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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 9517
February 5, 2008
Revision W
INSTRUCTION MANUAL
L-828 & L-829 CONSTANT CURRENT REGULATOR
Series 82860-D (L-828, 60 Hz); 82960-D (L-829, 60 Hz)
82850-D (L-828, 50 Hz) & 82950-D (L-829, 50 Hz)
4 KW, 7.5 KW, 10 KW
6.6 AMPS
Copyright © 2008 Cooper Technologies Company
9517
Rev. W
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
9517
Rev. W
REV.
A
REVISIONS
DESCRIPTION
LTR.
Added 10 inches to regulator height; Item P/N was A9631345; Item P/N 2 was 32184; Item P/N 5 was 261
31343; Item 6 was INTERLOCK COVER, P/N
32187; Item 10 Base P/N was 32173; Item 15 P/N
was 10047-884; Item 16 was Lightning Arrestor
Holder (for LA2 & LA3) ,P/N 31071; deleted E3
& E4 Bushing, P/N 10053-698; Item 22 P/N was
32158; Corrected 60 Hz Item 11 (T1) P/N’s
DATE
8/7/95
APVL
PG
A95382
6/26/95
PG
A95499
11/1/95
PG
A96026
Deleted 2.1.5.3 on Pg. 7; P/N 31879-3 was 31879- A971, deleted 31879-2, P/N 322771-1 was 31984-1 on 211
Pg. 49; Deleted P/N 32094-X-1-6H, Deleted
Regulation Board Assembly P/N 31879-2, P/N
32277-1 was 31984-1 on Pg. 52; Deleted P/N
32094--1-5H, Deleted Regulation Board Assembly
P/N 31879-1, P/N 32277-1 was 31984-1 on Pg. 57
1) Added last part of Par. 3.2.3 on Pg. 17.
A96244
1) Revised wiring diagram Figure 4-4, secondary A97of T20 was 12,6,0
327
1) Pg. 40, Fig. 4-4, re-routed wire 13 to T20
A97386
1/17/96
RBM
4/15/97
JAS
5/19/97
JAS
6/5/97
JAS
7/28/97
JAS
C
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 para. 1.4; added item 18
T5 P/N 32271 to Parts List.
Pg. 40, T2-X1 dest. was E13 &T2-X2 dest. was
E12.
D
Updated PCB Dwg. on Pg. 39.1; added Pg. 39.2.
B
E
F
G
H
J
Sheet 39.1, S2, S3 & S4 was S2-S4
A98071
6/1/98
RBM
L
REVISED SHEET 40
7/22/98
RBM
M
Changed notes on Figure 4-3c, Sheet 39.1
A98257
A98395
1/11/99
JAS
P
Figure 4-5c, 230V 50Hz connection was T2-H3
A205311
9/8/05
GFR
R
Sht 53 & 58, Item 33 added alternate mfg.
Added new copyright on pg i; “R” revision A206incorporated and issued; 1.2.3.1; 150/5345-10F 162
was -10E
7/28/06
PG
S
iii
9517
Rev. W
REV.
T
U
REVISIONS
DESCRIPTION
Title page, revised copyright to 2007, added page
III.1; 1.2.3.1, added 415V 50 Hz to voltages; Fig 11, added 415V to input voltages; Table 3-1, added
415V info; Fig 4-4, added “all voltages except
415V” to title; added pages 39.2 & 39.3; Tables 45a & c, added 415V info; parts index, added item
12 & 30 415V info; parts index item 34 p/n
10047-2230, added 4 & 7.5 to ref design & vendor
p/n was LC1D3210G5; parts index item 34 p/n
10047-2231, added 415V to ref design & vendor
p/n was LC1D4011G5; parts index item 34,
deleted p/n 10047-1245, contactor 50A used for
220-240V & 380V, 4 KW; vii, added 39.2 & 39.3
info; 3.1.5.3, added & Fig 4-3c; Fig 4-3b, added
31716 configuration note
Page vii, Figure 4-4b was System Wiring Diagram
(415V only); pg viii, added 415V to Figure 5-5; pg
10, 415V 10 kW rated input current was 24; Fig 43d, 32277 microprocessor board was 31984; Fig 45c, added note for jumper wire to 415V; Fig 4-4,
revised to add T1 varies by input & frequency and
added note to see Fig 4-4b for 415V T2
configuration; Fig 4-4b, deleted 415V only System
Wiring Diagram and replaced with 415V T2
configuration; Fig 5-5, added 415V to C1
configuration; pg 55, added 415V T1 part numbers
Table 3-1, revised rated input currents
V
W
TITLE PAGE, REVISED COPYRIGHT; Fig 4-4b,
Added wires 54, 55, 36 & 37 destinations
iii.1
LTR.
