ADB CCF Ferroresonant L-828 User manual

Document No. 96A0147
Issued: 6/1/92
Rev. Date
INSTRUCTION MANUAL
30 KW/6.6A
LC-TYPE
L-828 Constant Current Regulators
Manufactured per FAA Specification
AC 150/5345-10E
ADB
A SIEMENS COMPANY
977 Gahanna Parkway
Columbus, Ohio 43230
Tel: [phone]
Fax: [phone]
Additional manuals are available upon request for a nominal charge of $25.
Copyright ©1993 by ADB, Inc. All rights reserved.
The Leader in Airfield Lighting

Document No. 96A0147
Page ii
RECORD OF CHANGES
Page Rev. Description Chkd App'd

Document No. 96A0147
Page iii
TABLE OF CONTENTS
Page
1. GENERAL INFORMATION AND REQUIREMENTS................................................................................. 1-1
1.1 INTRODUCTION............................................................................................................................................... 1-1
1.2 SCOPE................................................................................................................................................................... 1-1
1.3 PURPOSE............................................................................................................................................................... 1-1
1.4 EQUIPMENT DATA .......................................................................................................................................... 1-2
1.5 PROTECTIVE DEVICES ................................................................................................................................... 1-2
1.6 REGULATION ................................................................................................................................................... 1-2
1.7 INDICATORS..................................................................................................................................................... 1-2
1.8 INPUT VOLTAGE.............................................................................................................................................. 1-3
2. THEORY OF OPERATION.............................................................................................................................. 2-1
2.1 INTRODUCTION..................................................................................................................................................... 2-1
2.2 THE SCRS............................................................................................................................................................ 2-1
2.3 CONTACTOR ......................................................................................................................................................... 2-1
2.4 TRANSFORMERS ................................................................................................................................................... 2-2
3. OPERATION....................................................................................................................................................... 3-1
3.1 CONTROL.............................................................................................................................................................. 3-1
3.1.1 Local Control............................................................................................................................................... 3-1
3.1.2 Remote Control ............................................................................................................................................ 3-1
3.2 SHUTDOWN PROCEDURE....................................................................................................................................... 3-2
4. PREVENTIVE MAINTENANCE ..................................................................................................................... 4-1
4.1 GENERAL........................................................................................................................................................... 4-1
4.2 PREVENTIVE MAINTENANCE....................................................................................................................... 4-1
4.3 SHORT-CIRCUIT TEST..................................................................................................................................... 4-1
4.4 OPEN-CIRCUIT TEST....................................................................................................................................... 4-2
5. TROUBLESHOOTING...................................................................................................................................... 5-1
5.1 TROUBLESHOOTING TABLE .................................................................................................................................. 5-1
5.2 PRELIMINARY TROUBLESHOOTING....................................................................................................................... 5-1
6. PARTS LIST........................................................................................................................................................ 6-1
6.1 PARTS LIST........................................................................................................................................................... 6-1
7. INSTALLATION ................................................................................................................................................ 7-1
7.1 INTRODUCTION..................................................................................................................................................... 7-1
7.2 UNPACKING.......................................................................................................................................................... 7-1
7.2.1 Damage........................................................................................................................................................ 7-1
7.3 INSTALLATION................................................................................................................................................ 7-1
7.4 WIRING CONNECTIONS AND STARTUP...................................................................................................... 7-1
7.5 CALIBRATION ....................................................................................................................................................... 7-5
7.5.1 Set-Up Procedure......................................................................................................................................... 7-5
7.5.2 Adjustment of Output Current...................................................................................................................... 7-5
7.5.3 Overcurrent Adjustment............................................................................................................................... 7-6
7.6 CHANGING INPUT VOLTAGE................................................................................................................................. 7-7

