Airport 828HC User manual

Ferroresonant Constant Current Regulator
Type 828HC
Instruction Manual
Revision 1.0
10/25/2019
Airport Lighting Company
108 Fairgrounds Drive
Manlius, New York 13104
[phone]
[email protected]

Airfield circuits are designed to supply a constant current series output. To power numerous
devices on a constant current series circuit, the constant current regulator (CCR) will produce a
high voltage across the output.
Input Voltage Warning
The input voltage for the 828HC is 120VAC. Ensure proper safety measures are taken before
servicing input power.
Input Current Warning
While the input current of the 828HC is low enough to run without issue on a 15A circuit, it may
be high enough to cause a hazard to personal safety. Ensure proper safety measures are taken
before servicing input power.
Output Voltage Warning
The nominal output voltage of the 828HC is 76VAC. Depending upon regulatory body, this may
qualify as a “low-voltage” output. Despite this, the CCR may provide output voltage in the
magnitude of 5x nominal output before open circuit protection circuits are activated. Ensure the
output lines of the 828HC are always populated. Always connect the male and female ends when
an isolation transformer is not plugged in.
Output Current Warning
The output current of the CCR is dangerous. It is designed to work in a 6.6 Amp series loop. The
CCR will shut down if there is an open circuit, but it will not turn off in a short circuit. Protective
devices are designed to protect equipment, not to protect personnel.
Prior to installation or servicing
Follow all local and national electrical codes for installation and service of the CCR.
Only qualified service personnel should be allowed to install and service the CCR.
Open all sources of electricity to the CCR. Follow lock out / tag out procedures to ensure
continued safety while completing work. Verify correctness of work done with a second set of
eyes before re-energizing the CCR.

Guarantee
Airport Lighting Company guarantees that the equipment manufactured by Airport Lighting
Company and covered by this manual has been manufactured to and will perform in accordance
with application specifications. 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
Airport Lighting Company, with transportation costs borne by the purchaser. This guarantee
covers the 828HC Ferroresonant Constant Current Regulator.

Changes from last Revision
•First Revision

Table of Contents
1.0 Introduction .............................................................................................................................. 1
1.1 Scope..................................................................................................................................... 1
1.2 Equipment Description ......................................................................................................... 1
1.3 Control Capabilities............................................................................................................... 1
1.3.1 Front Panel Display Control ........................................................................................... 1
1.3.2 Remote Control.............................................................................................................. 2
1.3.3 RS232 Serial Connection................................................................................................ 2
2.0 Shipping & Sizing Information .................................................................................................. 3
2.1 Sizing Information................................................................................................................. 3
3.0 Installing the CCR ...................................................................................................................... 4
3.1 Installation Precheck............................................................................................................. 4
3.2 Turning the CCR on for the First Time .................................................................................. 4
3.3 Checking Current Output...................................................................................................... 5
4.0 How to Navigate the CCR Display and Keypad ......................................................................... 6
4.1 The CCR Keypad .................................................................................................................... 6
4.2 Understanding the Digital Control Monitoring Unit (DCMU) Display .................................. 8
4.2.1 The Main Screen ............................................................................................................ 8
4.2.2 Navigating Menus .......................................................................................................... 9
5.0 CCR Configuration................................................................................................................... 11
5.0.1 Accessing the Configuration Menu.............................................................................. 12
5.0.2 Accessing the Diagnostics Menu.................................................................................. 12
5.1 Common CCR Configuration Changes................................................................................. 12
5.1.1 Changing the Step Count of the CCR ........................................................................... 12

