Document
Revision
July 27, 2006
2447
H
Instruction Manual
Constant Current Regulator
Switchgear System
Series 82XSGS
Cooper Industries
Crouse-Hinds Division
Crouse-Hinds Airport
Lighting
1200 Kennedy Road
Windsor, CT 06095
For Parts or Technical Service Call (860) 683-4300
Copyright © 2006 Cooper Technologies Company
Document 2447
Rev. H
Instruction Manual
Constant Current Regulator
Switchgear System
Series 82XSGS
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
Description
Option/Part Number
ii
Document 2447
Rev. H
Instruction Manual
Constant Current Regulator
Switchgear System
Series 82XSGS
2
Revisions
Revision
Number
A
B
Issue/Reissue
Letter Number
A204-304
A205-121
C
A205-182
D
A205-303
E
A206-107A
F
A206-176
G
H
A206-243
A206-275
Description
Initial Issue
Revised to add missing information and
clarify installation and trouble shooting
Sh 19 & 45, added 10047-2937 SSR
thermal pad; Sh 4, Figure 1, added 60 Hz
only to 30 kW sizes
Fig 6, 7 & 8, S-1 P/N was 30775 &
revised pictorial
Added Fig 9A; Fig 6, 30775 was 30771
& revised pictorial in all locations; added
copyright to cover page; 8.1.5.1 5. was 4.
& 4. was 5. & revised 5., was install
main circuit card to cabinet door per doc.
2512; re-numbered pages as req’d; Fig 8,
deleted K2 P/N 10047-2787 (4-10 kW);
Fig 7, added lock out brkt P/N’s; spare
parts list, item 4, deleted P/N 10047-2787
(4-10 kW); 6.2.3.2, added “Notice” &
“Warning” Information
Added 2006 to copyright on cover page;
6.2.3.2, revised NOTICE & WARNING
wording; Figure 1, revised option V
description; 7.1.5.3, F2 was 1A Slo-Blo;
Figure 11 & 11D, 34031 F2 was 1A SloBlo; pg 49, item 9, F2 was 1A Slo-Blo
6.2.3.1 spec 150/5345-10F was -10E
Figure 1, Kilowatt rating “31” was 30
iii
Checked
KF
03-29-05
Approved
JMM
PG
7/7/05
PG
8/25/05
PG
3/27/06
PG
6/23/06
PG
7/11/06
7/27/06
PG
PG
Document 2447
Rev. H
Instruction Manual
Constant Current Regulator
Switchgear System
Series 82XSGS
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.
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Constant Current Regulator
Switchgear System
Series 82XSGS
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.
See FAA Advisory Circular AC 150/5340-26 for additional information.
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Constant Current Regulator
Switchgear System
Series 82XSGS
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.
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Constant Current Regulator
Switchgear System
Series 82XSGS
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 ..........................................................................................................................24
9.0 Maintenance.............................................................................................................................26
9.1 Periodic Maintenance .......................................................................................................26
9.2 Corrective Maintenance ...................................................................................................26
9.3 Problem Solving Guide ....................................................................................................27
10.0 Spare Parts List ......................................................................................................................48
10.1 Recommended Spare Parts.............................................................................................48
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Constant Current Regulator
Switchgear System
Series 82XSGS
Figures
Figure 1 – Catalog Number Breakdown ..........................................................................................5
Figure 2 - CCR Cabinet ................................................................................................................14
Figure 3 – CCR Upper Track Extension........................................................................................15
Figure 4 – CCR Forklift Installation Front View...........................................................................16
Figure 5 – CCR Forklift Installation Top View.............................................................................17
Figure 6 – CCR Front View...........................................................................................................18
Figure 7 – CCR Top View .............................................................................................................19
Figure 8 – CCR Side View ............................................................................................................20
Figure 9 – CCR Interior Door........................................................................................................21
Figure 9A – CCR Door Exterior....................................................................................................22
Figure 10 – Remote Control Connections by Customer................................................................23
Figure 11 – CCR Wiring Diagram.................................................................................................29
Figure 11a – CCR Wiring Diagram (Partial Expanded)................................................................30
Figure 11b – CCR Wiring Diagram (Partial Expanded)................................................................31
Figure 11c – CCR Wiring Diagram (Partial Expanded)................................................................32
Figure 11d – CCR Wiring Diagram (Partial Expanded)................................................................33
Figure 12 – P/N 34031 Circuit Board – S1 DIP Switch Configuration.........................................34
Figure 13 – 34031 Circuit Board Detail ........................................................................................47
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Constant Current Regulator
Switchgear System
Series 82XSGS
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 Switchgear style regulators bearing Crouse-Hinds catalog number series 82XSGS 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 is “hot swappable” when used in a Crouse-Hinds Switchgear System Cabinet.
