INSTRUCTION MANUAL L-828 & L-829 CONSTANT CURRENT REGULATOR

Cooper Industries Crouse-Hinds Division Crouse-Hinds Airport Lighting Products 1200 Kennedy Road Windsor, CT 06095 860 683-4300 Fax 860 683-4354 DOCUMENT 9517 February 5, 2008 Revision W Title: 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

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: OPTION/PART NUMBER DESCRIPTION ii

REVISIONS REV. DESCRIPTION LTR. DATE APVL A Added 10 inches to regulator height; Item P/N was 31345; Item P/N 2 was 32184; Item P/N 5 was 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 A96-261 8/7/95 PG B 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. A95-382 A95-499 6/26/95 PG 11/1/95 PG D Updated PCB Dwg. on Pg. 39.1; added Pg. 39.2. A96-026 Deleted 2.1.5.3 on Pg. 7; P/N 31879-3 was 31879- A97- E 1, 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 F 1) Added last part of Par. 3.2.3 on Pg. 17. A96-244 G 1) Revised wiring diagram Figure 4-4, secondary A97- of T20 was 12,6,0 327 H 1) Pg. 40, Fig. 4-4, re-routed wire 13 to T20 A97-386 J Sheet 39.1, S2, S3 & S4 was S2-S4 A98-071 L REVISED SHEET 40 A98-257 M Changed notes on Figure 4-3c, Sheet 39.1 A98-395 P Figure 4-5c, 230V 50Hz connection was T2-H3 A205-311 R Sht 53 & 58, Item 33 added alternate mfg. S Added new copyright on pg i; R revision A206- incorporated and issued; 1.2.3.1; 150/5345-10F 162 was -10E 1/17/96 RBM 4/15/97 JAS 5/19/97 JAS 6/5/97 JAS 7/28/97 JAS 6/1/98 RBM 7/22/98 RBM 1/11/99 JAS 9/8/05 GFR 7/28/06 PG iii

REVISIONS REV. DESCRIPTION LTR. DATE APVL Title page, revised copyright to 2007, added page A207-5/16/07 PG T III.1; 1.2.3.1, added 415V 50 Hz to voltages; Fig 1-1, 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 4-5a & 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 106 Page vii, Figure 4-4b was System Wiring Diagram A207-11/27/07 PG U (415V only); pg viii, added 415V to Figure 5-5; pg 10, 415V 10 kw rated input current was 24; Fig 4-3d, 32277 microprocessor board was 31984; Fig 4-5c, 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 299 V Table 3-1, revised rated input currents A207-318 12/20/07 PG W TITLE PAGE, REVISED COPYRIGHT; Fig 4-4b, Added wires 54, 55, 36 & 37 destinations A208-017 2/5/08 PG iii.1

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

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

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

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 Catalog Number Breakdown... 4 Figure 3-1 Mechanical Dimensions, Front... 19 Figure 3-2 Mechanical Dimensions, Side... 20 Figure 3-3 Alternate Conduit Entry Location... 21 Figure 3-4 Controls and Indicators... 22 Figure 3-5 Calibration Flow Chart... 23 Figure 4-1 Control System Connector Operation... 29 Figure 4-2 Standard Model Diagnostic Indicators... 30 Figure 4-3 Remote Control Connections... 38 Figure 4-3c Remote Control Jumper Connections... 38.1 Figure 4-3d Dip Switch Configurations... 38.2 Figure 4-4 System Wiring Diagram (all voltages except 415V)... 39 Figure 4-4a Snubber Circuit Wiring Diagram (380 & 480V, 4 & 7.5 kw)... 39.1 Figure 4-4b T2 Configuration (415V only)... 39.2 Figure 4-4c Snubber Circuit Wiring Diagram 415V, 4 & 7.5 kw)... 39.3 Figure 4-5 Transformer Tap Connection... 40 Figure 4-6 Monitor Wiring... 41 vii