A207106
DATE
5/16/07
APVL
PG
A207299
11/27/07
PG
A207318
12/20/07
PG
A208017
2/5/08
PG
9517
Rev. W
LIMITED PRODUCT WARRANTY
THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER
WARRANTIES, WHETHER EXPRESSED, 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 time of delivery to the Buyer,
free of material and workmanship defects, provided that no warranty is made with respect to:
(a) any Product which has been repaired or altered in such a way, in Company’s
judgement, as to affect the Product adversely.
(b) any Product which has, in Company’s judgement, 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 Products, component parts or accessories manufactured by others but supplied by
Company (any claims should be submitted directly to the manufacturer thereof).
Crouse-Hinds Airport Lighting Product’s obligation under this warranty is limited to use reasonable
effects to repair or, in its option, replace, during normal business hours at any authorized service
facility of Company, any Products which in its judgement proved not to be as warranted within the
applicable warranty period. All 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 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
remainder 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 insure 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 is occurs first.
iv
9517
Rev. W
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
9517
Rev. W
SAFETY SYMBOLS
DANGER:
DANGER
The hazard or unsafe practice will result in severe injury or death.
WARNING:
WARNING
The hazard or unsafe practice could result in severe injury or death.
CAUTION:
CAUTION
The hazard or unsafe practice could result in minor injury.
NOTICE:
NOTICE
Possibly dangerous situation, goods might be damaged.
IMPORTANT:
IMPORTANT
Helpful information.
vi
9517
Rev. W
TABLE OF CONTENTS
Title Page ....................................................................................................................................................... i
Configuration Record.................................................................................................................................... ii
Revisions......................................................................................................................................................iii
Limited Product Warranty .......................................................................................................................... iv
Safety Notices ............................................................................................................................................... v
Safety Symbols ............................................................................................................................................ vi
Table of Contents........................................................................................................................................ vii
SECTION 1. GENERAL INFORMATION
1.1
Introduction...................................................................................................................................... 1
1.2
Equipment Description .................................................................................................................... 1
1.3
Installation Requirements ................................................................................................................ 3
SECTION 2 TECHNICAL DESCRIPTION
2.1
Theory of Operation......................................................................................................................... 5
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.............................................................................................................................................. 42
5.2
Arrangement .................................................................................................................................. 42
5.3
Reference Designation ................................................................................................................... 42
5.4
Option Parts ................................................................................................................................... 42
FIGURES
Figure 1-1
Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4
Figure 3-5
Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-3c
Figure 4-3d
Figure 4-4
Figure 4-4a
Figure 4-4b
Figure 4-4c
Figure 4-5
Figure 4-6
Catalog Number Breakdown.................................................................................................... 4
Mechanical Dimensions, Front .............................................................................................. 19
Mechanical Dimensions, Side................................................................................................ 20
Alternate Conduit Entry Location.......................................................................................... 21
Controls and Indicators .......................................................................................................... 22
Calibration Flow Chart........................................................................................................... 23
Control System Connector Operation .................................................................................... 29
Standard Model Diagnostic Indicators................................................................................... 30
Remote Control Connections ................................................................................................. 38
Remote Control Jumper Connections ................................................................................. 38.1
Dip Switch Configurations.................................................................................................. 38.2
System Wiring Diagram (all voltages except 415V) ............................................................ 39
Snubber Circuit Wiring Diagram (380 & 480V, 4 & 7.5 kW)........................................... 39.1
T2 Configuration (415V only) ........................................................................................... 39.2
Snubber Circuit Wiring Diagram 415V, 4 & 7.5 kW) ....................................................... 39.3
Transformer Tap Connection ................................................................................................. 40
Monitor Wiring ...................................................................................................................... 41
vii
9517
Rev. W
FIGURES CONTINUED.
