Instruction Manual
Edition 2.1
AM.07.360e
Microprocessor controlled
Constant Current Regulator
Type
MCR³ 2.5 kVA to 30 kVA
Record of Change AM07.360e
Revision
0.0
Initial description
1.0
2.0
2.1
Description
Final description
Editor Checked Date
DT
07/07/04
AHU
MR, PC 14/04/05
Spare part correction
EV
01/03/06
List of alarms added
CME
11/07/06
Spare part correction
EV
30/11/06
Spare part correction Table 5-3: Power components,
input
EV
DT
19/06/07
Please, read this carefully before installing the MCR³!
Safety
precautions
Regulatory safety precautions are applicable in some countries, on some
sites; in absence of such legal prescriptions, the operating and maintenance
personnel should refer to the FAA Advisory Circular AC 150/5340-26
"Maintenance of Airport Visual Aid Facilities" for instructions on safety
precautions. Personnel must observe the safety regulations at all times.
While every practicable safety precaution has been incorporated in this
equipment, the following rules must be strictly observed.
Keep away
from live
circuits
Operating and maintenance personnel must at all time observe all safety
regulations. Neither lamps nor components shall be changed or adjustments
shall be made inside equipment with the light circuit energised.
See FAA Advisory Circular AC 150/5340-26 concerning safety precautions.
See also IEC-61820
Resuscitation
Operating and maintenance personnel should familiarise and keep
themselves trained in the resuscitation techniques laid down in the First Aid
Instruction Manual.
Electrostatic
Discharge
ESD
Modules and components susceptible to electrostatic damage
Electronic modules and components should be touched only when this is
unavoidable e.g. soldering, replacement, etc.
Technicians, operators and all other persons working on the equipment must
first of all eliminate electronic charges from their own bodies just before
touching an electronic module or component. The easiest way of discharging
a human body is to touch a conductive earthed object.
Electronic modules or components must not be brought in contact with highly
insulating materials such as plastic sheets, synthetic fibre clothing, etc.
They must be laid down on conductive surfaces.
The tip of the soldering iron must be earthed.
Electronic modules and components must be stored and transported in
conductive packaging.
2 / 150
Please, read this carefully before installing the MCR³!
Use
restriction
notice
This Instruction Manual is the property of
n.v. ADB s.a .
585, Leuvensesteenweg
B-1930 Zaventem - Belgium
Tel 32 2 722 17 11
Fax 32 2 722 17 64
http://www.adb-air.com
This manual or parts thereof may not be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, nor otherwise, without ADB's prior written consent.
Guarantee
N.V. ADB S.A. guarantees that the performance of the equipment described
in this manual, when sold by ADB or its licensed representatives, meets the
requirements of FAA specification AC 150/5345-10E and IEC 61822.
Any defect in design, material or workmanship, which may occur during
proper and normal use over a period of one (1) year from date of shipment,
will be repaired or replaced by ADB free of charge, ex works. Operational
failure resulting from lamp burnt out, improper maintenance or installation,
damage due to runway maintenance equipment, snow ploughs or aircraft
arresting gear hooks is not considered a result of proper use and is beyond
the scope of the warranty.
Warranty does not cover natural wear and tear or damage arising after
delivery owing to faulty or negligent handling, excessive strain, unsuitable
materials for operation, deficient civil engineering work, unsuitable soil
conditions, and such chemical, electrochemical or electrical influences as
were not assumed at the time of the conclusion of the contract.
All liability for consequences of any inexpert alterations or repairs carried out
by Purchaser or a third party shall be waived.
N.V. ADB S.A. shall in no event be liable to Purchaser for any further claims,
particularly claims for damages not affecting the goods themselves.
The above constitutes the limits of ADB s liabilities in connection with the
constant current regulator covered by this manual.
3 / 150
Table of contents
1
Section 1 General Information and Requirements
1.1 Introduction
1.2 Technical description
1.2.1 Technical data
1.2.2 Output circuit values
1.2.3 Current regulation limits
1.2.4 RV-DV terminals and cut-out SCO
1.2.5 Door-open detection (optional)
1.2.6 Back-indication signals ON and REG. ERR.
1.2.7 Power factor and efficiency
1.2.8 Lightning protection
1.3 Basic configurations
1.3.1 General view
1.3.2 MCR³ 2.5 to 10 kVA rated
1.3.3 MCR³ 15 to 30 kVA rated
1.3.4 MCR³ components
1.3.5 User Interface
1.3.6 User Interface menus
1.4 Brightness steps
1.5 Monitoring functions
1.5.1 List of alarms made available to the ATC Controller / maintenance base
1.6 Remote control and back-indication
1.6.1 General
1.6.2 Straps and dip-switches
1.6.3 Interface module connection
1.7 Earth Fault Detector module (option)
1.8 Lamp Fault Detector module (option)
1.9 Cut-out SCO (option)
1.10 Circuit Selector (Option)
1.11 Hour Counters (Option)
1.12 Equipment required for installation, start-up and troubleshooting but not supplied
1.13 Equipment supplied
1.14 Nameplate
7
7
8
8
8
9
9
9
10
11
12
13
13
14
16
18
25
26
37
38
39
41
41
42
42
43
45
46
47
47
48
48
49
2
Section 2
Installation
2.1 Introduction
2.2 Installation
2.3 Electrical connection
2.3.1 Series circuit connection
2.3.2 Remote control connection
2.3.3 Remote control cable
2.3.4 Multiwire
2.3.5 J-Bus
2.3.6 Signals ON & REG.ERR. (PSL/X7)
2.4 Starting procedure
2.4.1 Tap selection
2.4.2 Tap wiring
2.5 Component replacement and software uploads
2.5.1 Replacement of modules
2.5.3 Replacement of the main contactor
2.5.4 Upload of application code
50
50
51
53
55
56
57
59
63
63
63
63
63
63
63
63
63
3
Section 3
Maintenance
63
4
Section 4
Troubleshooting
63
4 / 150
5
Section 5
Parts List
63
6
Section 6
Drawings
63
7
Section 7
PC Control and Monitoring
7.1 Program MCR3_WIN
7.2 Overview of the screens
7.2.1 MCR3 Control
7.2.2 MCR3 Setup
7.2.3 MCR3 EFD
7.2.4 MCR3 LFD
7.2.5 MCR3 IO Settings
7.2.6 MCR3 Installation Parameters
7.2.7 MCR3 Configuration
7.2.8. MCR3 Exit Screen
63
63
63
63
63
63
63
63
63
63
63
8
Section 8
Appendix
8.1 MODBUS settings
8.2 Default settings multiwire
63
63
63
5 / 150
Table of Pictures
Fig. 1-1: Power factor and efficiency for a MCR³ rated 30 kVA................................................................ 11
Fig. 1-2: MCR³ stand-alone unit................................................................................................................ 13
Fig. 1-3: MCR³ 2.5 to 10 kVA with EFD module, front view - open .......................................................... 15
Fig. 1-4: MCR³ 2.5 to 10 kVA, rear view - open........................................................................................ 15
Fig. 1-5: MCR³ 15 to 30 kVA with EFD / LFD modules, front view - open................................................ 17
Fig. 1-6: MCR³ 15 to 30 kVA, rear view - open......................................................................................... 17
Fig. 1-7: Earth Fault Detector module (MCR³ 15 to 30 kVA) .................................................................... 43
Fig. 1-8: MCR³ Nameplate ( 4072.03.500E) ........................................................................................... 49
Fig. 2-1: Detail of a typical installation ...................................................................................................... 52
Fig. 2-2: Multiwire Inputs........................................................................................................................... 61
Fig. 2-3: Multiwire Outputs ........................................................................................................................ 63
Fig. 2-4: J-Bus connector layout JB / P1, P2, P3 and P4 ......................................................................... 63
Fig. 2-5: Connector layout PSL / X7 ......................................................................................................... 63
Fig. 2-6: 2.5 kVA power transformer, top view ......................................................................................... 63
Fig. 2-7: Tap adjustment MCR³ 4 to 10 kVA............................................................................................. 63
Fig. 2-8: Tap adjustment MCR³ 15 to 30 kVA........................................................................................... 63
Fig. 2-9: Tap wiring ................................................................................................................................... 63
Table of Tables
Table 1-1: MCR³ output circuit values ........................................................................................................ 8
Table 2-1: Mains supply cable sections, fuses ..................................................................................... 54
Table 2-2: Maximum voltages (V RMS) for each tap setting, each power and output current................. 63
Table 3-1: Preventive maintenance .......................................................................................................... 63
Table 4-1: The regulator does not turn on. ............................................................................................... 63
Table 4-2: The regulator turns on but de-energises suddenly.................................................................. 63
Table 4-3: The regulator does not produce the requested output current................................................ 63
Table 4-4: Overview of the fuses .............................................................................................................. 63
Table 5-1: Basic printed circuit boards ..................................................................................................... 63
Table 5-2: Optional printed circuit boards................................................................................................. 63
Table 5-3: Power components, input ........................................................................................................ 63
Table 5-4: Hardware parts ........................................................................................................................ 63
Table 5-5: Connectors .............................................................................................................................. 63
6 / 150
1
Section 1
General Information and Requirements
1.1 Introduction
The MCR³
The ADB MCR³ is a microprocessor-controlled constant current regulator
specially designed for the supply of airport lighting series loops at various
intensity levels.
Purpose
This instruction manual provides general information about installation,
operation, troubleshooting and maintenance. It also contains a parts list.
Scope
This manual covers the ADB MCR³ microprocessor-controlled constant
current regulator manufactured in full compliance with:
ICAO: Aerodrome Design Manual, Part 5 paragraphs 3.2.1.4/5/6
FAA : AC 150/5345-10F and L829
IEC: IEC 61822.
Operation
limits
The constant current regulators are designed for use in airport series lighting
circuits.
They are designed to meet the requirements of the various specifications
mentioned above.
Operation outside the design limitations of these specifications may result in
degradation of performance, damage or failure of regulator components or
hazardous conditions.
All regulators are designed for indoor operation, at an ambient temperature
from -20°C (-40°C on special request) up to +55°C.
(Note: IEC requires only a range from 0°C to +50°C)
All MCR regulators are air-cooled without fans.
Using the regulator at ambient temperatures outside of the specified range
could cause damage. Good ventilation must be provided especially when
operation near the maximum temperature limit is expected.
EMC conformity
The MCR³ is designed to operate in an industrial electro-magnetic
environment, as required by IEC 61822, in accordance with IEC 61000-6-4
and IEC 61000-6-2 (generic standard for industrial environment) with
adapted test levels in accordance with IEC/TS61000-6-5, G (substation
environment, location G).
Accordingly, the MCR³ regulator must not be used in residential, commercial
and light-industrial environment or in harsher environments than substation
environment, location G.
7 / 150
1.2 Technical description
1.2.1 Technical data
Rated powers
2.5/ 4/ 5/ 7.5/ 10/ 15/ 20/ 25/ 30 kVA
Rated input voltages
FAA: 220/ 230/ 240/ 380/ 400/ 415 V (±15 %) (*)
IEC: 230/ 400 V (±15 %) (*)
Rated frequencies
50/ 60 Hz (± 7.5 %)
Series circuit current
Standard 6.6 A; also 20 A for 25 and 30 kVA.
Remote control and
monitoring
Multiwire, industrial field bus (J-Bus) or combined
* 25 and 30 kVA, only for 380/ 400/ 415 V
1.2.2 Output circuit values
Table 1-1
Table 1-1: MCR³ output circuit values
Rated
powers
2.5 kVA
4 kVA
5 kVA
7.5 kVA
10 kVA
15 kVA
20 kVA
25 kVA
30 kVA
25 kVA
30 kVA
Output
current
(A)
6.6
6.6
6.6
6.6
6.6
6.6
6.6
6.6
6.6
20
20
Max. RMS Dielectric test on Max. open circuit
output
output circuit - V RMS output
voltage
(1)
volt.(2)
378
606
757
1136
1515
2272
3030
3788
4545
1250
1500
1895
3030
3790
5680
7575
11360
15150
18940
22730
6250
7500
530
850
1060
1590
2120
3180
4240
5300
6360
1750
2100
Max. open circuit
peak voltage (3)
750
1200
1500
2250
3000
4490
5990
7490
8990
2470
2970
1 50 Hz RMS voltage during 1 min
2 Under worst condition, considered 1.4 times max. RMS output voltage
3 Same conditions as above
8 / 150
1.2.3 Current regulation limits
Limits
The current regulation is guaranteed within the limits of ± 1.5 %, under the
following conditions.
Conditions
From short circuit to full load
For nominal input voltage ± 10 % (IEC) or +10 %/-5 % (FAA)
For ambient temperatures from -20° - +55°C
For an altitude range from 0 (sea level) to 1000 metres
For a relative humidity range of 10 % RH to 95 % RH without dewing
Up to at least 30 % of lamps transformers with an open circuit in their
secondary side, for a load ranging from at least half-load to full-load
Limitations
Operation from -5 % to -15 % (FAA) or from -10 % to -20 % (IEC) of nominal
input voltage with full load can cause too low output current at maximum
brightness step.
Operation at +15 % of the nominal input voltage will be restricted to a
maximum period of 1 hour to avoid overheating or overstressing of the
components.
Readjustment
Although the nominal input voltage is factory-wired, some readjustments are
possible in the ranges 220 - 240 V and 380 - 415 (420 V): consult factory.
1.2.4 RV-DV terminals and cut-out SCO
RV-DV
The interlocking of the SCO (optional) cut-out microswitch and the MCR³ RVDV terminals allows to energise the regulator after the cut-out contacts are
engaged and to de-energise the regulator before the cut-out contacts are
totally opened.
Interrupting the RV-DV link results in removing the power supply to the logic
circuitry and main contactor coil, thus an almost immediate and safe
interruption of the regulator.
1.2.5 Door-open detection (optional)
LMC / CO12
A door switch (with normally open contact) connecting CO12/1 and 3 (2 and
3 are interconnected on the board) will be detected by the logic.
9 / 150
1.2.6 Back-indication signals ON and REG. ERR.
ON &
REG. ERR.
The back-indication signals ON and REG.ERR. are controlled directly by the
current control logic CCL and are available on connector PSL/X7.
This 4-terminal spring cage clamp terminal has the following layout:
terminal 1: ON
terminal 2: COMMON (for contacts to terminal 1, 3 and 4)
terminal 3: REG.ERR./NC (normally closed contact)
terminal 4: REG.ERR./NO (normally open contact)
The signal ON corresponds to the control of the main contactor K1.
The signal REG.ERR. (Regulation Error) will be in rest position in case of
current deviation (open circuit, overcurrent, overload, current deviation, etc.)
or in case of loss of input power (power switched off, input voltage too low,
etc.).
10 / 150
1.2.7 Power factor and efficiency
Power Factor
According to FAA:
At nominal input power, nominal resistive load and maximum brightness:
powers up to 10 kVA:
0.90
powers above 10 kVA:
0.95
According to IEC:
At nominal input power, nominal resistive load and maximum brightness: not
less than 0.90
Efficiency
According to FAA:
At nominal input voltage and resistive load and max. brightness: 90 to 92 %.
According to IEC:
At nominal input voltage and resistive load and all brightness steps the
average efficiency: not less than 80 %.
Taps
By means of output taps on the secondary (high-voltage) side of the power
transformer (PT) the power factor can be optimised in relation to the actual
load at full brightness. The following taps are provided:
actual load between 100 % and 82 % of nominal (8/8)
actual load between 81 % and 71 % of nominal (7/8) (*)
actual load between 70 % and 46 % of nominal (6/8) (*)
actual load between 45 % and 33 % of nominal (4/8)
actual load between 32 % and 22 % of nominal (3/8) (*)
actual load between 21 % and 0 % of nominal (2/8) (*)
* : not on MCR³ 2.5 kVA
Benefits of
Taps
The use of the taps offers the following advantages:
the power factor will be optimised
the main input current will decrease
the harmonic content in the main input current and in the output current will
decrease
the maximum output voltage in case of open-circuit will be reduced
the maximum possible output current in case of catastrophic thyristor failure
(short circuit) will be limited
the power losses will decrease
Example
2/8 3/8 4/8
Taps
6/8
7/8 8/8
100 %
90
Efficiency
80
Power Factor
70
60
50
40
Load
12 25 37 50 75 87 100 %
Fig. 1-1: Power factor and efficiency for a MCR³ rated 30 kVA
11 / 150
1.2.8 Lightning protection
General
Lightning is a natural phenomenon that varies in intensity and frequency
depending on the geographic location.
Therefore the need for additional lightning protection on an installation has to
be examined.
Output
voltage surge
protection
The lightning arrestors LA1 and LA2 (fig.1-3 and 1-5) on the output terminals
of the series circuit protect the output of the MCR³.
Input voltage
surge
protection
Optional lightning arrestors can be installed at the power supply input of the
MCR³.
12 / 150
1.3 Basic configurations
1.3.1 General view
Description
Each stand-alone MCR³ will accept, in one enclosure, a power rack fitted
with the logic boards, the user interface, a fused input switch (in the lowvoltage unit), and the high-voltage components (in the high-voltage unit). The
stand-alone regulators have optional rolling castors. The bolts to fix the top
plate can be replaced by standard lifting lugs.
Picture
Fig. 1-2: MCR³ stand-alone unit
1
4
3
2
5
Part
1
2
3
4
5
Function
Low-voltage compartment
High-voltage compartment
Fused input switch
User interface
SCO (optional)
13 / 150
1.3.2 MCR³ 2.5 to 10 kVA rated
Dimensions
400 x 600 x 930 mm (width x depth x height)
With wheels: height + 100 mm
With lifting lugs:
height + 50 mm
With Circuit Selector: height + 500 mm
With bolts M12:
height +15 mm
Technical data
Rated powers
2.5 / 4 / 5 / 7.5 / 10 kVA
Rated input voltages
220 / 230 / 240 / 380 / 400 / 415 V (±15 %)
Rated frequencies
50/ 60 Hz (± 7.5 %)
Series circuit current
6.6 A
Remote control and
monitoring
Multiwire, industrial field bus (J-Bus) or
combined
14 / 150
Pictures
Fig. 1-3: MCR³ 2.5 to 10 kVA with EFD module, front view - open
User Interface
Fused input switch
Electronic card cage and mains supply
terminals behind UI panel
Nameplate
Earth Fault Detector module (EFD option)
Output current transformers TI 1 and TI 2
Lightning arrestors LA1
LA 2
Choke L1
Fig. 1-4: MCR³ 2.5 to 10 kVA, rear view - open
Remote control interface
boards (MW and J-Bus)
Remote control cable, earth
connection of cable screens
Output transformer
Ground studs M6, one on each side
of the regulator
15 / 150
1.3.3 MCR³ 15 to 30 kVA rated
Dimensions
600 x 600 x 1260 mm (width x depth x height)
With wheels:
height + 100 mm
With lifting lugs:
height + 50 mm
With Circuit Selector:
height + 500 mm
With bolts M12:
height +15 mm
Technical data
Rated powers
15 / 20 / 25 / 30 kVA.
