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Cooper Industries
Crouse-Hinds Division
Crouse-Hinds Airport Lighting Products
1200 Kennedy Road
Windsor, CT 06095
860 683-4300
Fax 860 683-4354
Title:
DOCUMENT 9525
December 20, 2007
Revision P
INSTRUCTION MANUAL
L-828 & L-829 CONSTANT CURRENT REGULATOR
OIL FILLED
SERIES 82860-W(L-828,60HZ); 82960-W(L-829,60HZ)
SERIES 82850-W(L-828,50HZ); 82950-W(L-829,50HZ)
10 KW, 6.6A; 15, 20, 30 KW, 6.6 & 20A; 37.5, 50, 70 KW, 20A
10 KW, 6.6A; 15, 20, 30 KW, 6.6 & 20A; 50 KW, 20A
Copyright © 2007 Cooper Technologies Company
9525
Rev. P
CONFIGURATION RECORD
The following information is specific to the equipment described herein as shipped from
the factory and should be retained. It should be provided when contacting the factory
about this equipment for any reason.
Constant Current Regulator, FAA Type
Manufacturer’s Part Number
Serial Number
Date of Manufacture
Factory Installed Options:
DESCRIPTION
OPTION/PART NUMBER
ii
9525
Rev. P
REV.
A
REVISIONS
DESCRIPTION
Revised pictorials & related items due to physical
change to regulator & added additional clarifications
and made corrections as warranted before actual
production of this unit
LTR.
A96261
DATE
5/10/96
APVL
PG
B
Pg. 44, 51, 57 & 62, Item 25 P/N 31505-2 was
31505-3; Pg. 2 & 4, added note on 10 KW
qualification; Pg. 3, added
A96496-
9/25/96
JAS
C
Deleted 2.1.5.3 on Pg. 7; 31879-3L was 31879-1L,
Deleted 31879-2l, P/N 32277-1 was 31984-1 on Pg.
48; P/N 32323 was 32042-X-Y-6H, P/N 31879-3L
was 31879-2L, P/N 32277-1 was 31984-1 on Pg. 53;
P/N 32323 was 32042-X-Y-5H, P/N 31879-3L was
31879-2L, P/N 32277-1 was 31984-1 on Pg. 59.
A97211
4/15/97
JAS
D
1) Revised wiring diagram Figure 4-4, secondary of A97T20 was 12,6,0
327
6/5/97
JAS
E
1) Pg. 40, Fig.4-4, re-routed wire 13 to T20.
7/10/97
JAS
8/22/97
JAS
6/1/98
RBM
1/11/99
JAS
11/27/01
DCW
10/1/02
GFR
8/10/06
PG
10-06/06
PG
F
G
H
J
K
L
A97385
1) Pg. 19, Fig. 3-1, revised schematic to show
rerouting of wire 13 to T20, Added P/N 32330, A97Safety notice, moved warning label to accomodate; 479
2) Pg. 20, Fig. 3-2, revised sheetmetal behind control
cabinet; 3) Pg. 21, Fig. 3-3, flipped bolts on hold
down channel for easier assembly; 4) Pg. 44, Fig. 51, rotated TB1 90 deg. to avoid interference with
door; 5) Pg. 46, Fig. 5-3, flipped bolts on hold down
channel for easier assembly; 6) Pg. 47, Fig. 4-7,
revised sheetmetal behind control cabinet; 7) Pg. 49,
Fig. 5-6, rotated top half of K1 label 90 deg.
Sheet 39.1, S2, S3 & S4 was S2-S4
A98071
Changed notes on Figure 4-3c, Sheet 39.1
A98395
Added pilot relay (K2) and related data to 2400v A201Version
274
Revised graphics to agree with latest manufacturing; A202revised Figure 4-5 (cont) T3 part number was 30190; 233
updated parts lists to agree with latest manufacturing;
Item 14 fuse F1 10053-307 was 10047-1205
1.2.3.1, Specification 150/5345-10F was 10E; cover
A206page, revised copyright
260
iii
M
Pg 51, item 19 P/N for 480V was 31675; Fig 4-5, A206-
9525
Rev. P
N
P
revised 480V, 60 HZ connections
377
Pg 41, 208V , 60 Hz, SEE FIG-5b was 4-5a & 220V, A20760 Hz, SEE FIG 4-5c was 4-5b and added SEE FIG 221
4-5c to 240V, 60 Hz and SEE FIG 4-5d to 480V, 60
Hz and deleted SEE FIG 4-5a from 208V, 50 Hz and
SEE FIG 4-5d from 220V, 50 Hz; Pg 41.1, added
Figures 4-5b thru d; Pg 51, added item 19 T3 P/N
10047-2424 and 10047-1444 usage was 480V and
31675 usage was 208-240V
Table 3-1, revised input current ratings
A207318
iii.1
8-2-07
PG
12/20/07
PG
9525
Rev. P
LIMITED PRODUCT WARRANTY
THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
Crouse-Hinds Airport Lighting Products (the “Company”) warrants to
each original Buyer of Products manufactured by the Company that such Products
are, at the time of delivery to the Buyer, free of material and workmanship
defects, provided that no warranty is made with respect to:
a) any Product which has been repaired or altered in such a way, in Company’s
judgment, as to affect the Product adversely;
b) any Product which has, in Company’s judgment, been subject to negligence,
accident or improper storage;
c) any Product which has not been operated and maintained in accordance with
normal practice and in conformity with recommendations and published
specification of Company; and,
d) any Product, component parts or accessories
supplied by Company (any claims should be
manufacturer thereof).
manufactured by others
submitted directly to
but
the
Crouse-Hinds Airport Lighting Product’s obligation under this warranty
is limited to use reasonable effects to repair or, at its option, replace,
during normal business hours at any authorized service facility of Company, any
Products which in its judgment proved not to be as warranted within the
applicable warranty period. All costs of transportation of Products claimed not
to be as warranted and of repaired or replacement Products to or from such
service facility shall be borne by Purchaser. Company may require the return of
any Product claimed not to be as warranted to one of its facilities as designed
by Company, transportation prepaid by Purchaser, to establish a claim under this
warranty.
The cost of labor for installing a repaired or replacement product
shall be borne by Purchaser. Replacement parts provided under the terms of this
warranty are warranted for the remained of the warranty period of the Products
upon which they are installed to the same extent as if such parts were original
components thereof.
Warranty services provided under the Agreement do not
assure uninterrupted operations of Products; Company does not assume any
liability for damages caused by any delays involving warranty service.
The
warranty period for the Products is 24 months from date of shipment or 12 months
from date of first use whichever occurs first.
iv
9525
Rev. P
SAFETY NOTICES
This equipment is normally used or connected to circuits that may employ
voltages which are dangerous and may be fatal if accidentally contact by
operating or maintenance personnel.
Extreme caution should be exercised when
working with this equipment.
While practical safety precautions have been
incorporated in this equipment, the following rules must be strictly observed.
KEEP AWAY FROM LIVE CIRCUITS
Operating and maintenance personnel must at all times observe all safety
regulations. Do not perform maintenance on internal components or re-lamp with
power ON.
RESUSCITATION
Maintenance personnel should familiarize themselves with the technique for
resuscitation found in widely published manuals of first aid instructions.
v
9525
Rev. P
Title Page . . . . . . .
Configuration Record. . .
Revisions
. . . . . . .
List of Effective Pages .
Limited Product Warranty
Safety Notices . . . . .
Table of Contents . . . .
SECTION
1.1
1.2
1.3
1.4
SECTION
2.1
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TABLE OF
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1.
GENERAL INFORMATION
Introduction . . . . . . .
Equipment Description . . .
Installation Requirements .
Warning Notice. . . . . . .
2.
TECHNICAL DESCRIPTION
Theory of Operation . . . .
CONTENTS
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1
3
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5
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SECTION 3.
INSTALLATION AND OPERATION
3.1
Installation . . . . . . . . . . . . . . . . . . . . . 10
3.2
Operation . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 4.
MAINTENANCE
4.1
Periodic Maintenance . . . . . . . . . . . . . . . . . 24
4.2
Corrective Maintenance . . .. . . . . . . . . . . . . . 25
4.3
Problem Solving Guide . . . . . . . . . . . . . . . . . 25
SECTION 5.
PARTS LIST
5.1
Scope . . . . . . . . . . . . .
5.2
Arrangement . . . . . . . . . .
5.3
Reference Designation . . . . ..
5.4
Option Parts . . . . . . . . . .
5.5
Recommended Spares . . . . . . .
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43
43
43
43
62
Catalog Number Breakdown . . . . . . . . . .
Mechanical Dimensions, Front . . . . . . . .
Mechanical Dimensions, Side . . . . . . . .
