OCEM AUGIER energy DIAM3100 Series Maintenance and service guide

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
DIAM3100
Single-phase Compact SCR-type
Constant Current Regulator
Compliance with standards:
ICAO Aerodrom design manual, part 5
IEC (61822)
60 21562 Diam 3100
Installation & maintenance

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RECORD OF CHANGES
Rev.
Pages
Description
From S/N
By
App.
Date
1.0
First issue
ED
RG
30/11/12
1.1
New codification
>2018
RG
RG
20/02/18
1.2
New logo
RG
RG
23/05/18

DIAM3100©2012 AUGIER SA.
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WARRANTIES
Guarantee
AUGIER’s goods are guaranteed for one year from delivery date on the signed delivery note, and are
guaranteed to be free from defects in materials used, design and manufacture.
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
•If these are repaired in AUGIER’s factory;
•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-11
I.1 OVERVIEW ______________________________________________________________________ I-11
I.2 MECHANICAL DESCRIPTION_______________________________________________________ I-12
I.2.1 DESCRIPTION________________________________________________________________ I-12
I.2.2 GENERAL MECHANICAL FEATURES _____________________________________________ I-12
I.2.3 STORAGE CONDITIONS _______________________________________________________ I-12
I.2.4 DIMENSIONS_________________________________________________________________ I-13
I.3 ELECTRICAL DESCRIPTION _______________________________________________________ I-15
I.3.1 BLOCK DIAGRAMS____________________________________________________________ I-15
I.3.1.1 Overview: __________________________________________________________________ I-15
I.3.1.2 Electronic: __________________________________________________________________ I-15
I.3.2 GENERAL CIRCUIT DIAGRAMS _________________________________________________ I-15
I.3.3 GENERAL ELECTRICAL FEATURES______________________________________________ I-16
I.4 INSTRUCTIONS FOR USE__________________________________________________________ I-17
I.4.1 USER INTERFACE ____________________________________________________________ I-17
I.4.2 CONTROL ___________________________________________________________________ I-18
I.4.3 LOCAL INFORMATION FEEDBACK_______________________________________________ I-19
I.4.4 REMOTE INFORMATION FEEDBACK _____________________________________________ I-19
I.4.1 CONFIGURATION SOFTWARE UTILITY ___________________________________________ I-20
I.5 OPERATION _____________________________________________________________________ I-21
I.5.1 CONFIGURATION _____________________________________________________________ I-22
I.5.2 SETTING ____________________________________________________________________ I-22
I.5.2.1 Current range:_______________________________________________________________ I-22
I.5.3 PROTECTIONS _______________________________________________________________ I-22
I.5.3.1 LV power monitoring: _________________________________________________________ I-22
I.5.3.2 “Open circuit”: _______________________________________________________________ I-22
I.5.3.3 “Overcurrent”: _______________________________________________________________ I-23
I.5.3.4 Cancelling “Open circuit” and “Overcurrent” faults: __________________________________ I-23
I.5.4 AUTOMATIC OPERATION:______________________________________________________ I-23
I.6 SUB-ASSEMBLIES________________________________________________________________ I-24
I.6.1 LOAD ADAPTATION ___________________________________________________________ I-24
I.6.1.1 Adaptation to load: ___________________________________________________________ I-24
I.6.1.2 Automatic load plate position computation: ________________________________________ I-24

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I.7 OPTIONS________________________________________________________________________ I-24
I.7.1 EARTH FAULT DETECTOR (EFD) ________________________________________________ I-24
I.7.2 CUT OUT AND EARTHING PLATE________________________________________________ I-25
I.7.2.1 Normal position :_____________________________________________________________ I-25
I.7.2.2 Safety position: ______________________________________________________________ I-25
I.7.3 OUTPUT LIGHTING ARRESTORS________________________________________________ I-26
I.7.4 CASTERS____________________________________________________________________ I-26
I.7.5 BURNT LAMP DETECTION: _____________________________________________________ I-26
I.7.6 WIG WAG____________________________________________________________________ I-27
II INSTALLATION _____________________________________________________ II-29
II.1 PREPARATION___________________________________________________________________ II-29
II.1.1 EQUIPMENT RECEPTION ______________________________________________________ II-29
II.1.1.1 Equipment delivered:________________________________________________________ II-29
II.1.1.2 Checking the equipment:_____________________________________________________ II-29
II.1.2 TRANSPORTATION ___________________________________________________________ II-29
II.1.3 DEVICE LOCATION____________________________________________________________ II-30
II.1.4 STACKING DEVICES __________________________________________________________ II-30
II.1.5 CHECKING THE INSTALLATION _________________________________________________ II-31
II.1.5.1 Single phase power supply : __________________________________________________ II-31
II.1.5.2 LV Protection :_____________________________________________________________ II-31
II.1.5.3 Lighting loop :_____________________________________________________________ II-31
II.1.5.4 Control by remote control : ___________________________________________________ II-31
II.2 CONNECTIONS __________________________________________________________________ II-32
II.2.1 POWER AND EARTH __________________________________________________________ II-32
II.2.1.1 LV supply: ________________________________________________________________ II-32
II.2.1.2 Earthing__________________________________________________________________ II-32
II.2.1.3 Lighting loop:______________________________________________________________ II-33
II.2.2 REMOTE CONTROL CONFIGURATION ___________________________________________ II-34
II.2.2.1 Connectors:_______________________________________________________________ II-34
II.2.2.1 Remote control possibilities: __________________________________________________ II-34
II.2.2.1 RS485/RS422 JBUS link: ____________________________________________________ II-35
II.2.2.2 Ethernet link: ______________________________________________________________ II-37
II.2.2.1 SOURIAU multiwire remote control with 20 to 60Vdc control supply ___________________ II-38
II.2.2.1.1 Control (20 to 60 Vdc only) : __________________________________________________ II-38
II.2.2.1.2 Monitoring (dry contacts): ____________________________________________________ II-38
II.2.2.1.3 Wiring remote control voltage configuration ______________________________________ II-39
II.2.2.2 Circuit selector: ____________________________________________________________ II-40
II.3 ADJUSTING THE CCR_____________________________________________________________ II-41
II.3.1 ADAPTATION TO LOAD ________________________________________________________ II-41
II.3.2 PARAMETER MODIFICATION ___________________________________________________ II-42
II.3.2.1 Preferred configuration values: ________________________________________________ II-42
II.3.2.2 Brightness values:__________________________________________________________ II-43
II.3.2.3 Value of “Open Circuit” protection level: _________________________________________ II-43
II.3.2.4 Value of “Overcurrent” protection levels:_________________________________________ II-43