5.1.2 Calibrate Zeros............................................................................................................. 13
6.0 Warnings, Alarms, and Faults ................................................................................................. 14
6.1 Warnings and Alarms.......................................................................................................... 14
6.2 Faults................................................................................................................................... 14
7.0 Troubleshooting...................................................................................................................... 15
7.1 Troubleshooting Chart ........................................................................................................ 15
7.2 Restoring Known Good Settings ......................................................................................... 18
7.2.1 Restoring a Known Good Configuration ...................................................................... 18
7.2.2 Restoring a Known Good Calibration........................................................................... 18
7.3 Completing In-Field Recalibrations..................................................................................... 19
7.3.1 How to Determine if Recalibration is Needed............................................................. 19
7.3.2 Calibrating Output Current .......................................................................................... 20
7.3.3 Calibrating Output Voltage .......................................................................................... 21
7.3.4 Calibrating Input Voltage ............................................................................................. 23
8.0 Additional Information ........................................................................................................... 25
8.1 Replaceable Parts................................................................................................................ 25
8.2 Glossary of Terms................................................................................................................ 26
8.3 CCR Menu Navigation Flowchart ........................................................................................ 27
8.4 CCR Datasheet..................................................................................................................... 39

List of Figures
Figure 1: Cabinet Dimensions ......................................................................................................... 3
Figure 2: Keypad and Display of a 240V input CCR......................................................................... 6
Figure 3: The Configuration Menu................................................................................................ 10
Figure 4: Block Flow of Menu Navigation..................................................................................... 11
List of Tables
Table 1: Sizing Information ............................................................................................................. 3
Table 2: CCR Output Currents......................................................................................................... 5
Table 3: Main Screen Information .................................................................................................. 9

© Airport Lighting Company 1
1.0 Introduction
1.1 Scope
This instruction manual is provided for use with the 828HC Ferroresonant Constant Current
Regulator manufactured by Airport Lighting Company, Manlius, NY, USA.
1.2 Equipment Description
The 828HC is a 500W Ferroresonant Constant Current Regulator that is intended to test small
circuits, isolation transformers, and fixtures. It is powered by a 120VAC service, and draws 6A
nominal full load, meaning it can operate on a standard 15A circuit without issue.
It has standard L823 primary connectors to allow an operator to plug in an isolation transformer
of any size up to and including 500W for testing.
The 828HC is a device that is compliant with FAA AC150/5345-10, excepting input voltage and
nominal kW output capacity. It will operate to Type A, Class 1 specifications. It will operate to
both listed FAA CCR Styles, in addition to a one (1) step operation, as well as seven (7) step
operation. The brightness step selection is user-selectable to accommodate for all types of fixture
testing.
1.3 Control Capabilities
The regulator can be controlled by various means:
-The front panel keypad/display
-Remote-control connection to internal CCR terminal blocks with 24VDC, 48VDC, or
120VAC power
-RS232 serial connection to computer
1.3.1 Front Panel Display Control
The front panel display is the go-to method of entering the CCR settings and operating the CCR
in Local mode. Local mode operation allows the user to control the CCR with the press of a button,
independent of calls from a remote system. This can be used for setup, diagnosis of airfield circuit
problems, or troubleshooting. For more information about navigation of the CCR with the display,
see Section 4.0 How to Navigate the CCR Display and Keypad.

2© Airport Lighting Company
1.3.2 Remote Control
Remote control is available through an input terminal block on the DCMU. While the DCMU
installed allows for full parallel-input capability as required in FAA-spec CCRs, it is not connected
in the 828HC. For help setting up remote control for your 828HC, please contact Airport Lighting
Company.
1.3.3 RS232 Serial Connection
The 828HC allows for RS232 serial connection to be made at the DCMU. Each DCMU comes with
a RS232 connector that is used to connect directly to a PC using the DCMU Configurator software.
This connection is used primarily in factory setup and calibration of the CCR.