FIGURES CONTINUED. Figure 5-1 Front Parts Identification... 43 Figure 5-2 Internal Parts Identification... 44 Figure 5-3 Drawer Parts Identification... 45 Figure 5-3a Snubber Circuit Parts... 45.1 Figure 5-4 63A, 1000V SCR/Heatsink Detail... 46 Figure 5-5 K1 & 380V and 480V C1 Detail... 47 Figure 5-6 Control Box Circuit Card Identification... 48 Figure 5-7 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

SECTION I. GENERAL INFORMATION 1.1 INTRODUCTION 1.1.1 Purpose This instruction manual provides information for installing and maintaining Dry 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 4KW, 7.5KW and 10KW regulators bearing Crouse-Hinds catalog number series 82860- D, 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 1.2.2 Options 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. This regulator can be factory supplied with various options. Contact Crouse-Hinds Airport Lighting Products for a current list of options. 1

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: Class: Style: Ratings: L-828 Regulator L-829 Regulator (with monitoring) 1-6.6 amperes output current 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 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: (a) (b) Internal Supply - 120 VAC, standard (Other voltages optional) External Supply - 120 VAC, Standard (Other voltages optional) 1.2.3.3 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

Environmental: Temperature: Relative Humidity: -40 degrees C to + 55 degrees C (-40 degrees F to +131 degrees F) 10 percent to 95 percent Altitude: Zero to 6,600 feet (2000 m) 1.3 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

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. 9517 8 2 X X 0 - D - X X - X - X X - X X - X X 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 4

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. 5

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. 6

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 2.1.6.1 Power-Up The CCR Digital Display is used during power-up and fault conditions to provide data regarding system status. 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. 7

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. 8

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. 9

SECTION 3. INSTALLATION AND OPERATION WARNING: WARNING INSTALLATION, SERVICE, MAINTENANCE OR OPERATION SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY. 3.1 INSTALLATION 3.1.1 Location 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. 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. RATED INPUT VOLTAGE TABLE 3-1 POWER REQUIREMENTS RATED INPUT CURRENT (RMS AMPERES) 4KW 7.5KW 10KW 208 21 40 53 220 20 38 50 230 19 36 48 240 18 34 46 380 12 22 29 415 11 20 27 480 9 17 23 10

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 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. 3.1.5.2 Power Wiring and Checkout CAUTION 1. Connect the ground conductor to the equipment ground terminal. It is located on the lower right side toward the front of the regulator. CAUTION: DO NOT connect Counterpoise system to this terminal. 2. Verify that the line voltage is the same as the regulator nameplate voltage rating. This is very important. NOTICE: NOTICE CONNECTION TO THE WRONG LINE VOLTAGE MAY VOID THE WARRANTY. 11

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: 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 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. 12

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 Incorrect wiring can cause malfunction or damage to the control system and possibly void the equipment warranty. Re-check these connections before operating. 2. Make a final operation check using local and remote modes. Steps A-C below. (A) (B) (C) Apply main power to the regulator. Operate the regulator in the local mode at all brightness steps and check for correct current levels. (See Section 3.2 for keypad operation.) Operate the regulator in the Remote mode at all brightness steps and check for correct current levels. 3.1.5.4 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. 13

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 - To select Remote - Press OFF (no Enter required) or Press BO (Enter) or Press 0 (Enter) Press BB (Enter) For 1 step regulators: To select ON - Press B1 (Enter) For 3 step regulators: To select B10 - To select B30 - To select B100 - Press B10 (Enter) or Press B1 (Enter) Press B30 (Enter) or Press B2 (Enter) Press B100 (Enter) or Press B3 (Enter) Entering B4 or B5 will result in an ERROR message. 14

For 5 step regulators: To select B1 - To select B2 - To select B3 - To select B4 - To select B5 - Press B1 (Enter) Press B2 (Enter) Press B3 (Enter) Press B4 (Enter) 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. 15