Rated input voltages
220 / 230 / 240 / 380 / 400 / 415 V (±15 %) (*)
Rated frequencies
50 / 60 Hz (± 5 %).
Series circuit current
Standard 6.6 A; also 20 A for 25 and 30 kVA.
Remote control and
monitoring
Multiwire, industrial field bus (J-Bus) or combined
* 25 and 30 kVA, only with 380 / 400 / 415 V
16 / 150
Pictures
Fig. 1-5: MCR³ 15 to 30 kVA with EFD / LFD modules, front view - open
Nameplate
Earth Fault Detector module
(EFD option)
Output current
transformers TI1 and TI2
Tap S6 through S1 for
adjustment to actual load
Lightning arrestors
LA1 - LA2
SCO (optional)
Fig. 1-6: MCR³ 15 to 30 kVA, rear view - open
Remote control interface
boards (MW and J-Bus)
Remote control cable, earth
connection of cable screen
Output transformer
ttransfor
Ground studs M6
17 / 150
1.3.4 MCR³ components
Diagram
Refer to ADB drawing 3229.13.240BA.
Components
description
Power input
1.a
X1 - Input terminals
Accessible behind the User Interface panel.
The size of the input terminals depends on the input current rating.
Up to 50 A:
16 mm²
Up to 100 A: 35 mm²
Above 100 A: 70 mm²
1.b
Wire A02 - Common mode choke
The wires between X1 and F1 are passing through a ferrite core to block the
high frequency common mode currents from the power circuitry.
1.c
F1 Fused main switch
Accessible at the front of the regulator.
Permits to disconnect the regulator from the mains supply.
Fuse value depends on output power and input voltage range of regulator.
Depending on the current range there are two types of fused main switch.
Fuse links in the small cabinet (up to 63 A) are type Neozed DO2 (gL/gG
slow-blow).
In the big cabinet, from 50 A to 125 A the fuse links are type NH00 (gL/gG
slow-blow), knife-blade fuses.
1.d
F2 - To the F1 fuses switch disconnectors (F2/1 & F2/2) are
connected to protect the low current mains connected wiring.
Note: The fuses F3/1 & F3/2 serve to protect the wiring to measure the
primary voltage of the power transformer.
In case of the Circuit Selector an additional switch disconnector (F4/1 &
F4/2) is added to protect the mains wiring of the Circuit Selector (see 24.
CS/F4).
2.
MOV1/A & MOV1/B - (optional) Lightning arrestors (power input)
These lightning arrestors are equipped with a contact to signal if a lightning
arrestor is missing or defective. a local indication DEFECT (in small window
on the lightning arrestor) is given if the lightning arrestor is broken.
The lightning protection limits the voltage towards ground. (The voltage
between supply lines is limited to twice the voltage towards ground.)
3.
K1 - Input main contactor
Capable of interrupting the maximum input current and provide positive
interruption of the input power circuitry on both supply lines. The contactor
coil is equipped with a transient voltage suppressor network (resistorcapacitor network).
4.
TI 1 - Primary current measurement
By means of a small current transformer providing adequate isolation and
permitting precision measurement of the input current.
18 / 150
Components
description
Power input
5.
THP 1 - Series thyristors
To obtain the required output current by phase control (closed loop
regulation system).
6.
L1 - Series choke
To limit the current rise time for thyristors, output transformer and current
loop. This choke is mounted close to the output power transformer T1.
This choke also limits the harmonics on the current waveform.
7.
THP 2 - (optional) Crowbar thyristors
To protect the output circuit from large overloads. Thyristors parallel to load
to derive excessive overcurrents away from load.
This circuit has a small series choke to limit the half cycle short circuit current
below the maximum rated current for the thyristors.
Components
description
Power output
8.
T1 - Output power transformer
Equipped with primary taps to adapt for a typical input voltage of:
, 220, 240, 380, 400 or 416 V 50 or 60 Hz.
The secondary taps permit to adapt the load with the following steps:
8/8, 7/8, 6/8, 4/8 or 2/8 (thus 100 %, 87.5 %, 75 %, 50 % or 25 %).
The transformers are designed for 6.6 or 20 A current circuits.
Note: The power transformer for the 2.5 kVA CCR has only secondary taps
for 100 % and 50 %.
The power transformers for the 25 and 30 kVA CCR are limited to the
primary taps: 380, 400 or 416 V 50 / 60 Hz.
Only for the 25 and 30 kVA CCR, the 6.6 or 20 A versions of the power
transformer are available as standard versions.
9.
TI2 - Output current measurement (value)
By means of a small current transformer providing adequate isolation and
permitting precision measurement of the output current.
Two ways of wiring are possible depending on the maximum output current
value: 6.6 A or 20 A.
10.
TI3 (optional) Output current measurement (waveform)
By means of the same small current transformer as described for point 9.
11.
MOV2/A & MOV2/B - Lightning arrestors
The lightning arrestor size depends on the output power range of the
regulator.
12.
X2 - Output terminals
For output circuit voltages below 1515 V, the output circuit is connected to
screw terminals. (e.g. for regulators up to 10 kVA/ 6.6 A, but also for
regulators 25 and 30 kVA / 20 A).
For output circuit voltages above 1515 V, the series circuit is connected
directly to the lightning arrestors.
In case of the optional SCO the output terminals are replaced by this SCO.
19 / 150
Components
description Logic
13.
PCB1517 - Thyristor Block Module (TBM)
This is the interface between the Current Control Logic and the thyristor
gates. It produces the thyristor gate firing signals in accordance with the
requested conduction angle. It provides also fast over-current protection
(reaction in less than half a period for excessive output current peak value or
if the output current reaches more than 125 % of the nominal maximum
value) and asymmetric output voltage monitoring.
Furthermore this board is capable of producing gate-triggering signals for the
crowbar that can prevent over-currents that are due to excessive load
switching from flowing through the load.
14.
PCB1521 - Power supply of the logic (PSL)
This power supply is designed to deliver +12 / +5 / -12 V to the boards. It will
be fully operational after only 20 ms and will be capable to keep the +5 V
present for at least one half second to permit fast response of the regulator in
case of short power interruptions. In case the power supply to this board is
interrupted its signal Power Good will go low in less than 20 ms leaving
sufficient time to the CCL to prepare a fast restart without loosing control
data. This board provides also, through an autotransformer (100 VA),
230 V AC for the internal 230 V AC components of the regulator. The input
lines have supplementary filtering to reduce the conducted emission of the
regulator.
On this board the logic signals from the Current Control Logic (CCL) are
converted to 230 V AC-control signals.
Furthermore it interfaces several components (current transformer, main
contactor, SCO) with the logic boards of the regulator (low-voltage signals).
15.
PCB1516 - Current Control Logic (CCL)
The brightness step request received by the Current Control Logic and the
actual output current are compared and result in the optimal conduction
angle request.
The CCL checks the output current to be in tolerance, checks for overcurrent or open- circuit condition and produces the back-indication signals.
Furthermore the CCL also monitors the output circuit and the input
parameters (current and voltage values).
16.
PCB1513 - Local Master (LMC)
The Local Master exchanges information via the Local Bus with all the other
modules. This board processes and distributes the messages it receives
from the outer world or from the boards it is connected to.
The LMC is master of the communication on the Local Bus but each slave
has a control line to request transmission of data to the LMC.
One important feature of the Local Bus is the possibility to upgrade the
software of any module.
17.
PCB1507 - User Interface (UI)
Through the User Interface it is possible to operate the regulator and to
change parameters in local mode. The User Interface indicates the actual
measurements of output current and the status of the circuit (input current,
power, voltage, output load, output voltage, circuit insulation resistance and
all possible warnings) through selectable screens on the display.
20 / 150
Components
description
Remote
control
interfacing
18.
PCB1486 - (optional) Multiwire Boards (MW1, MW2 and MW3)
The multiwire interface is a straightforward, non-intelligent device with 8 input
and 8 output terminals.
For a regulator without Circuit Selector, only MW1 and MW2 are used.
The board provides a simple remote control interface through relays giving
total galvanic isolation between the remote control system and the constant
current regulator.
The multiwire interface is connected to the LMC by a flat cable.
Its presence is detected automatically on connection to the LMC.
In case the internal power supply is not used (external remote control power
supply is available) there is no need to connect this PCB to the mains supply.
Alternatively, the customer can use the internal power supply. This supply is
short-circuit protected by self-repairing polyswitches. Both the positive and
the negative pole of this supply can be used for the common pole.
The multiwire interface exists in 2 versions: 24 V DC or 48 V DC control
signals.
For the control signals any polarity is allowed. Suppression of switching
transients of the coils is done with resistor-capacitor networks.
The back-indication signals are given with simple, potential-free, contacts.
19.
PCB1502 - (optional) J-Bus Interface (JB)
This interface board is mounted close to and connected by means of a flat
cable to the LMC. The PCB is equipped with gas arrestors for overvoltage
protection of the external lines. For ease of wiring, there are 4 connectors, 2
for Bus A (standard bus) and 2 for Bus B (redundant bus), permitting one
connector for the cable to the preceding bus user and one connector for the
cable to the next slave on the bus.
For the end units on the bus, the line has to be terminated by means of
resistors (strap connectable to the LMC) to match the load closely to the
characteristic line impedance. This way we obtain a reflection-free, less
disturbance-sensitive communication bus.
The J-Bus interface board is click-mounted in the regulator enclosure. By
disconnecting the flat cable to the LMC and lifting the interface board out of
the regulator it permits to remove the regulator without interrupting the daisy
chain J-Bus connection link of the substation.
21 / 150
Components
description
Output circuit
monitoring
items
20.
PCB1519 - (optional) Lamp Fault Detector (LFD)
The Lamp Fault Detector checks the load of the circuit. If a pre-settable
number of lamp transformers is unloaded (lamp filament interruption) or if a
load falls below a pre-set level a warning signal is generated.
Furthermore this module monitors output current, output voltage and output
power independently of the CCL.
21.
PCB1514 + PCB1515 - (optional) Earth Fault Detector (EFD)
The Earth Fault Detector checks the insulation of the series circuit towards
ground. If the insulation drops below a pre-settable level, a warning signal is
generated.
The measured insulation value is also available for direct display on the UI
and on the bus.
This board is located in the high-voltage compartment close to the output
terminals.
The measurement range goes from about 10 kOhm TO 250 MOhm.
Components
description
Dongle /
Golden Key
22.
Dongle (optional maintenance part)
To change the operational parameters, to check the internal parameters or to
update the software of the equipment by means of a personal computer and
the dedicated parameterisation software (running under Microsoft Windows).
This item is not part of the regulator. It is a tool for maintenance personnel
and can also be used to configure other ADB equipment.
22 / 150
Components
description
Circuit
Selector
23.
PCB1523 - (optional) Circuit Selector Interface
This board is not part of the constant current regulator. It is located in the
Circuit Selector cabinet. The board converts the logic control signals (12 V
DC) from the Current Control Logic board to coil control voltages.
In case of remote control by multiwire signals the multiwire board MW3
serves as the remote control and back-indication interface for the circuit
selection.
24.
CS/F4 (optional) Fuses to protect the power supply to the auxiliary
transformer
These fuses are located close to the main fuse F1 and are accessible after
removing the User Interface panel.
25.
CS/T1 - (optional) Circuit Selector, auxiliary transformer
The coil voltage of the HV contactors is standardized to 230V 50/60Hz. This
autotransformer (250 VA) serves to adapt the MCR³ mains voltage level to
this voltage.
26.
CS/K1 K8 - (optional) Circuit Selector contactors
Depending on the cabinet size there are 2 types of high-voltage contactors.
The number of contactors depends on the number of circuits (2 to 8).
The Circuit Selector can be configured (CCL) to permit any circuit to be
selected (simultaneous mode) or only one circuit at the same time (alternate
mode).
For the large cabinet (above 10 kVA) the HV-circuit connection happens
directly to the HV contactor terminals.
In case of more than 4 circuits for the large cabinet, these circuits are to be
connected at the rear of the cabinet.
For the small cabinet (up to 10 kVA) there are separate connection terminals
for the circuit connection.
23 / 150
Concept
To obtain ease of manufacturing, maintenance and testing, the complete
power range from 2.5 to 30 kVA is based on 3 standardized groups of
primary power circuit wirings, one for a maximum input current rating of
50 A RMS, another for 63 A RMS and the last one for 125 A RMS. Each
group uses the same (or comparable) components, wire cross-sections and
wiring layout.
Type and size of components 1, 3, 4, 5 and 7 depend on these three current
ratings.
Components 6, 8, 11 and 12 depend on the power rating of the regulator.
Components 2, 9, 10, 13, 14, 15, 16, 17, 18, 19, 20 and 21 are common for
all power ratings.
Component 22 is not part of the product but permits to connect a personal
computer to any regulator and to change the operational parameters, to
check the internal parameters or to update the software of the equipment by
means of the dedicated parameterisation software
Components 23, 24 and 25 are for the optional Circuit Selector and are
independent of the output power.
Components 26 are the HV contactors for the Circuit Selector. The contactor
type depends on the enclosure size.
There are two enclosure sizes (ADB designed, metal sheet parts, welded
together) depending on the output power:
Regulators 2.5 - 10 kVA have a housing with a footprint of 400x600 mm.
Regulators 12.5 - 30 kVA have a housing with a footprint of 600x600 mm.
The enclosure is subdivided in a high-voltage compartment containing
components 6, 8, 9, 10, 11, 12 and 21 and a low-voltage compartment
containing the rest.
At the front of the low-voltage compartment are the power supply input
connections and at the rear side the control cable connections. At the left
side, on the outside of the cabinet, the heatsink for the thyristors is mounted.
The User Interface is located at the front side. The low-voltage compartment
contains internally no high power dissipating components.
The output circuit is connected to the output terminals (or the SCO) on the
front side at the bottom of the high-voltage compartment.
The air inlet of the high-voltage compartment is on the front bottom side
while the hot air exhaust is on the top rear side. The ventilation of this
compartment is assured by with non-forced air-cooling.
For the MCR³ 2.5 to 10 kVA, it is possible to mount one regulator on top of
another in this case wheels are NOT allowed.
Additionally the MCR³ can be equipped with a Circuit Selector (CSM)
mounted on top or underneath the regulator and containing components 23
to 26. The CSM has to be considered as an extension of the MCR³. The
control signals from the CCL to the CSM and and the back-indications from
the CSM to the CCL go through the 26-wire flat cable.
24 / 150
1.3.5 User Interface
General
The user interface consists of a 4-line, 40-character display (LCD) and 4
pushbuttons.
The current function of the button is always displayed on the last line of the
LCD just above the pushbutton.
The other lines of the LCD are used to display the regulator data.
For the start menu,
the 1st and 2nd button permit to switch between local or remote control,
the 4th button has the function to reset an error condition
and the 3rd button permits to switch to the next menu.
In this menu, pushing the 1st and 2nd button results in a current step change if
the regulator is operated in local (function STP DOWN and STP UP).
The 3rd and 4th buttons now serve to navigate throught the menus.
The back-lighting is activated on pushing the 1st, 2nd or 3rd button.
To obtain permanent back-lighting of the display: adjust the Display time out
to above 124.5 s. The display will indicate LOCK and the back-lighting of
the display will be permanently on. If the back lighting is "on" all the time,
the power supply will not be able to handle short power supply interruptions
>0.5 seconds. Therefore we recommend NOT leaving the backlighting on.
Note that parameter changing is only possible in local control.
Picture
User Interface
25 / 150
1.3.6 User Interface menus
START MENU
Note: The User Interface will only be operational after the message:
Please WAIT...
has disappeared (in the first line).
This menu displays in the first line the regulator name (maximum 20
characters) and control mode of the regulator: Local, Remote or GK active.
The second line displays the actual output current, actual circuit selection
and indicates if there are any errors ( No errors or Errors ! ).
The third line displays the actual Step and EFD measurement (if present).
The fourth line indicates the functions for the pushbuttons:
REMOTE
Pushbutton
REMOTE
LOCAL
MENU
RESET
LOCAL
MENU
RESET
Function
To switch between remote and local control
To gain access to the other menus
To clear fatal error conditions (overcurrent, open circuit, overload)
Pushing MENU leads you to the second main menu where the pushbuttons
have the following functions:
STP DOWN STP UP
Pushbutton
STP DOWN
STP UP
MENU
BACK
MENU
BACK
Function
To change the brightness step while the regulator is in Local control
To gain access to the other menus
To return to the start menu
Pushing MENU results in a changed functionality for the pushbuttons:
DOWN
Pushbutton
DOWN
UP
START
BACK
UP
START
BACK
Function
To scroll through the start menu line per line and display:
- input voltage and LFD measurement (if LFD present)
- output voltage, output loading
- input current
To gain access to the other submenus
To return to the previous pushbutton menu
Pushing START results in entering a list of submenus with the following
functionality for the pushbuttons:
DOWN
Pushbutton
DOWN
UP
SELECT
BACK
UP
SELECT
BACK
Function
To scroll through the list of submenus. The asterisk (as first character of the
line) indicates the selected item.
