AUGIER Energy OCEM DIAM3200 Series Maintenance and service guide

DIAM3200 1 to 2,5KVA
Single-phase stackable Sinus
Constant Current Regulator
Compliance with standards:
ICAO Aerodrom design manual, part 5
IEC (61822 ED2)
60 21742 Diam 3200 1 to 2.5KVA
Installation & maintenance
Energy Technology srl
Operating office :
Via della Solidarieta 2/1
40056 Valsamoggia –Loc. Crespellano (BO) –Italy
Ph : + 39 051 6656 611 Fax : [phone]
[email protected] –www.ocem.com
VAT Nr : IT 031 4821 1208
a division of Energy Technology srl

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RECORD OF CHANGES
Rev.
Pages
Description
From S/N
By
App.
Date
1.0
First issue
ED
RG
02-02-2019

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WARRANTIES
Guarantee
AUGIER’s goods has been manufactured and will perform in accordance with applicable specifications, and
any defect in design, materials or workmanship which may occur during proper and normal use during a period
of 1 year from date of installation or 2 years from date of shipment will be corrected by repair or replacement by
the manufacturers f.o.b factory.
The guarantee covers repair, modification or replacement of parts or products recognised to be defective, in
the shortest possible time, at AUGIER’s cost, provided always that the goods have been properly handled and
stored prior installation, properly installed and properly operated after installation.
Unless otherwise specifically laid down in contract, the guarantee does not cover:
Costs of consignment to factory and re-consignment of defective goods to Buyer
Travelling & sojourn expenses of AUGIER’s personnel if goods have to be repaired on site; assembly
and dismantling of any goods other than those recognised to be defective; expenses incurred for
waiting times by AUGIER’s personnel on site for reasons independent of their will;
Unjustified travel expenses.
Guarantee shall not apply in the following cases:
Defects in materials supplied by Buyer or from any designs imposed by them;
Repairs or replacements due to normal wear and tear, or damages or accidents.
Repairs or replacements due to damages or accidents resulting from negligence or lack of due care,
inadequate supervision or maintenance, or erroneous use of the equipment or software;
Any other causes for which AUGIER shall not be held responsible, e.g. resulting from an case of Force
Majeure.
When Buyer has replaced AUGIER’s parts with other parts.
Buyer must inform AUGIER in writing and without delay of any defects in goods, giving all necessary
information and detailed description of how equipment has been utilised, together with purchase date. Buyer
undertakes not to have repairs carried out by third parties; any repairs carried out without AUGIER’s express
prior agreement shall invalidate the guarantee.
It is expressly agreed between the two parties that Buyer cannot avail himself of the beneficial dispositions
contained in the guarantee without having first satisfied payment conditions laid down in contract
Disclaimers
This manual could contain technical or typographical errors. AUGIER reserves the right to make changes and
revise this manual from time to time without obligation to notify any person or organisation of such changes or
revision.
Values and measurements given in this manual are average values and are not binding. AUGIER disclaims any
liability for damages suffered as a result of reliance on the information given in this manual, or the use of
equipment or processes which this manual refers.
No guarantee is made that the use of the products, equipment, processes or information to which this manual
refers will not infringe any third party’s patent or rights. Information given does not release the buyer from
making their own tests.

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SAFETY
Safety precautions
This equipment is normally used or connected to circuits that may employ dangerous and lethal voltages.
Extreme caution should be exercised by operating or maintenance people when working on or with this
equipment.
See IEC 61820 & 61821 standard (CCR type IEC), or FAA AC150/5340-26 advisory circular (CCR type FAA),
concerning safety rules and precautions. While practical safety precautions have been incorporated in this
equipment, the following rules must be strictly observed :
KEEP AWAY FROM LIVE CIRCUITS :
Operating and maintenance people must at all time observe all safety regulations. Do not change
components nor perform maintenance inside equipment with power ON or the lighting loop energised.
RESUSCITATION :
Operating and maintenance personnel should familiarise and keep themselves trained with resuscitation
techniques found in widely published manuals about first aid instructions.
ELECTROSTATIC DISCHARGE (ESD) :
Electronic sub-assemblies and boards should be touched only for unavoidable operation (replacement,
for example). Before to operate, maintenance people must first of all eliminate unwanted electronic
charges, discharging his own body while touching a conductive earthed object or part. Electronic boards
and components as power semiconductors must be stored and carried an conductive packing.
DESTRUCTION :
In case of dismantling, scrapping or placing out of service, the user must follow all the required
precautions for component, materials or equipment elimination, according the local rules.
EEC DIRECTIVES
This equipment complies with the requirements of EC directives :
89/336/EEC, 92/31/EEC and 93/68/EEC with regard of Electromagnetic
Compatibility
73/23/EEC with regard of Low Voltage Equipment