Document No. 96A0147
Page iv
LIST OF TABLES
Page
TABLE 1-1. GENERAL ASSEMBLY PART NUMBERS.................................................................................................... 1-3
TABLE 1-2. EQUIPMENT DATA................................................................................................................................... 1-4
TABLE 1-3. EQUIPMENT NOT SUPPLIED BUT WHICH MIGHT BE REQUIRED................................................................ 1-5
TABLE 1-4. EQUIPMENT SUPPLIED............................................................................................................................. 1-6
TABLE 1-5. FAA OUTPUT CURRENT LEVELS AND TOLERANCES ............................................................................... 1-6
TABLE 1-6. RECOMMENDED INPUT POWER SUPPLY WIRE......................................................................................... 1-6
TABLE 1-7. INPUT CURRENT FOR L-828 CONSTANT CURRENT REGULATORS............................................................ 1-6
TABLE 3-1. ROTARY SWITCH S1 POSITION FOR 3- &5-STEP CCRS........................................................................... 3-1
TABLE 4-1. PREVENTIVE MAINTENANCE TASKS........................................................................................................ 4-3
TABLE 5-1. FUSES...................................................................................................................................................... 5-2
TABLE 5-2. TROUBLESHOOTING GUIDE..................................................................................................................... 5-3
TABLE 6-1. PARTS LIST............................................................................................................................................. 6-1
TABLE 6-2. RECOMMENDED SPARE PARTS................................................................................................................ 6-2
TABLE 7-1. REMOTE CONTROL CONNECTIONS .......................................................................................................... 7-4
TABLE 7-2. REMOTE 120 VAC CONTROL CONNECTIONS ........................................................................................... 7-4
TABLE 7-3. POTENTIOMETERS FOR SETTING OUTPUT CURRENT LEVELS................................................................... 7-6
LIST OF FIGURES
Page

Document No. 96A0147
Page v
SAFETY NOTICES
The operating and maintenance personnel should refer to FAA Advisory Circular AC 150/5340-26,
“Maintenance of Airport Visual Aids Facilities” for instructions on safety precautions. Personnel must
observe the safety regulations at all times. All operations on this unit shall be carried out by personnel
qualified to work on high voltage equipment. While every practicable safety precaution has been
incorporated in this equipment, the following rules must be strictly observed:
KEEP AWAY FROM LIVE CIRCUITS
Operating and maintenance personnel must at all times observe all safety regulations. Do not change
plug-in components or make adjustments inside equipment with high voltage supply on. To avoid
casualties, always remove power, then discharge and ground by use of a grounding rod, prior to touching
any parts. See FAA Advisory Circular AC 150/5340-26 concerning safety.
RESUSCITATION
Operating and maintenance personnel should familiarize themselves with the technique for resuscitation
found in the First Aid Instruction Manual.
GUARANTEE
ADB, Inc. guarantees that the LC-Type L-828 Constant Current Regulators described herein, when sold
by ADB, Inc. or its approved representatives, will perform in accordance with FAA specification AC
150/5345-10, L-828, and that any defect in design, materials or workmanship which may occur during
proper and normal use during a period of one (1) year from date of installation or a maximum of two (2)
years from date of shipment will be corrected by repair or replacement by ADB, Inc., f.o.b. factory.
Damage resulting from improper installation does not constitute proper and normal use and is not covered
by the warranty. Such corrections shall constitute the limit of all ADB, Inc. liabilities for the LC-type
L-828 Constant Current Regulators.