30 KW, 50 HZ & 37.5 KW, 70 KW Oil Tank . . .
Controls and Indicators . . . . . . . . . .
Calibration Flow Chart . . . . . . . . . . .
Control System Connector Operation . . . . .
Standard Model Diagnostic Indicators . . . .
Remote Control Connections . . . . . . . . .
Remote Control Jumper Connections . . . . .
Dip Switch Configurations . . . . . . . . .
System Wiring Diagram . . . . . . . . . . .
K2 Relay Wiring Diagram, 2400v . . . . . . .
Control Transformer Wiring Details . . . . .
Monitor Wiring . . . . . . . . . . . . . . .
Front View Part I.D. . . . . . . . . . . . .
Front View Part 1.D., 2400v. . . . . . . . .
Top View Part I.D . . . . . . . . . . . . .
10 KW-20 KW & 30 KW, 60 HZ Oil Tank . . . .
Regulator Left Side View . . . . . . . . . .
Control Box Circuit Card Identification. . .
2400V K1 & Lightning Arrestor Configuration.
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4
19
20
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22
23
30
31
39
39.1
39.2
40
40.1
41
42
44
44.1
45
46
47
48
49
FIGURES
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1-1
3-1
3-2
3-3
3-4
3-5
4-1
4-2
4-3
4-3c
4-3d
4-4
4-4a
4-5
4-6
5-1
5-1a
5-2
5-3
5-4
5-5
5-6
-
vi
9525
Rev. P
TABLE OF CONTENTS
Cont'd
TABLES AND CHARTS
Table 3-1 Power Requirements .
Display Messages and What They Mean
Quick Problem Solving Checklist . .
Power Supply Problem Checklist . . .
Protection Problem Checklist . . . .
Regulation Problem Checklist . . . .
Local Control Problem Checklist. . .
Remote Control Problem Checklist . .
Digital Problem Checklist. . . . . .
Display Problem Checklist. . . . . .
Parts List - 60 Hz . . . . . . . . .
Parts List - 50 Hz . . . . . . . . .
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10
27
28
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34
35
36
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38
50
56
9525
Rev. P
SECTION I.
1.1
INTRODUCTION
1.1.1
Purpose
GENERAL INFORMATION
This instruction manual provides information for installing and
maintaining oil-cooled (wet) FAA Type L-828 & L-829 Constant Current
Regulators manufactured by Crouse-Hinds Airport Lighting Products,
Windsor, Connecticut 06095, U.S.A.
1.1.2
Applicability
Only 10 - 70 KW regulators bearing Crouse-Hinds catalog number series
82860-W, 82960-W, 82850-W, & 82950-W are covered by this manual.
Refer
to
Figure
1-1
for
complete
part
number
information.
Instructions for standard options are provided as supplements to this
manual.
1.2
EQUIPMENT DESCRIPTION
1.2.1
Features
The Constant Current Regulator is a power supply designed for
precision operation of airfield lighting.
The output current is
regulated within +/-1% at any load and for line voltages form +10% to
-5% of nominal. The three or five discrete brightness steps conform
to FAA standards.
The regulator may be controlled both locally and
from a remote location.
Protective circuits are provided to sense an overcurrent or an open
circuit in the series lighting loop and shutdown the regulator. The
front panel display alerts maintenance personnel to the nature of the
shutdown.
The protective circuitry can be reset by setting the
regulator control switch to off for 1 second.
Provided no fault
condition remains, setting the control switch to the desired
brightness step will restore operation.
The regulator may be connected directly to an FAA approved load
switching device.
No regulator malfunction or damage to the series
lighting loop will occur.
1.2.2
Options
This regulator can be factory supplied with various options. Contact
Crouse-Hinds Airport Lighting Products for a current list of options.
1
9525
Rev. P
1.2.3
1.2.3.1
Specification
FAA Classification
Specification:
Constant
Current
Regulator
manufactured
and
qualified to FAA Advisory Circular 150/5345-10F
Type:
L-828 Regulator
L-829 Regulator (with monitoring)
Class:
1 - 6.6 amperes output current (10KW*, 15KW, 20KW, 30KW)
2 - 20 amperes output current (15KW, 20KW, 30KW, 37.5KW,
50KW, 70KW
Style:
1 - 3 Brightness Steps: 4.8, 5.5, 6.6 amperes or 14.5,
16.7, 20.0 amperes
2 - 5 Brightness Steps: 2.8, 3.4, 4.1, 5.2, 6.6 amperes
or 8.5, 10.3, 12.4, 15.8, 20.0 amperes
Ratings:
Sizes - 10KW*, 15KW, 20KW, 30KW, 37.5KW, 50KW, 70KW
Voltages - 208, 220, 240, 480, 2400V; 60 Hz
208, 220, 230, 240, 380, 400 & 415; 50 Hz
*10KW NOT FAA QUALIFIED.
1.2.3.2
Electrical Characteristics
Primary Power:
Refer to Table 3-1 for ampacity information based on regulator size
and line voltage.
Remote Control Power:
1.2.3.3
(a)
Internal Supply - 120 VAC, standard (Other voltages
optional)
(b)
External Supply - 120 VAC, Standard (Other voltages
optional
Physical Characteristics
Dimensions:
Refer to Outline Drawings, Figures 3-1 and 3-2.
Weight:
10
15
20
30
KW
KW
KW
KW
-
1575
1700
1825
2000
lbs.
lbs.
lbs.
lbs.
2
37.5 KW - 2400 lbs.
50 KW - 2600 lbs.
70 KW - 3000 lbs.
9525
Rev. P
Mechanical:
The regulator has a vented sheet steel enclosure painted blue with
light gray accents.
A removable cover provides access to line and
load connections.
The electronic controls are housed in a hinged
compartment which provides access to the remote control terminals when
open.
Removable covers and panels allows easy access to other
customer serviceable parts.
The Main Transformer is immersed in an
oil (No PCB’S) filled tank.
The tank contains between 85-90 U.S.
Gallons of electrical insulating Oil.
Environmental:
1.3
Temperature:
-40 degrees C to + 55 degrees C
(-40 degrees F to +131 degrees F)
Relative Humidity:
10 percent to 95 percent
Altitude:
Zero to 6,600 feet (2000 m)
Installation Requirements
The regulator is shipped from the factory complete and ready to
install.
The agency responsible for installation must supply all
necessary connectors, wire and conduit. The regulator is for indoor
use only. It must be floor mounted.
1.4
WARNING NOTICE
Exterior metal surfaces may exceed 120° (49°C) when regulator is
operated at full power for more than 10 hours. Radiator temperature
and oil tank may exceed 150°F (66°C).
3
9525
Rev. P
Figure 1-1
4
9525
Rev. P
SECTION 2.
2.1
TECHNICAL DESCRIPTION
THEORY OF OPERATION (BASIC REGULATOR)
The information presented here applies to a standard model Constant
Current Regulator (CCR).
Regulators supplied with options may have
minor operating differences, but the basic operation is the same for
all units.
Many functions in the CCR are controlled by a custom programmed
electronic circuit. This device performs brightness step and digital
display control, open circuit and over-current sensing, and handles
system fault conditions.
Several optional features also use the
programmed circuit to reduce the amount of additional circuitry
required.
Each of the standard functions is discussed in detail in
the following paragraphs.
Optional functions are discussed in
Supplemental sections of this manual.
2.1.1
Current Regulation
A ferro-resonant transformer is conjunction with a pair of silicon
controlled rectifiers (SCR) is used for current regulation.
This
design provides precise control regardless of the load size or line
voltage.
For very low loads or low brightness settings, the SCR
conduction angle will be large.
At increased loads or higher
brightness settings, the conduction angle will be smaller.
The SCR gating signal is controlled using closed-loop electronic
feedback control.
Load current is sensed by a current transformer
which generates an analog signal.
The signal is processed by an
electronic circuit and compared to a predetermined reference.
The
result is a time delayed SCR control signal. This control signal is
applied to a pulse transformer to generate a gating signal for the
SCR’s.
2.1.2
Brightness Control
Each brightness step has a specific digital reference value stored in
electronic memory. When the desired step is selected on the keypad,
the proper memory value is converted to an analog signal. This signal
is the reference used for comparison as discussed in paragraph 2.1.1.
Refer to Section 3.2 for keypad operation.
All remote brightness
connections are electrically isolated form the control electronics by
opto-couplers for transient protection.
5
9525
Rev. P
2.1.3
Remote Control Operation
The regulator can operate remotely using external switches connected
to the remote control terminal block TB1. The exact wiring of these
switches depends upon whether control power is obtained from the
regulator internal supply or from an external source.
The regulator turns on to brightness B1 (or B10) when control power is
applied to terminals CC and B1 (B10).