The output of the regulator may be connected directly to a FAA approved load switching device.
6.2.2
Options
This regulator can be factory supplied with various options. See Figure 1 for a list of options.
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Constant Current Regulator
Switchgear System
Series 82XSGS
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
2 – 20 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; 8.5, 10.3, 12.4, 15.8, 20.0
amperes
Ratings:
Sizes – 4kW, 7.5kW, 10kW, 15kW, 20kW, & 30kW
Voltages – 380VAC 50Hz, & 480VAC, 60Hz
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Constant Current Regulator
Switchgear System
Series 82XSGS
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)
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..
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Constant Current Regulator
Switchgear System
Series 82XSGS
6.2.3.3 Physical Characteristics
Dimensions:
Refer to Outline Drawings, Figures 2 thru 5
Weight
4 kW – 425 lbs.
7.5kW – 570 lbs.
10kW – 670 lbs.
15kW – 875 lbs.
20kW – 1,190 lbs.
30kW – 1,640 lbs.
Mechanical:
The regulator Power Module can only be installed in a Crouse-Hinds
Switchgear System Cabinet. The Power Module plugs into the mating CrouseHinds connector in the cabinet to obtain input power and also make ground
connection. An S1 Cutout safety switch is located on the main transformer in
the front of the regulator 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 aircooled 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 Power Module 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 in a Crouse-Hinds Switchgear system power supply cabinet only.
CAUTION:
CAUTION
Exterior metal surfaces may exceed 120ºF (49ºC) when regulator is
operated at full power for more than 10 hours.
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Switchgear System
Series 82XSGS
EXAMPLE: 82860SGS-480-15-5 is a 15KW L-828 Regulator with 480V, 60 Hz input and 6.6A output. It has five
brightness steps.
Ordering Information
8 2
S G S
-
-
-
-
FAA Type:
8 = L-828
Regulator Type
SGS = Switchgear System
Input Voltage:
380 = 380V, 50Hz
480 = 480V, 60Hz
Kilowatt Rating:
04 = 4kW, 6.6A
07 = 7.5kW, 6.6A
10 = 10kW, 6.6A
15 = 15kW, 6.6A
16 = 15kW, 20A
20 = 20kW, 6.6A
21 = 20kW, 20A
30 = 30kW, 6.6A (60 Hz only)
31 = 30kW, 20A (60 Hz only)
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:
** C = Computer ready interface
D = Digitrac ™ computerized control and monitoring system (includes option C)
M = Megatrac ™ integral earth leakage detector and door interface
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
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Constant Current Regulator
Switchgear System
Series 82XSGS
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 less.
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.
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Constant Current Regulator
Switchgear System
Series 82XSGS
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.
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Constant Current Regulator
Switchgear System
Series 82XSGS
7.1.5.3 Fuses
Fuse
Designator
F1
F2
F3
F4
F201
F202
Location
34031 Circuit Board
34031 Circuit Board
34031 Circuit Board
34031 Circuit Board
34054 Interface Board
34054 Interface Board
Purpose
Remote Control CC Fuse
Main DC Power Supply Fuse
Reference Voltage Fuse
Remote Control Neutral Fuse
120 VAC Control Fuse
120 VAC Option Fuse
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.
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Constant Current Regulator
Switchgear System
Series 82XSGS
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:
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. Cabinets should be
installed and bolted on a flat and level floor. Refer to cabinet manual for further mounting details.
8.1.2
Installation Drawings
Typical details and dimensions are provided in Figures 2 thru 10.
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Switchgear System
Series 82XSGS
8.1.3
Power Requirements
Table 1 lists the line current requirements for the different CCR power ratings.
Table 1
Power Requirements
CCR Rating
4kW
7.5kW
10kW
15kW
20kW
30kW
8.1.4
Rated Input Current
(RMS Amperes)
380V
480V
12A
9A
22A
17A
29A
23A
43A
34A
58A
46A
N/A
69A
Cable and Conduit
Do not locate line and load cables near sensitive control, radar, or communication lines. For
suggested cable entrance locations, see Figure 5.
8.1.5
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
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Constant Current Regulator
Switchgear System
Series 82XSGS
8.1.5.1 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 on the side of the
trolley. These should be used for lifting the CCR. NOTE: There is a flat metal plate the
fork must clear on the side nearest to the floor.