To gain access to the selected submenu
To return to the previous pushbutton menu
26 / 150
First level submenus are:
MCR3: Control
(1.3.6.1)
MCR3: View errors
(1.3.6.2)
3
MCR : Setup
(1.3.6.3)
CSM: Circuit Selector
(1.3.6.4)
EFD: Earth Fault Detector
(1.3.6.5)
LFD: Lamp Fault Detector
(1.3.6.6)
LFD: LFD Calibration
(1.3.6.7)
Hour Counters
(1.3.6.8)
Display
(1.3.6.9)
Each submenu permits again to select lower level submenus down to the
level where the required parameter is displayed.
1.3.6.1 The first submenu is MCR3: Control
*
MCR3 Master:
Step:
Circuit 1:
Circuit 2:
Circuit 3:
Circuit 4:
Circuit 5:
Circuit 6:
Circuit 7:
Circuit 8:
DOWN
UP
Local
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
SELECT
BACK
The asterisk indicates the item for which a submenu can be entered by
pushing SELECT..
Pushbutton
DOWN
UP
SELECT
BACK
Function
To scroll through the list of items to select a further submenu
To gain access to the selected submenu
To return to the previous pushbutton menu
Selecting the item MCR3 Master in the displayed list leads to a submenu
where it is possible to toggle between Remote and Local control:
TOGGLE
Pushbutton
TOGGLE
TOGGLE
SELECT
BACK
TOGGLE
ACCEPT
Function
To toggle between Local and Remote control
To confirm the selection
To return to the previous pushbutton menu
27 / 150
ABORT
Selecting item STEP in this list permits to change the step in LOCAL control:
DOWN
Pushbutton
DOWN
UP
ACCEPT
ABORT
UP
ACCEPT
ABORT
Function
To change the step in local control
To confirm the selection
To reject the selection
Selecting a Circuit x is only possible in local control if:
the Circuit Selector is present (hardware detection by logic of CCL)
and circuit x is enabled (see paragraph 1.3.6.4)
TOGGLE
TOGGLE
ACCEPT
ABORT
1.3.6.2 The second submenu is MCR3: View errors
(Note that the START MENU displays if there are any errors.)
The LCD displays now all the errors having occurred (if there are any) since
the regulator was powered up. The pushbutton functions are:
DOWN
Pushbutton
DOWN
UP
DELETE
BACK
UP
DELETE
BACK
Function
To scroll through this list
To clear this list
To return to the previous pushbutton menu
Note the following messages are possible
Faults
Alarm Status
MCR³ Faults
Overcurrent
Crest factor
Zero crossing detection
Open circuit
Measurement connector disconnected
Output current deviates
Overload
Output current unstable
Asymetric output current
Door open
MOV blown
AGL disconnected
Thermal sensor missing
E
W
W
E
W
W
W
W
W
E
W
W
W
28 / 150
Mains voltage low
Mains voltage high
Mains voltage unstable
Power loss imminent
Mains frequency out of range
CSM disconnected
CCL calibration error
CSM error
W
W
W
W
W
W
W
E
EFD Faults
EFD level 1 reached
EFD level 2 reached
EFD calibration is running
EFD is OFF because MCR³ is OFF
E
E
W
W
LFD Faults
LFD level 1 reached
LFD level 2 reached
LFD VA drop level 1 reached
LFD VA drop level 2 reached
LFD is calibrating
REFERENCE calibration not done
LAMPS REMOVED calibration not done
E
E
E
E
W
W
W
W
HOUR COUNTERS faults
Limit exceeded for any current hours couter
Limit exceeded for threshold hours counter
Limit exceeded for CSM circuit 1 8 hours counter
W
W
W
JBUS Faults
BUS A is DOWN
BUS B is DOWN
CCL calibration error
CSM error
E
E
W
E
EFD Faults
EFD level 1 reached
EFD level 2 reached
E
E
E= ERROR
W=WARNING
1.3.6.3 The third submenu is MCR3: Setup
29 / 150
With the following submenus:
Output current
Step data
Default mode
Supply voltage
MCR3 IO
Versions
Serial Numbers
(1.3.6.3.1)
(1.3.6.3.2)
(1.3.6.3.3)
(1.3.6.3.4)
(1.3.6.3.5)
(1.3.6.3.6)
(1.3.6.3.7)
1.3.6.3.1 Output current
Parameters
Range
Nominal output current
6.6 or 8.3 or 12 or 20
A
2.0 - 7.5 %
1.0 - 12.0 s
4.5 - 25 %
0.0 - 10.0 s
0.0 - 2.5 s
1.5 25%
1.0 - 12 s
0.0 - 1.0 s
NO / YES
0.00 - 2.40A
Overcurrent level 1
Overcurrent delay 1
Overcurrent level 2
Overcurrent delay 2
Step settling speed
Regulation error value
Regulation error delay
Switch ON delay
Switch OFF if overload
Shut-down current
value
Remote reset allowed
MCR in stopbar mode
YES / NO
NORMAL/STOPBAR
Adjustmen
t
Value
Pushbutton menu
0.1 %
0.1 s
0.1 %
0.1 s
0.1 s
0.1 %
0.1 s
0.1 s
Toggle
0.01 A
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
TOGGLE TOGGLE ACCEPT ABORT
DOWN UP ACCEPT ABORT
Toggle
Toggle
TOGGLE TOGGLE ACCEPT ABORT
TOGGLE TOGGLE ACCEPT ABORT
DOWN
UP ACCEPT ABORT
Note that access to the parameter nominal output current results in the
message:
* Critical parameter
Hit BACK to abort
Hit CONTINUE to proceed
CONTINUE
BACK
Because this value changes the regulated output current, the operator is
requested to confirm access to the parameter setting menu.
1.3.6.3.2 Step data
Parameters
Number of steps
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Step 7:
Step 8:
Range
3 or 4 or 5 or 6 or 7 or 8
1.8 up to value of next step
Value step 1 up to next step
Value step 2 up to next step
Value step 3 up to next step
Value step 4 up to next step
Value step 5 up to next step
Value step 6 up to next step
Value step 7 up to max. value
Adj.
Value
0.01 A
0.01 A
0.01 A
0.01 A
0.01 A
0.01 A
0.01 A
0.01 A
Pushbutton menu
DOWN UP ACCEPT
DOWN UP ACCEPT
DOWN UP ACCEPT
DOWN UP ACCEPT
DOWN UP ACCEPT
DOWN UP ACCEPT
DOWN UP ACCEPT
DOWN UP ACCEPT
DOWN UP ACCEPT
ABORT
ABORT
ABORT
ABORT
ABORT
ABORT
ABORT
ABORT
ABORT
Note that a difference of at least 0.1 A is required between two steps for a
6.6 A regulator (0.3 A for a 20 A regulator).
30 / 150
1.3.6.3.3 Default mode
Parameters
Default mode
Range
Use default / Use actual
Adj.
Toggle
Default time
Default step
Default CSM
3 - 240 s
OFF,1 ,2 ,3 ,4 ,5 ,6 ,7 or 8
Each circuit: select
and then toggle ON/OFF
1s
Value
Value
ON/OFF
Pushbutton menu
TOGGLE TOGGLE ACCEPT
ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
TOGGLE TOGGLE ACCEPT
ABORT
Note that default selections are only possible with Default mode activated.
Note that disabled circuits cannot be toggled.
1.3.6.3.4 Supply voltage
Parameters
Nominal supply
voltage
Mains frequency
Fuse range
Mains switch
OFF level
Mains switch
ON level
Mains warning level
Range
220, 230, 240, 380, 400 or
415 V
50 or 60 Hz (measured)
63 or 125
70 - 80 %
Adj.
Value
Pushbutton menu
DOWN UP ACCEPT ABORT
Toggle
1%
DOWN
DOWN
DOWN
UP ACCEPT ABORT
UP ACCEPT ABORT
UP ACCEPT ABORT
80 - 90 %
1%
DOWN
UP ACCEPT ABORT
110 - 130 %
1%
DOWN
UP ACCEPT ABORT
Note that access to the parameter nominal supply voltage results in the
message:
* Critical parameter
Hit BACK to abort
Hit CONTINUE to proceed
CONTINUE
BACK
Note that the mains frequency is a parameter that cannot be adjusted.
The regulator is capable of operating at 50 or 60 Hz. The displayed value is a
result of a measurement by the TBM.
31 / 150
1.3.6.3.5 MCR3 IO
Parameters
Multiwire 1
Multiwire 2
Multiwire 3
Bus A
Bus B
Display
Present / Missing
Present / Missing
Present / Missing
Present / Missing
Present / Missing
How obtained
Detection
Detection
Detection
System conf.
System conf.
Pushbutton menu
DOWN UP SELECT
DOWN UP SELECT
DOWN UP SELECT
DOWN UP SELECT
DOWN UP SELECT
Parameters
Arbiter
Local Kill
Range
MW only, Disabled
OFF/ON
Adj.
Value
Toggle
Temperature limit
Mains protection
40 TO 70°C
Present / Missing
1 °C
Toggle
Door Open
Present / Missing
Toggle
Pushbutton menu
DOWN UP ACCEPT ABORT
TOGGLE TOGGLE ACCEPT
ABORT
DOWN UP ACCEPT ABORT
TOGGLE TOGGLE ACCEPT
ABORT
TOGGLE TOGGLE ACCEPT
ABORT
Note
BACK
BACK
BACK
BACK
BACK
If multiwire is present, pushing SELECT leads to the following submenus:
o Multiwire input functions: permits to display the control signal function
for each input
o Multiwire output functions: permits to display the back-indication
function for each output
If Bus is present, pushing SELECT leads to the following submenus:
o Slave number: this message (only displayed for Bus A) indicates the
address of the regulator on the J-Bus (selected on LMC by means of
dip-switches).
o Bus x baudrate: permits to change the baudrate: 9600, 19200 or
38400 Baud.
o Bus x parity: permits selection of EVEN, ODD or NONE.
Arbiter: determines the remote control signal source and, if required,
governs the priority for different systems. Depending on the factory
configuration following selections are possible:
o Disabled
o MW only
o A only
o B only
o A then B
o B then A
o MW ctrl, A mon
o MW ctrl, B mon
o A then MW
o B then MW
Multiwire 3 is reserved for Circuit Selector functionality.
J-Bus baudrate and parity settings for channels A and B are independent.
32 / 150
1.3.6.3.6 Versions
Parameters
UI version
LMC version
EFD version
LFD version
CCL version
TBM version
Note
Display
Pushbutton menu
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
Display of currently used software version
and boot version of the microcontroller
The currently active software version is useful information for maintenance and
troubleshooting. In case a module is not detected by the Local Bus the software
version is represented as -.--".
1.3.6.3.7 Serial Numbers
Parameters
UI version
LMC version
EFD version
LFD version
CCL version
TBM version
Note
Display
Pushbutton menu
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
Display of serial number of module
and type identification of microcontroller
The serial number of the module is useful information for the traceability of the modules.
In case a module is not detected by the Local Bus the serial number is represented as
-.--".
1.3.6.4 The fourth submenu is CSM: Circuit Selector
CSM: Circuit Selector
Parameters
CSM installed
CSM mode
Circuit 1
Circuit 2
Circuit 3
Circuit 4
Circuit 5
Circuit 6
Circuit 7
Circuit 8
Note
Range
Missing / Present
Alternate / Simultaneous
Disabled / Enabled
Disabled / Enabled
Disabled / Enabled
Disabled / Enabled
Disabled / Enabled
Disabled / Enabled
Disabled / Enabled
Disabled / Enabled
Adj.
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Pushbutton menu
TOGGLE TOGGLE ACCEPT
TOGGLE TOGGLE ACCEPT
TOGGLE TOGGLE ACCEPT
TOGGLE TOGGLE ACCEPT
TOGGLE TOGGLE ACCEPT
TOGGLE TOGGLE ACCEPT
TOGGLE TOGGLE ACCEPT
TOGGLE TOGGLE ACCEPT
TOGGLE TOGGLE ACCEPT
TOGGLE TOGGLE ACCEPT
ABORT
ABORT
ABORT
ABORT
ABORT
ABORT
ABORT
ABORT
ABORT
ABORT
Note that access to the parameter CSM installed results in the message:
* Critical parameter
Hit BACK to abort
Hit CONTINUE to proceed
CONTINUE
33 / 150
BACK
1.3.6.5 The fifth submenu is EFD: Earth Fault Detector
EFD: Earth Fault Detector
Parameters
Range
EFD Control
disabled / enabled
EFD Reset error
NO / YES
3
EFD ON if MCR is
YES / NO
OFF
EFD Startup
4 - 120 s
EFD Level 1
1 - 255 MOhm
EFD Level 2
0.06 m - 9.99
MOhm
EFD Calibration
Note
Adj.
Toggle
Toggle
Toggle
Pushbutton menu
0.1 s
0.1
MOhm
0.01
MOhm
Toggle
DOWN
DOWN
UP ACCEPT ABORT
UP ACCEPT ABORT
DOWN
UP ACCEPT ABORT
TOGGLE TOGGLE ACCEPT ABORT
TOGGLE TOGGLE ACCEPT ABORT
TOGGLE TOGGLE ACCEPT ABORT
TOGGLE TOGGLE ACCEPT ABORT
Rule of thumb for the startup time = 4 s / km cable length (as long as cable
capacitance is less than 0.2 µF/km).
EFD Calibration performs the calibration of the EFD module.
1.3.6.6 The sixth submenu is LFD: Lamp Fault Detector
LFD: Lamp Fault Detector
Parameters
LFD Control
LFD Degraded mode
LFD Level 1
LFD Level 2
LFD VA-drop level 1
LFD VA-drop level 2
Range
Disabled / Enabled
NO / YES
1 - 4 lamps
3 - 31 lamps
1 - 19 %
11 - 50 %
Adj.
Toggle
Toggle
1 lamp
1 lamp
1%
1%
34 / 150
Pushbutton menu
TOGGLE TOGGLE ACCEPT ABORT
TOGGLE TOGGLE ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
DOWN UP ACCEPT ABORT
1.3.6.7 The seventh submenu is LFD: LFD Calibration
LFD: Lamp Fault Detector
Parameters
LFD View sets
LFD Active set
LFD Select CSM
circuits
Warm-up time
Do REFERENCE
Calibration
No. of lamps removed
Do LAMPS REMOVED
calibration
Erase calibration
Range
To check the different
circuit combinations
for the LFD
calibration (one out of
8 sets)
Selection of the
circuit combination
(set) to be calibrated.
As long as none is
selected the display
will indicate Invalid
Selection of the
circuit combination for
which the LFD
calibration should be
performed
10 1200s
Start of calibration
Adj.
Pushbutton menu
DOWN UP SELECT BACK
1s
Toggle
DOWN UP SELECT BACK
DOWN UP SELECT BACK
1-31 lamps
Start of calibration
1 lamp
Toggle
DOWN UP SELECT BACK
DOWN UP SELECT BACK
Erasure of the LFD
calibrations for the
active set
Toggle
DOWN UP SELECT BACK
DOWN UP SELECT BACK
DOWN UP SELECT BACK
35 / 150
1.3.6.8 The eighth submenu is Hour Counters
Depending on the configuration of the regulator, the Hour Counters are
disabled or enabled.
In case the Hour Counters are enabled and for a regulator without Circuit
Selector the following submenus are available (counting regulator ON times
or counting above threshold times):
Hour Counters
Parameters
Hrs. Cnt: any current
Hrs. Cnt: above threshold
Range
Adj.
Range
Adj.
1h
1h
0.01 A
Pushbutton menu
DOWN UP
BACK
DOWN UP
BACK
Hour Limits
Parameters
Hrs. Lim: any current
Hrs. Lim: above threshold
Threshold current
0 - 6.6 A
Pushbutton menu
DOWN UP SELECT BACK
DOWN UP SELECT BACK
DOWN UP SELECT BACK
In case the Hour Counters are enabled and for a regulator with a Circuit
Selector the following submenu is available (with one Hour Counter per
circuit):
Hour Counters
Parameters
Hrs.Cnt: Circuit 1
Hrs.Cnt: Circuit 2
Hrs.Cnt: Circuit 3
Hrs.Cnt: Circuit 4
Hrs.Cnt: Circuit 5
Hrs.Cnt: Circuit 6
Hrs.Cnt: Circuit 7
Hrs.Cnt: Circuit 8
Range
Adj.
1h
1h
1h
1h
1h
1h
1h
1h
Pushbutton menu
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
DOWN UP
BACK
1.3.6.9 The ninth submenu is Display
Default mode
Parameters
Display contrast
Display time out
Embedded language
Extra language
Note
Range
0 100 %
5.0 to 124.5 s (or LOCK)
English
None
Adj.
1%
0.1 s
None
None
Pushbutton menu
DOWN UP ACCEPT
DOWN UP ACCEPT
DOWN UP SELECT
DOWN UP SELECT
ABORT
ABORT
BACK
BACK
To obtain permanent back-lighting of the display: adjust the Display time-out
to above 124.5 s. The display will indicate LOCK and the back-lighting of
the display will be permanently on.
36 / 150
1.4 Brightness steps
Introduction
The regulator is delivered with factory programmed default brightness steps.
Each brightness step can be readjusted between the maximum and the
minimum current value with the PC software.
Default values
The table below shows the current values for each brightness step in
function of the number of steps.
Imax (A)
Imin (A)
Brightness step
selection
1
2
3
4
5
6
7
8
Imax (A)
Imin (A)
Brightness step
selection
1
2
3
4
5
6
7
8
6.6
1.8
3
4.8
5.5
6.6
4
3.3
4.4
5.5
6.6
No of steps
5
6
2.8 2.7
3.4 3.4
4.1 3.9
5.2 4.5
6.6 5.4
6.6
7
2.2
2.8
3.4
4.1
5.2
6.4
6.6
8
2.8
3.1
3.4
3.9
4.6
5.5
6.4
6.6
7
6.7
8.5
10.3
12.4
15.8
19.4
20
8
8.5
9.4
10.3
11.8
13.9
16.7
19.4
20
20
5.5
3
4
14.5 10
16.7 13.3
20 16.7
20
No of steps
5
6
8.5 8.2
10.3 10
12.4 11.8
15.8 13.6
20 16.4
20
37 / 150
1.5 Monitoring functions
Output current
monitoring for
open circuit
The MCR³ creates an alarm message and switches off when the output
current drops below the minimum output current. The restart of the MCR³ is
only possible after troubleshooting and reset (reset button is 4th button on
user interface in start menu).