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TABLE OF CONTENTS
RECORD OF CHANGE ……………………………………………………………………………………………… I-2
WARRANTIES …………………………………………………………………………………………………………… I-3
SAFETY ……………………………………………………………………………………………………………….….. I-4
TABLE OF CONTENTS ……………………………………………………………………………………………… I-5
IDESCRIPTION________________________________________________________I-9
I.1 OVERVIEW _______________________________________________________________________ I-9
I.2 MECHANICAL DESCRIPTION_______________________________________________________ I-10
I.2.1 DESCRIPTION________________________________________________________________ I-10
I.2.2 GENERAL MECHANICAL FEATURES _____________________________________________ I-10
I.2.3 STORAGE CONDITIONS _______________________________________________________ I-10
I.2.4 DIMENSIONS_________________________________________________________________ I-11
I.3 ELECTRICAL DESCRIPTION _______________________________________________________ I-13
I.3.1 BLOCK DIAGRAMS____________________________________________________________ I-13
I.3.1.1 Overview: __________________________________________________________________ I-13
I.3.2 GENERAL CIRCUIT DIAGRAMS _________________________________________________ I-13
I.3.3 GENERAL ELECTRICAL FEATURES______________________________________________ I-14
I.4 INSTRUCTIONS FOR USE__________________________________________________________ I-15
I.4.1 USER INTERFACE ____________________________________________________________ I-15
I.4.2 CONTROL ___________________________________________________________________ I-16
I.4.3 LOCAL INFORMATION FEEDBACK_______________________________________________ I-17
I.4.4 REMOTE INFORMATION FEEDBACK _____________________________________________ I-17
I.4.1 CONFIGURATION SOFTWARE UTILITY ___________________________________________ I-18
I.5 OPERATION _____________________________________________________________________ I-19
I.5.1 CONFIGURATION _____________________________________________________________ I-20
I.5.2 SETTING ____________________________________________________________________ I-20
I.5.2.1 Current range:_______________________________________________________________ I-20
I.5.3 PROTECTIONS _______________________________________________________________ I-20
I.5.3.1 LV power monitoring: _________________________________________________________ I-20
I.5.3.2 “Open circuit”: _______________________________________________________________ I-20
I.5.3.3 “Overcurrent”: _______________________________________________________________ I-21
I.5.3.4 Cancelling “Open circuit” and “Overcurrent” faults: __________________________________ I-21
I.5.4 AUTOMATIC OPERATION:______________________________________________________ I-21
I.6 OPTIONS________________________________________________________________________ I-22
I.6.1 EARTH FAULT DETECTOR (EFD) ________________________________________________ I-22
I.6.2 CUT OUT (OPTION) ___________________________________________________________ I-22
I.6.3 OUTPUT LIGHTING ARRESTORS ________________________________________________ I-23
I.6.4 CASTERS____________________________________________________________________ I-23