To get a higher brightness,
control power is applied to terminal B2, B3, B4 or B5.
(For threestep regulators, apply control power to B30 or B100, for one-step
regulators, apply control power to on).
Only the terminal for the
desired step and CC require control power. If two or more steps are
energized together, the regulator will operate at the highest
brightness step selected.
2.1.4
Digital Display
A multi-purpose Digital Display provides system operation data. Under
normal conditions, the display shows the output current being supplied
by the CCR. Under power-up and system fault conditions, it displays
specific CCR status data (refer to paragraph 2.1.6).
2.1.5
Protective System
2.1.5.1
Overcurrent Protection
Overcurrent protection is triggered by comparison of the value of the
feedback signal to predetermined limits.
In the event of a minor
overcurrent (between 5% and 25% above rated output), the control
system responds within 5 seconds.
If a major overcurrent (greater
than 25% above rated output) occurs, the control system responds
immediately.
The response consists of de-energizing the load by
opening the main contactor and providing status data to the digital
display.
To reset and re-energize the CCR, the keypad or remote
brightness control switch must be set to OFF for at least one second.
2.1.5.2
Open-Circuited Load Protection
This protection is triggered by comparison of the value of the
feedback signal to a minimum current level.
If the current remains
below 2 amps for about 2 seconds, the control system performs the same
shutdown sequence as for overcurrent protection.
6
9525
Rev. P
2.1.5.3
Not Used
2.1.5.4
Fuses
There are two fuses in the regulator for internal power supply
protection.
Fuse F1 protects the internal 120 VAC supply.
Fuse F2
protects the remote control system supply.
2.1.5.5
Transient Protection
Protection against transients from lightning or other sources is
provided. Lightning arrester LA1 protects the regulator power lines.
Arresters LA2 and LA3 protect the regulator load lines. Varistors are
provided on the control system assembly to protect it from transients
on the power and control lines.
The lightning protection provided exceeds the requirements of the
applicable Advisory Circular.
Lightning is a naturally occurring
phenomenon that varies in intensity and frequency based upon
geographic location. Therefore, each installation should be evaluated
to determine the need for additional lightning protection.
2.1.6
System Status Information
The CCR Digital Display is used during power-up and fault conditions
to provide data regarding system status.
2.1.6.1
Power-Up
When power is applied to the CCR and when resetting from a latched
fault mode, the control electronics performs a series of internal
checks. If these are completed without incident, the control program
number will be displayed for one second. The display will then begin
to indicate CCR output current.
If any check is not successfully
completed, the system will "lock-up" preventing further operation.
2.1.6.2
Fault Status Messages
If the CCR control circuits detect an abnormal system shutdown, a
message will automatically scroll across the display.
When two or
more fault conditions exist, the most recent occurrence is displayed.
Messages are cleared when the system is reset or conditions return to
normal.
Refer to the Operation and Maintenance Sections for
information on specific messages.
7
9525
Rev. P
2.1.7
Monitoring (L-829 Only)
The monitor circuitry utilizes runway circuit and regulator signals to
perform its function.
The runway circuit current and voltage are
applied to current and potential transformers which perform isolation
and step-down functions.
The outputs of these transformers are
applied to the electronic circuitry for processing.
Also, the
regulator brightness step signals are used by the monitor circuit.
2.1.7.1
Calibration (L-829 Only)
The calibration function is used to initialize the monitor.
Upon
selection of this mode, the operator is prompted for information on
the specific load circuit and the desired alarm levels. When all the
information has been entered, the monitor turns on the regulator and
automatically adjusts itself for each brightness step.
When this
adjustment period is completed (usually within 2 minutes), the
regulator is returned to the off state.
2.1.7.2
Normal Operation (L-829 Only)
The monitor continuously checks the runway circuit for faults. If no
system faults have been detected, the monitor relay is in the
energized state, the lampout warning and alarm relays are in the deenergized state, and the digital display functions as a true-RMS
ammeter.
2.1.7.3
Regulator Power Fault (L-829 Only)
Any removal of input power will de-energize
immediately, thereby signaling a regulator fault.
2.1.7.4
the
monitor
relay
Protective Circuit Faults
In the event of an open circuit or overcurrent shutdown (see section
2.1.5), the monitor relay will be de-energized, signaling a regulator
fault.
In addition, the display will indicate what fault was
encountered.
2.1.7.5
Brightness Step Fault (L-829 Only)
The monitor continuously checks the load current. This current value
is compared with reference values selected by information from the
brightness step control inputs. If the fault is continuously present
for a five second period, the monitor relay is de-energized. A star
(*) will appear to the right of the current reading on the digital
display to indicate an alarm. This fault condition will reset when (1)
the current returns to an in-tolerance value, (2) another properly
operating brightness step is selected, (3) the regulator is set to the
off position.
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9525
Rev. P
2.1.7.6
Ten Percent Drop in Load Volt-Amperes (L-829 Only)
When a large change in load volt-amperes occurs, it is an indication
that there are either two ground paths in the runway circuit or that
there are many lamp burned out in the circuit.
After a five second
delay, the monitor relay is energized and a star (*) appears on the
digital display to indicate an alarm. The fault condition remains
until the situation is corrected.
Connection of a runway circuit
selector between the monitor and the loads will affect monitor
performance.
2.1.7.7
Lamp Failure Detection (L-829 Only)
The lamp failure detection feature of the monitor is performed in
essentially the same manner as the monitoring of volt-amperes
discussed in paragraph 2.1.7.6. It is important to note that because
of the method used to detect lampouts, it is not necessary to
eliminate lamp shorting devices commonly used in some lighting
circuits. If the number of lampouts exceeds the warning level entered
by the user, the lampout warning relay will energize. If the number
of lampouts exceed the alarm level entered by the user, the lampout
alarm relay will energize as well, and the monitor relay will deenergize.
2.1.8
Elapsed Time Meter
The regulator is equipped with an electronic elapsed time meter. It
records the total on-time of the regulator as well as the individual
brightness steps.
It will record up to 9999.9 hours of operation
before starting at zero hours again. It can be viewed by entering the
appropriate command at the regulator keypad. The total or individual
brightness step on-time may be viewed while the regulator is in the on
or off state.
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9525
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SECTION 3.
INSTALLATION AND OPERATION
WARNING
INSTALLATION, SERVICE, MAINTENANCE OR OPERATION SHOULD BE PERFORMED BY
QUALIFIED PERSONNEL ONLY.
3.1
INSTALLATION
The Constant Current Regulator is supplied ready for operation with
all ordered options installed. When properly connected, no electrical
adjustments other than noted in this section should be necessary
before use.
3.1.1
Location
The regulator is designed for indoor locations meeting the environment
specified in Section 1.2.3.3.
The area should be clean and dry,
protected from rain, snow, dust, etc., and have adequate ventilation.
The equipment should be accessible to qualified personnel only.
3.1.2
Installation Drawings
Typical details and dimensions are provided in Figures 3-1, 3-2, 3-3
and 5-3.
3.1.3
Power Requirements
Table 3-1 lists the line current requirements for the different CCR
power and voltage ratings.
It is recommended that the distribution
circuit breaker or fuses be sized to carry 125% of the rated circuit.
TABLE 3-1
POWER REQUIREMENTS
RATED
INPUT
VOLTAGE
208
220
230
240
380
400
415
480
2400
10KW
15KW
53
50
48
46
29
28
27
23
5
80
75
72
69
43
41
40
35
7
RATED INPUT CURRENT
(RMS AMPERES)
20KW
30KW
37.5KW
106
100
96
92
58
55
53
46
9
159
150
143
138
87
83
80
68
14
10
------172
------86
17
50KW
70KW
--------145
138
133
115
23
--------------160
32
9525
Rev. P
3.1.4
Cable and Conduit
Do not locate line and load cables near sensitive control, radar, or
communications lines.
For suggested cable entrance locations, see
Figures 3-2 and 3-3.
3.1.5
3.1.5.1
3.1.5.2
Installation Check List
(1)
Read these instructions before attempting installation.
Improper installation can damage this regulator and may void the
warranty!
If the equipment fails to perform properly at any
step of this procedure, consult the troubleshooting guide in
Section 4.
Call Crouse-Hinds Airport Lighting Products (860)
683-4300 if further information is required during installation.
(2)
Instructions for each equipment option included should also be
read before proceeding with installation.
(3)
SUGGESTION: To stay organized, make a check mark next to each
step as it is completed.
Mechanical Installation
1.
Unpack the Constant Current Regulator, and check for
shipping damage.
any
2.
For handling, a 2” fork-lift clearance is provided underneath
the unit and 4 lifting lugs are provided. The regulator cover
should be in place before lifting.
3.