Document No. 96A0147
Page 1-1
1. GENERAL INFORMATION AND REQUIREMENTS
1.1 INTRODUCTION
The ADB, Inc. 30 kW L-828 “LC-Type” Constant Current Regulators are designed to supply either three
or five precision output current levels (6.6 amp maximum) for series lighting circuits on airport runways
and taxiways. The regulators are air cooled and designed to accurately regulate the output current to
within ±3% of the adjustable nominal level from no load to full load and with input voltage variations of
-5% to +10% of nominal (-40oC to +55oC). The nominal output current levels are maintained even when
50 percent of the isolation transformers in the series lighting circuit supplied by the regulator have open
secondaries. The ADB, Inc. “LC-Type” regulators have the exclusive feature of being the only true output
“soft-start” current regulators available (see Figure 8-5). Also, the on/off circuitry in the LC-Type
regulators eliminates the need for special “slow-acting” circuit breakers on the input power supply lines.
The regulators may be operated manually or by 120 V ac or +48 V dc remote control signals from a
distant location (10,000 feet round-trip using AWG #19 control cable). The universal remote control used
in the LC-Type CCR requires no circuitry changes between 120 V ac and +48 V dc remote control
signals. Both 120 V ac and +48 V dc remote control source signals (CCI) are provided.
Protective circuits automatically shut down the regulators if an overcurrent or open-circuit occurs in the
series lighting circuit. After an input power loss, operation automatically resumes at the same brightness
level within 5 seconds after input power is restored. Output lightning and current-surge protection is
provided on all units.
1.2 Scope
This manual covers 30 kW L-828 “LC-Type” Constant Current Regulators (CCRs) manufactured to FAA
specification AC 150/5345-10 (current edition). Operation outside the design limitations of this
specification may result in degradation of performance, damage or failure of regulator components or
hazardous conditions.
1.3 Purpose
This manual describes procedures for the installation, operation, and maintenance of ADB, Inc.
manufactured 30 kW L-828 “LC-Type” Constant Current Regulators.
________________________________
;Note: (1) The LC-Type CCR should not be used to power an L-849 REIL system unless the CCR is
at least half loaded with steady burning lights. (2) The LC-Type CCR is not currently designed to be
used with an ADB Mark II or MARK III (PC board) lamp-out monitor. Monitoring is accomplished
using the ADB “Scanner” type monitor. See ADB Catalog Sheet #1228.

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Page 1-2
1.4 EQUIPMENT DATA
Table 1-1 gives the part numbers for the 30 kW “LC-Type” regulators manufactured by ADB, Inc.
Reference data pertinent to the equipment is listed in Table 1-2. Table 1-3 lists equipment and
accessories supplied. Information on items not supplied but which might be required for installation is
given in Table 1-4. Table 1-5 gives the FAA-approved output current levels and tolerances, while Table
1-7 gives the input current. Recommended input power supply wire for the regulators is listed in Table
1-6.
1.5 PROTECTIVE DEVICES
The following protective devices are provided on each regulator:
1. Output open-circuit protection
2. Output overcurrent protection
3. Input power-line undervoltage protection
4. Lightning protection on output terminals
5. Fuse protection: remote control supply voltage (48 V dc and 120 V ac), and power supply
for printed circuit board
6. Input breaker for supply voltage
7. W VA (load Wattage in excess of maximum available Volt-Amperes)
1.6 REGULATION
Current regulation is obtained under the following conditions:
1. Load variations of zero (short circuit) to full load with input voltage variations of -5% to
+10%, at -40oC up to +55oC (-40oF to +131oF) ambient temperature.
2. With up to 50% of the series isolation transformers open-circuited.
1.7 INDICATORS
1. A true rms-reading ammeter mounted on the front panel indicates the output current. The
screw of the face of the ammeter is for zeroing the indicator needle.
2. W VA output LED (load Wattage in excess of maximum available Volt-Amperes)
3. Regulator On (green) LED (system in normal operation)
4. Overcurrent LED
5. Open-circuit LED