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I.6.5 BURNT LAMP DETECTION:______________________________________________________I-23
I.6.6 WIG WAG ____________________________________________________________________I-24
II INSTALLATION _____________________________________________________ II-25
II.1 PREPARATION __________________________________________________________________ II-25
II.1.1 EQUIPMENT RECEPTION ______________________________________________________ II-25
II.1.1.1 Equipment delivered: _______________________________________________________ II-25
II.1.1.2 Checking the equipment: ____________________________________________________ II-25
II.1.2 TRANSPORTATION ___________________________________________________________ II-25
II.1.3 DEVICE LOCATION ___________________________________________________________ II-26
II.1.4 STACKING DEVICES __________________________________________________________ II-26
II.1.5 CHECKING THE INSTALLATION_________________________________________________ II-27
II.1.5.1 Single phase power supply : _________________________________________________ II-27
II.1.5.2 LV Protection : ____________________________________________________________ II-27
II.1.5.3 Lighting loop : ____________________________________________________________ II-27
II.1.5.4 Control by remote control :___________________________________________________ II-27
II.2 CONNECTIONS __________________________________________________________________ II-28
II.2.1 POWER AND EARTH __________________________________________________________ II-28
II.2.1.1 LV supply:________________________________________________________________ II-28
II.2.1.2 Earthing _________________________________________________________________ II-28
II.2.1.3 Lighting loop: _____________________________________________________________ II-29
II.2.2 REMOTE CONTROL CONFIGURATION ___________________________________________ II-30
II.2.2.1 Connectors: ______________________________________________________________ II-30
II.2.2.2 Circuit selector:____________________________________________________________ II-31
II.3 ADJUSTING THE CCR ____________________________________________________________ II-32
II.3.1 MULTI TERMINAL INDUCTANCE ________________________________________________ II-32
II.3.2 PARAMETER MODIFICATION___________________________________________________ II-33
II.3.2.1 Preferred configuration values: _______________________________________________ II-33
II.3.2.2 Brightness values: _________________________________________________________ II-33
II.3.2.3 Value of “Open Circuit” protection level:_________________________________________ II-34
II.3.2.4 Value of “Overcurrent” protection levels: ________________________________________ II-34
II.4 REMOTE CONTROL ______________________________________________________________ II-35
III COMMISSIONING__________________________________________________III-36
III.1 PROCEDURE____________________________________________________________________ III-36
III.2 TESTS__________________________________________________________________________ III-37
III.2.1 SHORT-CIRCUIT TESTS _______________________________________________________III-37
III.2.2 OVERLOAD TESTS ___________________________________________________________III-37
III.2.3 OPEN-CIRCUIT TEST__________________________________________________________III-37
IV MAINTENANCE___________________________________________________ IV-38
IV.1 FORMALISATION ________________________________________________________________IV-38

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IV.2 PREVENTIVE ___________________________________________________________________ IV-38
IV.2.1 FIRST MONTHS______________________________________________________________ IV-38
IV.2.2 ANNUAL PROCEDURE________________________________________________________ IV-38
IV.2.3 EVERY THREE YEARS________________________________________________________ IV-38
IV.3 CORRECTIVE ___________________________________________________________________ IV-39
IV.3.1 MOTHER BOARD FUSES______________________________________________________ IV-39
IV.3.1.1 In front of the CCR ________________________________________________________ IV-40
IV.3.1.2 At the rear of the CCR______________________________________________________ IV-41
IV.3.2 FAULT DIAGNOSIS ___________________________________________________________ IV-42
IV.3.2.1 LV power fault: ___________________________________________________________ IV-42
IV.3.2.2 “Open Circuit” fault: ________________________________________________________ IV-42
IV.3.2.3 “Overcurrent” fault: ________________________________________________________ IV-43
IV.3.2.4 Other faults ______________________________________________________________ IV-44
IV.4 SPARE PARTS LIST _____________________________________________________________ IV-46
VAPPENDIX A: DIAGRAM______________________________________________ V-48

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ABBREVIATIONS
Abbreviation
Definition
A
Ampere
AC
Alternating Current
B
Brightness
CCR
Constant Current Regulator
DC
Direct Current
HV
High Voltage
IT
Isolation Transformer
LFD
Lamp Fault Detector
LV
Low Voltage
OO
Out of order
V
Volt
VA
Volt-Ampere

