ADB Safegate IDM 8000 User manual

IDM 8000
CCR
User Manual
UM_IDM-8000, Rev. 1.7, 2021/05/06

A.0 Disclaimer / Standard Warranty
CE certification
The equipment listed as CE certified means that the product complies with the essential requirements concerning safety and
hygiene. The European directives that have been taken into consideration in the design are available on written request to
ADB SAFEGATE.
ETL certification
The equipment listed as ETL certified means that the product complies with the essential requirements concerning safety and
FAA Airfield regulations. The FAA directives that have been taken into consideration in the design are available on written
request to ADB SAFEGATE.
All Products Guarantee
ADB SAFEGATE will correct by repair or replacement per the applicable guarantee above, at its option, equipment or parts
which fail because of mechanical, electrical or physical defects, provided that the goods have been properly handled and
stored prior to installation, properly installed and properly operated after installation, and provided further that Buyer gives
ADB SAFEGATE written notice of such defects after delivery of the goods to Buyer. Refer to the Safety section for more
information on Material Handling Precautions and Storage precautions that must be followed.
ADB SAFEGATE reserves the right to examine goods upon which a claim is made. Said goods must be presented in the same
condition as when the defect therein was discovered. ADB SAFEGATE furthers reserves the right to require the return of such
goods to establish any claim.
ADB SAFEGATE's obligation under this guarantee is limited to making repair or replacement within a reasonable time after
receipt of such written notice and does not include any other costs such as the cost of removal of defective part, installation
of repaired product, labor or consequential damages of any kind, the exclusive remedy being to require such new parts to be
furnished.
ADB SAFEGATE's liability under no circumstances will exceed the contract price of goods claimed to be defective. Any returns
under this guarantee are to be on a transportation charges prepaid basis. For products not manufactured by, but sold by ADB
SAFEGATE, warranty is limited to that extended by the original manufacturer. This is ADB SAFEGATE's sole guarantee and
warranty with respect to the goods; there are no express warranties or warranties of fitness for any particular purpose or any
implied warranties of fitness for any particular purpose or any implied warranties other than those made expressly herein. All
such warranties being expressly disclaimed.
Standard Products Guarantee
Products of ADB SAFEGATE manufacture are guaranteed against mechanical, electrical, and physical defects (excluding lamps)
which may occur during proper and normal use for a period of two years from the date of ex-works delivery, and are
guaranteed to be merchantable and fit for the ordinary purposes for which such products are made.
Note
See your sales order contract for a complete warranty description.
FAA Certified product installed in the United States and purchased or funded with monies through the
Airport Improvement Program (AIP) installations guarantee
ADB SAFEGATE L858 Airfield Guidance Signs are warranted against mechanical and physical defects in design or manufacture
for a period of 2 years from date of installation, per FAA AC 150/5345-44 (applicable edition).
ADB SAFEGATE L858(L) Airfield Guidance Signs are warranted against electrical defects in design or manufacture of the LED or
LED specific circuitry for a period of 4 years from date of installation, per FAA EB67 (applicable edition).
ADB SAFEGATE LED light fixtures (with the exception of obstruction lighting) are warranted against electrical defects in design
or manufacture of the LED or LED specific circuitry for a period of 4 years from date of installation, per FAA EB67 (applicable
edition). .
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Note
See your sales order contract for a complete warranty description.
Liability
WARNING
Use of the equipment in ways other than described in the catalog leaflet and the manual may result in personal injury,
death, or property and equipment damage. Use this equipment only as described in the manual.
ADB SAFEGATE cannot be held responsible for injuries or damages resulting from non-standard, unintended uses of its
equipment. The equipment is designed and intended only for the purpose described in the manual. Uses not described in the
manual are considered unintended uses and may result in serious personal injury, death or property damage.
Unintended uses, includes the following actions:
•Making changes to equipment that have not been recommended or described in this manual or using parts that are not
genuine ADB SAFEGATE replacement parts or accessories.
•Failing to make sure that auxiliary equipment complies with approval agency requirements, local codes, and all applicable
safety standards if not in contradiction with the general rules.
•Using materials or auxiliary equipment that are inappropriate or incompatible with your ADB SAFEGATE equipment.
•Allowing unskilled personnel to perform any task on or with the equipment.
© ADB SAFEGATE BV
This manual or parts thereof may not be reproduced, stored in a retrieval system, or transmitted, in any form or by any means,
electronic, mechanical, photocopying, recording, nor otherwise, without ADB SAFEGATE BV's prior written consent.