Refer to Figures 3-1 through 3-3 and 5-3 for mechanical
installation details. Adequate clearance should be left around
the regulator for access and cooling.
4.
Level the transformer so that the
degrees off of vertical.
Check the
The oil level should be visible in
gauge at 25 degrees C (77 degrees F)
operating temperature.
tank is not more than 5
oil level in sight gage.
the lower portion of the
and will rise somewhat at
Power Wiring and Checkout
1.
Connect the ground conductor to the equipment ground terminal.
It is located on the lower right side toward the front of the
regulator. CAUTION: DO NOT connect counterpoise
system
to
this terminal.
2.
Verify that the lien voltage is the same as the regulator
nameplate voltage rating.
This is very important.
CONNECTION
TO THE WRONG LINE VOLTAGE MAY VOID THE WARRANTY.
3.
Make required conduit holes as suggested in Figures 3-2 and 3-3.
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Rev. P
4.
Connect the line voltage source to the input terminals.
On 2400 volt WYE unites, the phase wire connects to the left
terminal (LA1A) and the neutral connects to the right terminal
(LA1B). Do not rely on the ground wire as a neutral conductor.
5.
Connect the series lighting circuit to the output terminals.
CAUTION: DO NOT MEGGER test the series lighting load while it is
connected to the regulator.
6.
Before
connecting
remote
control
lines,
check
regulator
operation using the front panel control switch. Follow steps AC below.
NOTICE: The regulator is equipped with a safety
interlock.
Be sure the control module is in its normal
operating position before operating.
(A)
Apply main power to the regulator.
(B)
Operate the regulator at all brightness steps and check
that the load current levels are correct. See regulator
nameplate for load current levels. (See Section 3.2 for
keypad operation.)
Only a True RMS instrument can accurately
IMPORTANT:
measure
the
regulator
output
externally.
Other
instruments will provide improper readings.
(C)
3.1.5.3
Shut off main power to the regulator.
Control Wiring and Checkout
1.
Connect remote control lines to terminal block TB1 using the
appropriate wiring diagram. Refer to Figure 4-3.
Units which are shipped without an internal primary contactor
(Option 92) must use 120Vac external control.
See the
instructions in the Option 92 Supplement for connection data.
Incorrect wiring can cause malfunction or damage to
CAUTION:
the control system and possibly void the
equipment
warranty.
Re-check
these
connections
before
operating.
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Rev. P
2.
Make a final operation check using local and remote
Steps A-C below.
3.1.5.4
modes.
(A)
Apply main power to the regulator.
(B)
Operate the regulator in the local mode at all rightness
steps and check for correct current levels.
(See
Section 3.2 for keypad operation.)
(C)
Operate the regulator in the Remote mode at all
rightness steps and check for correct current levels.
Monitor Wiring (L-829 Only)
This regulator is equipped with monitor relay, and a warning and alarm
lampout relay. Connect the relay contacts to the monitor and lampout
circuits per Figure 4-6.
Each relay is rated for 120 VAC, 2 AMPS resistive load.
relays are protected by 2 AMP fuses on the P.C. board.
3.1.5.5
The lampout
Final Installation Steps
1.
Make any option related connections discussed in the
Supplements.
option
2.
Check that all cables an wiring are dressed within the
Reinstall all covers.
cabinet.
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Rev. P
3.2
OPERATION
Figure 3-4 shows the standard controls and indicators on the front
control panel.
3.2.1
Local Control Keypad
The local control keypad in conjunction with the digital display acts
as an interactive control terminal for entering many different
operational commands into the regulator.
All keypad entries are
echoed to the display for a period of five seconds for operator
verification.
In all instances, with two exceptions, the command
sequence ends with the “E” key ( for Enter). The two exceptions are
the “ABORT” command - which erases any un-entered command, and the
“OFF” command - which will immediately turn off the regulator.
To select an operating brightness step, simply press
according to the following list:
(Remember - If you make a mistake, press “A” for ABORT.)
To select OFF -
Press “OFF” (no Enter required)
or
Press “BO (Enter)”
or
Press “0 (Enter)”
To select Remote -
Press “BB (Enter)”
For 1 step regulators:
To select ON -
Press “B1 (Enter)”
For 3 step regulators:
To select B10 -
Press “B10 (Enter)”
or
Press “B1 (Enter)”
To select B30 -
Press “B30 (Enter)”
or
Press “B2 (Enter)”
To select B100 -
Press “B100 (Enter)”
or
Press “B3 (Enter)”
Entering B4 or B5 will result in an “ERROR” message.
14
the
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9525
Rev. P
For 5 step regulators:
To select B1 -
Press “B1 (Enter)”
To select B2 -
Press “B2 (Enter)”
To select B3 -
Press “B3 (Enter)”
To select B4 -
Press “B4 (Enter)”
To select B5 -
Press “B5 (Enter)”
Entering B10, B30 or B100 will result in an “ERROR” message.
The brightness step command is stored in what is called ‘non-volatile’
electronic memory which is reliable for at least 10 years without
power applied.
This enables the regulator to immediately return to
the selected brightness after a power interruption without operator
intervention - just as if a rotary switch were used for brightness
control.
3.2.2
Digital Display
During normal operation, the digital display functions as a True RMS
ammeter, displaying the regulator load current.
during power-up,
under system fault conditions and when the keypad is in use, the
display performs other functions.
When these other functions are
finished using the display, it automatically returns to reading load
current. If the display is echoing keypad entries and no new entry is
made within 5 seconds, the display returns to reading load current.
They key entries are not lost.
When power is initially applied to the regulator, the computer
performs checks for valid operation.
If these checks are completed
successfully, the display will read “VER. X.X.”, where X.X is the
software program version number, for a period of 1 second.
Then
normal display activity will begin.
If the regulator should shut down due to system fault, a message will
immediately begin to scroll across the display to explain the reason
for the shut down. See Section 3.2.4 for further information.
L-829 only
If a lamp out monitor or brightness step monitor fault is detected,
the display will continue to read current, but a “*” will appear to
the right of the current reading.
See Section 3.2.4 for further
information.
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9525
Rev. P
3.2.3
Monitor Calibration (L-829 only)
Calibrating the monitor does not require any tools. All that you need
to know is the number of lamps in the circuit and at what number of
lamp burn outs you want the warning and alarm functions to activate.
If you wish, you may elect to calibrate the monitor in percentage
rather than lamp count. This is recommended when there are different
lamp wattages, very few lamps, many lighted signs or more than 200
lamps on the circuit.
Complete instructions are provided below.
A
flow chart is also provided in Figure 3-5.
TO CALIBRATE THE MONITOR:
BEFORE CALIBRATING THE MONITOR, BE SURE ALL THE LAMPS ARE OPERATING
PROPERLY.
IF SOME ARE BURNED OUT, THEY WILL BE IGNORED BY THE
MONITOR!!.
(Remember - Press “A” to ABORT if you make a mistake.)
Press “CC(Enter)” -
This enters the calibrate mode. The
CCR will turn off and the prompt LMPS =
XXX where XXX equals the number of lamps
previously entered (100 if in percent
mode) will appear on the display.
If you wish to use the lamp mode:
Press the keys for the number of lamps in the load, followed by
All future prompts will refer to number of
“E” for Enter.
lamps.
If you wish to use the percent mode:
Press “C” for “Change” - the display will now prompt “PERCENT?”.
If you change your mind and want to go back to lamp mode, press
“C” again.
If you are sure you want percent mode press
The number of lamps is not important in percent
“(Enter)”.
mode. All future prompts will refer to percentage of the total
load.
The next prompt in either monitor mode is “WARN = XX”. Where “XX” =
the lamps or percent previously entered.
Press the keys for the
number or percentage of lamps at which the warning signal is to be
If you are not using the
activated, followed by “E” for Enter.
warning signal, enter any number (a number must be entered).
At the prompt NORM = XX, WHERE “XX” equals the lamps or percent
previously entered, press the keys for the number or percentage of
lamps at which the Primary Alarm signal should activate, followed by
“E” for Enter. In the FAA Advisory Circular this is called the Normal
operation mode.
16
9525
Rev. P
The last data entry is at the DEGR = “XX” where XX equals the lamps or
percent previously entered prompt. Press the keys for the number or
percentage of lamps at which the Secondary Alarm signal should
activate followed by “E” for Enter. In the FAA Advisory Circular this
is called the degraded operation mode. This entry must be higher than
the Primary Alarm entry or an error message will appear.
At this point the monitor will ask permission to perform automatic
calibration with the prompt “AUTOCAL?”.
Check to be sure the load
circuit is connected and no personnel are working on it. When you are
sure of these things, press “E” (for Enter).
The monitor now will assume control of the regulator, turning it on to
the highest brightness step.