Figure 5-1
Figure 5-2
Figure 5-3
Figure 5-3a
Figure 5-4
Figure 5-5
Figure 5-6
Figure 5-7
Front Parts Identification ....................................................................................................... 43
Internal Parts Identification.................................................................................................... 44
Drawer Parts Identification .................................................................................................... 45
Snubber Circuit Parts .......................................................................................................... 45.1
63A, 1000V SCR/Heatsink Detail ......................................................................................... 46
K1 & 380V and 480V C1 Detail............................................................................................ 47
Control Box Circuit Card Identification ................................................................................ 48
T1 Transformer Location ....................................................................................................... 49
TABLES AND CHARTS
Table 3-1 Power Requirements .............................................................................................................. 10
Display Messages and What They Mean.................................................................................................... 26
Quick Problem Solving Checklist............................................................................................................... 27
Power Supply Problem Checklist ............................................................................................................... 31
Protection Problem Checklist...................................................................................................................... 32
Regulation Problem Checklist .................................................................................................................... 33
Local Control Problem Checklist................................................................................................................ 34
Remote Control Problem Checklist ............................................................................................................ 35
Digital Problem Checklist........................................................................................................................... 36
Display Problem Checklist ......................................................................................................................... 37
Parts List - 60 Hz ........................................................................................................................................ 50
Parts List - 50 Hz ........................................................................................................................................ 55
viii
9517
Rev. W
SECTION I. GENERAL INFORMATION
1.1
INTRODUCTION
1.1.1
Purpose
This instruction manual provides information for installing and maintaining Dry FAA Type L828 & L-829 Constant Current Regulators manufactured by Crouse-Hinds Airport Lighting
Products, Windsor, Connecticut 06095, U.S.A.
1.1.2
Applicability
Only 4KW, 7.5KW and 10KW regulators bearing Crouse-Hinds catalog number series 82860D, 82960-D, 82850-D, & 82950-D 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 from
+10% to -5% of nominal. The three or five discrete brightness steps conform to FAA
standards. The regulator may be controlled both locally and from a remote location.
Protective circuits are provided to sense an overcurrent or an open circuit in the series lighting
loop and shutdown the regulator. The front panel display alerts maintenance personnel to the
nature of the shutdown. The protective circuitry can be reset by setting the regulator control
switch to off for 1 second. Provided no fault condition remains, setting the control switch to
the desired brightness step will restore operation.
The regulator may be connected directly to an FAA approved load switching device. No
regulator malfunction or damage to the series lighting loop will occur.
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
9517
Rev. W
1.2.3
Specification
1.2.3.1
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
Style:
1 - 3 Brightness Steps: 4.8, 5.5, 6.6 amperes
2 - 5 Brightness Steps: 2.8, 3.4, 4.1, 5.2,
6.6 amperes
Ratings:
Sizes - 4KW, 7.5KW & 10KW
Voltages - 208, 200, 240, & 480; 60 Hz
220, 230, 240, 380 & 415; 50 Hz
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:
4 KW - 225 lbs.
7.5 KW - 295 lbs.
10 KW - 345 lbs.
Mechanical:
The regulator has a louvered sheet steel enclosure painted blue with light gray accents. A
removable front panel 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. A removable cover allows easy access to other customer serviceable
parts.
2
9517
Rev. W
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 may be floor mounted, or mounted on a rack or shelf. Rack
mounting schemes are the sole responsibility of the engineer and/or contractor.
3
9517
Rev. W
EXAMPLE:
82960-D-10-4-66-05 IS A 10KW FAA L-829 Regulator with 240V, 60HZ input and 6.6A
output. It has five brightness steps.
8 2 X X 0 - D - X X -
X -
X X - X X - XX
TYPE
8 = L-828
9 = L-829
FREQUENCY
5 = 50HZ
6 = 60HZ
KW RATING
04 = 4KW
07 = 7.5KW
10 = 10KW
INPUT VOLTAGE
1 = 208*
2 = 220
3 = 230**
4 = 240
5 = 380**
7 = 415**
8 = 480*
0 = NON-STANDARD
* = 60 Hz only, ** = 50 Hz only
OUTPUT CURRENT
66 = 6.6A
OUTPUT BRIGHTNESS
01 = FIXED: FULL BRIGHTNESS
03 = 3 STEPS
05 = 5 STEPS
OPTIONS
See Sales Data Sheet.