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.
4.
Adjust CCR power module circuit breaker position so breaker switch actuator and
lockout tabs protrude through the cabinet door. Use a 3/8 inch socket to adjust door plate
and a 5/16 inch wrench to adjust the four circuit breaker bracket screws
DANGER:
DANGER
5.
POWER IS LIVE TO CCR POWER CIRCUIT BREAKER LINE SIDE
WHEN MAIN SYSTEM CIRCUIT BREAKER IS ON AND CCR
POWER IS ENGAGED INTO BUS STABS. THE POWER IS
PRESENT IN THE PROCEEDING CONDITIONS EVEN WHEN
THE CCR POWER MODULE CIRCUIT BREAKER IS IN THE OFF
POSITION.
Install the main circuit card to the cabinet door. Refer to document 2512 included with
the circuit board for further details.
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Switchgear System
Series 82XSGS
8.1.5.2 Load Wiring and Check out
CAUTION:
CAUTION
Do not connect counterpoise system to this terminal.
1. 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:
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.
2. Connect the series lighting circuit to the output of S-1 Safety Switch. Note: There is
connected to S-1 output (load) size provided with L-823 connectors (one male and
one female) attached. Use caution when handling load cable. Electrical hazards may
be present on cable due to field conditions.
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Switchgear System
Series 82XSGS
8.1.5.3 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 figure 9, 10, and 11. See Figure 10
“Connections for use of external control Power.” Be sure to read the notes when
connecting a regulator to an external source of control power. Regulators are shipped for
configured “Internal” control power.
CAUTION:
CAUTION
Incorrect wiring can cause malfunction or damage to the control
system and possibly void the equipment warranty. Recheck these
connections before operating.
2. Apply the yellow “Caution – This Equipment is Supplied By More Than One Power
Source” label supplied with this manual to the cabinet door above its associated CCR
Power Module circuit breaker if you connect to an external remote control source.
3. 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.
8.1.5.4 Final Installation Steps
1. Remove input and control power.
2. Make any option related connections discussed in the option supplements.
3. Check that all cables and wiring are dressed within the cabinet. Reinstall all covers.
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Switchgear System
Series 82XSGS
DEVICE
FUNCTION
ENTER
SETUP
CONTRAST
REMOTE
OFF
1
2
LOCAL
CONTROL
SWITCH
3
5
4
DEVICE
FUNCTION
ENTER
SETUP
CONTRAST
REMOTE
OFF
1
2
LOCAL
CONTROL
SWITCH
3
5
4
Figure 2
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Series 82XSGS
Figure 3
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Figure 4
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Series 82XSGS
Figure 5
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Figure 6
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Figure 7
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Figure 8
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Figure 9
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Series 82XSGS
Figure 9A
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Switchgear System
Series 82XSGS
EXTERNAL NOTE:
Figure 10
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Switchgear System
Series 82XSGS
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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Switchgear System
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8.2.4
Circuit Breaker
The circuit breaker on the regulator turns on/off the main input voltage to the regulator.
WARNING:
WARNING
8.2.5
Power is still present to the circuit breaker line side even when breaker
is in the off position
Bus Engaged Indicator Light
When the CCR power module bus stabs are engaged into their mating halves on the cabinet bus,
the indicator light will illuminate. Note, only turning off the main input power circuit breaker or
de-engaging its associated CCR power module from its cabinet bus stab half, will remove 120V
power from is associated 480/120V step-down transformer. The CCR power module circuit
breaker and door interlock switch are not connected to the indicator light voltage source.
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9
Maintenance
WARNING:
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. Refer to cabinet manual for bus maintenance.
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Series 82XSGS
WARNING:
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.
The control assembly contains parts that 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:
CAUTION
The circuit cards located on the door are static sensitive. Do not
remove or handle them without 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)
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Switchgear System
Series 82XSGS
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.
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Switchgear System
Series 82XSGS
Figure 11 – CCR Wiring Diagram
See following pages for expanded views
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Constant Current Regulator
Switchgear System
Series 82XSGS
Figure 11a
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Switchgear System
Series 82XSGS
Figure 11b
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Series 82XSGS
Figure 11c
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Switchgear System
Series 82XSGS
Figure 11d
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Constant Current Regulator
Switchgear System
Series 82XSGS
Figure 12
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Switchgear System
Series 82XSGS
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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Switchgear System
Series 82XSGS
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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Series 82XSGS
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:
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:
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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Series 82XSGS
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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Switchgear System
Series 82XSGS
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:
CAUTION
Turn off main and control power before removing or installing circuit
cards.