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III COMMISSIONING__________________________________________________III-44
III.1 PROCEDURE ___________________________________________________________________ III-44
III.2 TESTS _________________________________________________________________________ III-45
III.2.1 SHORT-CIRCUIT TESTS_______________________________________________________ III-45
III.2.2 OVERLOAD TESTS___________________________________________________________ III-45
III.2.3 OPEN-CIRCUIT TEST _________________________________________________________ III-45
IV MAINTENANCE __________________________________________________ IV-46
IV.1 FORMALISATION________________________________________________________________ IV-46
IV.2 PREVENTIVE ___________________________________________________________________ IV-46
IV.2.1 FIRST MONTHS______________________________________________________________ IV-46
IV.2.2 ANNUAL PROCEDURE________________________________________________________ IV-46
IV.2.3 EVERY THREE YEARS________________________________________________________ IV-46
IV.3 CORRECTIVE ___________________________________________________________________ IV-47
IV.3.1 COMPONENT LAYOUT________________________________________________________ IV-47
IV.3.1.1 Door components _________________________________________________________ IV-47
IV.3.1.2 LV components ___________________________________________________________ IV-48
IV.3.1.3 HV components___________________________________________________________ IV-48
IV.3.2 FAULT DIAGNOSIS ___________________________________________________________ IV-49
IV.3.2.1 LV power fault: ___________________________________________________________ IV-49
IV.3.2.2 “Open Circuit” fault: ________________________________________________________ IV-49
IV.3.2.3 “Overcurrent” fault: ________________________________________________________ IV-50
IV.3.2.4 Other faults ______________________________________________________________ IV-51
IV.4 VERIFICATION PROCEDURES_____________________________________________________ IV-53
IV.4.1 THYRISTORS _______________________________________________________________ IV-53
IV.5 SPARE PARTS LIST _____________________________________________________________ IV-54
VAPPENDIX A: DIAGRAM______________________________________________ V-56
VI APPENDIX B: JBUS TABLE ________________________________________ VI-57
VII APPENDIX C: PART NUMBER IDENTIFICATION (OLD CODE < 2018) ______ VII-66
VIII APPENDIX C: PART NUMBER IDENTIFICATION (NEW CODE > 2018) _____ VIII-67

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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
DIAM3100 series CCRs are stackable fully static devices controlled by two thyristors (anti-parallel mounting
type dimmer). They are designed to maintain a constant, pre-displayed and adjustable output current
independently from the load and power supply fluctuations.
They are intended to offer a low voltage device, thus ensuring that voltage will not exeed 1000V on either
side of the CCR.
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.
•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
▪IEC : 61822 (concern the present manual)

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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 thyristors and associated driver boards, the master switch, the LV fuses 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 tapping terminals are also
accessible from this side.
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 : 500mm Wide x 700mm Deep x 550mm High (+130mm for rollers)
•Protection Index for the Casing: IP 20.
•Usage: Ambient temperature from -20°C (IEC type) to +55°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 6.5kVA : 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/+55°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.3.1.2 Electronic:
DSP FRONT BOARD
Keyboard Display
INTERFACE REAR BOARD
RS485/
RS422 MODBUS TCP Wires control & monitoring 4-20mA outputs
CAN Bus
Measurement
board
Output current
Output voltage
Earth Fault
Detect board
Main power supply
208V~ to 480V~
Autotransformer
Output 230V~
230V~
Control thyristors
board
I.3.2 GENERAL CIRCUIT DIAGRAMS
See APPENDIX A: DIAGRAM
Input
circuits
Thyristors
dimmer
LV/HV
Transformer
Output
circuits
Control &
Monitoring
Measuring
Board
Interfaces

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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 Hz 5%.
•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, 4KVA, 5KVA or 6.5 KVA.
•Power factor: > 90%
•Efficiency : > 90% at nominal voltage and rated resistive load.
•Output Current Regulation:
Better than 100mA under the following conditions: Power supply voltage –10/+10%, Frequency: 5%,
Load: from 0 to 100%
•Load adaptation:
The output transformer is equipped with adjustment taps in order to adapt the rated output voltage of
the CCR to the present load. Six terminals allow load adaptation with steps of 12.5%.
•Protection:
The electronic circuitry is protected against fluctuations by the use of a Hall effect sensor for current
measurement, and fibre optics for thyristors control. Electronic board manages all overcurrent, open
circuit or mains under/over voltage.
•LV Protection:
A set of power fuses, a set of fuses for auxiliaries power supply, and “glass” fuses on the circuit boards
provide LV protection.
•Lightning arrestors :
These regulators are provided with output lightning arrestors.

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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
•Load plate tap value from 0 to 100% (0 to 4/4 by increments of 1/4)
•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 appendix b: jbus table, 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