This manual could contain technical inaccuracies or typographical errors. ADB SAFEGATE BV reserves the right to revise this
manual from time to time in the contents thereof without obligation of ADB SAFEGATE BV to notify any person of such
revision or change. Details and values given in this manual are average values and have been compiled with care. They are not
binding, however, and ADB SAFEGATE BV disclaims any liability for damages or detriments suffered as a result of reliance on
the information given herein or the use of products, processes or equipment to which this manual refers. No warranty is made
that the use of the information or of the products, processes or equipment to which this manual refers will not infringe any
third party's patents or rights. The information given does not release the buyer from making their own experiments and
tests.
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TABLE OF CONTENTS
1.0 Safety ....................................................................................................................................................................................... 1
1.1 Safety Messages ........................................................................................................................................................................................................ 1
1.1.1 Introduction to Safety ................................................................................................................................................................................. 2
1.1.2 Intended Use .................................................................................................................................................................................................. 2
1.1.3 Material Handling Precautions: Storage .............................................................................................................................................. 3
1.1.4 Material Handling: Heavy Equipment .................................................................................................................................................. 3
1.1.5 Operation Safety ........................................................................................................................................................................................... 3
1.1.6 Maintenance Safety ..................................................................................................................................................................................... 4
1.1.7 Material Handling Precautions, ESD ..................................................................................................................................................... 4
1.1.8 Arc Flash and Electric Shock Hazard ..................................................................................................................................................... 5
2.0 About this Manual ................................................................................................................................................................. 7
3.0 Introduction ............................................................................................................................................................................ 9
3.1 General .......................................................................................................................................................................................................................... 9
3.1.1 IDM 8000 ......................................................................................................................................................................................................... 9
3.1.2 Airfield lighting serial circuit (AFL-circuit) ........................................................................................................................................... 9
3.1.3 Airfield lighting power circuit (AFL-circuit) design guidelines .................................................................................................... 9
3.1.4 Specifications ................................................................................................................................................................................................. 9
3.2 CCR Technical Data ................................................................................................................................................................................................ 10
3.2.1 Input Voltage (U 1) and Frequency (F1) ............................................................................................................................................ 10
3.2.2 Efficiency and Power Factor ................................................................................................................................................................... 10
3.2.3 Environmental ............................................................................................................................................................................................. 10
3.2.4 Output Current (I2) .................................................................................................................................................................................... 10
3.2.5 CCR Standard Sizes and Output Voltages ........................................................................................................................................ 10
3.2.6 Protective Functions ................................................................................................................................................................................. 11
3.2.7 Monitoring Functions ............................................................................................................................................................................... 11
3.2.8 Display Functions ....................................................................................................................................................................................... 11
3.2.9 Remote Control Interfaces ..................................................................................................................................................................... 12
3.3 CCR functional components ............................................................................................................................................................................... 12
3.3.1 General ........................................................................................................................................................................................................... 12
3.3.2 Power Circuit ................................................................................................................................................................................................ 14
3.3.3 Main Transformer, Efficiency and Power Factor ............................................................................................................................. 14
3.3.4 High Voltage Circuit .................................................................................................................................................................................. 15
3.3.5 Control Unit .................................................................................................................................................................................................. 15
3.3.6 Serial Control Interface ............................................................................................................................................................................ 16
3.3.7 Parallel control interface ......................................................................................................................................................................... 17
4.0 User Interface ....................................................................................................................................................................... 19
4.1 Control functions .................................................................................................................................................................................................... 19
4.1.1 Control functions with Operation switches ..................................................................................................................................... 19
4.1.2 Circuit Selector Control via Display unit ........................................................................................................................................... 20
4.1.3 Led Indicators .............................................................................................................................................................................................. 20
4.2 Display Unit ............................................................................................................................................................................................................... 20
4.2.1 Display Interface Main Menu Structure ............................................................................................................................................ 24
4.2.2 The set menu is divided into 3 sub menus: ..................................................................................................................................... 24
4.2.3 Commonly used symbols in all display menus: ............................................................................................................................. 24
4.3 View functions ......................................................................................................................................................................................................... 24
4.4 Calibration functions ............................................................................................................................................................................................. 27
4.4.1 Output Current I2 and Voltage U2 Calibration .............................................................................................................................. 27
4.4.2 Input Voltage U1 Calibration ................................................................................................................................................................. 28
4.4.3 Lamp Fault and VA-Drop Calibration ................................................................................................................................................. 29
4.4.4 Earth Fault Calibration ............................................................................................................................................................................. 30
4.5 Protective Functions .............................................................................................................................................................................................. 31
4.5.1 Open Circuit Protection ........................................................................................................................................................................... 33
4.5.2 Over Current Protection .......................................................................................................................................................................... 34
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4.5.3 Over Current Protection, Fast Reset .................................................................................................................................................... 34
4.5.4 Input Voltage Protection ......................................................................................................................................................................... 34
4.5.5 Input Frequency and Temperature Protection ................................................................................................................................ 35
4.6 Setting Functions .................................................................................................................................................................................................... 37