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Series 82XSGS
PROTECTION PROBLEM CHECKLIST
SYMPTOMS
Display reads ‘LOOP;
WHAT TO DO
1. Operate the regulator into shorted load. If
problem clears, open airfield load is
suspected.
2. Observe feedback indicator on the control
board. If OFF, check current transformer
T3 for an open winding. If T3 is OK,
replace 34031 board.
3. While de-energized, check to see if K2
(Solid State Relay) SSR is shorted. If SSR
is shorted replace relay.
4. 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.
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Switchgear System
Series 82XSGS
CAUTION:
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 = 300uF
10kw, 60Hz = 400uF
15kw, 60Hz = 500uF
20kw, 60Hz = 700uF
30kw, 60Hz = 950uF
WARNING:
WARNING
C1 capacitors contain stored energy and should be handled
accordingly.
High steps OK, but low steps are high.
One-step high or low.
Low steps OK, but high steps are low.
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.
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Switchgear System
Series 82XSGS
WARNING:
WARNING
C1 capacitors contain stored energy and should be handled
accordingly.
REGULATION PROBLEM CHECKLIST CONTINUED
SYMPTOM
Current fluctuates over a wide range.
WHAT TO DO
1. Operate the regulator into shorted
load. If problem clears, excessive
lamps out on load is suspected.
2. 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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Switchgear System
Series 82XSGS
CAUTION:
CAUTION
Turn off main and control power before removing or installing circuit
card.
LOCAL CONTROL PROBLEM CHECKLIST
SYMPTOMS
System will not turn on.
1.
2.
System will not turn off.
1.
2.
WHAT TO DO
Observe Contactor indicator.
It
should go on and off when
switching from off to a step. If it
doesn’t then replace 34031 board.
Check K1 coil for open. If open
replace K1. If OK replace 34031
board.
If system will not turn off when the
interlock switch is opened, K1 may
be welded closed.
Observe Contactor indicator. If on
all the time, replace 34031 board.
For further help contact Crouse-Hinds Airport Lighting Products.
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Switchgear System
Series 82XSGS
CAUTION:
CAUTION
Turn off main and control power before removing or installing circuit
card.
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.
2. Test in Local
For further help contact Crouse-Hinds Airport Lighting Products
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Constant Current Regulator
Switchgear System
Series 82XSGS
CAUTION:
CAUTION
Turn off main and control power before removing or installing circuit
card.
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.
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Constant Current Regulator
Switchgear System
Series 82XSGS
CAUTION:
CAUTION
Turn off main and control power before removing or installing circuit
card.
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.
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Switchgear System
Series 82XSGS
Figure 13
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Switchgear System
Series 82XSGS
10
Spare Parts List
10.1 Recommended Spare Parts
Parts that are option related (when installed) are discussed in the respective drawing for that option
at the end of this manual.
RECOMMENDED SPARE PARTS
Item
Number
1
2
Reference
Designation
LA1
T2
3
K1
3
K1
3
K1
4
K2 SSR
4A
5
6
Capacitor
Bank
7
8
T3
8
T3
8
T3
Description
Input Lightning Arrestor
36V/120V Control
Transformer
Contactor, 75A Resistive
(4-10kW Units)
Contactor, 94A Resistive
(15kW Units)
Contactor, 120A Resistive
(20kW Units)
Solid State Relay.
SSR thermal transfer pad
for SSR P/N 10047-2789
Control Board
Capacitor, 50uF, 600V
Display Board
Current Transformer, 6.6A
(4-10kW)
Current Transformer, 6.6A
(15-30kW)
Current Transformer, 20A
48
Crouse-Hinds
Part Number
10047-885
32279
Manufacturer Part
Number
GE 9L15ECB001
10047-1249
32084
32085
10047-2789
(4-30kW)
10047-2937
34031-1
32990
32752
31329
31374
31394
Ronken Industries
91D23506H32
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Constant Current Regulator
Switchgear System
Series 82XSGS
Item
Number
9
Reference
Designation
LA2, LA3
F1, F3, F4
F201, F202
F2
10
11
Description
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
Display PC Board/Switch
Assembly (knob not
included)
Ribbon Cable (Display
Board to Control Board)
49
Crouse-Hinds
Part Number
10053-703
32752
10047-2912
Manufacturer Part
Number
Cooper Power
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