FIGURE 1-1
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Rev. W
SECTION 2. TECHNICAL DESCRIPTION
2.1
THEORY OF OPERATION (BASIC REGULATOR)
The information presented here applies to a standard model Constant Current Regulator (CCR).
Regulators supplied with options may have minor operating differences, but the basic operation
is the same for all units.
Many functions in the CCR are controlled by a custom programmed electronic circuit. This
device performs brightness step and digital display control, open circuit and over-current
sensing, and handles system fault conditions. Several optional features also use the
programmed circuit to reduce the amount of additional circuitry required. Each of the standard
functions is discussed in detail in the following paragraphs. Optional functions are discussed in
Supplemental sections of this manual.
2.1.1
Current Regulation
Current regulation is achieved by varying the output voltage of the main power transformer as
required to maintain the desired current under varying load conditions. This is achieved by
providing a gating signal to control the conduction angle of a pair of silicon-controlled
rectifiers, (SCR) in series with the input of the main power transformer. For very low loads or
low brightness settings, the conduction angle will be small. At increased loads or higher
brightness settings, the conduction angle will be greater.
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.
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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 three-step regulators, apply control power to B30 or B100, for one-step regulators,
apply control power to on). Only the terminal for the desired step and CC require control
power. If two or more steps are energized together, the regulator will operate at the highest
brightness step selected.
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 1 second, the control system
performs the same shutdown sequence as for overcurrent protection.
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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 "lockup" 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.
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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 de-energized 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 the monitor relay immediately, thereby signaling
a regulator fault.
2.1.7.4
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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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 de-energize.
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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SECTION 3. INSTALLATION AND OPERATION
WARNING:
INSTALLATION, SERVICE, MAINTENANCE OR OPERATION SHOULD BE
PERFORMED BY QUALIFIED PERSONNEL ONLY.
WARNING
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 are provided in Figures 3-1, 3-2 and 3-3.
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
415
480
RATED INPUT CURRENT
(RMS AMPERES)
4KW
21
20
19
18
12
11
9
7.5KW
40
38
36
34
22
20
17
10
10KW
53
50
48
46
29
27
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9517
Rev. W
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
Installation Check List
(1)
Read these instructions before attempting installation.
NOTICE:
NOTICE
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.
3.1.5.1
3.1.5.2
Mechanical Installation
1.
Unpack the Constant Current Regulator, and check for any shipping damage.
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 for mechanical installation details, including required
clearance for access and proper cooling.
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:
CAUTION
DO NOT connect Counterpoise system to this terminal.
2. Verify that the line voltage is the same as the regulator nameplate voltage rating. This is
very important.
NOTICE:
NOTICE
CONNECTION TO THE WRONG LINE VOLTAGE MAY VOID THE WARRANTY.
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3.
Make required conduit holes as suggested in Figures 3-2 and 3-3.
4.
Connect the line voltage source to the input terminals E1 and E2.
5.
Connect the series lighting circuit to the output terminals LA2 and LA3.
CAUTION:
CAUTION
6.
DO NOT MEGGER TEST the series lighting load while it is connected to the regulator.
Before connecting remote control lines, check regulator operation using the front panel
control switch. Follow steps A-C below.
NOTICE:
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.)
IMPORTANT:
IMPORTANT
Only a True RMS instrument can accurately measure the regulator output externally. Other
instruments will provide improper readings.
(C)
IMPORTANT:
IMPORTANT
For best regulator efficiency, measure the connected regulator load using an RMS meter.
Turn main power off and adjust load tap connection per Figure 4-5b. Repeat Steps A and B.
NOTE: If additional load is added to regulator in the future, this tap
connection may have to be re-adjusted.
(D)
Shut off main power to the regulator.
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3.1.5.3
Control Wiring and Checkout
1.
Connect remote control lines to terminal block TB1 using the appropriate wiring
diagram. Refer to Figure 4-3 and Figure 4-3c.