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I DESCRIPTION
I.1 OVERVIEW
DIAM3200 series CCRs are stackable fully static devices controlled by four Igbts (alternative dimmer). They
are designed to maintain a constant, pre-displayed and adjustable output current independently from the load
and power supply fluctuations.
Unlike the thyristors CCR, the power factor measured at the input of the CCR is the load power factor any of
output level current (all brightness).
They are intended to offer a low voltage device, thus ensuring that voltage will not exeed 1000V on either
side of the CCR.
An USB front socket allows the connection of a portable computer for parameter setting, this setting being
possible without live voltage. However, this link is not a hardened industrial link, such as the JBus, Ethernet or
Interbus communication ports of the CCR: all precautions must be taken not to introduce electrostatic or
electrical disturbances, which could disrupt the operation of the CCR, (using ESD protections).
These devices are specifically designed for airfield lighting on runways, taxiways, aprons. They meet IEC
and international standards.
In order to do this, they use an adapted triggering and regulation mechanism that is not affected by external
interference and does not emit measurable interference in the Aviation Band between 100 and 400 MHz.
This type of regulator uses natural air-cooling. The output current remains constant with an accuracy of +/-
100mA for mains voltage fluctuations of +/-10% (IEC type). At the rated load and the rated or higher voltage,
accuracy of regulation is maintained for all load between 0 and 100%, and for up to 30% of transformers with
open secondary. The output power of the regulator can be adjusted to the load by means of transformers taps,
by steps of 25%.
Here are some of its advantages:
Flexibility of use :
The alphanumeric display and menu type keyboard allow the CCR to be configured without connection
with a computer.
Regulation is fully digital which enables parameters to be simply modified for a particular load.
Emergency and warning messages are clearly displayed.
Simplicity:
CCR type regulators have a very simplified architecture both for the electronic control unit and the LV
and HV power parts.
No load tapped setting.
Construction:
It has been optimised to keep the number and variety of spare parts to a strict minimum. The device is
made up of modular sub-assemblies.
They can be stacked up to 3 CCRs one on top of the other.
Standards:
ICAO: Airport design manual, part 5
CENELEC: prENV 50231
FAA: AC150/5345-10 L828 & L829
AENA: PPT02-05/13 (2013)
IEC: 61822 (CCRs), 61821 (Maintenance)

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I.2 MECHANICAL
DESCRIPTION
I.2.1 DESCRIPTION
Each CCR is housed in a cabinet fitted with removable lifting rings. The frame has two distinct parts: a control
part (in front) and a power compartment (at the back).
The Control part of the CCR contains all the components connected to the power supply with, for example,
the mother board and associated driver boards, the master switch, the LV breaker and connection
terminals. It is located after opening the front door. The main electronic circuit board and the EFD board are
fitted to the front door of the cabinet. All these parts are accessible from the front of the CCR.
The Power part, situated at the back of the CCR, contains all the components connected to the output loop
such as the power transformer and the lightning arrestors (option). The power board is located on the rear
door.
The LV, loop connections are connected at the rear of the CCR. The remote control is connected in front of
the CCR.
All these components are easily accessible from the front, or the back of the cabinet.
I.2.2 GENERAL MECHANICAL FEATURES
All regulator’s component are contained in the same cabinet. Cabinets are provided with lifting rings and can be
located side by side. Up to 3 units can be stacked.
Dimensions for 1 CCR: 530mm Wide x 730mm Deep x 550mm High (+130mm for rollers)
Dimensions for 2 CCR: 530mm Wide x 730mm Deep x 1100mm High (+130mm for rollers)
Dimensions for 3 CCR: 530mm Wide x 730mm Deep x 1650mm High (+130mm for rollers)
Protection Index for the Casing: IP 20.
Usage: Ambient temperature from 0°C (IEC type) to +50°C with maximum relative humidity of 95%.
Natural air cooling.
Three units can be stacked, in order to save floor space.
Weight : (Can be modified according options)
1 unit 2.5kVA : 115kg
I.2.3 STORAGE CONDITIONS
The components are designed to be stored in a dry, airy location, sheltered from rain, water discharges
and chemical agents. We must be consulted if the components are to be stored outside, or in an ambient
temperature out of the range -40°C/+50°C.