The monitor will automatically adjust
for the load circuit and then proceed to the lower steps.
For a 5
step CCR, it will do B2-B5, A 1 or 3 step will be monitored at every
step.
This normally takes about 5 minutes.
You can check on the
progress of this calibration by watching the starts (“*”) on the
display. Each time a step change take place, one star will go out.
When the calibration procedure is finished, the display will read
“COMPLETE” for about one second and then normal display operation will
resume.
If the regulator was in remote control mode before
calibration, it must be reset to remote by pressing “BB(Enter)”.
If the load is less than 50% of the regulator’s capacity, the
regulator will shut off and the display will read “Load Too Small.”
The regulator must be loaded to 50% or more of its capacity to use the
lamp-out monitor.
3.2.4
Monitor Operation (L-829 only)
After calibration the monitor will continuously operate in both local
and remote control modes. The lamp-out monitor always begins in the
Primary Alarm (Normal) mode.
To switch to the Secondary Alarm
To return to
(Degraded) mode, press “CD(Enter)” on the keypad.
Primary Alarm mode, press “CB(Enter)” on the keypad.
If a regulator shutdown occurs you can find out what happened by
reading the display:
“HIGH LOAD CURRENT” -
Over current protection trip.
“OPEN LOAD CURRENT” -
Open Load protection trip.
“LOW INPUT LINE”
Low line voltage trip.
-
17
9525
Rev. P
Other monitor alarms, which do not result from complete regulator
shutdown, are indicated by one star (“*”) to the right of the load
current reading on the display.
To find out exactly what is
One of the following
happening, press “CF(Enter)” on the keypad.
messages will scroll across the display.
“10% LOAD OUT” -
More than 10 percent of the load is
not operating, typically the
indication of a ‘double ground’ on the
load circuit.
“STEP CURRENT OUT OF SPEC.” -
The brightness step which is selected
is not operating within the FAA
Advisory Circular limits.
WARNING “XXX” LAMPS OUT
or
“XXX% LAMPS OUT
The actual number or
percentage of lamps out, only
if the alarm limit has been exceeded.
-
“NO WARNINGS OR ALARMS”” 3.2.5
Self-explanatory.
Elapsed Time Meter Operation
To display the elapsed operating time of the brightness step, press
“DB” followed by the selected step. (1-3 for a three step regulator,
1 for a one step regulator, or 1-5 for a five step regulator) Press
“E” for Enter on the keypad.
To display the total elapsed operating time of the regulator, press
“DBO(Enter)”.
18
9525
Rev. P
19
9525
Rev. P
20
9525
Rev. P
21
9525
Rev. P
22
9525
Rev. P
23
9525
Rev. P
MAINTENANCE
WARNING
INSTALLATION, SERVICE, MAINTENANCE, OR OPERATION SHOULD BE PERFORMED
BY QUALIFIED PERSONNEL ONLY.
4.1
PERIODIC MAINTENANCE
The Constant Current Regulator should be inspected periodically as
shown below:
INTERVAL
PROCEDURE
6 months
(1)
Remove main power from the regulator.
(2)
Remove the front access
control box compartment.
(3)
Check all wiring connections for loose or missing
screws.
(4)
Check for broken or damaged wires and parts.
(5)
Remove dust build-up.
(6)
Inspect housing for rush or chipped paint.
and touch up with paint as required.
(7)
Check the oil level.
The oil level should be
visible in the lower portion of the gauge at 25
degrees C (77 degrees F).
Add oil if necessary
(Crouse-Hinds P/N 10053-25).
(8)
Secure control box and re-install access panel.
(9)
Restore primary power to the regulator. Operate
the regulator at all brightness steps, first by
local control, then by remote control. Check for
proper load currents.
24
panel
and
open
the
Clean
9525
Rev. P
4.2
CORRECTIVE MAINTENANCE
Corrective maintenance is required when the regulator does not work
properly. This usually requires the replacement of parts or
subassemblies. The use of easily removable subassemblies make repair
a simple task. The removal and replacement method should be obvious
to qualified maintenance personnel.
WARNING
VOLTAGES ABOVE 1000 VOLTS ARE PRESENT WHEN THE REGULATOR IS OPERATING.
DO NOT REPAIR OR SERVICE WITHOUT FIRST REMOVING POWER FROM THE
REGULATOR. THE USE OF LOCK-OUT DEVICES IS RECOMMENDED.
The control assembly contains parts which can be replaced in the field
by a service person. If properly trained personnel are not available,
replace the entire control assembly. Improper removal and handling
can cause damage to the equipment. Particular areas of concern are:
4.3
(A)
Remove power from the regulator before disconnecting the
connector plug from the control compartment.
(B)
Depress the serrated release on the connector to remove it from
the control compartment. DO NOT try to remove by pulling on
the wire harness. See Figure 4-1 for operation of the
connector.
(C)
CAUTION: The circuit cards within the control assembly are
STATIC SENSITIVE. Do not remove or handle them without an
static control wrist strap.
PROBLEM SOLVING GUIDE
This guide will assist qualified airport maintenance personnel in
locating and correcting equipment failures. Problems associated with
option functions are addressed in the specific option Supplement. If
further assistance is required, contact the Customer Service
Department at Crouse-Hinds Airport Lighting Products, Windsor,
Connecticut.
4.3.1
FAULT ISOLATION
The first step in fault isolation is the preliminary evaluation.
Start by checking for disconnected wires, switches in the wrong
position, blown or missing fuses, etc. Determine if other equipment
on the same circuit is operating properly. Be sure that the equipment
is being used properly by checking the operation instructions.
Finally, if the digital display is working, use the displayed message
to localize the problem.
25
9525
Rev. P
If these checks do not pinpoint the problem, try operating the
regulator with a short across the load terminals. OPERATING INTO A
SHORT WILL NOT HARM THE REGULATOR. This is the best way to find out
if the problem is with the regulator or the load circuit. Once these
checks have been made, refer to the checklist for further
instructions.
26
9525
Rev. P
DISPLAY MESSAGES AND WHAT THEY MEAN
DISPLAY MESSAGE
WHAT IT MEANS
‘VER.X.X’ (where X.X is
a number like 1.1)
This is the indication that all
power-up checks are OK. The
number is the program version.
This should appear for 1 second.
The line voltage supplied to the
regulator is too low for proper
operation. Check to be sure the
supply voltage is the same as the
regulator nameplate. If OK then
see section on power supply
problems.
The regulator has tripped off-line
due to an over current condition.
See the section on protection
problems to fix.
The regulator has tripped off-line
due to an open circuit condition.
Try operating the regulator into a
short circuit. If it doesn’t trip
again, check the field wiring for
an open. If no open is found, or
the unit trips even with a short
circuit see the section on
protection problems.
See the option supplement to find
out what the message means.
See the section on display
problems.
‘LOW INPUT LINE’
‘HIGH LOAD CURRENT’
‘OPEN LOAD CIRCUIT’
Display shows some other readable
message.
Display shows a bunch of funny
things or garbage.
27
9525
Rev. P
QUICK PROBLEM SOLVING CHECKLIST
SYMPTOM
WHAT TO DO
System will not turn on.
(1) Check power source turned on.
(2) Check for 120VAC across X1
to X2 on transformer T3. It
is probably bad.
Control display OFF.
(3) Check F1. If good, see the
section on power supply
problems.
(1) If display reads ‘0.00A’ see
the section on local control
problem.
(2) See section on digital
problems.
(1) See section on local control
problems.
(2) See section on remote control
problems.
(3) If supplied with Option 92,
contact Crouse-Hinds Airport
Lighting Products.
(1) If display reads ‘Open in load
circuit’ or “High load
current’ see section on
protection problems.
(2) See section on digital
problems.
(1) See section on remote control
problems.
(1) Check for overload.
(2) If problem is only in remote
see section on remote control
problems.
(3) Otherwise, see section on
regulation problems.
(1) See section on display
problems.
System will not turn on.
display ON.
Control
System will not turn off.
System turn on for 1 to 5 seconds,
then trips out.
System works find in Local but
does not work in Remote.
Wrong current levels in any or
all steps.
Regulator works but display is
out or showing ‘funny’ data.
Monitoring Problems (L-829 only)
(1) Check load circuit.
(2) Re-calibrate (Section 3.2.3
(3) See section on monitor
problems.
28
9525
Rev. P
4.3.2
DETAIL PROBLEM SOLVING GUIDE
On the next few pages are detail problem solving guides. These guides
make use of the digital display and the indicators on the control box
circuit cards to speed repair.
4.3.2.1
OPENING THE CONTROL BOX
TURN OFF MAIN POWER TO THE REGULATOR BEFORE STARTING:
To open the control box, swing it away from the cabinet and unplug the
connector. Then use a screw driver to remove the top cover screws.