Extend the drawer assembly fully forward on its slides before making any wiring
connections to the terminal blocks. This will ensure that wire length will be adequate
to fully extend drawer for service or maintenance. Route leads utilizing P-Clip on right
side panel of drawer assembly.
CAUTION:
CAUTION
2.
3.1.5.4
Incorrect wiring can cause malfunction or damage to the control system and possibly void the
equipment warranty. Re-check these connections before operating.
Make a final operation check using local and remote modes. Steps A-C below.
(A)
Apply main power to the regulator.
(B)
Operate the regulator in the local mode at all brightness steps and check for
correct current levels. (See Section 3.2 for keypad operation.)
(C)
Operate the regulator in the Remote mode at all brightness 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. The lampout relays are protected by 2
AMP fuses on the P.C. board.
3.1.5.5
Final Installation Steps
1.
Make any option related connections discussed in the option Supplements.
2.
Check that all cables and wiring are dressed within the cabinet. Reinstall all covers.
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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 the keys 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.
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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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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 “E” for Enter. All
future prompts will refer to number of 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 “(Enter)”. The number of lamps is not important
in percent 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 activated, followed by “E” for Enter. If you are not using the 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.
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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 at least 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 (Degraded) mode, press “CD(Enter)” on the keypad. To return to 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.
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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
happening, press “CF(Enter)” on the keypad. One of the following messages will scroll across
the display.
3.2.5
“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”
-
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)”.
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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 panel and remove the (2) outermost
screws which secure control box and drawer to regulator frame.
Extend the drawer for ease of inspection. The top cover may also
be removed if desired.
(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. Clean and touch up
with paint as required.
(7)
Secure control box and drawer to frame an re-install access panel
and cover.
(8)
Restore primary power to the regulator. Operate the regulator at
all brightness steps, first by local control, then by remote control.
Check for proper load currents.
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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:
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:
(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.
CAUTION:
CAUTION
4.3
The circuit cards within the control assembly are STATIC SENSITIVE. Do not remove or
handle them without a 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.
If these checks do not pinpoint the problem, try operating the regulator with a short across the
load terminals. OPERATING INTO A SHORT WILL NOT HARM THE REGULATOR.
This is the best way to find out if the problem is with the regulator or the load circuit. Once
these checks have been made, refer to the checklist for further instructions.
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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.
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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 T2. It
is probably bad.
Control display OFF.
(3) Check F1. If good, see the
section on power supply
problems.
System will not turn on. Control
display ON.
(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.
(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.
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 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.
(1) Check load circuit.
(2) Re-calibrate (Section 3.2.3
(3) See section on monitor
problems.
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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
WARNING:
WARNING
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. BE CAREFUL!
THE CIRCUITS INSIDE THE CONTROL BOX ARE LIVE.
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.
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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.
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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 T3 for an open winding.
If T3 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.
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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 ON, replace Circuit
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.
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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) 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.
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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
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DIGITAL 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) 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 T4.
(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.
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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.
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38.1
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38.2
9517
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39.1
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39.2
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39.3
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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.
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44
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45
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45.1
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46
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47
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49
INDEX
NO.
1
2
3
4
5
6
7
8
9
10
11
12
REFERENCE
DESIGNATION
Not shown
T1
DESCRIPTION
Regulator Frame & Enclosure
Panel, Lower Front
Cover
Bracket, Drawer Slide
Drawer Slide
Spacer, LA2 & LA3
Eye Bolt
Label, Warning
Service Post Connector
Fixed Panel Assembly, 4 & 7.5 KW
Fixed Panel Assembly, 10 KW
Transformer, 4KW, 6.6A
Transformer, 7.5KW, 6.6A
Transformer, 10KW, 6.6A
Drawer Assembly, 208-240V, 4KW
Drawer Assembly, 208-240V, 7.5 KW
Drawer Assembly, 208-240V, 10 KW
Drawer Assembly, 480V, 10 KW
Drawer Assembly, 480V, 4 & 7.5 KW
CROUSE-HINDS
AIRPORT
LIGHTING
PART NO.
32218
32209
31335
31333
32213
32219
31381
31683
10047-1933
32215-1
32215-2
31361
31362
31363
32169-1
32169-2
32169-3
32169-4
32169-9
MANUFACTURER
PART NO.