© Airport Lighting Company 3
2.0 Shipping & Sizing Information
The 828HC enclosure is sized as shown below:
2.1 Sizing Information
kW Rating
Install Weight
Install Size
(Without Pallet)
.5
74 lbs
18”W x 17”D x 9.2”H
Table 1: Sizing Information
Figure 1: Cabinet Dimensions

4© Airport Lighting Company
3.0 Installing the CCR
3.1 Installation Precheck
□Unpack the CCR and inspect for shipping damage.
□Verify that a grounded receptacle is available to power the unit.
□Using the dimensions in Section 2.0, verify the installation footprint is adequate.
3.2 Turning the CCR on for the First Time
Exercise caution at all times
It is recommended to do an initial startup of the 828HC to ensure familiarity with the controls
and operation.
Before starting, review Section 4.0 How to Navigate the CCR Display and Keypad for information
about the user interface.
Once you are familiar with the display keypad: Connect the male and female output
connections.
With the output connections shorted, plug in the 828HC.
The CCR display screen will turn on and show you the main screen. Reference Table 3: Main
Screen Information for a list of all information displayed.
Place a current clamp on an output wire and connect the clamp to a DMM. Using the LOCAL UP
and LOCAL DOWN buttons, increment through each brightness step and verify the current
output. Use the Table 2 in Section 3.3 for current references of each step.
Once the current measurements are verified, push the OFF button once to turn the CCR output
off.
LEAVE THE OUTPUT CONNECTIONS SHORTED AT ALL TIMES WHEN NOT PLUGGED INTO AN
ISOLATION TRANSFORMER.

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3.3 Checking Current Output
The following table is a direct reference to FAA AC 150/5345-10H Section 3.3.1.1, Table 1. Once
your CCR is installed, set up, and operational, you may choose to verify the measured output
current with a digital multimeter (DMM) and current clamp.
Maximum
Output
Current
Total
Step
Count
Step
Nominal
Output
Current
Allowable
Current
Range
Measured
Current
Displayed
Current
6.6
3
B10
4.8
4.7 –4.9
B30
5.5
5.4 –5.6
B100
6.6
6.5 –6.7
6.6
5
B1
2.8
2.7 –2.9
B2
3.4
3.3 –3.5
B3
4.1
4.0 –4.2
B4
5.2
5.1 –5.3
B5
6.6
6.5 –6.7
Table 2: CCR Output Currents

6© Airport Lighting Company
4.0 How to Navigate the CCR Display and Keypad
Figure 2: Keypad and Display of a 240V input CCR
The CCR display will show 4 lines of information at any given time. The display communicates
directly with the DCMU inside the panel. The information on the screen can be scrolled through
and will cycle around as if on a rolling drum.
Figure 6 shows the main screen of the CCR; this is the first screen that will come up when the
CCR is powered on. Refer to Section 4.2 Understanding the Digital Control & Monitoring Unit
(DCMU) Display for additional information.
4.1 The CCR Keypad
The OFF button will turn the CCR off from any brightness step in Local
or Remote.
The ON button will turn the CCR on to the most previous brightness
step. There is an LED on the button that will illuminate when the CCR
is on.
The LOCAL UP and LOCAL DOWN buttons change the brightness step
of the CCR when it is in Local mode. If LOCAL DOWN is pressed when
the CCR is at Step B10 (3 step configuration) or B1 (5 step
configuration), the CCR will turn off.

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The REMOTE button engages or disengages the Remote Control
option of the CCR. The LED in the button will illuminate if Remote is
enabled. Pressing the button while already in remote will put the CCR
back into Local mode.
The FAULT button has a red LED that will illuminate when a fault
condition occurs. If a fault occurs, the CCR will turn off and the fault
description will be displayed on the screen. Pressing the FAULT button
will clear the fault code and force the CCR to attempt operation again.
DO NOT continue to press the fault button to reset the CCR if the
actual fault condition is not fixed. Doing so may cause damage to the
CCR. See Section 6.2 Faults for information about faults and how to
remediate them.
The WARNING button has a yellow LED that will illuminate when a
warning condition occurs. Pressing the WARNING button will cycle
through any concurrent warnings. The CCR will still operate even if
there are warnings. It is recommended to identify the cause of the
warning and fix them as prolonged runtime with warning conditions
may cause damage to the CCR. See Section 6.1 Warnings and Alarms
for information about warnings and alarms, and how to remediate
them.
The CONFIG button is used to access multiple screens and menus. If
equipped, pressing the CONFIG button once will access the “Megger
Now” function. To access the configuration menu, press the CONFIG
button again.
If IRMS/Megger functionality is not installed, pressing the CONFIG
button once will access the configuration menu of the DCMU. See
Section 5.0 CCR Configuration for more information.
Pressing the CONFIG button again will show the diagnostics menu,
which among other information stores the most recent faults and
warnings. See Section 5.0.2 Accessing Diagnostics Menu for more
information.
The UP and DOWN buttons are the buttons that navigate the screen.
If on the main screen, the information will cycle through as if on a
rolling drum. If navigating the menus, you will see an arrow-cursor on