Output current
monitoring for
overcurrent
The MCR³ creates an alarm message and switches off when the output
current is higher than one of the two preset levels and after the
corresponding delay of each level. The restart of the MCR³ is only possible
after troubleshooting and reset (reset button on the front panel).
Mains supply
voltage
monitoring
Undervoltage: if the mains supply voltage drops below a certain (useradjustable) level, the MCR³ switches off.
When the mains supply voltage has reached a higher (user-adjustable) level
again, the MCR³ restarts automatically.
Overvoltage: an alarm will be generated when the mains supply voltage
reaches a (user-adjustable) level.
Monitoring of
overload
In case of overload the output current may be lower than required.
The MCR³ can be programmed by the user to consider this as an opencircuit condition and to switch off in this case, requiring local reset.
(The default reaction is not to switch off the MCR³!)
38 / 150
Monitoring of
output current
surge
limitation
A fast response network fires back the thyristors if the peak value of the
output current reaches a value greater than twice the maximum peak value
in normal operation. The thyristors remain in the off-state for at least one
period followed by smoothly increasing the firing angle from zero back to the
normal value.
At the instance the peak is detected, the optional crowbar will be switched
on during one half-period to prevent any overcurrent in the field circuit
Monitoring of
output current
for
overcurrents
During operation, due to load switching or sudden load variation, the output
current may exceed 125 % of the nominal maximum.
To improve the reaction time of the regulator a fast rough current
measurement circuit (approximated RMS value) is used to readjust the
conduction angle (half the value) as soon as the overcurrent is about 115 %
of the nominal current.
1.5.1 List of alarms made available to the ATC controller / maintenance base
Faults
Alarm Status
MCR³ Faults
Overcurrent
Crest factor
Zero crossing detection
Open circuit
Measurement connector disconnected
Output current deviates
Overload
Output current unstable
Asymetric output current
Door open
MOV blown
AGL disconnected
Thermal sensor missing
Mains voltage low
Mains voltage high
Mains voltage unstable
Power loss imminent
Mains frequency out of range
CSM disconnected
CCL calibration error
CSM error
E
W
W
E
W
W
W
W
W
E
W
W
W
W
W
W
W
W
W
W
E
E= ERROR
W=WARNING
39 / 150
Faults
Alarm Status
EFD Faults
EFD level 1 reached
EFD level 2 reached
EFD calibration is running
EFD is OFF because MCR³ is OFF
E
E
W
W
LFD Faults
LFD level 1 reached
LFD level 2 reached
LFD VA drop level 1 reached
LFD VA drop level 2 reached
LFD is calibrating
REFERENCE calibration not done
LAMPS REMOVED calibration not done
E
E
E
E
W
W
W
W
HOUR COUNTERS faults
Limit exceeded for any current hours couter
Limit exceeded for threshold hours counter
Limit exceeded for CSM circuit 1 8 hours counter
W
W
W
JBUS Faults
BUS A is DOWN
BUS B is DOWN
CCL calibration error
CSM error
E
E
W
E
EFD Faults
EFD level 1 reached
EFD level 2 reached
E
E
E= ERROR
W=WARNING
To make the warnings available to the tower, this option should be activated via
the U/I.
40 / 150
1.6 Remote control and back-indication
1.6.1 General
Basics
The MCR³ permits the combination of multiwire and J-Bus (single or dual)
systems. The LMC is equipped with the RS485 interfacing circuitry for the JBus and permits the connection of up to 3 multiwire interface boards.
The microcontroller of the LMC processes the J-Bus communication and
controls the data transfer over the Local Bus between the different modules.
In case a multiwire board is connected to the LMC this module is recognized
on powering up and depending on the configuration of the system the remote
control is executed via with the MW modules or via J-Bus.
Multiwire
In case a multiwire is connected to the LMC this module is recognized by the
logic.
Up to 3 modules can be used.
All inputs and outputs of MW1 and MW2 are configurable.
MW3 is reserved for the circuit selection operation
Each multiwire board contains 8 inputs and 8 outputs, each individually
configurable.
Two versions exist: 48 V DC or 24 V DC remote control voltage. The internal
remote control voltage can be wired so that any polarity is permitted of the
relay coils.
For an external remote control voltage source any polarity is allowed.
(Suppression of switching transients of the coils is done with resistorcapacitor networks.)
The internal remote control source is floating towards ground level and shortcircuit protected by self-repairing polyswitches. The maximum current is
200 mA for 48 V DC and 400 mA for 24 V DC. Note that the output voltage of
this power supply is fully dependent on the input voltage.
Remote control input characteristics:
Remote control voltage
Minimum voltage
Maximum voltage
Current consumption
per relay input
48 V DC
40 V DC
65 V DC
about 9 mA at
48 V DC
24 V DC
21.6 V DC
35 V DC
about 16 mA
at 24 V DC
The back-indication signals are given with simple, potential-free contacts.
If necessary, the positive pole of the internal remote control voltage can be
connected to the common of the back-indication signals by means of a strap.
The maximum contact load is:
AC
DC
110 V - 0.5 A
110 V - 0.5 A
60 VA
30 W
41 / 150
J-Bus
RS485 signals: differential mode, 5 V (max.) signals.
Possible over 2 or 4 wires.
The RS485 signals are isolated from the other board signals (500 V DC
level) and the 0V of the RS485 signal is available on the terminal block.
Cable length of the J-Bus is limited to 1200 m for copper wire.
Operation is possible with a single J-Bus or A dual J-Bus version (factory
programmed).
The dual J-Bus makes the control system fully redundant up to the CCR.
The J-Bus can be configured (by setting the switches on the LMC) for 2-wire
or 4-wire communication.
The 0V of the isolated power supply for the RS458 serial bus must be
interconnected between all the MCR³ s. This 0V is kept close to the ground
level by means of a power zener diode
J-Bus
Master/ Slave
A MCR³ is always a slave on the J-Bus. There can be a maximum of 31
MCR³s on one bus section with one common bus master.
Signal ON &
REG.ERR.
(PSL/X7)
These back-indication signals are given with simple, potential-free contacts.
The maximum contact load is:
AC 110 V 2 A 220 VA
DC 110 V 2 A 60 W
1.6.2 Straps and dip-switches
For a detailed description of strap setting and dip-switch setting:
see section 6.
1.6.3 Interface module connection
For a detailed description of the interface module connection:
see section 2.3.
42 / 150
1.7 Earth Fault Detector module (option)
Principle
The Earth Fault Detector module measures the insulation resistance
between the series circuit and the ground or the cable screen with the
regulator switched to the supply, even when not running. A stabilised,
current-limited voltage of 500 V DC is applied between the series circuit and
the ground or cable screen, irrespective of the operating voltage, via a highvoltage resistor. The insulation resistance is determined on the basis of the
resulting leakage current.
Measurement
range
The measurement range is from 10 kOhm to 0.5 GOhm. The insulation
resistance can be displayed on the User Interface.
Two levels
Two alarm levels are available.
Level 1 can be set from 1 MOhm to 225 MOhm.
Level 2 can be set from 60 kOhm to 10 MOhm.
Alarm
If the insulation value drops below the alarm level, an earth-fault error
message is displayed on the User Interface and a back-indication signal is
generated. If the insulation level returns above that level, the alarm remains
latched. Reset is possible with the RESET EFD button on the User
Interface (submenu EFD) or via a remote control command.
PC settings
For the settings and calibration, refer to section 7.
Picture
Fig. 1-7: Earth Fault Detector module (MCR³ 15 to 30 kVA)
EFD HV resistors
EFD logic
43 / 150
1.8 Lamp Fault Detector module (option)
Theory
The Lamp Fault Detector module (LFD) measures the reactive power
required to saturate the unloaded lamp transformers of the series loop by
integrating the series loop voltage (obtained through the voltage transformer)
during a measuring window (derived from the output current and voltage
measurement).
The measured voltage with all the lamps of the series loop intact is
compensated to obtain a zero-volt reading.
With a defined number of lamps in open circuit the module can be calibrated
to obtain a read-out corresponding to the number of lamps deactivated.
Restrictions
To obtain acceptable measurements by the LFD, the following restrictions
apply:
All lamp transformers have to be of the same rating and type because the
LFD detects unloaded lamp transformers, not lamp power. This means
also that defective lamps shorted out by cut-outs will not be detected.
Low reactive and constant loadings:
The cable capacitance towards ground should be less than 1 µF and
should be equally distributed over the loop. (Note: The cable capacitance
towards ground can be checked. Without output current but with the EFD
operational, a multimeter with an internal resistance of 10 MOhm is
connected to the output of the MCR³. A reading of 400 V DC corresponds
to a perfect insulation of the cable. After disconnecting the 500 V DC
source of the EFD the discharging time of the cable capacitance through
the multimeter from 400 V DC to 147 V DC is measured. The measured
voltage should decrease in about 10 seconds for a cable capacitance of
1 µF from 400 V DC to 147 V DC (=0.37x400). If the initial voltage has
already dropped to 330 V DC this means that the cable leakage
resistance equals about 10 MOhm. The discharge time in this case will
be about 5 seconds for a cable capacitance of 1 µF.)
No non-linear loads (guidance signs, BRITE, serial-to-parallel adapter...).
Poor contacts at primary or secondary of lamp transformers will also
cause arcing and non-linear loading.
Only two circuits or circuit combinations can be calibrated. For other
circuit combinations the readings will be neglected. The LFD is not
compatible with Circuit Selectors or switching, variable loads.
Tolerances
If the above mentioned restrictions are fulfilled, the tolerance will be:
for 0 to 5 burnt lamps : + 1 lamp
for 6 to 10 burnt lamps: + 2 lamps
PC settings
For the settings and calibration refer to section 7.
44 / 150
1.9 Cut-out SCO (option)
Cut-out SCO
As an option, the MCR³ regulator can be delivered with a cut-out SCO
mounted onto the bottom part of the front panel.
The purpose is to isolate safely the series circuit from the CCR during
maintenance or testing operations. It also allows periodical isolation
resistance measurement series circuit to ground without disconnecting the
series cable.
Refer to instruction manual AM.06.455e.
Mode of
operation
The table below describes the different working positions.
Switch off the constant current regulator before manipulating the cut-out.
Position A
Position B
Position C
Allows the
regulator to deliver
current to the
series circuit.
Maintenance can
be done safely on
the series circuit.
The series circuit insulation relative to
ground can be measured by applying the
measurement voltage, max. 9000 V DC,
between the measurement terminal (7)
and the ground strip.
Handle
horizontal
turned 90° ccw.
from position A
turned 90° cw. from position A
The series
circuit is
connected to the
CCR
shorted and
grounded
disconnected from the CCR, shorted and
connected to the measurement terminal
The CCR is
delivering current
to the series circuit
shorted and
grounded
shorted and grounded
activated and
The microswitch
allows the CCR to
(2) is
be ON
not activated and
inhibits the CCR to
be ON
activated and allows the CCR to be ON
can be locked with
the key
can be locked with
the key
can be locked with the key
Mode of
operation
Diagram
Cover
The cover
1. The position of the cover intermediate between B and C, i.e. turned 180°
from position A, cannot be used and the cover cannot be plugged into the
body.
2. An activated microswitch means that the normally open contact is closed
and that the normally closed contact is open. For interlocking with the
CCR, only the normally open contact will be used.
45 / 150
1.10 Circuit Selector (Option)
Circuit
Selector
Additionally the MCR³ can be equipped with a Circuit Selector mounted
underneath the regulator.
The Circuit Selector is to be considered as an extension of the MCR. The
control signals from the CCL to the CSM and the back-indications from the
CSM to the CCL go through a 26-wire flat cable.
Depending on the power rating of the regulator there are two types of highvoltage contactors. The number of contactors depends on the number of
circuits (2 TO 8).
The power supply for the coils of the high-voltage contactors is derived from
the input power of the regulator. By means of a transformer this input voltage
is adapted to a typical coil voltage of 230 V AC.
The Circuit Selector can be configured (CCL) to permit any circuit to be
selected (simultaneous mode) or only one circuit at the same time (alternate
mode).
For the large cabinet (above 10 kVA) the HV circuit connection happens
directly to the HV contactor terminals.
In case of more than four circuits for the large cabinet, these circuits (5 to 8)
are to be connected at the rear of the cabinet.
For the small cabinet (up to 10 kVA) there are separate connection terminals
for the circuit connection.
1.11 Hour Counters (Option)
Hour counters
As an option, the regulator MCR³ can be delivered with Hour Counters.
The Hour Counter can be configured to measure the ON time (Hour
counting starts as soon as the MCR³ is switched ON) or to measure the
operating time above a preset level.
In case of a Circuit Selector there is one Hour Counter per circuit available.
46 / 150
1.12 Equipment required for installation, start-up and troubleshooting but not
supplied
Tools
True RMS Voltmeter
(Note that the output voltage of the 30 kVA / 6.6 A regulator can reach
about 4600 V at full load. An isolating measurement transformer for use on
the 5000 V AC line is recommended in this case.)
Multimeter
Insulation tester "Megger" 500 V or 1000 V to test the series circuit
insulation
Clamp or A-meter true RMS scale 10 and 30 A.
(Note that the current regulation is + 1 %. To make an acceptable readjustment of the output current the precision of the meter should be
better than 0.5 % for the adjusted value.)
Complete set of tools for electrician and mechanic (no special tool
required), with screwdrivers and spanner set (ring or socket spanners)
Allen key 8 mm (front and rear panel, door lock)
Connection
equipment
Screened remote control cable (between regulator and marshalling panel
or control desk)
Earth wire to ground the cabinet (ground reference for the output lightning
arrestors)
Feeder cable
Series loop supply cable
1.13 Equipment supplied
Packaging
Each unit is individually packaged in a durable crate.
On this crate the nameplate of the equipment is attached to permit
identification without unpacking the crate.
47 / 150
1.14 Nameplate
Picture
Fig. 1-8: MCR³ Nameplate ( 4072.03.500E)
MCR³
a1
50/60Hz
f
Rep.
a
a1
b
c
d
e
Function
Supply voltage
FAA or IEC performance
Max. input current
Output power
Nominal output current
Max. output voltage
Rep.
f
h
i
j
Function
Type of remote control
Options
Serial number
Bar code = code number
Values
Output power
Output current
c
d
2.5 kVA
6.6 A
4 kVA
6.6 A
5 kVA
6.6 A
7.5 kVA
6.6 A
10 kVA
6.6 A
15 kVA
6.6 A
20 kVA
6.6 A
2.5 kVA
6.6 A
4 kVA
6.6 A
5 kVA
6.6 A
7.5 kVA
6.6 A
10 kVA
6.6 A
15 kVA
6.6 A
20 kVA
6.6 A
20 kVA
6.6 A
25 kVA
6.6 A
30 kVA
6.6 A
25 kVA
20 A
30 kVA
20 A
b: input current see table 2-1
48 / 150
Supply voltage
a
220/ 230/ 240
220/ 230/ 240
220/ 230/ 240
220/ 230/ 240
220/ 230/ 240
220/ 230/ 240
220/ 230/ 240
380/ 400/ 415
380/ 400/ 415
380/ 400/ 415
380/ 400/ 415
380/ 400/ 415
380/ 400/ 415
380
400/ 415
380/ 400/ 415
380/ 400/ 415
380/ 400/ 415
380/ 400/ 415
e
378
606
757
1136
1515
2272
3030
378
606
757
1136
1515
2272
3030
3030
3788
4545
1250
1500
2
Section 2
Installation
2.1 Introduction
Introduction
This section provides instructions for the installation of the MCR³ regulators.
Refer to the substation drawings and specifications for specific installation
instructions.
Unpacking
Unpack the crate upon receipt and examine the regulator to make sure that
no damage has occurred during shipping. Note any exterior damage to the
crate, which might lead to the detection of equipment damage. When
handling the regulator, care should be taken to maintain the regulator in the
upright position.
If damage to any equipment is noted, a claim form should be filed with the
carrier immediately. Inspection of the equipment by the carrier may be
necessary.
Installation
criteria
The regulator has to be installed in a well-ventilated room with sufficient
clearance for personnel to inspect and maintain the regulator.
The person that installs the regulator should refer to the specific installation
plan for implantation.
For special models, refer also to the appropriate manuals (outside, portable,
rack-mounted version).
49 / 150
2.2 Installation
Regulator
with wheels
If the regulator is equipped with rolling castors, it can simply be pushed to the
right location in the substation, provided the floor is flat and level.
Adequate precautions should be taken to avoid overbalancing the regulator if
there are obstacles on the floor such as wires or small unevenness.
Note that the 4 to 10 kVA regulators do not have a square footprint.
Regulator
without
wheels
The regulator can be lifted by lifting lugs (Optional). The bolts to fix the top
plate are then replaced by four lifting lugs M12 ADB P/N 7015.20.120.
Ventilation
Air outlets are provided at the rear of the regulator.
CAUTION:
Always use the four lifting lugs and adequate lifting cables to lift the load.
Take the necessary precautions to prevent personal injuries during the lifting
of the regulator. Prevent sudden movements or swinging of the load.
Air intakes are provided at the bottom and the front of the regulator.
The top cabinet and the high-voltage compartment have separate air outlets
and intakes.
To avoid overheating of CCR components, take care never to block these
ventilation grids.
The heatsink for the thyristors is located at the top of the left side wall seen
from the front.
Note that this heatsink will become hot during operation of the regulator.
To obtain adequate ventilation, a minimum clearance of about 0.5 m from the
rear of the regulator to the wall is required.
Side by side, the regulators are to be installed at a minimum distance of 5 cm
from each other.
50 / 150
Removable
panels
Top, front and rear panels are removable. They can only be mounted in one
way.
The front and rear panels have ventilation grids. At the bottom, the side walls
have air inlets and the bottom plate has ventilation slots.
Each of these removable panels is grounded with a green/yellow wire
equipped with a fast-on connector. This wire must be disconnected before
taking the panel away and it is mandatory to reconnect it on the panel
when re-installed.
The auxiliary fuses, optional input lightning arrestors and power supply
connection terminals are located behind the User Interface panel.