Be careful to keep screws from falling into the box, as they could
short out components inside. Plug the connector back in. Default the
interlock switch by pulling the interlock switch actuator out. Turn
on main power to regulator to begin trouble-shooting. DANGER; BE
CAREFUL! THE CIRCUITS INSIDE THE CONTROL BOX ARE LIVE AND CONTAIN
DANGEROUS CURRENT LEVELS.
4.3.2.2
CIRCUIT CARD INDICATORS
Before doing any problem solving, take a few minutes to become
familiar with the circuit card indicators. They are provided as an
aid in deciding what part or subassembly to change. A diagram showing
the indicators is shown in Figure 4-2. Now go to the detail checklist
for the problem being addressed.
29
9525
Rev. P
30
9525
Rev. P
31
9525
Rev. P
POWER SUPPLY PROBLEM CHECKLIST
SYMPTOM
WHAT TO DO
All board indicators are OFF.
(1) Remove the power supply board
an check fuse F1. If blown,
replace it. If not blown,
replace the power supply
board.
(2) If the fuse blows again right
away, replace the power
supply board.
(3) If the indicators light, but
the regulator still does not
work, go to the next symptom.
(1) Remove all boards except the
power supply and display. If
the problem is still there,
replace the power supply
board. If the problem goes
away, install one board at a
time until it reappears.
Replace the faulty board.
One power supply board indicator
is OFF or it is very dim.
For further help contact Crouse-Hinds Airport Lighting Products.
32
9525
Rev. P
9525
PROTECTION PROBLEM CHECKLIST
PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING
CIRCUIT CARDS:
SYMPTOMS
WHAT TO DO
Display reads ‘OPEN LOAD CIRCUIT.’
(1) Observe feedback indicator on
the Regulation Circuit Card
before shutdown. If OFF,
check T2 for an open winding.
If T2 is OK, replace
Regulation Circuit Card.
(2) Observe both SCR drive
indicators. If both are off,
replace Regulation Circuit
Card. If both are on, replace
SCRs Q1 and Q2.
(1) If regulator operates on lower
steps but currents are high,
replace Regulation Circuit
Card.
(2) If regulator trips right away,
regardless of step, observe
SCR drive indicators. They
should be dim before out. If
they are, then replace SCRs
Q1 an Q2. Otherwise, replace
Regulation Circuit Card.
(1) Observe +12V power supply
indicator. If dim, see
section on power supply
problems. If OK, replace
Regulation Circuit Card.
Display reads ‘HIGH LOAD CURRENT.’
Display reads ‘LO INPUT LINE.’
For further help contact Crouse-Hinds Airport Lighting Products.
33
9525
Rev. P
REGULATION PROBLEM CHECKLIST
PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING
CIRCUIT CARDS!
SYMPTOM
WHAT TO DO
All currents low.
(1) Observe SCR Drive indicators.
They should go from dim to
bright when the unit is
turned on. If one or both
stay dim all the time,
replace Regulation Circuit
Card. If OK, replace SCRs
Q1 and Q2.
High steps OK, but low steps
are high.
(1) Observe SCR Drive indicators.
They should change brightness
together. If they don’t then
replace Regulation Circuit
Card. If OK, replace SCRs
Q1 and Q2.
(1) If in local and remote
control replace Control
Interface card.
(2) See section on Remote Control
problems.
(1) Run regulator in a short. If
OK, regulator is over-loaded.
(2) Observe Control indicator
with local switch in OFF. If
it is OFF, replace Regulation
Circuit Card. If it is ON,
replace Control Interface
Card.
(1) Observe +12V indicator. If
it blinks, then be sure area
temperature is below 130
degrees F. If it is OK,
replace the Regulation
Circuit Card.
One step high or low.
Low steps OK, but high steps are
low.
Current fluctuates over a wide
range.
For further help contact Crouse-Hinds Airport Lighting Products.
34
9525
Rev. P
LOCAL CONTROL PROBLEM CHECKLIST
PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING
CIRCUIT CARDS!
SYMPTOMS
WHAT TO DO
System will not turn on.
(1) Observe Control and
Contactor indicators. They
should go on and off
together when switching from
off to a step.
If they don’t then replace
Microcontroller Circuit
Card.
(2) Check K1 coil for open. If
open replace K1. If OK
replace Regulation Circuit
Card.
(1) If system will not turn off
when the interlock switch
is opened, K1 may be welded
closed.
(2) Observe Contactor indicator.
If on all the time, replace
Microcontroller Circuit
Card.
If it turns off, replace
Control Interface Card.
(1) Check for damage to keypad.
If found, replace.
(2) Replace display card.
System will not turn off.
Keypad does not respond to one or
more key presses.
For further help contact Crouse-Hinds Airport Lighting Products.
35
9525
Rev. P
REMOTE CONTROL PROBLEM CHECKLIST
PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING
CIRCUIT CARDS!
SYMPTOM
WHAT TO DO
System will not turn on.
(1) Check in local control. If
not OK, see section on local
control problems.
(2) Check remote supply and
wiring. If OK, replace
Control Interface Card.
(1) Check for control lines
longer than 10,000 feet in
length.
(1) Check for control lines
longer than 10,000 feet in
length.
System will not turn off.
Current fluctuates up or down.
For further help contact Crouse-Hinds Airport Lighting Products
36
9525
Rev. P
DIGITAL PROBLEM CHECKLIST
PLEASE REMEMBER TO TURN OFF MAIN AN CONTROL POWER BEFORE REMOVING OR INSTALLING
CIRCUIT CARDS!
SYMPTOM
WHAT TO DO
System will not turn on.
(1) Observe Run and Halt
indicators. If they are
blinking, replace Regulation
Circuit Card. If the Half
indicator is always on,
replace Microcontroller
Circuit Card. If the Run
indicator is on all the
time, see the section on
local control problems.
For further help contact Crouse-Hinds Airport Lighting Products.
MONITOR PROBLEM CHECKLIST (L-829 ONLY)
SYMPTOM
WHAT TO DO
Remote indicators out.
(1) Check for power source on.
(2) Check fuses on load monitor
board.
(3) If relay indicators on monitor
board switch on and off,
replace K1, K2 and/or K3.
(4) Replace load monitor board.
(1) Try percent mode calibration
(2) Replace load monitor board.
(3) Replace transformer T5.
(1) Re-calibrate.
(2) Replace load monitor board.
Unit will not calibrate.
Erroneous readings or alarms.
For further help contact Crouse-Hinds Airport Lighting Products.
37
9525
Rev. P
DISPLAY PROBLEM CHECKLIST
PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING
CIRCUIT CARDS!
SYMPTOM
WHAT TO DO
Regulator runs but no display.
(1) Check for a loose cable from
the display to the Control
Interface Card. If OK replace
Display Card.
(1) Check switch settings on the
Control Interface Card.
(2) Replace Control Interface
Card.
(1) If display reads ‘VER.X.X.’
and does not change, see the
section on digital problems.
(2) Replace Microcontroller
Circuit Card.
Regulator runs but Display shows
wrong current.
For further help contact Crouse-Hinds Airport Lighting Products.
38
9525
Rev. P
39
9525
Rev. P
39.1
9525
Rev. P
39.2
9525
Rev. P
40
9525
Rev. P
40.1
9525
Rev. P
41
9525
Rev. P
41.1
9525
Rev. P
42
9525
Rev. P
5.1
SCOPE
The Parts List provides ordering data for all replaceable parts and
subassemblies.
5.2
ARRANGEMENT
The Figures and Tables in this section are arranged to show each
replaceable part or assembly. The parts are identified in each Figure
by Index Number. The Index Number appears in the corresponding Parts
List which also provides the part number and description.
5.3
REFERENCE DESIGNATION
A reference designation number is assigned to each electrical part
contained in the regulator. These reference designations are shown on
the wiring diagram.
5.4
OPTION PARTS
Parts that are option related are discussed in the respective
Supplement for that Option.
43
9525
Rev. P
44
9525
Rev. P
44.1
9525
Rev. P
45
9525
Rev. P
46
9525
Rev. P
47
9525
Rev. P
48
9525
Rev. P
49
REFERENCE
DESIGNATION
DESCRIPTION
INDEX
NO.