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Page 1-3
1.8 INPUT VOLTAGE
The standard power transformer for the L-828 regulators is designed for an input voltage of either
208/220/240 V ac (using field-adjustable tap, see Section 7.6) or 480 V ac. See the nameplate on the
regulator for the input voltage rating.
Table 1-1. General Assembly Part Numbers
44D1380-XXX0
;Note: ALCS and Scanning Monitor Interface—This L-828 is designed for connection to the ADB
Airfield Lighting Computer System and the ADB Scanning Monitor. The ADB Scanning Monitor
provides state-of-art accuracy in computer monitoring of the status of L-828 regulators and the series
circuits powered by them. In addition to providing all the functional capability of an FAA L-827 airport
lighting monitor, the ADB Scanning Monitor’s software-controlled monitoring can be easily changed to
provide additional monitoring information or updated to monitor new equipment installed on the lighting
circuits. Contact ADB Sales Department for details and additional literature. See ADB Catalog Sheet
#1041 for details on the ADB Airfield Lighting Computer System.
Type
0 = Standard L-828
1 = L-828 with ALCS & Scanning Monitor Interface with Remote Box*
2 = L-828 with ALCS & Scanning Monitor Interface without Remote Box**
____________________________
*The current and voltage transformers for ALCS/Scanning Monitor feedback are
installed inside the L-828 regulator.
**The current and voltage transformers for ALCS/Scanning Monitor feedback are
mounted external to the regulator on the wall.
Input Voltage
1 = 208, 220, 240 V ac
2 = 480 V ac
Style
1 = 3-Step
2 = 5-Step

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Table 1-2. Equipment Data
FAA Type: L-828 (air-cooled LC-Type) Constant Current Regulator (CCR)
Rating: 30 kW
Nominal Input Voltage: 208, 220, 240 Vac (field-adjustable tap);
480 V ac
Class 1 (6.6 A maximum output current)
Style 1—3 step (4.8, 5.5 & 6.6 amp); Style 2—5 step (2.8, 3.4, 4.1, 5.2 & 6.6 amp)
Minimum Power Factor: 0.95
Minimum Efficiency: 95%
Soft-Start: The only true output “soft-start” current regulators produced by any manufacturer (see Figure
8-5) and eliminates the need for a special slow-trip circuit breaker on the input power lines.
Control:
•Local operation using front panel rotary switch S1;
•Universal remote operation using either +48 V dc or 120 V ac signals. Both +48 V dc or 120
V ac remote control source signals (CCI) are provided, but only one may be used.
•On/off switching under any load
Built-in True RMS-Reading Ammeter: 10 amps (maximum scale)
Protection:
•Overcurrent
•Open-circuit
•Lightning and transient protection
•Output current-surge limitation (protects series incandescent lamps)
•Power-supply current is self-limited
(After an input power loss, operation resumes within 5 seconds after power is restored)
Output Current Level: Maintained within ±0.1 amp at any intensity step.
Reactive Loading: The CCRs maintain the current within the limits of Table 1-5 for all brightness steps
when the load is connected via isolating transformers, and secondaries of 50% of these transformers
become open-circuited. The load before opening the isolation transformer secondaries may be any value
from half to full load.
Optional Input Lightning Protection: ADB #94B0011-1 for 480 V ac input; #94B0011-2 for 208-
240 V ac input.
Terminal Blocks: Pressure-type for external remote control wiring

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Page 1-5
Table 1-2. Equipment Data (continued)
Compatibility:
•Compatible with L-847 circuit selector switches
•The LC-type CCR should not be used to power an L-849 REIL system unless the CCR is at
least half loaded with steady burning lights.
•The LC-type CCR is not currently designed to be used with an ADB Mark II or III (PC
board) lamp-out monitor. Monitoring is accomplished using the ADB “Scanning Monitor”.
See Catalog Sheet #1228.
Environmental Operating Conditions: Designed for indoor use only in an area with adequate ventilation
for cooling the constant current regulator.
Temperature Range: -40°C to +55°C (-40°F to +131°F)
Relative Humidity: 0 to 100%
Altitude: Sea level to 6,600 ft (2000 m)
Dimensions: 32 x 26 x 36 inches (H x W x D)
Footpad: 24.75 x 28 inches (W x D)
Weight: 918 lb
Table 1-3. Equipment not Supplied but Which Might be Required
Quantity Description
A/R Wire, input power (see Table 1-6)
A/R Wire, remote control, AWG 19 minimum, AWG 12 maximum
A/R Wire, ground, AWG 4 minimum
A/R Wire, output load, AWG 8, 5000 V dc, L-824 type
A/R Wire, shorting jumper, AWG 8 minimum
1 Disconnect switch or main circuit breaker
2 Input lightning arrestor, can be ordered separately from ADB
1 Circuit breaker for input power lines (The soft-start feature eliminates the need for a
special slow-trip circuit breaker on the input power lines.
1 Screwdriver
1 True rms voltmeter, 600 V ac scale
1 Voltmeter, 60 V dc full scale
1 Ammeter, true rms-reading , 10-amp maximum scale
1 Ohmmeter
A/R Mounting bolts and washers