ILSCO P/N AUU70
60 HZ PARTS
9517
Rev. W
50
INDEX
NO.
REFERENCE
DESIGNATION
13
DESCRIPTION
14*
LA1
Control Assembly (insert 1, 3 or 5 in place of
“X” for number of steps desired). The
standard Control Assembly consists of the
following major replaceable items:
Keyboard/Display Card
Power Supply Board Assembly
Control Interface Board Assembly *(1)
Microcontroller Board Assembly
Regulation Board
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.
Lightning Arrestor
15
LA2 & LA3
Lightning Arrestor
MANUFACTURE
R
PART NO.
31765-1
31971
31716-1
32277-1
31879-3
31926-1
10047-2176
10047-885
10053-693
G.E. P/N
9L15ECB001
Cooper Power
AZLP1983 or
G.E. P/N
9L23BXX003XH
9517
Rev. W
51
60 HZ PARTS
CROUSE-HINDS
AIRPORT
LIGHTING
PART NO.
32322-X-X
Add -61 @ end for L829
INDEX
NO.
T3
E1 & E2
Lightning Arrestor Bracket
Transformer
Bushing
CROUSE-HINDS
AIRPORT
LIGHTING
PART NO.
32199
31329
10053-696
20*
21*
Used on E1-E2
E5-E8
Solderless Lug
Bushing
10047-1933
10053-698
22*
24**
25**
26**
Used on E1-E2
Bus Bar
Chassis Slide
Power Supply Transformer Subassembly
Fuseholder
32185
10037-732
32044
10047-1660
16*
17*
18*
REFERENCE
DESIGNATION
T20
DESCRIPTION
27**
F1
Fuse, 1 amp, slo-blo
10047-1205
28**
29**
30**
F2
RV2
T2
Fuse 1/8 amp slo-blo
Varistor
Transformer
10047-1005
31665
31790
MANUFACTURER
PART NO.
Glastic P/N 16032A
ILSCO P/N SAU 70
Glastic P/N 18721A
Buss P/N HKP-HH
Littlefuse P/N
342858
Buss P/N MDL-1
Littlefuse P/N
313001
Buss P/N MDL 1/8
60 HZ PARTS
9517
Rev. W
52
INDEX
NO.
REFERENCE
DESIGNATION
DESCRIPTION
31**
R1
Resistor, 100 ohm, +/- 3% max.
CROUSE-HINDS
AIRPORT
LIGHTING
PART NO.
10047-1359
32**
33**
TB1
TB4 (208-240V, 4 & 7.5
KW & 480V, 4-10 KW)
Terminal Block Assembly
Terminal Block Assembly, #14-4 AWG
31364
10047-1482
TB4 (209-240V, 10 KW)
Terminal Block Assembly, #10-0 AWG
10047-1684
K1 (208-240V, 4 & 7.5 KW
& 480V, 4-10 KW)
K1 (208-240V, 10 KW)
Contactor, 50A
10047-1245
Contactor, 75A
10047-1249
SCR/Heatsink Assembly, 63A, 1000V
31814
SCR/Heatsink Assembly, 100A, 1200V
31817
34**
35**
Q1 & Q2 (208-240V, 4 &
7.5 KW & 480V, 4-10 KW)
Q1 & Q2 (208-240V, 10
KW)
MANUFACTURER
PART NO.
Dale Type RH-25
Ohmite P/N 825F100
Square D P/N 9080D3 w/4” lg. mtg.
Channel or
Bussmann NC3-WH
Square D P/N 9080E3
w/4” mtg. Channel
Telemecanique P/N
2200EB420AA-15
Telemecanique P/N
2200EBA620AA-15
60 HZ PARTS
9517
Rev. W
53
INDEX
NO.
36**
37**
REFERENCE
DESIGNATION
DESCRIPTION
RV1 (208-240V, 4-10KW)
Varistor, 275V, 40J
CROUSE-HINDS
AIRPORT
LIGHTING
PART NO.