4.6.1 Output Current Step Setting ................................................................................................................................................................. 38
4.6.2 Lamp Fault Setting .................................................................................................................................................................................... 38
4.6.3 Earth Fault Setting ..................................................................................................................................................................................... 39
4.6.4 VA-Drop Setting ......................................................................................................................................................................................... 40
4.6.5 Current fault setting .................................................................................................................................................................................. 41
4.6.6 Time and date setting .............................................................................................................................................................................. 41
4.6.7 Hardware system settings ...................................................................................................................................................................... 42
4.6.8 System settings ........................................................................................................................................................................................... 44
4.6.9 Remote control settings .......................................................................................................................................................................... 46
4.6.10 Circuit selector minimum current setting ...................................................................................................................................... 47
4.6.11 LCD contrast setting ............................................................................................................................................................................... 48
4.6.12 Language setting ..................................................................................................................................................................................... 48
5.0 Installation ............................................................................................................................................................................ 49
5.1 General ....................................................................................................................................................................................................................... 49
5.1.1 Air conditioning .......................................................................................................................................................................................... 49
5.1.2 Transportation, Unpacking and Storage ........................................................................................................................................... 49
5.1.3 Moving and Handling the CCR at Site ............................................................................................................................................... 51
5.1.4 Installation Requirements ....................................................................................................................................................................... 51
5.2 Mechanical Installation ......................................................................................................................................................................................... 51
5.3 Electrical Installation .............................................................................................................................................................................................. 51
5.3.1 Mains Connection ...................................................................................................................................................................................... 52
5.3.2 AFL-Circuit Connection ............................................................................................................................................................................ 53
5.3.3 Serial Remote Control Connection ..................................................................................................................................................... 53
5.3.4 Parallel Remote Control Connection .................................................................................................................................................. 53
5.4 Load matching ......................................................................................................................................................................................................... 53
5.5 Commissioning Procedure .................................................................................................................................................................................. 56
6.0 Maintenance ......................................................................................................................................................................... 59
6.1 Content of Maintenance Work .......................................................................................................................................................................... 59
6.2 Standard of Maintenance Work ........................................................................................................................................................................ 59
6.3 Cycle of Maintenance Work ............................................................................................................................................................................... 59
6.4 Tools ............................................................................................................................................................................................................................. 60
7.0 Troubleshooting ................................................................................................................................................................... 61
7.1 CCR Does Not Start ............................................................................................................................................................................................... 61
7.2 CCR Trips .................................................................................................................................................................................................................... 62
7.3 Incorrect Performance of the CCR ................................................................................................................................................................... 63
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A.0 Appendix A – Serial communication interface – Profibus DP connection .................................................................... 65
B.0 Appendix B – Serial communication interface – Modbus TCP connection ................................................................... 67
C.0 Appendix C – Serial control interface signal list – Profibus DP ...................................................................................... 69
D.0 Appendix D – Serial control interface signal list – Modbus TCP .................................................................................... 73
E.0 Appendix E – Parallel control interface signal list ............................................................................................................ 77
F.0 Appendix F – Parallel remote control example ................................................................................................................. 79
G.0 Appendix G – Profibus DP design notes/AFL-control system designers ...................................................................... 81
H.0 Appendix H – Modbus TCP design notes/AFL-control system designers ..................................................................... 83
I.0 Appendix I – Commissioning test report form .................................................................................................................. 85
J.0 Appendix J – Spare part list ................................................................................................................................................. 89
K.0 Appendix K – Components of electronics ......................................................................................................................... 93
L.0 Appendix L – CCR components ........................................................................................................................................... 95
M.0 Appendix M – Output Terminals ....................................................................................................................................... 97
M.1 Slide Switch Terminal, Option .......................................................................................................................................................................... 97
M.2 Terminal Taps .......................................................................................................................................................................................................... 98
M.3 Series Cut Out (SCO), Option ........................................................................................................................................................................... 99
N.0 SUPPORT ............................................................................................................................................................................ 103
N.1 ADB SAFEGATE Website ................................................................................................................................................................................... 103
N.2 Recycling ................................................................................................................................................................................................................. 104
N.2.1 Local Authority Recycling .................................................................................................................................................................... 104
N.2.2 ADB SAFEGATE Recycling .................................................................................................................................................................... 104
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List of Figures
Figure 1: Parallel control unit IDM 8000-03 layout and HW settings ................................................................................................................. 17
Figure 2: Control rack with display unit and control switches ............................................................................................................................... 19
Figure 3: Circuit selector control via display unit ........................................................................................................................................................ 20
Figure 4: Display unit ............................................................................................................................................................................................................. 22
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List of Tables
Table 1: Air conditioning relevant values ....................................................................................................................................................................... 49
Table 2: Heat dissipation for air conditioning calculation ....................................................................................................................................... 51
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1.0 Safety
Introduction to Safety
This section contains general safety instructions for installing and using ADB SAFEGATE equipment. Some safety instructions
may not apply to the equipment in this manual. Task- and equipment-specific warnings are included in other sections of this
manual where appropriate.
