, F3, F4
11
F201, F202
12
F2
13
Ref K2
Description
Input Lightning Arrestor
36V/120V Control
Transformer
Contactor, 75A Resistive
Contactor, 120A Resistive
(20kW Units)
Solid State Relay (also
requires item 13)
Control Board
Capacitor, 50uF, 600V
Display Board
Current Transformer, 6.6A
Output Lightning Arrestor,
3kV
Fuse, 1/8 A Slo-Blo 5 x 20
mm
Fuse, 1A Slo-Blo 5 x 20
mm
Fuse, 2A Slo-Blo 5 x 20
mm
Solid State Relay Thermal
Pad (apply to SSR bas)
42
Crouse-Hinds
Part Number
10047-885
32279
10047-1249
Manufacturer Part
Number
GE 9L15ECB001
Square D
8910-DPA62-V02
32085
10047-2789
34031-1
32990
32752
31329
10053-703
10047-2937
Ronken Industries
91D23506H32
Cooper Power
Systems
UHS0303-0A0D0A1A
Bussman GMD125mA
Bussman GMD1A
Bussman GMD2A