10047-712
RV1 (480V, 4-10 KW)
Varistor, 550V, 40J
10047-1411
C1 (208-240V, 4-10KW)
Capacitor, 1 uf, 360VAC
10047-1489
C1 (480V, 4-10 KW)
Capacitor, 2 uf, 360VAC
10047-1412
Spacer, 3/8 O.D., 1/2 lg, nylon
10047-1715
T4
S2
Potential Transformer (L-829 only)
Interlock Switch
31789
10047-1878
DS1
RV3
RV4
E12 & E13
R2 (480V, 4 & 7.5 KW)
Indicator Light
Varistor
Varistor
Standoff
Resistor, 100 ohm +/- 3% max
10047-938
31665-3
10047-1297
10053-10
10047-1359
42**
43
44
45
Not shown**
46**
Not shown**
47
48
49
*
**
C2 (480V, 4 & 7.5 KW)
(480V, 4 & 7.5 KW)
Capacitor, 1 uf, 2K
Insulator Strip (C2)
60 HZ PARTS
Included as part of fixed panel assembly, Item 10
Included as part of Drawer Assembly, Item 12
MANUFACTURER
PART NO.
G.E. P/N
V275LA40A
G.E. P/N
V575LA40A
CDE P/N DMMABP1K
CDE P/N DMMACW2K
Amaton P/N 9321-N171
R.A.F. P/N 1190-8-N
Unimax P/N 23TLG4 or
equal
Leecraft R2911-T
G.E. V150LA20B
H.H. Smith 2615
Dale Type RH-25
Ohmite P/N 825E100
10047-2595
31349-1
9517
Rev. W
54
INDEX
NO.
1
2
3
4
5
6
7
8
9
10
11
12
REFERENCE
DESIGNATION
Not shown
T1
DESCRIPTION
Regulator Frame & Enclosure
Panel, Lower Front
Cover
Bracket, Drawer Slide
Drawer Slide
Spacer, LA2 & LA3
Eye Bolt
Label, Warning
Grounding Lug
Fixed Panel Assembly, 4 & 7.5 KW
Fixed Panel Assembly, 10KW
Transformer, 4KW, 6.6A
Transformer, 7.5KW, 6.6A
Transformer, 10KW, 6.6A
Drawer Assembly, 220-240V, 4KW
Drawer Assembly, 220-240V, 7.5 KW
Drawer Assembly, 220-240V, 10 KW
Drawer Assembly, 380V, 4 KW
Drawer Assembly, 380V, 7.5 KW
Drawer Assembly, 380V, 10 KW
Drawer Assembly, 415V, 4 KW
Drawer Assembly, 415V, 7.5 KW
Drawer Assembly, 415V, 10 KW
CROUSE-HINDS
AIRPORT LIGHTING
PART NO.
32218
32209
31335
31333
32213
32219
31381
31683
10047-1933
32215-1
32215-2
31351 (34202 for 415V)
31352 (34203 for 415V)
31353 (34204 for 415V)
32169-1
32169-5
32169-6
32169-9
32169-7
32169-8
32169-10
32169-11
32169-12
MANUFACTURER
PART NO.
ILSCO P/N SAU70
50 HZ PARTS
9517
Rev. W
55
INDEX
NO.
REFERENCE
DESIGNATION
13
DESCRIPTION
14*
LA1
Control Assembly (insert 1, 3 or 5 in place of
“X” for number of steps desired). The
standard Control Assembly consists of the
following major replaceable items:
Keyboard/Display Card
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.
Lightning Arrestor
15
LA2 & LA3
Lightning Arrestor
CROUSE-HINDS
AIRPORT
LIGHTING
PART NO.
32322-X-X
Add -61 @ end for
L-829
MANUFACTURER
PART NO.
31765-1
31971
31716-1
32277-1
31879-3
31926-1
10047-2176
10047-885
10053-693
G.E. P/N
9L15ECB001
Cooper Power
AZLP19B3 or
G.E. P/N
9L23BXX003XH
50 HZ PARTS
9517
Rev. W
56
INDEX
NO.
16*
17*
18*
20*
21*
22*
24**
25**
26**
REFERENCE
DESIGNATION
T3
E1 & E2
Used on E1-E2
E5-E8
Used on E1-E2
T20
DESCRIPTION
Lightning Arrestor Bracket
Transformer
Bushing
Solderless Lug
Bushing
Bus Bar
Chassis Slide
Power Supply Transformer Subassembly
Fuseholder
CROUSE-HINDS
AIRPORT
LIGHTING
PART NO.