1.1 Safety Messages
HAZARD Icons used in the manual
For all HAZARD symbols in use, see the Safety section. All symbols must comply with ISO and ANSI standards.
Carefully read and observe all safety instructions in this manual, which alert you to safety hazards and conditions that may
result in personal injury, death or property and equipment damage and are accompanied by the symbol shown below.
WARNING
Failure to observe a warning may result in personal injury, death or equipment damage.
DANGER - Risk of electrical shock or ARC FLASH
Disconnect equipment from line voltage. Failure to observe this warning may result in personal injury, death, or
equipment damage. ARC Flash may cause blindness, severe burns or death.
WARNING - Wear personal protective equipment
Failure to observe may result in serious injury.
WARNING - Do not touch
Failure to observe this warning may result in personal injury, death, or equipment damage.
CAUTION
Failure to observe a caution may result in equipment damage.
Qualified Personnel
Important Information
The term qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe
operation, maintenance and repair. Qualified personnel are physically capable of performing the required tasks, familiar
with all relevant safety rules and regulations and have been trained to safely install, operate, maintain and repair the
equipment. It is the responsibility of the company operating this equipment to ensure that its personnel meet these
requirements.
Always use required personal protective equipment (PPE) and follow safe electrical work practice.
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1.1.1 Introduction to Safety
CAUTION
Unsafe Equipment Use
This equipment may contain electrostatic devices, hazardous voltages and sharp edges on components
• Read installation instructions in their entirety before starting installation.
• Become familiar with the general safety instructions in this section of the manual before installing,
operating, maintaining or repairing this equipment.
• Read and carefully follow the instructions throughout this manual for performing specific tasks and
working with specific equipment.
• Make this manual available to personnel installing, operating, maintaining or repairing this
equipment.
• Follow all applicable safety procedures required by your company, industry standards and
government or other regulatory agencies.
• Install all electrical connections to local code.
• Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All
wiring must meet local codes.
• Route electrical wiring along a protected path. Make sure they will not be damaged by moving
equipment.
• Protect components from damage, wear, and harsh environment conditions.
• Allow ample room for maintenance, panel accessibility, and cover removal.
• Protect equipment with safety devices as specified by applicable safety regulations
• If safety devices must be removed for installation, install them immediately after the work is
completed and check them for proper functioning prior to returning power to the circuit.
Failure to follow this instruction can result in serious injury or equipment damage
Additional Reference Materials
Important Information
•IEC - International Standards and Conformity Assessment for all electrical, electronic and related technologies.
•IEC 60364 - Electrical Installations in Buildings.
•FAA Advisory: AC 150/5340-26 (current edition), Maintenance of Airport Visual Aid Facilities.
•Maintenance personnel must refer to the maintenance procedure described in the ICAO Airport Services Manual,
Part 9.
•ANSI/NFPA 79, Electrical Standards for Metalworking Machine Tools.
•National and local electrical codes and standards.
1.1.2 Intended Use
CAUTION
Use this equipment as intended by the manufacturer
This equipment is designed to perform a specific function, do not use this equipment for other purposes
• Using this equipment in ways other than described in this manual may result in personal injury, death
or property and equipment damage. Use this equipment only as described in this manual.