Cable routing
The side channels of the enclosure can be used to route and fix the cables.
Seen from the front: the front left hand channel is reserved for mains supply
wiring and the front right hand channel for low-voltage signals.
Seen from the rear: the rear left hand channel is reserved for remote control
signals and the rear right hand channel for the high-voltage connection of the
optional Circuit Selector.
Cut-out SCO
As an option, the regulator MCR³ can be delivered with a cut-out SCO
mounted onto the bottom part of the front panel.
Refer to the instruction manual AM.05.455e for more information.
Picture
Fig. 2-1: Detail of a typical installation
51 / 150
2.3 Electrical connection
Warning
Only personnel qualified to work on high-voltage equipment is allowed
to perform installation and operation.
Before connection, check if the supply voltage of the regulator corresponds
to the local supply voltage.
Panels to
remove
The power supply connection terminals are accessible behind the User
Interface panel in the top cabinet.
Notice that the User Interface has two electrical connections (power supply
of the logic and Local Bus flat cable). These wires must be disconnected on
removing the User Interface panel and have to be connected before the User
Interface panel is re-installed.
The remote control terminals are located in the top cabinet, at the rear side
and are accessible by means of the removable rear panel.
The output terminals are accessible from the front, at the bottom behind the
removable front panel.
Refer to the previous page for the precautions to take.
Grounding
Although the supply cable includes a ground wire, additional safety
grounding is required. Use one of the ground studs M6 on each bottom side
of the regulator (in the middle, accessible from the side wall and the bottom).
The grounding wire must have a cross-section of at least 16 mm² and be as
short as possible.
Mains supply
cable
The minimum section of the mains supply cable (see table 2.1) is valid under
following conditions:
mean ambient temperature of 35°C
PVC insulated cables
cable separation at least 1x the cable diameter
cable length from the low-voltage distribution board to the MCR³ is about
15 m
52 / 150
Table 2-1
Table 2-1: Mains supply cable sections, fuses
Input supply voltage 220 / 230 / 240 V
Output
power
(kVA)
2.5
4
5
7.5
10
15
20
Fuse in fused
switch
Rating
Type
20 A
25 A
35 A
50 A
63 A
100 A
125 A
Neozed
Neozed
Neozed
Neozed
Neozed
NH00
NH00
Input current (max.)
220V
230V
240V
14
22
28
42
56
80
106
13
21
27
40
54
76
102
13
21
26
39
51
73
97
Section
supply
wire mm
²
4
6
10
16
25
35
50
Stripping
(mm)
16
16
16
16
22
22
22
Section
earth
wire mm
²
4
6
10
16
16
16
25
Stripping
(mm)
External
fuse
16
16
16
16
18
18
18
25 A
35 A
50 A
63 A
80 A
100 A
125 A
Section
earth
wire mm
²
4
4
4
6
10
16
16
16
25
Stripping
(mm)
External
fuse
16
16
16
16
16
18
18
18
18
25 A
25 A
25 A
35 A
50 A
63 A
80 A
100 A
125 A
Input supply voltage 380 / 400 / 415 V
Output
power
(kVA)
2.5
4
5
7.5
10
15
20
25
30
Notes
Fuse in fused
switch
Rating
Type
20 A
20 A
20 A
25 A
35 A
50 A
80 A
80 A
100 A
Neozed
Neozed
Neozed
Neozed
Neozed
NH00
NH00
NH00
NH00
Input current (max.)
380V
400V
415V
8
13
16
24
32
46
62
77
90
8
12
15
23
31
44
58
73
86
7
12
15
22
30
42
56
70
83
Section
supply
wire mm
²
4
4
4
6
10
16
25
35
50
Stripping
(mm)
16
16
16
16
16
18
22
22
22
The power supply cable can be routed through the front left hand channel
(seen from the front) from the bottom up to the low-voltage compartment and
be fixed to the channel wall by means of nylon straps.
Up to a wire section of 35 mm² the connection is executed with screw
terminals. For higher cross-sections, 70 mm² bolt terminals (socket or ring
spanner 13 mm) are used for the connection.
Check that the connecting wires do not hinder the mounting of the User
Interface and that the mains wiring does not mix with low-voltage signal
wiring.
53 / 150
2.3.1 Series circuit connection
Description
The series circuit cables enter the cabinet through the bottom plate of the
regulator at the rear for the big cabinet and at the front or the rear for the
small cabinet.
These cables shall be routed such that they do not touch the transformer
winding because the latter can become extremely hot. (Transformer winding
material is designed to withstand temperatures up to 180°C.)
These cables are to be routed by preference at the right-hand side of the big
cabinet (seen from the front) and shall be routed and fixed to prevent mixture
of low-voltage wiring with the series circuit wiring.
For the small cabinet (or the big cabinet, 20 A series circuit current): connect
the series cables to the output terminals (screw terminal block).
For the big cabinet (6.6 A loop current): connect the series cables to the
lightning arrestors; do not remove the other wires connected to them (stud
diameter = 10 mm).
If the series cable is screened or armoured it is mandatory to connect the
screen or the armature to the ground inside or outside the regulator
Refer to the instruction manual AM.05.455e for the connection of the series
circuit in case of the optional SCO.
If an optional Circuit Selector is present, the high-voltage connection wires
from the Circuit Selector are routed through the rear right-hand side channel
(seen from the rear) to the output terminals of the regulator. The series
circuits are connected to the corresponding terminals of the Circuit Selector.
Note
In case of the optional Circuit Selector, if a circuit is disabled but the highvoltage contactor is energised, the output of the inhibited circuit has to be
short-circuited. Otherwise this could result in an open-circuit condition.
54 / 150
2.3.2 Remote control connection
Description
The remote control cable(s) can be routed through the rear right-hand
channel (seen from the front) from the bottom up to the low-voltage
compartment and be fixed by means of nylon straps to the channel wall.
For strain relief and grounding of the cable screen there is a cable clamp
usable for cable diameters ranging from 7 up to 16 mm, click mountable on
the grounded rail at the rear of the card cage. (Use one cable clamp per
cable.) If this grounding clamp is mounted it is not recommended to connect
the screen also to terminal 12 (PE).
The connection of the remote control signals is by means of pluggable
spring-terminals.
For multiwire, connectors P1 and P2, the connector type is WAGO 231312/026-000 cage-clamp connector (ADB code number 6112.33.112).
For J-Bus, connectors P1 to P4 are WAGO 231-306/026-000 cage-clamp
connector (ADB code number 6112.32.518).
For the back-indication signals ON and REG. ERR. the connector PSL /
X7 is a WAGO 231-304/026-000 cage-clamp connector (ADB code number
6112.32.517).
These WAGO cage-clamp connectors accept wires of 0.08 to 2.5 mm² (28
12 AWG). Recommended stripping length: 6 mm.
(Connector spring activation is possible with screwdriver blade 3.5x0.5 mm
or with operating lever WAGO 231-131.)
55 / 150
2.3.3 Remote control cable
Multiwire
We recommend a screened cable with screen connected to the ground at
both ends to limit high frequency disturbance.
Each signal requires a wire. We recommend also a separate wire for the
commons (input and output) for each multiwire board.
Twisted pairs are not obligatory for this kind of signals but using one wire for
the signal and the other wire of that pair as return gives minimal voltage drop
and optimal coupling between these two wires. (This, however, requires an
intermediate terminal in the regulator to interconnect the return wires.)
Combining the remote control and back-indication signals in one cable is
only possible if there is no (or only low level) isolation required between
these signals (as in the case of one common energy source for remote
control and back-indication signals).
To determine the required cross-section of these cable wires:
Check the tolerances of the power supply.
The maximum permitted voltage drop on the line is the difference of the
minimum available power supply voltage minus the minimum required
voltage for the load.
Consider for copper wires a typical resistance of 0.1 Ohm/m for diameter
0.5 mm (about 0.2 mm²) and 0.04 Ohm/m for diameter 0.8 mm (about
0.5 mm²). This is a typical value at ambient temperature of 55°C.
Check the required load current in each line.
Determine the number of signals that may exist at the same time.
Size the cable to obtain less or equal than the maximum permitted voltage
drop with the required load current.
E.g.: Maximum cable length in case of copper wire if only one remote control
signal will be transmitted at any time.
(If two signals may be sent at the same time then the common wire has to be
doubled in diameter or the maximum cable length will be only 2/3 of the
indicated value.)
Diameter
0.5 mm
(0.2 mm²)
0.8 mm
(0.5 mm²)
Power supply tolerance
-5 %
-10 %
-5 %
-10 %
48 V DC
3 km
1.7 km
7.5 km
4 km
24 V DC
0.65 km
1.5 km
-
For strain relief and grounding of the cable screen there is a cable clamp
usable for cable diameters ranging from 7 up to 16 mm, click-mountable on
the grounded rail at the bottom of the compartment. (Use one cable clamp
per cable.) If this grounding clamp is mounted it is not recommended to
connect the screen also to terminal 12 (PE).
56 / 150
J-Bus
We recommend a screened cable with screen connected to the ground at
both ends to limit high frequency disturbance.
The factor (number of pairs) depends on the installation: transmission over
two or four wires, combination of J-Bus A and J-Bus B in 1 cable or in 2
separate cables. (Notice that there is at least 1 wire required for the
interconnection of the 0V-signal.)
Signals Tx+ and Tx- form a pair and (in case of 4 lines) signals Rx+ and Rxform the other pair.
Signals for J-Bus A and J-Bus B may not be mixed in one pair.
Because this is a data-transmission cable with a very low power signal the
wire cross-section is less important, but a minimum diameter of 0.5 mm
(0.2 mm²) is required for mechanical strength.
In all cases the screen or the armour must be connected to the earth lug
(PE) of the cabinet.
For strain relief and grounding of the cable screen there is a cable clamp
suitable for cable diameters ranging from 7 up to 16 mm, click-mountable on
the grounded rail at the bottom of the box. (Use one cable clamp per cable).
If this grounding clamp is mounted it is not required in additition to connect
the screen also to terminal 6 (PE).
Signals ON &
REG.ERR.
We recommend a screened cable with screen connected to the ground at
both ends to limit high-frequency disturbance. The best screening result is
obtained by grounding the cable on entering the cabinet.
The wire cross-section depends on the load connected to this terminal block.
The cable insulation level depends on the operation voltage level of the load.
57 / 150
2.3.4 Multiwire
Description
The function of each input and output terminal is defined in the configuration
software (Menu MCR3: IO / Multiwire). Configuration of this terminal block
has to be known to make the right connections.
Attributing a certain function to several terminals would result in only one
terminal given the correct operation.
There can be a maximum of 3 multiwire PCBs attached to the LMC.
Their presence is detected by the system.
They are identified as MW1, MW2 and MW3.
MW3 is reserved for Circuit Selector functionality.
Seen from the rear side of the regulator: MW1 is the one farthest on the left,
MW2 is on its right-hand side and MW3 is the one farthest to the right.
If an attempt is made to attribute a function to a contact that has already
been attributed to some other contact, then only the last attribution will be
executed. The contact that had the function originally will become FREE.
It is possible to set each contact individually (input and output) to POSITIVE
or NEGATIVE logic. E.g. if an output contact is attributed to a certain function
and if the condition of that function becomes TRUE, then the contact closes
in positive logic, but opens in negative logic. The same is true for INPUT
functions, in positive logic applying a voltage to a contact starts the
corresponding function whereas in negative logic, the function is executed
when the contact opens.
Input connector (P2)
MW1 and MW2
Possible input functions are:
Function
Free
ON/OFF
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Reset EFD error
Use LFD degraded mode
Allow WRITE via bus
Function description
This terminal is unused.
Separate ON/OFF control signal
Brightness step selection
Reset of EFD alarms, level 1 and level 2
LFD alarm level 1 back-indication cancelled with this signal
This external signal permits the bus to change parameters under
multiwire control (only in case of the following arbiter setting:
Multiwire control, Bus A monitoring or Multiwire control, Bus B
monitoring ).
58 / 150
MW3
Function
Free
Circuit 1
Circuit 2
Circuit 3
Circuit 4
Circuit 5
Circuit 6
Circuit 7
Circuit 8
Possible input functions are:
Function description
This terminal is unused.
Circuit selection
Wiring: see next page.
59 / 150
12
12
12
11
11
11
10
10
10
9
9
9
8
8
8
7
7
7
6
6
6
5
5
5
4
4
4
3
3
3
2
2
2
1
1
1
Fig. 2-2: Multiwire Inputs
60 / 150
Output connector (P1)
MW1 and
MW2
Possible output functions are:
Function
Free
Step 1 obtained
Step 2 obtained
Step 3 obtained
Step 4 obtained
Step 5 obtained
Step 6 obtained
Step 7 obtained
Step 8 obtained
Overcurrent alarm
Open circuit alarm
EFD warning level
EFD alarm level
LFD warning level
LFD alarm level
Lamp life warning
Local Bus error
Bus A down
Bus B down
Overtemperature
MOV blown alarm
Function description
This terminal is unused.
Back-indication of actual step
Regulator has switched OFF due to overcurrent in the loop.
Regulator has switched OFF due to open circuit in the loop.
EFD, level 1 has been exceeded (fault condition may actually
not be present anymore).
EFD, level 2 has been exceeded (fault condition may actually
not be present anymore).
LFD, level 1, preset quantity of burnt lamps has been reached
or preset value of VA drop has been surpassed. (This warning
disappears if the condition is no longer detected.)
LFD, level 2, preset quantity of burnt lamps has been reached
or preset value of VA drop has been surpassed. (This warning
disappears if the condition is no longer detected.)
Preset time for the lamp life is exceeded.
LMC detects that one or more modules on the Local Bus are
no longer communicating.
LMC detects that there are no messages received on Bus A.
LMC detects that there are no messages received on Bus B.
When the inside temperature of the regulator (measured on the
LMC) exceeds the programmed maximum temperature, this
terminal is activated. As soon as the temperature drops under
the limit on all devices, the terminal is inactivated again.
The optional lightning arrestor protection of the input voltage is
missing or needs replacement.
Notify that warnings will only be available if option is activated via U/I. Otherwise, only
errors will be available!
61 / 150
MW3
Function
Free
Circuit 1
Circuit 2
Circuit 3
Circuit 4
Circuit 5
Circuit 6
Circuit 7
Circuit 8
CSM fault
Possible output functions are:
Function description
This terminal is unused.
Circuit selection
Actual detected circuit selection deviates from request.
Wiring: see next page.
Note
Internal connections
The connector J1 is for the power supply (230 V AC) of the multiwire.
P3 is a flat-cable connector to the LMC.
62 / 150
12
12
12
11
11
11
10
10
10
9
9
9
8
8
8
7
7
7
6
6
6
5
5
5
4
4
4
3
3
3
2
2
2
1
1
1
Fig. 2-3: Multiwire Outputs
63 / 150
2.3.5 J-Bus
Connectors
For ease of wiring, there are 4 connectors, 2 for Bus A and 2 for BUS B. P1
and P2 are for the connection to the preceding / next user respectively. P3
and P4 are for Bus B.
If the LMC to which the bus will be connected is the last on the bus, the bus
should be terminated (see section 6: LMC for line termination of the J-Bus).
Note
Internal connection
The flat-cable connector P6 is for internal distribution of the bus signal.
The wiring of connectors P1, P2, P3 and P4 is as follows:
Tx +
1
Rx +
2
Tx
3
Rx
4
0V
5
PE
6
Fig. 2-4: J-Bus connector layout JB / P1, P2, P3 and P4
During the installation care must be taken that the bus polarity is
homogenous, i.e. that all the contacts of the same type are on the same wire
in all connected units.
The use of a twisted pair for Tx+ and Tx- and for Rx+ and Rx- is imperative.
Note that if a polarity is inverted on the bus, this will not cause damage, but
the communication will not be established. A clear give away are the LEDs
indicating bus communication (see LMC): instead of lighting up at each
message received, they will remain permanently ON.
In case the transmission is executed via 2 wires (instead of 4 wires), the pair
has to be connected to Tx+ (1) and Tx- (3). Note that, in this case, the
selection on the LMC (Local Master) has to be for a 2-wire system (see
LMC).
64 / 150
2.3.6 Signals ON & REG.ERR. (PSL/X7)
The wiring of connector X7 is as follows:
ON
1
COMMON
2
REG.ERR. / NC
3
REG.ERR. / NO
4
5
6
Fig. 2-5: Connector layout PSL / X7
65 / 150
2.4 Starting procedure
Caution
Read the safety instructions and check if the installation complies with
section 2.3. Do the following preliminary checks:
grounding
mains supply cable, routing, wiring and voltage
series circuit cable, routing, wiring and insulation resistance to earth
remote control cable, routing, wiring and voltage
In order to obtain a fast response of the regulator the last request is
memorized. This means that the regulator will start producing the same
output current that was valid on powering down.
The same rule applies for remote or local control.
Once all the information is obtained by the User Interface, this User Interface
can be switched to local or remote control.
Therefore, if the powering-down status of a regulator is unknown; the series
circuit has to be disconnected prior to switching the regulator on, in order to
prevent a regulator to produce output current.
With the series circuit disconnected, a regulator that would try to reproduce
output current will switch off in open-circuit condition.
By then the brightness step request can be cancelled in local control and the
failure condition be reset.
Procedure
The first start-up will be done in local control only. It is advised, as far as
possible, to disconnect (unplug) the remote control. We recommend to start
the regulator first with its output short circuited
Step
1
2
3
4
5
6
7
Action
Open the fused input switch (fig. 1-2).
Disconnect the series circuit (if already connected) and short the
output terminals. Put an AC current clamp around the shorting
wire to measure the output current. Warning: High Voltage!
Switch ON the regulator supply on the low-voltage distribution
board and measure the input voltage on the mains supply
terminals. The measured voltage must match the input voltage
indicated on the nameplate (within tolerances).
Check if the input fuses are correctly positioned.
Close the fused input switch. Note: The regulator memorizes its
last selection. If the regulator was switched off without selecting
brightness step OFF the last selection will be recalled at the
moment of energizing. The display on the User Interface will
indicate the actual measured output current and the selected
brightness step.