1
2
R1
C2
Resistor Assembly
Capacitor
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
31499
10047-1051
3
4
TB1
S2
Terminal Block Assembly
Interlock Safety Switch
32048
10047-1878
5
DS1
Neon Indicator
10047-938
Label, Indicator Light
Standoff, 3/4” Dia
31683
10053-10
12
Warning Label
Wiring Diagram
Varistor Assembly
Current Transformer, 6.6A
Current Transformer, 20A
Electrical Insulating Oil
32272
32152
31665
31374
31394
10053-25
13
Fuse Holder
10047-1660
Fuse, 1 amp Slo-Blo
Fuse, 2Amp, Slo-Blo,
(30KW 208/220/240V; 37.5KW 240V;
70KW 480V and 2400V)
10053-307
10047-1141
6
7
50
8
9
10
11
14
RV1
T2
F1
C.S.I. P/N
2N256T
Unimax P/N
23TL604
Ledtronics
PF50-CRN120VAC-T
H.H. Smith
2615 or equal
Exxon Univolt
N61, Product
Code 33183101831
Buss P/N HKPHH
Buss P/N MDL-1
Buss P/N MDL-2
9525
REV P
9525
Rev. K
60 HZ PARTS
MANUFACTURER
PART NO.
INDEX
NO.
REFERENCE
DESIGNATION
DESCRIPTION
15
F2
Fuse, 1/8 amp Slo-Blo
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
10047-1005
16
RV2 & RV3
Varistor, 150V RMS, 20J
10047-1297
17
T20
32044
18
T5
20
E1-E6
Power Supply Transformer
Subassembly
Potential Transformer
Potential Transformer (15KW, 20A
Units only)
Potential Transformer (30KW, 6.6A
Units only)
Transformer (208-240V, 10-20 KW &
240V, 37.5 KW & 480V, 30, 37.5 &
50 KW)
Transformer (208V, 30 KW)
Transformer (2400V)
Transformer (220-240V, 30 KW &
480V, 70 KW)
Bushing
21
E7
Standoff Insulator
10053-698
22
LA1A & LA1B
Standoff Insulator (480V & Lower)
10053-696
23
24
LA1
Danger Label
Lighting Arrestor (208-480V)
41222
10047-885
25
Q1 & Q2
SCR/Heatsink Assembly (10, 15 & 20
KW)
SCR/Heatsink Assembly (30, 37.5,
50 & 70 KW)
31505-1
19
T3
51
Buss P/N MDL1/8
G.E. P/N
V150LA20B
31436
31789
32271
31675
10047-2424
32414
10047-1444
10053-24
Porcelain
Products 71118
Glastic P/N
1872-1A
Glastic P/N
1603-2A
G.E. P/N
9L15ECB001
31505-2
9525
REV P
60 HZ PARTS
MANUFACTURER
PART NO.
INDEX
NO.
26
27
52
REFERENCE
DESIGNATION
DESCRIPTION
LA2 & LA3
Lightning Arrestor, 3KV (10 KW;
15 KW; 20 KW, 20A; 30 KW, 20A;
37.5 KW)
LA2 & LA3
Lightning Arrestor, 6 KV (20 KW,
6.6A; 30 KW, 6.6A; 50 KW, 70 KW)
10053-351
LA1A (2400V)
Lightning Arrestor, 6 KV (All KW
Sizes)
Contactor, 75A (15 KW, 480V; 20
KW, 480V)
10053-351
Contactor, 95A (10 KW; 15 KW,
208-240V; 30 KW, 480V)
Contactor, 120A (20 KW, 208-240V)
Contactor, 150A (37.5 KW, 480V;
50 KW, 480V)
Contactor, 200A (30 KW, 208-240V;
37.5 KW, 240V; 70 KW, 480V)
Relay, 125A, Single Pole (2400V)
32084
K1
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
10053-693
10047-1249
MANUFACTURER
PART NO.
Cooper Power
UHS0303-0A0A1A1A or G.E. P/N
9L23BXX003XH
Cooper Power
UHS0604-0A0A1A1A or G.E. P/N
9L23BXX006XH
Square DP/N
8910-DPA62-V02Y236
32085
32087
10047-2774
10047-2757
Joslyn Clark P/N
CVC77U022006-76
Joslyn Clark
P/N VC77U0143676
60 HZ PARTS
9525
REV P
INDEX
NO.
28
29
53
REFERENCE
DESIGNATION
DESCRIPTION
C1
Capacitor (10 KW; 37.5 KW; Qty 1)
Capacitor (20 KW; 50 KW, Qty 1)
Capacitor (30 KW; 50 KW, Qty 1; 70
KW, Qty 1; 37.5 KW, Qty 1
Capacitor (15 KW)
Capacitor (70 KW, Qty 1)
Capacitor (70 KW, Qty 1)
Control Assembly (insert 1, 3, or
5 in place of “X” for number of
steps desired. Insert 1 for 6.6A
or 2 for 20A in place of Y for
current desired. The standard
Control Assembly consists of the
following major replaceable items:
Digital Display Board Assembly
Power Supply Board Assembly
Control Interface Board Assembly
*(1)
Microcontroller Board Assembly
Regulation Board Assembly
Load Monitor Board Assembly *(2)
(L-829 only)
Keyboard, 4 x 4 Matrix
*(1) If complete Control Assembly
is not ordered, set dip switch on
board per instructions.
*(2) Specify KW rating of
regulator when ordering.
60 HZ PARTS
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
30062-01
30062-02
30062-03
MANUFACTURER
PART NO.
30062-04
30956
30957
32323
Add 61 @ end for
L-829
31765-1
31971
31716-1
32277-1
31879-3L
31926-1
10047-2176
9525
REV P
INDEX
NO.
30
54
REFERENCE
DESIGNATION
DESCRIPTION
T1
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
10
10
10
10
10
15
15
15
15
15
15
15
15
15
15
20
20
20
20
20
20
20
20
20
20
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
6.6A, 208V
6.6A, 220V
6.6A, 240V
6.6A, 480V
6.6A,2400V
6.6A, 208V
6.6A, 220V
6.6A, 240V
6.6A, 480V
6.6A,2400V
20A, 208V
20A, 220V
20A, 240V
20A, 480V
20A, 2400V
6.6A, 208V
6.6A, 220V
6.6A, 240V
6.6A, 480V
6.6A,2400V
20A, 208V
20A, 220V
20A, 240V
20A, 480V
20A, 2400V
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
32143-10-1
32143-10-2
32143-10-4
32143-10-8
32143-10-9
32143-15-1
32143-15-2
32143-15-4
32143-15-8
32143-15-9
32143-16-1
32143-16-2
32143-16-4
32143-16-8
32143-16-9
32143-20-1
32143-20-2
32143-20-4
32143-20-8
32143-20-9
32143-21-1
32143-21-2
32143-21-4
32143-21-8
32143-21-9
MANUFACTURER
PART NO.
60 HZ PARTS
9525
REV P
INDEX
NO.
REFERENCE
DESIGNATION
DESCRIPTION
30
(Cont’d)
T1
32143-50-8
32143-50-9
32143-70-8
32143-70-9
10047-1898
10047-1899
(REF K2)
32
K2
Relay Octal Plug (2400V Only)
55
31
Main X’fmr Assy, 30 KW, 6.6A, 208V
Main X’fmr Assy, 30 KW, 6.6A, 220V
Main X’fmr Assy, 30 KW, 6.6A, 240V
Main X’fmr Assy, 30 KW, 6.6A, 480V
Main X’fmr Assy, 30 KW, 6.6A,2400V
Main X’fmr Assy, 30 KW, 20A, 208V
Main X’fmr Assy, 30 KW, 20A, 220V
Main X’fmr Assy, 30 KW, 20A, 240V
Main X’fmr Assy, 30 KW, 20A, 480V
Main X’fmr Assy, 30 KW, 20A, 2400V
Main X’fmr Assy, 37.5 KW, 20A,240V
Main X’fmr Assy, 37.5 KW, 20A,480V
Main X’fmr Assy, 37.5 KW, 20A,
2400V
Main X’fmr Assy, 50 KW, 20A, 480V
Main X’fmr Assy, 50 KW, 20A, 2400V
Main X’fmr Assy, 70 KW, 20A, 480V
Main X’fmr Assy, 70 KW, 20A, 2400V
Socket, Octal Relay (2400V Only)
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
32143-30-1
32143-30-2
32143-30-4
32143-30-8
32143-30-9
32143-31-1
32143-31-2
32143-31-4
32143-31-8
32143-31-9
32143-37-4
32143-37-8
32143-37-9
MANUFACTURER
PART NO.
Potter &
Brumfield 27E122
Potter &
Brumfield
KRPA-5AG-120V
60 HZ PARTS
9525
REV P
INDEX
NO.