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I.2.4 DIMENSIONS

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Stacked CCRs :

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I.3 ELECTRICAL
DESCRIPTION
I.3.1 BLOCK DIAGRAMS
See paragraph I.5 for the device operating description
I.3.1.1 Overview:
I.3.2 GENERAL CIRCUIT DIAGRAMS
SEE: APPENDIX A: DIAGRAM

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I.3.3 GENERAL ELECTRICAL FEATURES
Power supply voltage:
Single phase: 220, 230, 240, 380, 400 or 415 Vac, +/-10% (IEC), 50/60Hz.
Maximum rated current: 6.6 A
Number of Brightness Levels: maximum 8, adjustable.
Heating Brightness (“Black current”):
The CCR can produce “heating” level brightness at low current (1.8A preferred), which is used to
remove condensation from the interior of the lamp lenses without lighting up their bulb. The symbol for
local setting is ‘B0’.
Remote Control: serial network, Ethernet (Modbus/TCP), souriau connectors
Output power: 1KVA, 2.5KVA
Power factor: > 98% (resistive load)
Efficiency : > 80% at nominal voltage and rated resistive load.
Output Current Regulation:
Better than 100mA under the following conditions: Power supply voltage –10/+10%, Load: from 0 to
100%
Protection:
The electronic circuitry is protected against fluctuations by the use of a Hall effect sensor for current
measurement. Electronic board manages all overcurrent, open circuit or mains under/over voltage.
LV Protection:
A circuit breaker for power and “glass” fuses on the circuit boards provide LV protection for electronic
control.
Lightning arrestors :
These regulators can be provided with output lightning arrestors (Option)

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I.4 INSTRUCTIONS FOR USE
I.4.1 USER INTERFACE
Operating mode:
Stop mode :
Preferred information displayed: they can be changed by a long press on the “STOP” key, meanwhile the CCR
is in Stop mode. The choice can be :
Output current Io –Brightness state Bx (as seen in examples below and above)
Output current Io –Output power Po (in kVA)
Output current Io –Output voltage Uo
Local mode :
Access is given to B+ and B-, in order to increase / decrease the brightness step.
Remote control mode :
“Auto” is highlighted, in order to indicate the current state.
Brightness selection in local mode:
Decrease brightness in local mode Increase brightness in local mode
Menus:
Access to menu
Keys used to navigate in the menus
Io:0.00A STOP
stop local auto menu
Io:0.00A STOP
stop local auto menu
Io:6.60A <B5>
stop B- B+ menu
Io:5.20A <B4>
stop local auto menu
Io:6.60A <B5>
stop B- B+ menu
Monitoring
esc OK

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Alarms and Warnings:
Alarm : (the CCR failed to supply the load); for example, the CCR is stopped by a loop open circuit :
Cancel fault(s)
Warning : (the CCR doesn’t stop; warning is only indicative); It is the case for EFD and LFD faults.
Alphanumeric display:
VFD display (16 x 140 pts) : upper text provide data information, and lower text the key definition.
Screen saver : The brightness decreases automatically or turn off after one hour if the keyboard is not used.
Turns on again instantly when a key is pressed. (Function user-definable)
Rx: indicator Data reception on ETHERNET connection
Tx: indicator Data transmission on ETHERNET connection
Rx Tx
I.4.2 CONTROL
The device is controlled by mean of a 4 buttons on the keypad which allows to change the operating mode:
“Stop” – Manual or “Local” mode – Remote or “Auto” control mode.
Stop mode:
In that mode, “Stop” is highlighted. The CCR stops, whatever the current brightness orders (remote control or
local selection).
Menus can then be accessed.
Local mode:
In that mode appears brightness controls : The brightness is chosen by pressing buttons B- and B+ (from B0 to
B7 maximum, according to the number of brightness levels configured).
Remote control mode:
In that mode, “Auto” is highlighted. Operation of the CCR is controlled the serial network.
See paragraph I.5.2 to adjust brightness current and protection levels.
ALARM: I<<Open Cir.
reset
Io:0.00A STOP
stop local auto menu
Io:6.60A <B5>
stop B- B+ menu
Io:0.00A <-->
stop local auto menu
Io:5.20A <B4>
stop local auto menu