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. 16

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 - OPEN LOAD CURRENT - Over current protection trip. Open Load protection trip. LOW INPUT LINE - Low line voltage trip. 17

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. 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. WARNING XXX LAMPS OUT Or XXX% LAMPS OUT - The brightness step which is selected is not operating within the FAA Advisory Circular limits. - The actual number or percentage of lamps out, only if the alarm limit has been exceeded. NO WARNINGS OR ALARMS - Self-explanatory. 3.2.5 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

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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. 24

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) (B) Remove power from the regulator before disconnecting the connector plug from the control compartment. 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 The circuit cards within the control assembly are STATIC SENSITIVE. Do not remove or handle them without a static control wrist strap. 4.3 PROBLEM SOLVING GUIDE This guide will assist qualified airport maintenance personnel in locating and correcting equipment failures. Problems associated with option functions are addressed in the specific option Supplement. If further assistance is required, contact the Customer Service Department at 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. 25

DISPLAY MESSAGES AND WHAT THEY MEAN DISPLAY MESSAGE VER.X.X (where X.X is a number like 1.1) LOW INPUT LINE HIGH LOAD CURRENT OPEN LOAD CIRCUIT Display shows some other readable message. Display shows a bunch of funny things or garbage. WHAT IT MEANS 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. 26

QUICK PROBLEM SOLVING CHECKLIST SYMPTOM System will not turn on. Control display OFF. System will not turn on. Control display ON. 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) WHAT TO DO (1) Check power source turned on. (2) Check for 120VAC across X1 to X2 on transformer T2. It is probably bad. (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. (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. (1) Check load circuit. (2) Re-calibrate (Section 3.2.3 (3) See section on monitor problems. 27

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. 28

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POWER SUPPLY PROBLEM CHECKLIST SYMPTOM All board indicators are OFF. One power supply board indicator is OFF or it is very dim. WHAT TO DO (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. For further help contact Crouse-Hinds Airport Lighting Products. 31

PROTECTION PROBLEM CHECKLIST PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING CIRCUIT CARDS: SYMPTOMS Display reads OPEN LOAD CIRCUIT. Display reads HIGH LOAD CURRENT. Display reads LO INPUT LINE. WHAT TO DO (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. For further help contact Crouse-Hinds Airport Lighting Products. 32

REGULATION PROBLEM CHECKLIST PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING CIRCUIT CARDS! SYMPTOM All currents low. High steps OK, but low steps are high. One step high or low. Low steps OK, but high steps are low. Current fluctuates over a wide range. WHAT TO DO (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. (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. For further help contact Crouse-Hinds Airport Lighting Products. 33

LOCAL CONTROL PROBLEM CHECKLIST PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING CIRCUIT CARDS! SYMPTOMS System will not turn on. System will not turn off. Keypad does not respond to one or more key presses. WHAT TO DO (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. For further help contact Crouse-Hinds Airport Lighting Products. 34

REMOTE CONTROL PROBLEM CHECKLIST PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING CIRCUIT CARDS! SYMPTOM System will not turn on. System will not turn off. Current fluctuates up or down. WHAT TO DO (1) Check in local control. If not OK, see section on local control problems. (2) Check remote supply and wiring. If OK, replace 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. For further help contact Crouse-Hinds Airport Lighting Products 35

DIGITAL PROBLEM CHECKLIST PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING CIRCUIT CARDS! SYMPTOM System will not turn on. WHAT TO DO (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 Remote indicators out. Unit will not calibrate. Erroneous readings or alarms. WHAT TO DO (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. For further help contact Crouse-Hinds Airport Lighting Products. 36

DISPLAY PROBLEM CHECKLIST PLEASE REMEMBER TO TURN OFF MAIN AND CONTROL POWER BEFORE REMOVING OR INSTALLING CIRCUIT CARDS! SYMPTOM Regulator runs but no display. Regulator runs but Display shows wrong current. WHAT TO DO (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. For further help contact Crouse-Hinds Airport Lighting Products. 37