8© Airport Lighting Company
the left side of the screen. The UP and DOWN arrows control the
cursor.
The DOT buttons are selector buttons. If applicable, a command will
be displayed above the DOT buttons. For example, when navigating
the configuration menu, the left DOT button has the word “Enter”
above it and the right DOT button has the word “Exit” above it.
Pressing the corresponding button will execute the command.
4.2 Understanding the Digital Control Monitoring Unit (DCMU) Display
As stated in Sections 4.0 and 4.1, the CCR display is controlled by pushing the UP, DOWN, and
DOT buttons that are located below the screen. Each screen that is displayed will scroll
continuously, as if on a rolling drum. Once you attempt to navigate past the last line of
information, you will be returned to the first line.
4.2.1 The Main Screen
The main screen of the display shows the most important, at-a-glance information. The following
table shows all the available information on the main screen:
[Table on next page]

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Current Brightness Step & Local or Remote Indication
Note: This line will not scroll
Vin –Input (Source) Voltage Measurement
Iin –Input Current Measurement, if
equipped. If not equipped, this line will show:
“Iin=-----"
Vout –The voltage reading of the connected
field output circuit
Iout –The current reading of the connected
field output circuit
kVAo –The kVA calculation of the connected
field output circuit
kWo –the kW calculation of the connected
field output circuit
*kVAi –The kVA calculation of the supply
*kWi –The kW calculation of the supply
*PFIn –Power factor calculation of the
supply
*PFOut –Power factor calculation of the
output
Lamps Out –Current count of lamps out,
must be configured, enabled, and calibrated.
If not equipped, this line will show:
“Lamps Out=---"
Hz –The configured AC voltage frequency
Temperature –Displays the current
temperature reading at the DCMU in
centigrade
Mgr –Displays the current megger reading (if
equipped). Until a megger test is run, this line
will show: “Mgr=?????”
HwVer –Hardware version of the DCMU
SwVr –Software version of the DCMU
Table 3: Main Screen Information
Note: The kVAi, kWi, PFIn, and PFOut options only appear on the screen if the CCR is equipped
with an input CT.
4.2.2 Navigating Menus
The menus of the CCR are set up as a collection of folders within folders, similar to a file cabinet.
By using the UP, DOWN, and DOT buttons, it is possible to scroll through folder selections, and
open a folder with its own options and sub-folders.

10 © Airport Lighting Company
Figure 3: The Configuration Menu
Figure 3 shows the main configuration menu. While navigating the menus the top line, in this
case “Config”, and the bottom line, in this case “Enter” and “Exit”, will not scroll upon pressing
the UP or DOWN buttons.
Above each DOT button, on the fourth line, are commands that can be executed by the
corresponding DOT button.
As you can see, the second and third lines have arrows. The ↓ (down arrow) on the third line is
showing you that there are additional options to look at. Pressing the DOWN button will scroll
through the options.
The → (right arrow) is a cursor for the menu. Upon scrolling up or down, the option next to the
→ cursor will change. When you have reached the menu you’d like to open, use the Enter button
to navigate to the next sub-folder.