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I.4.3 LOCAL INFORMATION FEEDBACK
Alphanumeric display:
The display shows the RMS current flowing in the loop and the selected brightness (preferably).
In the “Monitoring” menu, the following information is shown:
Uo: RMS output voltage in Vrms
Po: RMS output power in KVA
Ui: Mains power supply voltage in Vrms
If option “LFD” is activated: Number of burnt lamps
If option “Time meters” is activated: The operating time (powered on and for each brightness) in Hours
Warning:
WARNING is an indicative message, which does not change the regulation function, and supply function in
connection with the load. (Except for mains warning)
If any warning have been detected, the following message(s) can be shown on the display:
With the LFD option (“Burnt lamps”) :
“Level 1 Burnt lamps” (The current number of burnt lamps is greater than level 1)
“Level 2 Burnt lamps” (The current number of burnt lamps is greater than level 2)
Mains power supply outside limits (Input voltage lower or greater than +/-10%)
Regulation outside limits (as “error regulation” programmed values)
Fault:
ALARM represents a major fault of the CCR or due to an external event, which have stopped the CCR (in order
to protect itself or the lighting loop).
In case of fault or damage, the display shows that the CCR stopped and that one or more faults have been
detected. The following message(s) are shown on the display :
Overcurrent Level 1 (after a trial to restart, the CCR cannot contain the output current which had reach
the 1st level as programmed)
Overcurrent Level 2 (ditto, for 2nd level)
Overcurrent Level 3 (ditto, for 3rd level)
Peak Overcurrent (ditto, for a 4th level, not configurable)
Open circuit (the CCR detected an output current lower and during a greater time than the programmed
parameters)
In order to re-start (after having fixed the fault), cancel the ALARM pressing the RESET key.
I.4.4 REMOTE INFORMATION FEEDBACK
RS485/RS422 Jbus link is fitted in standard.
One supplementary RS485/RS422 Jbus link can be provided in option.
One or two Insulated ETHERNET link can be provided in option.
Multiwire remote control (SOURIAU CONNECTORS) can be provided in option.
See II.2.for more details.
See the JBUS table in the Erreur ! Source du renvoi introuvable., for more details.

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I.4.1 CONFIGURATION SOFTWARE UTILITY
A software has been developed to set all parameters in the CCR. This software named ALIZE4100 can be
download using the following link: http://www.augier.com/soft/ALIZE4100.exe

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I.5 OPERATION
The “Parameter Access” function must be activated before changing parameters, in order to
avoid unwanted changes.
Pressing the menu touch, the display shows:
then scroll through the top-level menu items using the and keys. When the “Options” item is shown
like:
press OK to go into the “Options” menu, then scroll through the items until the “Param. access: NO” item is
displayed:
Press modif in order to modify the parameter. When the "NO" displayed blinks, it is possible to change the
parameter : press <or >to in order to change “NO” to “YES” :
Save the modification by pressing OK .
Press esc twice to go back to the initial state.
ALL PARAMETERS ARE MODIFIED USING THE SAME PROCEDURE.
Monitoring
esc OK
Options
esc OK
Param. access: No
esc modif
Param. access: Yes
esc OK

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I.5.1 CONFIGURATION
The “Configuration” menu is used to define the basic parameters of the CCR (for example when replacing the
main board):
Rated mains voltage in Vrms: 240
Rated power in KW : 2.5
Number of brightness (Including B0): from 1 to 8
Mains frequency in Hz: 50
IEC type
I.5.2 SETTING
The “Setting” menu is used to assign values of current to brightness levels B0 to B7.
Minimum value = 1 Arms
Maximum value = 6.8 Arms
I.5.2.1 Current range:
The “Regulation Error” warning is triggered if the measured current is outside the ranges defined for each
setting B0 to B7.
Each range is automatically calculated when a setting is changed (as described below) in the following way:
Minimum value = Setting –100mA
Maximum value = Setting + 100mA
Nevertheless it is possible to set two limits of the current range manually using the “Current range”menu.
I.5.3 PROTECTIONS
I.5.3.1 LV power monitoring:
Mains voltage
Duration
CCR status
Ui < 75% of rated voltage
0s
CCR stops (Power supply Warning)
Ui > 130% of rated voltage
0s
CCR stops (Power supply warning)
Ui < 85% of rated voltage
60s
CCR stops (Power supply warning)
Ui > 120% of rated voltage
60s
CCR stops (Power supply warning)
90% < Ui < 110% of rated voltage
0s
CCR automatically restarts
I.5.3.2 “Open circuit”:
Open Circuit Protection is activated if the output current goes below a defined value (I level OC) for a
defined period (Duration OC). The CCR stops instantly, and the display shows the message “Open Circuit”.
Setting I level OC and Duration OC:
Go into the menu “Alarms and Warnings” then “Open Circuit”.