Select the brightness steps by means of the User Interface and
compare each reading on the display with the reading of the
external A-meter.
The value of the actual measured output current depends on the
number of programmed steps (see section 1.4).
Switch the regulator OFF by selecting the brightness step OFF
(0) and open the fused input switch.
66 / 150
8
9
10
11
Remove the short circuit on the output and switch the regulator
ON (close the fused main switch and select any brightness step).
The main contactor will switch ON and after a short period OFF.
The display will indicate the open circuit error message.
Switch the regulator OFF by selecting the brightness step OFF
(0) and open the fused input switch.
Connect the series circuit to the regulator. Switch ON the
regulator and check the output current. Check that the regulator is
not in overload.
With the maximum output current, check that the main input
voltage is not less than the minimum tolerated value.
Proceed with the adjustment of the output transformer secondary
taps to the actual load (see section 2.4.1).
Calibration of the EFD and LFD option, if installed (see section 7).
67 / 150
2.4.1 Tap selection
Target
Adjustment of the regulator to the installed load by adjusting the tap setting.
Three
methods are
possible
1. Measurement of the output voltage directly on the output terminals
(This might require the use of an isolation step down transformer)
Warning: High Voltage!
2. By means of the MCR³ output voltage measurement
3. By means of the conduction angle measurement
Preliminary
check
For each method a preliminary visual check will be made on the series
circuit.
Switch the regulator ON at a convenient brightness and check that all the
lamps of the circuit are operational. If not, take corrective actions until all
lamps are OK.
Check that the mains voltage is at its nominal value.
First method
Output voltage measurement
Step
1
2
3
4
Table 2-2
Action
Switch the MCR³ ON to the max. brightness step 6.6 A or 20 A.
Measure the RMS output voltage at the output terminals after
about 10 minutes. Determine the correct tap using table 2-2,
choose the tap with the nearest higher voltage than the measured
RMS output voltage.
Switch the MCR³ OFF and wire the chosen tap (see section 2.4.2).
Warning: High Voltage!
Switch ON the regulator at the maximum brightness for about 10
minutes and check that the output current is not lower than the
maximum value. If the output current is too low, wire to the next
higher tap.
Close the MCR³ taking into account the requirements given in
section 2.2.
Table 2-2: Maximum voltages (V RMS) for each tap setting, each power
and output current
PWR/ Iout
Tap 8/8
7/8
6/8
4/8
2/8
2.5 kVA/ 6.6 A
4 kVA/ 6.6 A
5 kVA/ 6.6 A
7.5 kVA/ 6.6 A
10 kVA/ 6.6 A
15 kVA/ 6.6 A
20 kVA/ 6.6 A
25 kVA/ 6.6 A
30 kVA/ 6.6 A
25 kVA/ 20 A
30 kVA/ 20 A
378
606
757
1136
1515
2272
3030
3788
4545
1250
1500
530
660
990
1320
1980
2645
3305
3965
1090
1310
68 / 150
450
565
850
1130
1695
2260
2825
3390
930
1120
190
300
375
565
755
1130
1505
1880
2255
620
745
150
185
280
375
560
745
935
1120
310
370
Second
method
Output voltage measurement by means of the User Interface (or PC
software).
This is less accurate than measuring with a voltmeter but will be sufficiently
accurate for the tap setting.
Use the values in table 2-2 to adjust the tap setting.
Third method
You can also use the PC software (see section 7) to determine which tap to
select by using the conduction angle reading.
Procedure
Conduction angle reading
Step
1
2
3
Action
Wire the 8/8 tap and switch the regulator ON to the maximum
brightness.
Connect the PC to the regulator, open the program and go to the
menu MCR3 Setup . In the sub-menu MCR3 Input/Output
measurements select the Thyristor conduction angle reading.
Read the thyristor conduction angle and select the tap according to
the table below:
If the thyristor conduction
angle is
between 115° and 130°
between 90° and 115°
between 67° and 90°
<67°
4
5
select the tap
7/ 8
6/ 8
4/ 8
2/ 8
Switch the regulator OFF and wire the chosen tap.
Switch ON again at maximum brightness and check the thyristor
conduction angle .
If the thyristor conduction
angle is
< 145°
> 145°
69 / 150
then
the chosen tap is correct.
go to the next higher step.
2.4.2 Tap wiring
Tap wiring
2.5 to 30 kVA
To wire the tap, proceed as follows.
(2.5 to 30 kVA: a spare strap is provided on S5.)
Note that the 2.5 kVA has only two possible tap settings: half and full load.
Step
1
2
3
4
5
Picture
Action
Remove the front panel and disconnect the ground wire.
Wire the tap according to fig. 2-9.
Switch the regulator ON at the maximum brightness step for about
10 minutes.
Check that the output current is not below the maximum value.
If it is too low, wire to the next higher step and check again till the
output current attains its maximum value.
Close the MCR³ taking into account the requirements given in
section 2.3.
Fig. 2-6: 2.5 kVA power transformer, top view
70 / 150
Fig. 2-7: Tap adjustment MCR³ 4 to 10 kVA
Terminal identification label
Picture
Tap S6 through S1 for adjustment to actual load
Fig. 2-8: Tap adjustment MCR³ 15 to 30 kVA
Spare strap
71 / 150
Picture
Fig. 2-9: Tap wiring
S1
S1
wire m1
S2
82 to 100 %
(8/8)
71 to 81 %
(7/8)
S3
S4
S3
S4
wire m2
S5
S5
strap B
wire m2
strap B
S6
S6
S1
S1
S2
wire m1
S2
wire m1
S2
wire m1
59 to 70 %
(6/8)
22 to 46 %
(4/8)
S3
S3
S4
S4
strap A
S5
wire m2
S5
wire m2
strap B
strap B
S6
S6
S1
wire m1
S2
8 to 22 %
(2/8)
S3
strap B
S4
S5
S6
72 / 150
wire m2
2.5 Component replacement and software uploads
Material
handling
precautions
This equipment contains electrostatic sensitive devices.
Please take care not to damage components by electrostatic discharges.
Electronic modules and components should be touched only when this is
unavoidable, e.g. for soldering, replacement etc.
Before touching any component of the cabinet you should bring your body to
the same potential as the cabinet by touching a conductive earthed part of
the cabinet.
Electronic modules or components must not be brought in contact with highly
insulating materials such as plastic sheets, synthetic fibre clothing etc. They
must be laid down on conductive surfaces.
The tip of the soldering iron must be earthed.
Electronic modules and components must be stored and transported in
conductive packing.
Take care not to cause electrostatic discharges on plugging or unplugging
connectors on the boards (e.g. Dongle connection to LMC), i.e. also Dongle
and PC must be at the same potential as the equipment.
2.5.1 Replacement of modules
Procedure
Disconnect the power to the MCR³.
Take note of connector positions and switch coding.
All boards are mounted with nuts (M3 socket or ring spanner: 5.5 mm) on
standoffs.
All the boards for the remote control interfacing are located at the rear of the
top cabinet.
The EFD boards (logic and HV resistor) are mounted in the HV compartment,
close to the output terminals and are accessible from the front door. (Note
the slots in the HV resistor board. They serve to fix the HV connecting wires
so they cannot touch low-voltage parts in case the connection is broken.)
The Circuit Selector interface board is located in the Circuit Selector cabinet.
In the small cabinet (up to 10kVA) it is accessible from the rear, and in the
big cabinet from the front.
All the other boards - PSL, LMC, CCL, TBM and LFD - are mounted on a
removable card cage.
Caution
Be careful when removing the PSL.
The rest energy of capacitor C6 can be lethal. Discharge this capacitor prior
to handling this board to prevent injuries or component damage.
See section 6: PSL for further explanation.
Be careful of the 500 V DC voltage present on the EFD boards and the highvoltage wiring. The energy of this source is limited but still sufficient to startle
a person coming in contact with it.
Always take car to discharge the series circuit loop, and connect the series
circuit to the ground at both sides, prior to touch any HV part.
73 / 150
Procedure
(continued)
Set the dip-switches of the replacement board exactly in the same position
as the removed board.
Mount the replacement board and re-install the connectors.
If possible, check the installed software. If required, make an upload of the
most recent software version.
If measurements of the module are necessary, it is required to adjust the
parameter settings in accordance with the MCR³ (input voltage, input fuse
range, regulator power, tap setting).
Check always the parameter setting CS installed / not installed"
Check the operation of the board.
74 / 150
2.5.2 Replacement of the thyristor pack
Procedure
Disconnect the power to the MCR³.
Please note the connections.
The connection of the gates is done with fast-on tabs 2.8/0.8.
Please note that the position of these gates may differ for different brands
(see drawing 3229.13.240BA).
A heat-conducting paste between thyristor pack and heatsink is required to
keep the junction temperature of the thyristors as low as possible. Apply a
thin layer of heat-conducting paste (e.g. DOW CORNING 340) on the flat
mounting surface of the thyristor pack. Clean the heatsink thoroughly prior to
mounting the thyristor pack.
The mounting of the thyristors on the heatsink and the power connection is
done with M5 screws. These screws have to be mounted with an adequate
mounting torque.
Recommended mounting torques according to the manufacturer data sheets:
Manufacturer
EUPEC
EUPEC
SEMIKRON
SEMIKRON
Thyristor model
Mounting torque in Nm (lb in)
Heatsink
3.4-4.6 (30.1-40.7)
5.1-6.9 (45.1-61)
2.55-3.45 (22.6-30.5)
4.25-5.75 (37.6-50.9)
TT92N
TT162N
SKKT92E
SKKT162E
Terminal
3.6-4.4 (31.9-38.9)
5.4-6.6 (47.8-58.4)
2.55-3.45 (22.6-30.5)
4.25-5.75 (37.6-50.9)
2.5.3 Replacement of the main contactor
Procedure
Disconnect the power to the MCR³.
Take note of the connections.
The contactor is clip-mounted on a rail (symmetric 35 mm rail).
It is kept in position on this rail by means of two end blocks.
Recommended mounting torques according to the manufacturer data sheets:
Contactor model
3RT1326
3RT1336
3RT1344
Mounting torque in Nm (lb in)
Coil terminals A1 & A2
Power terminals L1 - L4 and T1 - T4
0.8-1.2 (7.1-10.6)
0.8-1.2 (7.1-10.6)
0.8-1.2 (7.1-10.6)
2-2.5 (17.7-22.1)
3-4.5 (26.5-39.8)
4-6 (35.4-53.1)
Check that the coil transient protection block is mounted correctly on top of
the contactor.
A transient suppressor RC network is mounted on the output terminals of the
contactor to prevent switching transients from disturbing the logic circuitry.
75 / 150
2.5.4 Upload of application code
The Dongle
The Dongle is the interface between the MCR³ and a PC running the MCR³
configuration program under one of the Window brands (operating system:
Windows98, WindowsNT, Windows2000, WindowsXP). It is normally only
used during installation, adjustment of system parameters and potentially
repair.
By means of the Dongle it is possible to upload software to the MCR³ boards
containing a microcontroller.
The Dongle is connected to the LMC on the female DB9-connector and to a
COM port (male DB9) of a PC (RS232 connection). The Dongle receives its
power from the LMC.
Note that when the Dongle is connected to a laptop running the configuration
software, then all MCR³ control is transferred to the laptop. This means that
changing brightness or parameters via the User Interface will not be possible
and the remote control by multiwire or bus is disabled.
Shortly after connecting the Dongle the UI will display GK active .
The actual brightness step and circuit(s) stay selected.
In this case control will only be possible by means of the configuration
software.
After unplugging the Dongle the message GK active stays displayed until
the Dongle is fully disconnected from the LMC. The LMC requires some time
to notice that the Dongle is disconnected. By interrupting the power supply
for several seconds (until the display goes blank) this transition time can be
reduced.
To disable the Dongle without unplugging the serial link to the LMC: in the
window Configuration/Communication port switch to DEMO -mode instead
of a COM port.
Upload
There are 6 different types of PCB with on-board intelligence in the regulator:
LMC, UI, CCL, TBM, EFD, LFD.
All these boards are equipped with a FLASH EEPROM device for storing the
application code in replacement of the EPROMs of older types of equipment.
This allows the user to install new code in the equipment without having to
replace EPROMs on the boards. Also the Dongle is equipped with a FLASH
EEPROM permitting easy installation of new code.
If it is necessary to update the software, the customer will receive from ADB
a floppy disk, a CD or an e-mail with the new code in a proprietary format (file
extension: UPL). This file must be copied by the customer to the same
directory on his PC where the configuration software is located.
He then connects the Dongle between PC/serial port and regulator/
LMC/CO5 and starts the configuration software, which will automatically
detect the presence of new upload software. In the configuration menu there
is a header for uploading new software. Clicking on it opens a window that
shows all upload versions available on the PC.
76 / 150
Upload
(continued)
The first step is the transmission of the upload to the Dongle, where it is
temporarily stored. Then the destination device is switched to upload mode,
this means that the CPU stops executing the normal application and jumps to
the boot-loader code. (reserved EEPROM zone in the micro-controller
containing this fixed code). At that point the laptop transmits the new code to
the devices concerned where it is stored in RAM. After termination of the
transfer, the integrity of the code is checked in several ways and then the
command is given to reprogram the FLASH memory. When the transfer is
complete, the code is checked again in the FLASH and if correct, the device
goes into reset and restarts with the new code.
During the upload operation, the user/operator can monitor its execution on
the PC. After its termination, he can consult the list of the software versions
currently active on the system and verify that the upload was executed
correctly.
An upload can take up to several minutes depending on the file volume.
Although many precautions are taken in this automatic sequence, there are
critical moments during which e.g. a power failure might lead to an unusable
system because only part of the FLASH is reprogrammed. If this happens,
the CPU itself will detect at the next power-up that the application is
incomplete and go into boot-loader mode. The customer must then restart
the upload.
As a last resort, a strap is provided on each PCB to force the CPU in bootloader mode and wait for the upload of a new application.
Note that the user can find out if a PCB is running in application or in bootloader mode by looking at the RUN LED. If there is a fixed flashing sequence
of ½ s ON and ½ s OFF, then the CPU is running in application mode. If the
RUN LED flashes at a higher rate, then the CPU has switched to boot-loader
mode.
77 / 150
3
Section 3
Maintenance
Introduction
The MCR³ regulators have been developed using future-oriented technologies
and in view of reducing the maintenance tasks to a minimum.
This section establishes the maintenance procedures required for the MCR³
regulator. The maintenance tasks must be performed on a securing basis to
insure optimum performance, minimise service interruption and avoid major
breakdowns.
Caution
Only personnel authorised to work on high-voltage equipment should perform
maintenance on the regulators.
Operate the regulator under local control when performing maintenance
tasks. This will prevent the regulator from being accidentally turned on and
causing serious injury or death.
Table 3-1
Table 3-1: Preventive maintenance
Operational
Electrical
Check
the operation of the
regulation on all
brightness steps
all readings
the input voltage
the output current
(RMS value)
Visual
the wiring of the
regulator and circuit
the housing for rust
spots and damage.
the housing for dust
accumulation
78 / 150
Action
Use a PC to log the data, if
desired.
If the regulator voltage is not
within the tolerances, notify
the power company to correct
the voltage.
Record and adjust if out of
tolerance; use a RMS-reading
A-meter.
Repair damaged or loose
wires.
Replace damaged
components.
Clean and repaint rust spots.
Repair eventual damages.
Clean by blowing dry air over
the dirty components, PCBs
4
Section 4
Troubleshooting
Important
precaution!
Only personnel qualified to work on high-voltage systems should be
permitted to troubleshoot on the regulator.
If the regulator de-energises the output suddenly, the circuit might have
been interrupted by an overcurrent, open circuit or undervoltage
condition. Before inspecting the output circuit, place the local control in
the OFF position. Without this precaution, a rise on the power line may
produce an ON cycling and re-energise the regulator, resulting in an
output voltage of several hundreds or thousands of volts that may cause
serious injury or death.
Preliminary
checks
Before any operation or adjustment check for the obvious:
User Interface indications (or back-indication signals)
power supply voltage off
fused input switch
blown input fuses and blown auxiliary fuses
loose connections
charred or burned components
openings in wiring
79 / 150
Guideline
As a guideline for troubleshooting, use tables 4-1 to 4-3. Three different
cases are treated:
Table
Table 4-1
Table 4-2
Table 4-3
Display and
LEDs info
What to do if the regulator
does not turn on
turns on but de-energises suddenly
does not produce the requested output
See section 1.3.6 for the interpretation of the indications on the User
Interface.
Several LEDs are available on the boards to indicate the operation of the
modules. See section 6 for the function of these LEDs.
In general terms:
The LED RUN blinking at a rate of once per second indicates that the
microcontroller is operational.
If this LED RUN blinks at a much higher rate this means that the
microcontroller is in boot-loader mode and a software upload is required.
The LEDs indicating bus activity are blinking at the communication rate
during transmission or reception.
The busses operate on a voltage source isolated from the logic supply. The
LED for this isolated power supply should always remain lit.
PC:
MCR3_WIN
With the help of the program MCR3_WIN it is easy to check the operation of
the Local Bus, the modules and the parameter setting.
See section 7 for a detailed description of this program.
Fuses
Table 4-4 gives an overview of the fuses (main fuses, fuses on the power
module, etc.) in the MCR³.
80 / 150
Table 4-1
Table 4-1: The regulator does not turn on.
Observations
No local indications
Possible cause
power supply to the
board
Indication "Error" and
the main contactor in
the power module
(K on drawing 3229.
13.240BA) is not
energised.
power supply level
too low (less than
the pre-set value)
fuse PSL/F1
blown
failure in the CCL or
PSL module or
wiring
Main contactor (K) is
energised but no
output current is
generated.
failure in the CCL or
TBM module
81 / 150
Solutions
Power supply
interrupted, check:
- fuses of the fused
switch (fig. 1-2)
- auxiliary power fuses in
the top cabinet (F3/F4
fig. 1-12 and 1-13)
- PSL defective (fig. 1-12
and 1-13)
- internal fuses on PCBs
Check the power supply.
Correct if possible the
voltage level.
Check the calibration of
the input voltage
measurement.
Check the wiring and
main contactor coil.