Failure to follow this instruction can result in serious injury or equipment damage
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1.1.3 Material Handling Precautions: Storage
CAUTION
Improper Storage
Store this equipment properly
• If equipment is to be stored prior to installation, it must be protected from the weather and kept free
of condensation and dust.
Failure to follow this instruction can result in equipment damage
1.1.4 Material Handling: Heavy Equipment
DANGER
Unstable load
Use caution when moving heavy equipment
• Use extreme care when moving heavy equipment.
• Verify that the moving equipment is rated to handle the weight.
• When removing equipment from a shipping pallet, carefully balance and secure it using a safety
strap.
Failure to follow this instruction can result in death, serious injury, or equipment damage
1.1.5 Operation Safety
CAUTION
Improper Operation
Do Not Operate this equipment other than as specified by the manufacturer
• Only qualified personnel, physically capable of operating the equipment and with no impairments in
their judgment or reaction times, should operate this equipment.
• Read all system component manuals before operating this equipment. A thorough understanding of
system components and their operation will help you operate the system safely and efficiently.
• Before starting this equipment, check all safety interlocks, fire-detection systems, and protective
devices such as panels and covers. Make sure all devices are fully functional. Do not operate the
system if these devices are not working properly. Do not deactivate or bypass automatic safety
interlocks or locked-out electrical disconnects or pneumatic valves.
• Protect equipment with safety devices as specified by applicable safety regulations.
• If safety devices must be removed for installation, install them immediately after the work is
completed and check them for proper functioning.
• Route electrical wiring along a protected path. Make sure they will not be damaged by moving
equipment.
• Never operate equipment with a known malfunction.
• Do not attempt to operate or service electrical equipment if standing water is present.
• Use this equipment only in the environments for which it is rated. Do not operate this equipment in
humid, flammable, or explosive environments unless it has been rated for safe operation in these
environments.
• Never touch exposed electrical connections on equipment while the power is ON.
Failure to follow these instructions can result in equipment damage
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1.1.6 Maintenance Safety
DANGER
Electric Shock Hazard
This equipment may contain electrostatic devices
• Do not operate a system that contains malfunctioning components. If a component malfunctions,
turn the system OFF immediately.
• Disconnect and lock out electrical power.
• Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component
according to instructions provided in its manual.
Failure to follow these instructions can result in death or equipment damage
1.1.7 Material Handling Precautions, ESD
CAUTION
Electrostatic Sensitive Devices
This equipment may contain electrostatic devices
• Protect from electrostatic discharge.
• Electronic modules and components should be touched only when this is unavoidable e.g. soldering,
replacement.
• Before touching any component of the cabinet you shall bring your body to the same potential as the
cabinet by touching a conductive earthed part of the cabinet.
• Electronic modules or components must not be brought in contact with highly insulating materials
such as plastic sheets, synthetic fiber clothing. They must be laid down on conductive surfaces.
• The tip of the soldering iron must be grounded.
• Electronic modules and components must be stored and transported in conductive packing.
Failure to follow this instruction can result in equipment damage
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1.1.8 Arc Flash and Electric Shock Hazard
DANGER
Series Circuits have Hazardous Voltages
This equipment produces high voltages to maintain the specified current - Do NOT Disconnect while
energized.
• Allow only qualified personnel to perform maintenance, troubleshooting, and repair tasks.
• Only persons who are properly trained and familiar with ADB SAFEGATE equipment are permitted to
service this equipment.
• An open airfield current circuit is capable of generating >5000 Vac and may appear OFF to a meter.
• Never unplug a device from a constant current circuit while it is operating; Arc flash may result.
• Disconnect and lock out electrical power.
• Always use safety devices when working on this equipment.
• Follow the recommended maintenance procedures in the product manuals.
• Do not service or adjust any equipment unless another person trained in first aid and CPR is present.
• Connect all disconnected equipment ground cables and wires after servicing equipment. Ground all
conductive equipment.
• Use only approved ADB SAFEGATE replacement parts. Using unapproved parts or making
unapproved modifications to equipment may void agency approvals and create safety hazards.
• Check the interlock systems periodically to ensure their effectiveness.
• Do not attempt to service electrical equipment if standing water is present. Use caution when
servicing electrical equipment in a high-humidity environment.
• Use tools with insulated handles when working with airfield electrical equipment.
Failure to follow these instructions can result in death or equipment damage
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2.0 About this Manual
This document includes information with focus on safety, installation and maintenance procedures.
For more information, see www.adbsafegate.com.
Note
It is very important to read this document before any work is started.
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IDM 8000
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