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Page 1-6
Table 1-4. Equipment Supplied
Quantity Description
1 L-828 Constant Current Regulator
1 Instruction Manual
Table 1-5. FAA Output Current Levels and Tolerances
3-Step Nominal Output Current Allowable Current Range
B100 6.6A 6.40-6.70A
B30 5.5A 5.33-5.67A
B10 4.8A 4.55-4.94A
5-Step Nominal Output Current Allowable Current Range
B5 6.6A 6.40-6.70A
B4 5.2A 5.04-5.36A
B3 4.1A 3.98-4.22A
B2 3.4A 3.30-3.50A
B1 2.8A 2.72-2.88A
;Note: It is recommended that the circuit breaker on the input power supply lines have a rating of
125% of the CCR’s input current, as given in Table 1-7, unless local codes require a different rating
technique. See the CCR’s nameplate for the kW rating and input voltage to determine the input current
from Table 1-7. If no standard size circuit breaker exists at the 125% value, use the next larger standard
size circuit breaker.
Table 1-6. Recommended Input Power Supply Wire
[Recommended input power supply wire (130°C, 600V minimum) for less
than 100 feet between CCR and power source. For 100 to 250 feet, use the
next larger (even) gage wire.]
kW
Rating 208 V Input 220 V Input 240 V Input 480 V Input
30 kW AWG 4, 600V AWG 44, 600V AWG 44, 600V AWG 8, 600V
Table 1-7. Input Current for L-828 Constant Current Regulators
kW
Rating 208 V Input 220 V Input 240 V Input 480 V Input
30 kW 168 amps 158 amps 146 amps 73 amps

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Page 2-1
2. THEORY OF OPERATION
2.1 Introduction
Current regulation is obtained by using SCRs to switch the supply power (varying the “on” duration of
the AC cycle) to the power transformer and by using feedback circuitry to monitor the transformer’s
output. The brightness level is selected from one of three or five preset values. When the load varies, the
feedback circuit changes the control-voltage level, which changes the conduction angle of the AC voltage
to the SCRs to allow power to flow into the power transformer. This changes the supply power flow to
the main transformer to compensate for the load variation and maintain the output current at the preset
level.
2.2 The SCRs
See Figure 8-6. When power is applied to the constant current regulator (CCR) at fuse block F1 and F2
and the contactor K1 and circuit breaker CB1 are closed, no current will flow in the primary of the power
transformer T1 until the SCRs receive a triggering pulse. When this pulse occurs, the SCRs turn on,
allowing current to flow into the primary of the power transformer T1 until the SCR is switched off by the
zero crossing (+ to −) of the input power. The path of the current flow is from fuse block F1 and F2
(circuit breaker CB1) through contactor K1, SCR1 terminals 1B and 3 to L2, L1 and primary of T1, and
back to K1, and F1 and F2 (circuit breaker CB1). Since alternating current is used for the regulator
operation, after zero-crossing the current flows in the opposite direction using the other SCR (see SCR1
terminals 1A and 2).
The power level in the primary of the power transformer is controlled by varying the phase of the
conduction angle. If very low output current is desired, the conduction angle would be near zero
degrees, i.e., the SCR is not triggered until the input voltage is near zero-crossing. Little power is then
available to power transformer T1.
For maximum power to occur in the primary of the power transformer T1, the conduction angle will be
near 180 degrees. Immediately after zero-crossing of the input-power sine wave, the SCR is triggered and
operates continuously throughout the 180-degree duration of the input sine wave.
For 67% power from the power transformer, the conduction angle will be nearly 90 degrees. This occurs
approximately at the voltage peak of the sine wave when the SCR switches into conduction. Switching
the transformer on-line at this time creates a rather abrupt rise time, since the input sine wave is at its peak
voltage. Choke L1 slows this rapid rise time from the conduction of the SCRs.
2.3 Contactor
In the event of an SCR failure, the contactor provides a means to break the current driving the primary of
the power transformer T1. The contactor K1 (see Figure 8-6) has no making or breaking current across it,
since the SCR is off when the contactor is opening and closing. This is accomplished by the coil-control
circuitry and provides increased life for the contactor.