32199
31329
10053-696
10047-1933
10053-698
32185
10037-732
32044
10047-1660
27**
F1
Fuse, 1 amp, slo-blo
10047-1205
28**
29**
30**
F2
RV2
T2 (220-240, 380V, 4, 7.5 &
10 KW)
T2 (415V, 4, 7.5 & 10 KW)
Fuse 1/8 amp slo-blo
Varistor
Transformer
10047-1005
31665
31790
Transformer
31675
30**
MANUFACTURER
PART NO.
Glastic P/N 1603-2A
ILSCO P/N SAU 70
Glastic P/N 1872-1A
Buss P/N HKP-HH
Littlefuse P/N 342858
Buss P/N MDL-1
Littlefuse P/N 313001
Buss P/N MDL 1/8
50 HZ PARTS
9517
Rev. W
57
INDEX
NO.
REFERENCE
DESIGNATION
DESCRIPTION
31**
R1
Resistor, 100 ohm, +/- 3% max.
CROUSE-HINDS
AIRPORT
LIGHTING
PART NO.
10047-1359
32**
33**
TB1
TB4 (220-380V, 4 & 7.5 KW
Terminal Block Assembly
Terminal Block Assembly, #14-4 AWG
31364
10047-1482
TB4 (220-380V, 10 KW)
Terminal Block Assembly, #10-0 AWG
10047-1684
K1 (220-240V, 380 & 415V,
4 & 7.5KW)
K1 (220-240V, 380 & 415V
10 KW)
Q1 & Q2 (220-240V, 4 & 7.5
KW & 480V, 4 & 7.5 KW
& 380V, 4-10 KW)
Q1 & Q2 (220-240V, 10
KW)
Contactor, 50A
10047-2230
Contactor, 60A
10047-2231
SCR/Heatsink Assembly, 63A, 1000V
31814
SCR/Heatsink Assembly, 100A, 1200V
31817
34**
35**
MANUFACTURER
PART NO.
Dale Type RH-25
Ohmite P/N 825F100
Square D P/N 9080D3
w/4” lg. mtg. channel
Square D P/N 9080E3 w/4” mtg.
Channel or
Bussmann NC3-WH
Telemecanique P/N
LC1D32G7
Telemecanique P/N
LC1D40G7
50 HZ PARTS
9517
Rev. W
58
INDEX
NO.
36**
37**
43
44
45
Not shown**
46**
Not shown**
47
48
49
REFERENCE
DESIGNATION
DESCRIPTION
Varistor, 275V, 40J
CROUSE-HINDS
AIRPORT
LIGHTING
PART NO.
10047-712
RV1 (220-240V, 410KW)
RV1 (380V, 4-10
KW)
C1 (220-240V, 410KW)
C1 (380V, 4-10 KW)
G.E. P/N V275LA40A
Varistor, 550V, 40J
10047-1411
G.E. P/N V575LA40A
Capacitor, 1 uf, 360VAC
10047-1489
Capacitor, 2 uf, 360VAC
10047-1412
CDE P/N DMMABP1K
CDE P/N DMMACW2K
T4
S2
Potential Transformer (L-829 Only)
Interlock Switch
31789
10047-1878
DS1
RV3
RV4
E12 & E13
R2 (380V, 4KW)
Indicator Light
Varistor
Varistor
Standoff
Resistor, 100 ohms, +/- 3% max.
10047-938
31665-3
10047-1297
10053-10
10047-1359
C2 (380V, 4 KW)
(380V, 4 KW)
Capacitor, 1 uf, 2K
Insulator Strip (C2)
10047-2595
31349-1
MANUFACTURER
PART NO.
Unimax P/N 23TLG-4
or
Equal
Leecraft R2911-T
G.E. V150LA20B
H.H. Smith 2615
Dale Type RH-25
Ohmite P/N 825F100
50 HZ PARTS
*
**
Included as part of fixed panel assembly, Item 10.
Included as part of Drawer Assembly, Item 12
9517
Rev. W
59