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
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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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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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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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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