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Page 2-2
2.4 Transformers
Transformer T6 provides 120 V ac remote-control source voltage at TB2 terminal 8 through fuse F5.
Transformers T3 and T4 provide AC voltage to the Control PCB. T3 provides 120/60 V ac. T4 provides
36/18 V ac.

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Page 3-1
3. OPERATION
3.1 Control
The rotary switch S1 on the front panel is used for local control of the regulator. This control switch has
seven positions for 5-step CCR labeled: REM (remote), OFF, and brightness steps 1, 2, 3, 4 and 5 (or
five positions for 3-step CCR: REM, OFF, 10, 30, 100). For regulator operation by +48 V dc or 120 V
ac remote control signals, rotary switch S1 must be set to REM. Remote control is disengaged when
switch S1 is set to any position other than REM.
3.1.1 Local Control
1. Rotary switch (S1), positions 1 through 5 (or 10, 30 and 100 for a 3-step CCR), provides
local control of the CCR’s output current level. For a three-step CCR, positions 10, 30 and
100 give an output current of 4.8, 5.5 and 6.6 amps, respectively. For a five-step CCR,
positions 1 through 5 give an output current of 2.8, 3.4, 4.1, 5.2 and 6.6 amps, respectively.
2. When rotary switch S1 is set to the OFF position, the regulator is deenergized and cannot be
remotely turned on.
3. When switch S1 is set to REM, operation of the regulator is by remote control signals.
Table 3-1. Rotary Switch S1 Position for 3- & 5-Step CCRs
3-Step CCR
S1 SET TO: REM OFF 10 30 100
RESULT: Operation of CCR by remote
control signals
CCR off 4.8 A current
output 5.5 A current output 6.6 A current output
5-Step CCR
S1 SET
TO: REM OFF 1 2 3 4 5
RESULT: Operation of CCR by
remote
control
signals
CCR off 2.8 A
current
output
3.4 A
current
output
4.1 A
current
output
5.2 A
current
output
6.6 A
current
output
3.1.2 Remote Control
1. When the rotary switch S1 is set to position REM and remote control wiring is connected to
remote control terminal block TB2 on the regulator, the output current of the regulator will
correspond to the brightness setting energized by remote 120 V ac or +48 V dc control
signals. When switch S1 is set to OFF, remote control signals will not operate the regulator,
i.e., turn the regulator on to a particular brightness setting or turn the regulator off. Switch
S1 must be set to REM for operation of the regulator by remote control.

Document No. 96A0147
Page 3-2
2. When there are no remote control connections on terminal block TB2, the position REM
becomes an additional OFF position, i.e., the regulator is deenergized when switch S1 is set
to REM.
3. If more than one remote intensity is accidentally selected, the highest intensity will be
selected.
3.2 Shutdown Procedure
Set rotary switch S1 to position OFF. Power to the output terminals is now off, and the regulator cannot
be energized by remote control signals. Power is still present on the input power fuse block F1 and F2.
To remove input power, disengage disconnect switch or external circuit breaker.