Replace the fuse.
Check the wiring.
Replace the defective
module.
Check the wiring.
Replace the defective
module.
Table 4-2
Table 4-2: The regulator turns on but de-energises suddenly.
Observations
Possible cause
Protection of the
too fast acting or
power supply to the
too low level
CCR became
operational.
power supply
wiring or CCR
components
CCR produced
considerable more
noise and the fuses
of the fused switch
blew.
Indication
"Overcurrent error"
one thyristor not
operating or shortcircuited
failure in thyristor
control pulses
one thyristor
interrupted
overcurrent
Indication
"Open circuit error
An open circuit in
the loop occurred.
CCR malfunction
Indication
"Overload error
open circuit in the
loop .
CCR malfunction
82 / 150
Solutions
Check values on drawing
3229.13.240BA
and in manual.
Check the wiring to the
CCR and the internal
wiring; check the fused
switch and the terminals.
Check the wiring to the
thyristor gates and
inspect the TBM.
Replace the TBM.
Replace the TBM.
Check the maximum
output current and, if
necessary, readjust.
Check the overcurrent
alarm level and, if
necessary, readjust.
Check the series loop for
an interruption.
Check the thyristors, the
wiring of the transformer
and the choke, the main
contactor, the output
current measurement
transformer and TBM.
Check the load of the
series loop.
Check the power
components, the wiring
and the parameter setting
of TBM and CCL.
Table 4-3
Table 4-3: The regulator does not produce the requested output
current.
Observations
Always maximum
output current
Possible cause
maximum brightness
step always selected
failure of the logic
All steps above but
none below a certain
step can be selected
Only the minimum
brightness step is
selected.
The output current is
not reached and
signal "I fault" is
given.
No output current
one brightness step
always selected
failure of the logic
failure of the remote
control line
failure of the logic
CCR is overloaded
input voltage too low
failure of the logic
No display at all and
none of the LEDs lit
on the boards.
power supply failure
83 / 150
Solutions
Disconnect the remote
control line for the max.
brightness step and
check the remote
control signals.
Check the parameter
setting and the CCL.
Check the remote
control signals.
Check MW or CCL.
If the module operates
correctly in local, then
check the remote
control line.
Check MW or CCL.
Check the output
transformer tap, the
power supply voltage
and the load.
Check input voltage
and parameter setting
of the regulator.
Check local control,
Local Bus, MW, LMC,
CCL or TBM.
Check mains power
supply, fuses, wiring
and PSL.
Table 4-4
Table 4-4: Overview of the fuses
Fuses
Position
Main fuses F1 (*)
Fused switch
Auxiliary fuses F2, F3 and F4 (**)
Behind the User Interface panel
Internal fuses on the boards: see below.
Reference
Fig. 1-2 rep 3
(*) See diagram 3229.13.240BA, page 2, for the value in accordance with
power rating and input voltage.
These fuses have a visual indication in case of overload:
for type NEOZED (up to 63 A): the centre point of the fuse
for type NH00 (up to 125 A): the spring clip on top of the fuse.
(**) See section 5: Parts List for the value of these fuses.
F2 serves to protect the internal auxiliary mains wiring.
F3 protects the wiring of the voltage measurement circuit (primary voltage of
transformer T1).
F4 protects the wiring of the mains to the Circuit Selector (HV contactor coil
control voltage).
On the boards:
Miniature glass fuses (DIA 5 L20):
PCB
1521
(PSL)
1523
(CS)
Fuse
PSL/F1
Type
T 1A DIA 5 L20
PSL/F2
CS/F1
T 1A DIA 5 L20
T 4A DIA 5 L20
Protects
the power supply (230 V AC) for the main contactor, the
logic supply (PSL) and the coil for the SCO lock.
the power supply (230 V AC) of the multiwire modules.
the mains supply to the coils of the contactors K1 to K8.
Some boards have polyswitch resettable fuses (PPTC: Polymeric Positive
Temperature Coefficient Devices). These devices do not require replacement
after a fault event, and allow the circuit to return to the normal operating
condition after the power has been removed and/or the failure causing the
overcurrent is eliminated.
PCB
1516
(CCL)
Fuse
VR1
VR2
VR3
1486
(MW)
VR4
VR1
VR2
VR3
Protects
the control voltage (+12V) to check the back-indication signals of the Circuit
Selector.
the control voltage (+12 V) to the relays CS / K1 to K4.
the control voltage (+12 V DC) to the relays PSL/K1, K2 and K3.
the control voltage (+12 V) to the relays CS / K5 to K8.
the 24 V DC or 48 V DC internal remote control signals supply of the
regulator.
VR1 and VR3 are mounted in case of 24 V DC.
Only VR2 is mounted in case of 48 V DC.
84 / 150
5
Section 5
Parts List
Introduction
This section covers the main replaceable parts for the MCR³ regulators.
Caution
Replacement of electronic components may be done, only with original spare
parts delivered by ADB. Not doing so can result in severe damage to the unit
and hazardous conditions for the user or the operator.
Reference
designation
A reference code number is assigned to each part contained in the
equipment. When ordering, always mention the reference code number of
the ordered part and also the serial number, type, power rating, input voltage,
frequency, number of brightness steps, output current, which are indicated
on the nameplate of the regulator.
Recomm.
spare parts
On major airports or when an important quantity of regulators are installed, it
is recommended to have one or more regulators in standby inside the
substation, to allow quick replacement of a defective unit. This procedure is
recommended when it is desirable to reduce the downtimes caused by
maintenance, troubleshooting and repair procedures.
Other parts should be kept in stock to cope with repair: fuses, lightning
arrestors, PCBs, terminals and connectors, fused input switches, circuit
breaker, power packs and others.
Orders
All spare parts orders shall be addressed to ADB or our local representative.
n.v. ADB s.a.
585, LEUVENSESTEENWEG
B - 1930 ZAVENTEM, BELGIUM
Tel.: 32/2/722.17.11
Fax: 32/2/722.17.64
Table 5-1
Table 5-1: Basic printed circuit boards
(reference on drawing 3229.13.240BA)
Basic printed circuit boards
Ref.
ADB part
number
1593.14.000
UI
1593.14.113
LMC
1590.03.541
CCL
1593.14.213
TBM
1593.14.400
PSL
Description
PCB1507
PCB1513
PCB1516
PCB1517
PCB1521
85 / 150
User Interface
Local Master Circuit
Current Control Logic
Thyristor Block Module
Power Supply Logic
Order quantity
(per)
1
1
1
1
1
Table 5-2
Table 5-2: Optional printed circuit boards
(reference on drawing 3229.13.240BA)
Optional printed circuit boards
Ref.
ADB part
number
Order quantity
(per)
Description
MW1, MW2, MW3
MW1, MW2, MW3
JB
EFD
1593.13.510
1593.13.520
1590.03.490
1590.03.521
PCB1486
PCB1486
PCB1502
EFD RES.
1590.03.530
LFD
1590.03.551
CS
DONGLE
1590.03.561
1440.00.010
PCB1515 Earth Fault Detector, resistor
board
PCB1517 Lamp Fault Detector, logic
board
PCB1523 Circuit Selector board
PCB1505.1 - DONGLE
Table 5-3
PCB1514
board
multiwire board 24 V DC
multiwire board 48 V DC
J-Bus Interface
Earth Fault Detector, logic
1
1
1
Order quantity
ADB part number Description
Fused switch F1 6132.00.210
Fused switch F1 6130.54.460
Fused switch F1 6130.57.360
Fused switch F1 6130.61.363
Fused switch F1 6130.63.363
Fused switch F1 6130.66.270
Fused switch F1 6132.00.220
Fused switch F1 6130.63.366
Fused switch F1 6130.68.330
Fused switch F1 6130.71.280
Fused switch F1 6130.75.330
Note
1
Table 5-3: Power components, input
Power components, input fuses
Ref.
1
1
1
1
5SG7 fused switch fuse interrupter
for Neozed fuses (small cabinet)
Input fuse for 5SG7 20 A - Neozed,
2 per fused switch
Input fuse for 5SG7 25 A Neozed,
2 per fused switch
Input fuse for 5SG7 35 A - Neozed,
2 per fused switch
Input fuse for 5SG7 50 A - Neozed,
2 per fused switch
Input fuse for 5SG7 63 A - Neozed,
2 per fused switch
NH00 fused switch fuse interrupter
(big cabinet)
Input fuse for NH00 50 A -NH00,
2 per fused switch
Input fuse for NH00 80 A - NH00,
2 per fused switch
Input fuse for NH00 100 A - NH00,
2 per fused switch
Input fuse for NH00 125 A - NH00,
2 per fused switch
For the selection of the input power fuses refer to table 2-1.
86 / 150
(per)
10
2
2
2
2
2
2
2
2
2
2
Power components, input
Ref.
Fused switch
F2, F3, F4
Fused switch
F2, F3
Fused switch
F4 (optional)
PSL / F1
PSL / F2
CS F1
(optional)
MOV1/A, MOV1/B
(optional)
ADB part
number
6112.45.203
Order quantity
(per)
Description
6130.26.134
Fuse holder for symmetric rail 35 mm,
fuses DIA 6.3 L 32
Fuse M1.6A HBC DIA 6.3 L 32
(medium)
Fuse T4A HBC DIA 6.3 L 32 (slowblow)
Fuse T1A HBC DIA 5 L20 (slow-blow)
6130.37.132
Fuse T4A HBC DIA 5 L20 (slow-blow)
10
6134.03.010
Lightning arrestor for mains input
2
6300.03.160
Autotransformer 250 VA for Circuit
Selector
1
K1
K1
K1
For K1
6148.45.580
6148.45.630
6148.45.600
6148.45.590
1
1
1
1
For K1
6148.45.610
For K1
T.I.1
6322.99.055
or
6322.99.065
6302.03.200
Main contactor - 50 A
Main contactor - 63 A and 80 A
Main contactor - 100 A and 125 A
Main contactor, RC coil protection - up
to 80 A
Main contactor, RC coil protection 100 A and 125 A
Mains filtering at contactor contacts, all
power ratings
Input current measurement transformer
200/0.2 A
1
THP-1, THP-2
6351.85.320
Thyristor pack CRPTT90GK (up to
50 A)
1
THP-1, THP-2
6351.85.330
Thyristor pack CRPTT165GK (above
50 A)
1
Wire A2
6304.10.600
Common mode choke, ferrite core
OC/2
1
CS T1
(optional)
Note
6130.27.005
6130.37.180
2
10
10
10
1
1
For the selection of the main contactor and the thyristor pack refer to
table 2-1.
87 / 150
Power components, output
Ref.
LA1-LA2
ADB part
number
6314.32.750
LA1-LA2
6134.03.322
LA1-LA2
6134.03.622
T.I.2, T.I.3
6302.03.180
Description
Lightning arrestor for 2.5 kVA - 10 kVA
- 6.6 A - Siemens B32K750
2
Lightning arrestor for 15 kVA - 6.6 A.
Qty 2x1 - G.E. 3kV-XEP
Lightning arrestor for 20 to 30 kVA6.6 A. Qty 2x1 - G.E. 6kV-XEP
Output current measurement
transformer for 6.6 A. 50 / 0.05 A
2
Spare parts for optional Circuit Selector
Ref.
SCO
ADB part
number
1475.92.030
Order quantity
(per)
2
1
Order quantity
(per)
Description
Cut-out SCO
1
CS
K1
K8
6148.47.510
High-voltage contactor, up to 1515 V /
6.6 A RMS
1
CS
K1
K8
6148.45.229
High-voltage contactor, up to 4545 V /
6.6 or 1515 V / 20 A RMS
1
CS K1 K8,
RC coil protection
6148.98.250
RC coil protection, for contactors up to
1515 V RMS
1
CS K1 K8,
RC coil protection
6148.45.238
RC coil protection, for contactors up to
4545 V / 6.6 A or 1515 V / 20 A RMS
1
CS K1 K8,
Auxiliary contact
6148.45.484
Auxiliary contact, for contactors up to
1515 V RMS
1
CS K1 K8,
Auxiliary contact
6148.45.236
Auxiliary contact, for contactors up to
4545 V / 6.6 A or 1515 V / 20 A RMS
1
88 / 150
Power components, transformers
Ref.
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
ADB part
number
1476.03.195
1476.03.742
1476.03.752
1476.03.762
1476.03.772
1476.03.783
1476.03.793
1476.03.813
1476.03.803
1476.03.843
1476.03.833
Description
Power transformer, 2.5 kVA, 6.6 A
Power transformer, 4 kVA, 6.6 A
Power transformer, 5 kVA, 6.6 A
Power transformer, 7.5 kVA, 6.6 A
Power transformer, 10 kVA, 6.6 A
Power transformer, 15 kVA, 6.6 A
Power transformer, 20 kVA, 6.6 A
Power transformer, 25 kVA, 6.6 A
Power transformer, 30 kVA, 6.6 A
Power transformer, 25 kVA, 20 A
Power transformer, 30 kVA, 20 A
1
1
1
1
1
1
1
1
1
1
1
Wiring depends on input voltage.
Note
Power components, choke
Ref.
L1
L1
L1
L1
L1
L1
L1
L1
L1
Note
Order quantity
(per)
ADB part
number
1476.02.500
1476.02.504
1476.02.505
1476.02.507
1476.02.510
1476.02.515
1476.02.520
1476.02.525
1476.02.530
Order quantity
(per)
Description
Series choke, 2.5 kVA
Series choke, 4 kVA
Series choke, 5 kVA
Series choke, 7.5 kVA
Series choke, 10 kVA
Series choke, 15 kVA
Series choke, 20 kVA
Series choke, 25 kVA
Series choke, 30 kVA
Wiring depends on input voltage.
89 / 150
1
1
1
1
1
1
1
1
1
Table 5-4
Table 5-4: Hardware parts
Hardware parts
Ref. .
Wheels (optional)
Wheels (optional)
Lifting lugs
(optional)
PCB
PCB
Wiring
Wiring
Table 5-5
ADB part
number
7015.35.240
7015.35.250
7015.20.120
Description
Wheel
Wheel with wheel lock
lifting lugs M12
7510.08.300
7154.04.010
6126.83.810
6126.83.820
Standoffs for PCBs M3 L10
Nut Hex M3 for PCB mounting
Cable clamp, up to DIA 8 mm
Cable clamp, for DIA 7 up to 16 mm
2
2
4
10
100
10
10
Table 5-5: Connectors
Hardware parts
Ref.
PSL/X7
MW1-2 or 3 / P1 or
P2
JB / P1, P2, P3 or
P4
Cage-clamp
ADB part
number
6112.32.517
6112.33.112
Description
4-pole cage-clamp
12-pole cage-clamp
1
1
6112.32.518
6-pole cage-clamp
1
6112.32.500
Connector accessory, operating lever,
231-131
10
90 / 150
6
Section 6
Drawings
Introduction
Overview of the printed circuit boards: silk screens, switch settings, LED
functions and remarks.
Electrical diagram 3229.13.240BA.
Local Bus
This bus is used for communication between all modules and the LMC.
The LMC is master of this communication.
Note that the Local Bus connection on the TBM is only used for software
uploads of this board. The TBM is connected primarily to the CCL and
connects to the LMC through the CCL.
The Local Bus connection uses RS485 protocol, in differential mode, 5 V
(max.) signals over 2 wires.
These RS485 signals are isolated from the other board signals (500 V DC
level).
Line
termination
resistors
The line termination resistors (150 to 850 Ohm) are only to be placed on the
modules that are at the extremities of the line, to prevent line reflections.
J-Bus
In case of a 2-line system (J-Bus or Local Bus) only the straps of the used
channel are to be set, thus only on the line Transmit / E .
In case of a J-Bus 4-line system the straps on the lines Transmit / E and
Receive / R have to be set.
Make sure that only the line termination resistors at the end of the line are
placed. When other straps are also placed, the signals on the line are
weakened. This can cause an incorrect functioning of the MCR³!
Local Bus
For the Local Bus the line termination is done on the TBM and the LMC.
LED RUN
In general terms:
The LED RUN blinking at a rate of once per second indicates that the
microcontroller is operational.
If this LED RUN blinks at a much higher rate this means that the
microcontroller is in boot-loader mode and a software upload is required.
91 / 150
TBM
PCB1517 1593.14.212
92 / 150
Dip-switches - TBM
S1
S2
Local Bus - Line termination
Switch
1
2
3
Various functions
Switch
1
2
3
4
S3
5
6
7
8
Various functions
Switch
1
2
3
4
5
6
7
8
Function
ON: Transmit / E pull up 680 Ohm
ON: Transmit / E line termination 150 Ohm
ON: Transmit / E pull down 680 Ohm
Function
Recall default parameters
CCL-TBM communication, parity:
For 115200 Bd: 0 = even / 1 = odd
For 38400 Bd: 0 = even / 1 = no parity
ON: Lock in boot-loading mode
CCL-TBM communication, baudrate: 0 = 115200 Bd /
1 = 38400 Bd
Local Bus
0 9600 1 19200 0 38400 1 9600
baudrate:
Bd
Bd
Bd
Bd
0
0
1
1
Local Bus
0
NO
1
NO
0 ODD 1 EVEN
parity:
0 parity 0 parity 1 parity 1 parity
Function
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
LEDs
LED
D1
D2
D3
D4
D5
Function
Local Bus isolated 5 V present
Microcontroller RUN
Local Bus TXD
Local Bus TXD
Local Bus enabled
Note
Strap J5 has to be installed in case of an input voltage range of 208 to 240 V.
In case of an input voltage range 380 to 415 V, the strap J5 has to be
removed.
Incorrect placing of strap J5 will cause inaccurate output voltage monitoring.
Strap J4 is only for factory use (removed for normal operation).