REFERENCE
DESIGNATION
DESCRIPTION
1
2
R1
C2
Resistor Assembly
Capacitor
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
31499
10047-1051
3
4
TB1
S2
Terminal Block Assembly
Interlock Safety Switch
32048
10047-1878
5
DS1
Neon Indicator
10047-938
Label, Indicator Light
Standoff, 3/4” Dia
31683
10053-10
12
Warning Label
Wiring Diagram
Varistor Assembly
Current Transformer, 6.6A
Current Transformer, 20A
Electrical Insulating Oil
32272
32152
31665
31374
31394
10053-25
13
Fuse Holder
10047-1660
F1
Fuse, 1 amp Slo-Blo
10053-307
Exxon Univolt
N61, Product
Code 33183101831
Buss P/N HKPHH
Buss P/N MDL-1
10047-1141
Buss P/N MDL-2
F2
Fuse, 2 amp Slo-Blo (30KW
208/220/230V)
Fuse, 1/8 amp Slo-Blo
10047-1005
Buss P/N MDL1/8
6
7
56
8
9
10
11
14
15
RV1
T2
MANUFACTURER
PART NO.
C.S.I. P/N
2N256T
Unimax P/N
23TL604
Ledtronics P/N
PF50-CRN120VAC-T
H.H. Smith
2615 or equal
50 HZ PARTS
9525
Rev P
INDEX
NO.
REFERENCE
DESIGNATION
DESCRIPTION
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
10047-1297
16
RV2 & RV3
Varistor, 150V RMS, 20J
17
T20
18
T5
31675
10053-24
57
19
20
T3
E1-E6
Power Supply Transformer
Subassembly
Potential Transformer
Potential Transformer (15KW, 20A
Units only)
Potential Transformer (30KW, 6.6A
Units only)
Transformer (208-415V)
Bushing
21
E7
Standoff Insulator
10053-698
22
LA1A & LA1B
Standoff Insulator
10053-696
23
24
LA1
Danger Label
Lighting Arrestor (208-415V)
41222
10047-885
25
Q1 & Q2
SCR/Heatsink Assembly (10, 15 & 20
KW)
SCR/Heatsink Assembly (30 & 50 KW)
31505-1
MANUFACTURER
PART NO.
G.E. P/N
V150LA20B
32044
31436
31789
32271
Porcelain
Products 71118
Glastic P/N
1872-1A
Glastic P/N
1603-2A
G.E. P/N
9L15ECB001
31505-2
50 HZ PARTS
9525
REV P
INDEX
NO.
26
27
REFERENCE
DESIGNATION
DESCRIPTION
LA2 & LA3
Lightning Arrestor, 3KV (10 KW;
15 KW; 20 KW, 20A; 30 KW, 20A)
K1
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
10053-693
58
Lightning Arrestor, 6 KV (20 KW,
6.6A; 30 KW, 6.6A; 50 KW)
10053-351
Contactor, 75A (10 KW; 15 KW,
380-415V; 20 KW, 380-415V)
10047-1249
Contactor, 95A (15 KW, 208-240V;
30 KW, 380-415V)
32084
Contactor, 120A (20 KW, 208-240V)
32085
Contactor, 150A (50 KW 380-415V)
32087
Contactor, 200A (30 KW, 208-240V)
10047-2774
MANUFACTURER
PART NO.
Cooper Power
UHS0303-0A0A1A1A
Cooper Power
UHS0604-0A0A1A1A
Square D P/N
8910-DPA62-V02Y236
Square D P/N
DPA72V02 or
Arrow-Hart P/N
ACC720U20
Square D P/N
DPA92V02 or
Arrow-Hart P/N
ACC927U20
Arrow-Hart P/N
ACC1220U20
Joslyn Clark P/N
CVC77U022006-76
50 HZ PARTS
9525
REV P
INDEX
NO.
28
29
59
REFERENCE
DESIGNATION
DESCRIPTION
C1
Capacitor (30 KW, Qty 1)
Capacitor (50 KW, Qty 1)
Capacitor (20 KW; 30 KW, Qty 1; 50
KW, Qty 1)
Capacitor (10 KW)
Capacitor (15 KW)
Control Assembly (insert 1, 3, or
5 in place of “X” for number of
steps desired. Insert 1 for 6.6A
or 2 for 20A in place of Y for
current desired. The standard
Control Assembly consists of the
following major replaceable items:
Digital Display Board Assembly
Power Supply Board Assembly
Control Interface Board Assembly
*(1)
Microcontroller Board Assembly
Regulation Board Assembly
Load Monitor Board Assembly *(2)
(L-829 only)
Keyboard, 4 x 4 Matrix
*(1) If complete Control Assembly
is not ordered, set dip switch on
board per instructions.
*(2) Specify KW rating of
regulator when ordering.
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
30062-01
30062-02
30062-03
MANUFACTURER
PART NO.
30062-04
30062-05
32323
Add 61 @ end for
L-829
31765-1
31971
31716-1
32277-1
31879-3L
31926-1
10047-2176
50 HZ PARTS
9525
Rev P
INDEX
NO.
30
60
REFERENCE
DESIGNATION
DESCRIPTION
T1
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
X’fmr
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
Assy,
10
10
10
10
10
10
10
15
15
15
15
15
15
15
15
15
15
15
15
15
15
20
20
20
20
20
20
20
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
KW,
6.6A, 208V
6.6A, 220V
6.6A, 230V
6.6A, 240V
6.6A, 380V
6.6A, 400V
6.6A, 415V
6.6A, 208V
6.6A, 220V
6.6A, 230V
6.6A, 240V
6.6A, 380V
6.6A, 400V
6.6A, 415V
20A, 208V
20A, 220V
20A, 230V
20A, 240V
20A, 380V
20A, 400V
20A, 415V
6.6A, 208V
6.6A, 220V
6.6A, 230V
6.6A, 240V
6.6A, 380V
6.6A, 400V
6.6A, 415V
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
32144-10-1
32144-10-2
32144-10-3
32144-10-4
32144-10-5
32144-10-6
32144-10-7
32144-15-1
32144-15-2
32144-15-3
32144-15-4
32144-15-5
32144-15-6
32144-15-7
32144-16-1
32144-16-2
32144-16-3
32144-16-4
32144-16-5
32144-16-6
32144-16-7
32144-20-1
32144-20-2
32144-20-3
32144-20-4
32144-20-5
32144-20-6
32144-20-7
MANUFACTURER
PART NO.
50 HZ PARTS
9525
REV P
INDEX
NO.
REFERENCE
DESIGNATION
DESCRIPTION
30
(Cont’d)
T1
(Ref K2)
32
K2
Relay Octal Plug (2400v Only)
61
31
Main X’fmr Assy, 20
Main X’fmr Assy, 20
Main X’fmr Assy, 20
Main X’fmr Assy, 20
Main X’fmr Assy, 20
Main X’fmr Assy, 20
Main X’fmr Assy, 20
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 30
Main X’fmr Assy, 50
Main X’fmr Assy, 50
Main X’fmr Assy, 50
Socket, Octal Relay
KW, 20A, 208V
KW, 20A, 220V
KW, 20A, 230V
KW, 20A, 240V
KW, 20A, 380V
KW, 20A, 400V
KW, 20A, 415V
KW, 6.6A, 208V
KW, 6.6A, 220V
KW, 6.6A, 230V
KW, 6.6A, 240V
KW, 6.6A, 380V
KW, 6.6A, 400V
KW, 6.6A, 415V
KW, 20A, 208V
KW, 20A, 220V
KW, 20A, 230V
KW, 20A, 240V
KW, 20A, 380V
KW, 20A, 400V
KW, 20A, 415V
KW, 20A, 380V
KW, 20A, 400V
KW, 20A, 415V
(2400V Only)
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
32144-21-1
32144-21-2
32144-21-3
32144-21-4
32144-21-5
32144-21-6
32144-21-7
32144-30-1
32144-30-2
32144-30-3
32144-30-4
32143-30-5
32144-30-6
32144-30-7
32144-31-1
32144-31-2
32144-31-3
32144-31-4
32144-31-5
32144-31-6
32144-31-7
32144-50-5
32144-50-6
32144-50-7
10047-1898
10047-1899
MANUFACTURER
PART NO.
Potter & Brumfield
27E122
Potter & Brumfield
KRPA-5AG-120V
50 HZ PARTS
9525
REV P
RECOMMENDED SPARES
DESCRIPTION
PART NUMBER
Interlock Safety Switch
10047-1878
1
Fuse, 2 amp, Slo-Blo
10047-1141
5
Fuse, 1 amp, Slo-Blo
10053-307
5
Fuse, 1/8 amp, Slo-Blo
10047-1005
5
SCR/Heatsink Assembly
(10, 15 & 20 KW)
31505-1
2
SCR/Heatsink Assembly
(30, 37.5, 50 & 70 KW)
31505-2
2
Controller Assembly
SEE ITEM 29 DESCRIPTION
*
*Minimum of one.
NUMBER REQUIRED
Consider having 1 controller for every ten CCRS.
62