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Page 4-1
4. PREVENTIVE MAINTENANCE
4.1 GENERAL
This section establishes the maintenance procedures required for the constant current regulators. The
maintenance tasks must be performed on a recurring basis to insure optimum performance, minimize
service interruptions and avoid major breakdowns.
WARNING
Only personnel authorized to work on high-voltage equipment
should perform maintenance on the regulator.
Operate regulator under local control (using rotary switch S1)
when performing maintenance tasks on the regulator. This will
prevent the regulator from accidentally being turned on and
causing serious injury or death.
Always deenergize regulator by turning rotary switch S1 to OFF,
and remove input power to regulator by turning off disconnect
switch or main circuit breaker before opening access door to
service regulator.
4.2 PREVENTIVE MAINTENANCE
The preventive maintenance checks for the regulator are listed in Table 4-1.
4.3 SHORT-CIRCUIT TEST
WARNING
Since high open-circuit voltages may result by opening the
primary of a series lighting circuit, only personnel authorized to
work on high-voltage equipment should be allowed to perform
the short-circuit test.
1. Remove input power to regulator (turn off disconnect switch or main circuit breaker) and turn
rotary switch S1 to OFF.
2. Remove leads from output terminals TB1, and short output terminals using AWG #8 or larger
wire.
3. Energize regulator and turn rotary switch S1 to the lowest brightness step 1(10) and then to the
remaining brightness steps. Check the output current on a true-rms-reading ammeter at each step.
The output current should be within the tolerance given below.

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3-Step CCR S1 Position Allowable Range (Panel Ammeter) Amperes
10 4.55-4.94
30 5.33-5.67
100 6.40-6.70
5-Step CCR S1 Position Allowable Range (Panel Ammeter) Amperes
1 2.72-2.88
2 3.30-3.50
3 3.98-4.22
4 5.04-5.36
5 6.40-6.70
4. If the output current is not within the above specified limits, check the input voltage to regulator.
The supply voltage should be within -5% to +10% of the nominal input voltage shown on the
regulator nameplate. If supply voltage is correct, readjust output current per Section 7.5.2.
5. Turn off disconnect switch or main circuit breaker to remove input power to regulator.
6. Disconnect the shorting jumper and reconnect output cables.
7. Close input-power disconnect switch or main circuit breaker.
4.4 OPEN-CIRCUIT TEST WARNING
Since high open-circuit voltages may result by opening the
primary of a series lighting circuit, only personnel authorized to
work on high-voltage equipment should be allowed to perform
the open-circuit test.
1. Remove input power to regulator (turn off disconnect switch or main circuit breaker) and turn
rotary switch S1 to OFF.
2. Disconnect cables from the output terminals TB1.
3. Turn on input power to regulator.
4. Turn rotary switch S1 to the lowest brightness position 1(10). The open-circuit protective
device should automatically deenergize the regulator in less than 2 seconds.
5. Turn rotary switch S1 to OFF. The open-circuit protective device should reset.
6. Turn rotary switch S1 to position 1(10). The regulator should turn on and then deenergize in
less than 2 seconds.
7. If regulator operation is satisfactory, turn rotary switch to OFF, and turn off disconnect
switch or main circuit breaker before reconnecting the load.
8. After the load has been reconnected, turn on input power to the regulator.

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Page 4-3
Table 4-1. Preventive Maintenance Tasks
INTERVAL MAINTENANCE TASK ACTION
Daily (1) Check all control equipment
for proper operation
(1) Check local and remote control (if used) on each
brightness step.
Monthly (1) Check input voltage
(2)Check and record output
current on each brightness step
(1) If input voltage is not within -5% to +10% of the nominal
value specified on the nameplate of the regulator, notify power
company to correct voltage.
(2) Use true a rms-reading instrument. Adjust current levels if
out of tolerance (see Table 1-5).
Annually (1) Check wiring and insulation
(2) Inspect housing for rust
spots
(3) Inspect lightning arrestor
connections
(4) Perform a short-circuit test
(5) Perform an open-circuit test
(1) Make sure input and output connections are tight and that
there are no damaged wires or frayed or burnt insulation.
(2) Clean and touch-up rust spots with paint.
(3) Tighten any loose connections. Replace charred or burnt
wiring or broken arrestors.
(4) See paragraph 4.3.
(5) See paragraph 4.4.
Unsched-
uled Check load on regulator At installation and subsequent load changes make sure that the output voltage times the output current does not exceed the
rated load on the nameplate of the regulator.