Factory
setting
Factory setting of the switches:
S1 - all ON
S2 - 1:OFF 2:OFF 3:OFF 4:ON 5:OFF 6:ON 7:ON 8:ON
93 / 150
PSL
PCB1521
1593.14.400
Test points - PSL
Test point
TP1
TP2
TP3
TP4
TP5
TP6
TP7
Caution
Function
+12 V DC - Relay control common
Ground, relative to +12 V DC signal
Relay control signal - K1 (main contactor)
Relay control signal - K2 (regulation error)
Relay control signal - K3 (SCO locking)
5 V AC1 - input voltage reference, AC signal
5 V AC2 - input voltage reference, AC signal
Capacitor C6 will remain charged at about 70 V DC long after disconnecting the
power supply. To prevent any damage or electrical shock it has to be discharged
by means of a power resistor. (Remaining energy in capacitor about 2 Joule. A
resistor of about 1000 Ohm / 3 W across the capacitor terminals will discharge
the capacitor to below 24 V in less than half a second.)
94 / 150
CCL - PCB1516
1590.03.541
95 / 150
Dip-switches - CCL
SW1
Local Bus - Line termination
Switch
Function
1
ON: Transmit / E pull up 680 Ohm
2
ON: Transmit / E line termination 150 Ohm
3
ON: Transmit / E pull down 680 Ohm
SW2
Various functions
Switch
1
2
3
4
5
6
7
8
Function
Recall default parameters
CCL-TBM communication, parity:
For 115200 Bd: 0 = even / 1 = odd
For 38400 Bd: 0 = even / 1 = no parity
ON: Lock in boot-loader
CCL-TBM communication, baudrate: 0 = 115200 Bd / 1 = 38400 Bd
Local Bus
0 9600 Bd 1 19200 0 38400 1 9600
baudrate:
Bd
Bd
Bd
0
0
1
1
Local Bus
0
NO
1
NO
0 ODD 1 EVEN
parity:
0 parity 0 parity 1 parity 1 parity
LED
DS1
DS2
DS3
DS4
Function
Microcontroller RUN
Local Bus isolated 5 V present
Local Bus TXD
Local Bus TXD
LEDs
Factory
setting
Factory setting of the switches:
SW1 - all OFF
SW2 - 1:OFF 2:OFF 3:OFF 4:ON 5:OFF 6:ON 7:ON 8:ON
96 / 150
LMC - PCB1513
1593.14.111
97 / 150
Dip-switches - LMC
SW1
J-Bus A - Line termination and 2- or 4-wire transmission selection
Switch
Function
1
ON: Transmit / E pull up 680 Ohm
2
ON: Transmit / E line termination 150 Ohm
3
ON: Transmit / E pull down 680 Ohm
4
OFF = 2 wire / ON = 4 wire
5
ON: Receive / R pull up 680 Ohm
6
ON: Receive / R Line termination 150 Ohm
7
ON: Receive / R pull down 680 Ohm
8
Not used
SW2
J-Bus B - Line termination and 2- or 4-wire transmission selection
Switch
Function
1
ON: Transmit / E pull up 680 Ohm
2
ON: Transmit / E line termination 150 Ohm
3
ON: Transmit / E pull down 680 Ohm
4
OFF = 2 wire / ON = 4 wire
5
ON: Receive / R pull up 680 Ohm
6
ON: Receive / R line termination 150 Ohm
7
ON: Receive / R pull down 680 Ohm
8
Not used
SW3
Local Bus and Sync line - Line termination
Switch
Function
1
ON: Local Bus - Transmit / E pull up 680 Ohm
2
ON: Local Bus - Transmit / E line termination 150 Ohm
3
ON: Local Bus - Transmit / E pull down 680 Ohm
4
Not used
5
ON: Sync line - Transmit / E pull up 680 Ohm
6
ON: Sync line - Transmit / E line termination 150 Ohm
7
ON: Sync line - Transmit / E pull down 680 Ohm
8
Not used
SW4
J-Bus slave number (composed by the switches in the position OFF)
Switch
Hexadecimal value
Decimal value
1
01 hex
1
2
02 hex
2
3
04 hex
4
4
08 hex
8
5
10 hex
16
6
20 hex
32
7
40 hex
64
8
80 hex
128
98 / 150
SW5
Local Bus Enabling or disabling of modules
Switch setting on LMC permits disabling of the detection of the optional units.
(Local Bus to these units will be deactivated.)
Switch
Function
1
ON: UI enabled
2
ON: EFD enabled
3
ON: LFD enabled
4
Not used
5
Not used
6
Not used
7
Not used
8
ON: GK enabled
SW6
Various functions
Switch
1
2
3
4
5
Local Bus
baudrate:
6
7
Local Bus
parity:
8
SW7
0
0
0
0
Function
ON: Local Kill
ON: E2P init
ON: Lock in boot-loader
Not used
9600 1 19200 0 38400
Bd
Bd
Bd
0
1
NO
1
NO
0 ODD
parity 0 parity 1 parity
1
1
1
1
9600 Bd
EVEN Parity
Not used
LEDs
LED
DS1
DS2
DS3
DS4
DS5
DS6
DS7
DS8
DS9
DS10
DS11
Factory
settings
Function
J-Bus A isolated 5 V present
J-Bus B isolated 5 V present
Local Bus isolated 5 V present
Local Bus TXD
Sync line signal
Local Bus RXD
J-Bus A RXD
J-Bus A TXD
J-Bus B RXD
J-Bus B TXD
Microcontroller - RUN
Factory setting of the switches:
SW1 - all OFF
SW2 - all OFF
SW3 - 1:ON 2:ON 3:ON 4:OFF 5:OFF 6:OFF 7:OFF 8:OFF
SW4 - J-Bus slave number
SW5 - Depending on the presence of the modules
SW6 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON
99 / 150
UI - PCB1507
1593.14.000
Dip-switches - UI
SW1
Local Bus - Line termination
Switch
Function
1
ON: Transmit / E pull up 680 Ohm
2
ON: Transmit / E line termination 150 Ohm
3
ON: Transmit / E pull down 680 Ohm
4
Not used
100 / 150
SW2
Various functions
Switch
1
2
3
4
5
Local Bus
baudrate:
6
7
Local Bus
parity:
8
Function
Not used
Not used
ON: Lock in boot-loader mode
Not used
0 9600 1 19200 0 38400 1 9600
Bd
Bd
Bd
Bd
0
0
1
1
0
NO
1
NO
0 ODD 1 EVEN
parity
parity
0
0
1 parity 1 parity
LEDs
LED
D2
D3
D4
D5
Factory
settings
Function
Local Bus RXD
Local Bus TXD
Microcontroller RUN
Local Bus isolated 5 V present
Factory setting of the switches:
SW1 - all OFF
SW2 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON
101 / 150
Multiwire - PCB1486
Note
1593.13.510 & 1593.13.520
The multiwire board delivers a remote control voltage usable to control the
relays of this board.
It is protected with polyswitch fuses.
This internal remote control voltage is brought to the terminal block P2:
terminal P2/10: positive pole.
terminal P2/11: negative pole.
With strap W5 installed, the internal remote control voltage (negative pole
also internally wired to P2/11) is connected to the common of the remote
control line (P2/9).
With strap W6 installed, the positive pole of the internal remote control
voltage is connected to the common pole for the back-indication signals.
102 / 150
J-Bus Connection - PCB1502
1590.03.490
This small PCB provides the interconnection of the user J-Bus(ses) with the
LMC.
The PCB is equipped with gas arrestors for overvoltage protection.
103 / 150
LFD - PCB1519
1590.03.551
DIP-switches - LFD
S1
Local Bus - Line termination
Switch
Function
1
ON: Transmit / E pull up 680 Ohm
2
ON: Transmit / E line termination 150 Ohm
3
ON: Transmit / E pull down 680 Ohm
4
Not used
S2
Various functions
Switch
1
2
3
4
5
Local Bus
baudrate:
6
7
Local Bus
parity:
8
Function
Not used
Not used
ON: Lock in boot-loader mode
Not used
0 9600 1 19200 0 38400 1 9600
Bd
Bd
Bd
Bd
0
0
1
1
0
NO
1
NO
0 ODD 1 EVEN
0 parity 0 parity 1 parity 1 parity
LEDs
LED
DS1
DS2
DS3
DS4
Function
Microcontroller RUN
Local Bus isolated 5 V present
Local Bus TXD
Local Bus RXD
104 / 150
Factory
setting
Factory setting of the switches:
S1 - all OFF
S2 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON
EFD Logic - PCB1514
1590.03.520
Dip-switches
EFD
SW1
Local Bus - Line termination
Switch
Function
1
ON: Transmit / E pull up 680 Ohm
2
ON: Transmit / E line termination 150 Ohm
3
ON: Transmit / E pull down 680 Ohm
4
Not used
SW2
Various functions
Switch
1
2
3
4
5
Local Bus
baudrate:
6
7
Local Bus
parity:
8
Function
Not used
Not used
ON: Lock in boot-loader
Not used
0 9600 1 19200 0 38400 1 9600
Bd
Bd
Bd
Bd
0
0
1
1
0
NO
1
NO
0 ODD 1 EVEN
0 parity 0 parity 1 parity 1 parity
105 / 150
LEDs
LED
DS1
DS2
DS3
DS4
DS5
DS6
Function
Local Bus isolated 5 V present
Ohm-test activated
Output disconnected
Microcontroller RUN
Local Bus TXD
Local Bus RXD
Factory
settings
Factory setting of the switches:
SW1 - all OFF
SW2 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON
Caution
The EFD produces a voltage of 500 V DC. This voltage is connected to the
output circuit of the regulator, thus all high-voltage components will have this
voltage level relative to ground. The energy is limited but still sufficient to
startle a person coming in contact with it.
EFD-Res - PCB1515
1590.03.530
106 / 150
Circuit Selector
Test points
PCB1523
1590.03.561
CS
Test point
Function
TP1
Ground, relative to +12 V DC signal
TP2
+12 V DC signal for relay control K1 to K4
TP3
+12 V DC signal for relay control K5 to K8
LEDs
LED
DS1
DS2
DS3
DS4
DS5
DS6
DS7
DS8
Function
Relay K1 energised / Circuit 1 short-circuited
Relay K2 energised / Circuit 2 short-circuited
Relay K3 energised / Circuit 3 short-circuited
Relay K4 energised / Circuit 4 short-circuited
Relay K5 energised / Circuit 5 short-circuited
Relay K6 energised / Circuit 6 short-circuited
Relay K7 energised / Circuit 7 short-circuited
Relay K8 energised / Circuit 8 short-circuited
107 / 150
Dongle
PCB1505.1
1444.00.010
The Dongle is the interface between the CCR and a PC running the CCR
configuration program under one of the Window brands. It is normally only
used during installation, adjustment of system parameters and repair, if
necessary.
It connects on the one hand to the connector CO5 of the LMC and on the
other hand to the COM port of the PC on which the regulator configuration
software is running. Both connections use RS232.
When the Dongle is connected to the system and to the PC and the regulator
configuration software is running, then the LMC relinquishes bus mastership
in favour of the Dongle. Control through the User Interface is no longer
possible.
The Dongle receives its power from the LMC.
DB9 Male
to PC
LED Isolated
power supply
LEDs for RXD & TXD LED - RUN
Communication to LMC
Communication to PC
LEDs for
TXD & RXD
1
SW1
DB9 Female
to LMC
SW1
8
Baudrate and parity settings
Switch
1
2
3
4
5
6
7
8
PC link (RS232) baudrate:
PC link (RS232) parity:
Local Bus baudrate:
Local Bus parity:
0
0
0
0
0
0
0
0
Function
9600 1 38400
Bd
Bd
0
NO
1 EVEN
parity 0 parity
9600 1 38400
Bd
Bd
0
NO
1 EVEN
parity 0 parity
0 19200 1
Bd
1
1
0
NO
1
parity
1
1
0 19200 1
Bd
1
1
0
NO
1
1 parity 1
9600
Bd
ODD
parity
9600
Bd
ODD
parity
LEDs
LED Isolated Power supply: indicates the presence of the isolated
supply. It must always remain lit.
LED RUN: This LED flashes at a rate of 1 flash per second during normal
operation. If it blinks at a much higher rate this means that the
microcontroller is in boot-loader mode and a software upload is required.
Bus LEDs: All these LEDs are normally OFF and light up for a short time
during transmission or reception.
Factory
setting
Factory setting of the switches:
SW1 - 1:ON 2:OFF 3:ON 4:OFF 5:ON 6:OFF 7:ON 8:OFF
108 / 150
Electrical Diagrams (3229.13.240BA)
109 / 150
7
Section 7
PC Control and Monitoring
Preliminary
The regulator does not require the use of a PC to operate.
Use
The PC with the dedicated ADB software and the Dongle is required to
modify parameters, in particular for the adjustment of the lamp fault detection
module and for the Circuit Selector.
It can also be used to control the regulator.
Caution!
If the PC with the Dongle is connected to the LMC, local control will only be
possible by means of this software. The User interface will give backindications but brightness control or parameter access will be disabled.
110 / 150
7.1 Program MCR3_WIN
With a connected Dongle, an operational regulator and the program
MCR3_WIN started, the communication between PC and regulator enters an
infinite loop.
The program performs two tasks:
a regular and automatic data exchange with the MCR³
possibility to change parameter settings, control and calibration of the
MCR³ by means of a screen interface using a menu
Structure of
the screen
The screen is divided in windows with a menu bar at the top.
To the left, the status window is always present and shows:
the output current (as a thermometer-like vertical bar graph and as a
numeral value)
the mains voltage
the luminosity in %
the currently active step
the selected circuits (if the CS option is installed)
the number of burnt lamps (if the LFD option is installed)
the insulation resistance of the series circuit (if the EFD option is
installed)
the status of the J-Bus
The display in the right-hand window can be selected by the user via the
menu bar at the top of the screen.
Eight different dialogue screens are accessible: Control, MCR3 Setup, EFD,
LFD, IO, Installation, Configuration and Exit.
Some screens contain more lines than visible in one window. A scroll bar at
the right side of the window permits to scroll through these screens.
Parameters can be changed by clicking on the text or the value.
A small window appears to make a selection between various settings or to
enter a value.
The small window on the bottom left displays informative messages.
The small window on the bottom right shows warnings and alarm messages.
Note
Calibration of the current, voltage and power measurements:
See menu MCR3 Setup / MCR3 Input/Output measurements / Calibration
Rough calibration is possible with regulator in short circuit.
Fine-tuning is possible with full load.
After the calibration procedure of input voltage , input current , input
power , output voltage , output current or output power has been
selected, the MCR³ (CCL) starts a zeroing of the measurement. After this is
finished, the MCR³ switches on at the maximum brightness step and asks for
the reading to be entered. Wait until the regulation and the measurement are
stabilized and enter the reading. Check if the calibration is concluded
successfully.
111 / 150
Calibration of
the EFD
After the EFD calibration has been started, the module itself checks the
status without any leakage current and the status with the maximum leakage
current. After successful conclusion of this calibration the module will
measure correctly the leakage current of the field circuit and translate this to
a corresponding leakage resistance.
Control of the regulator (brightness step and circuit selection) is also possible
in the status window by selecting a displayed brightness step or circuit
selection.
To exit the program, select the window EXIT and answer YES or click on the
screen-button in the right top corner:
Caution
Via menu Installation / MAXIMUM OUTPUT CURRENT the parameter
Maximum output current can be changed. This is considered to be a factory
adjustment! Changing this parameter requires calibration of output current
and output power to obtain correct readings.
112 / 150
7.2 Overview of the screens
7.2.1 MCR3 Control
113 / 150
7.2.2 MCR3 Setup
114 / 150
115 / 150
116 / 150
117 / 150
118 / 150
119 / 150
120 / 150
121 / 150
122 / 150
123 / 150
124 / 150
125 / 150
126 / 150
127 / 150
7.2.3 MCR3 EFD
Note
Rule of thumb for the startup time = 4s / km cable length (as long as cable
capacitance is less than 0.2µF/km).
:
128 / 150
129 / 150
7.2.4 MCR3 LFD
130 / 150
131 / 150
132 / 150
7.2.5 MCR3 IO Settings
133 / 150
134 / 150
135 / 150
136 / 150
137 / 150
138 / 150
139 / 150
140 / 150
7.2.6 MCR3 Installation Parameters
141 / 150
142 / 150
7.2.7 MCR3 Configuration
143 / 150
144 / 150
7.2.8. MCR3 Exit Screen
145 / 150
8
Section 8
Appendix
8.1 MODBUS settings
Hardware present
Arbiter
Local kill
Default
Bus
Bus A
Bus B
Arbiter
Local kill
Breakdown mode
Default mode
Default step
Default step REIL
Slave number
Bus A
Bus B
Time-out
Baudrate
Parity
Time-out
Baudrate
Parity
146 / 150
8.2 Default settings multiwire
Back-indication signals multiwire 1
P1
1
2
3
4
5
6
7
8
9
10
11
12
Function
Step 1 obtained
Step 2 obtained
Step 3 obtained
Step 4 obtained
Step 5 obtained
MCR3 is ON
Regulation error
Overtemperature alarm
Common
GNDext
Vext+
PE
Back-indication signals multiwire 2
P1
1
2
3
4
5
6
7
8
9
10
11
12
Function
Overcurrent alarm
Open-circuit alarm
EFD warning level
EFD alarm level
LFD lamps warning level
LFD lamps alarm level
LFD VA warning level
LFD VA alarm level
Common
GNDext
Vext+
PE
Back-indication signals multiwire 3
P1
1
2
3
4
5
6
7
8
9
10
11
12
Function
Circuit 1 active
Circuit 2 active
Circuit 3 active
Circuit 4 active
Circuit 5 active
Circuit 6 active
Circuit 7 active
Circuit 8 active
Common
GNDext
Vext+
PE
147 / 150
Remote control signals multiwire 1
P2
1
2
3
4
5
6
7
8
9
10
11
12
Function
Step 1
Step 2
Step 3
Step 4
Step 5
Common
Vext+
GNDext
PE
Remote control signals multiwire 2
P2
1
2
3
4
5
6
7
8
9
10
11
12
Function
Reset EFD error
Use LFD degraded mode
Allow WRITE via bus
Common
Vext+
GNDext
PE
Remote control signals multiwire 3
P2
1
2
3
4
5
6
7
8
9
10
11
12
Function
Circuit 1
Circuit 2
Circuit 3
Circuit 4
Circuit 5
Circuit 6
Circuit 7
Circuit 8
Common
Vext+
GNDext
PE
148 / 150
149 / 150