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5. TROUBLESHOOTING
5.1 Troubleshooting Table
Preliminary troubleshooting information is given in Section 5.2. The troubleshooting guide for the LC-
type L-828 constant current regulator is given in Table 5-2.
WARNING
Only personnel authorized to work on high-voltage equipment
should perform troubleshooting on the regulator.
Deenergize regulator by turning rotary switch S1 to OFF, and
remove input power to regulator by turning off disconnect switch
or main circuit breaker. Ground output terminals by using a
grounding rod prior to touching any parts.
If regulator deenergizes suddenly, the output circuit could be
interrupted by an overcurrent, open-circuit, or undervoltage
condition. Before inspecting the output circuit, place rotary
selector switch S1 in the OFF position and turn off disconnect
switch or main circuit breaker. Without this precaution, a dip in
the power line may produce an on-cycling and reenergize the
regulator, resulting in an output voltage of several hundreds or
thousands of volts which can cause serious injury or death.
5.2 Preliminary Troubleshooting
The following is a check list of steps to perform:
1. Check all LED indicators, fuses, and circuit breakers. See Table 5-1.
2. Visually examine all areas of the CCR. Are there any burnt or loose connections/parts?
3. Is the input voltage present and within +10% to -5% of nominal? Is Regulator ON (green)
LED lit?
4. If CCR works in local but not in remote, check voltage on remote control lines. Check fuse F5
if 120 V ac or fuse F4 (on Control PCB) if +48 V dc remote control source voltage is used. If
correct, replace Control PCB.
5. Can the CCR be reenergized by turning rotary switch S1 from OFF to step 1(10)? If it can be,
problem is due to open circuit (open-circuit LED lit?) or overcurrent (overcurrent LED lit?).
6. Short the output of the CCR with an AWG 10 (2000 V, minimum) wire and turn CCR on. If
the regulator operates normally, problem may be load related.

Document No. 96A0147
Page 5-2
Table 5-1. Fuses
Circuit Breaker CB1
(on 208-240 V LC) Protects K1 (contacts), SCR1, L1, L2, and main transformer T1
Fuse F1, F2
(on 480 V LC) 90A, Slo-Blo for 480 V CCRs 200A, Slo-Blo for 208, 220, & 240
CCRs
Protects main transformerT1, contactor
K1 (contacts),SCR1, L1, and L2
Fuse F3, F4 1A, 500 V, Slo-Blo for 480 V CCRs
2A, 250 V, Slo-Blo for 208-240 V
CCRs
Protects transformers T3 and T4,
contactor K1 (coil), triac Q21 and DC
power supplies on Control PCB
Fuse F5 1/4A, 250 V, Slo-Blo Protects the internal 120 V ac CCI
source and transformer T6
Fuse F4 1/4A, 250 V Slo-Blo Protects the internal +48 V dc (on
Control PCB) CCI source circuitry on
the Control PCB
7. If the CCR turns on for a few seconds and then shuts off and the ammeter indicates 0 amps,
the problem is either an open circuit (open-circuit LED lit?) or current transformer T2 is open.
T2 can be checked by comparing the primary and secondary current readings.
8. If the CCR turns on and then shuts off after a few seconds and there is a high current reading
on the ammeter, the problem is an overcurrent (overcurrent LED lit?). Adjust the output
current accordingly. If this does not work, replace Control PCB and then SCR1.
9. If the CCR does not energize at all (Regulator ON (green) LED lit?), check for undervoltage.
If correct, replace Control PCB.