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ADB Safegate IDM 8000, User Manual

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1.1.3 Material Handling Precautions: Storage

CAUTION

Improper Storage

Store this equipment properly

• If equipment is to be stored prior to installation, it must be protected from the weather and kept free

of condensation and dust.

Failure to follow this instruction can result in equipment damage

1.1.4 Material Handling: Heavy Equipment

DANGER

Unstable load

Use caution when moving heavy equipment

• Use extreme care when moving heavy equipment.
• Verify that the moving equipment is rated to handle the weight.
• When removing equipment from a shipping pallet, carefully balance and secure it using a safety

strap.

Failure to follow this instruction can result in death, serious injury, or equipment damage

1.1.5 Operation Safety

CAUTION

Improper Operation

Do Not Operate this equipment other than as specified by the manufacturer

• Only qualified personnel, physically capable of operating the equipment and with no impairments in

their judgment or reaction times, should operate this equipment.

• Read all system component manuals before operating this equipment. A thorough understanding of

system components and their operation will help you operate the system safely and efficiently.

• Before starting this equipment, check all safety interlocks, fire-detection systems, and protective

devices such as panels and covers. Make sure all devices are fully functional. Do not operate the

system if these devices are not working properly. Do not deactivate or bypass automatic safety

interlocks or locked-out electrical disconnects or pneumatic valves.

• Protect equipment with safety devices as specified by applicable safety regulations.
• If safety devices must be removed for installation, install them immediately after the work is

completed and check them for proper functioning.

• Route electrical wiring along a protected path. Make sure they will not be damaged by moving

equipment.

• Never operate equipment with a known malfunction.
• Do not attempt to operate or service electrical equipment if standing water is present.
• Use this equipment only in the environments for which it is rated. Do not operate this equipment in

humid, flammable, or explosive environments unless it has been rated for safe operation in these

environments.

• Never touch exposed electrical connections on equipment while the power is ON.

Failure to follow these instructions can result in equipment damage

UM_IDM-8000, Rev. 1.7, 2021/05/06

3

Copyright 

©

 ADB Safegate, All Rights Reserved

Summary of Contents for IDM 8000

Page 1: ...IDM 8000 CCR User Manual UM_IDM 8000 Rev 1 7 2021 05 06 ...

Page 2: ......

Page 3: ... furnished ADB SAFEGATE s liability under no circumstances will exceed the contract price of goods claimed to be defective Any returns under this guarantee are to be on a transportation charges prepaid basis For products not manufactured by but sold by ADB SAFEGATE warranty is limited to that extended by the original manufacturer This is ADB SAFEGATE s sole guarantee and warranty with respect to t...

Page 4: ...propriate or incompatible with your ADB SAFEGATE equipment Allowing unskilled personnel to perform any task on or with the equipment ADB SAFEGATE BV This manual or parts thereof may not be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording nor otherwise without ADB SAFEGATE BV s prior written consent This manual could con...

Page 5: ...y Functions 11 3 2 9 Remote Control Interfaces 12 3 3 CCR functional components 12 3 3 1 General 12 3 3 2 Power Circuit 14 3 3 3 Main Transformer Efficiency and Power Factor 14 3 3 4 High Voltage Circuit 15 3 3 5 Control Unit 15 3 3 6 Serial Control Interface 16 3 3 7 Parallel control interface 17 4 0 User Interface 19 4 1 Control functions 19 4 1 1 Control functions with Operation switches 19 4 1...

Page 6: ...lation 49 5 1 General 49 5 1 1 Air conditioning 49 5 1 2 Transportation Unpacking and Storage 49 5 1 3 Moving and Handling the CCR at Site 51 5 1 4 Installation Requirements 51 5 2 Mechanical Installation 51 5 3 Electrical Installation 51 5 3 1 Mains Connection 52 5 3 2 AFL Circuit Connection 53 5 3 3 Serial Remote Control Connection 53 5 3 4 Parallel Remote Control Connection 53 5 4 Load matching...

Page 7: ... design notes AFL control system designers 81 H 0 Appendix H Modbus TCP design notes AFL control system designers 83 I 0 Appendix I Commissioning test report form 85 J 0 Appendix J Spare part list 89 K 0 Appendix K Components of electronics 93 L 0 Appendix L CCR components 95 M 0 Appendix M Output Terminals 97 M 1 Slide Switch Terminal Option 97 M 2 Terminal Taps 98 M 3 Series Cut Out SCO Option 9...

Page 8: ...IDM 8000 TABLE OF CONTENTS viii Copyright ADB Safegate All Rights Reserved ...

Page 9: ...8000 03 layout and HW settings 17 Figure 2 Control rack with display unit and control switches 19 Figure 3 Circuit selector control via display unit 20 Figure 4 Display unit 22 UM_IDM 8000 Rev 1 7 2021 05 06 ix Copyright ADB Safegate All Rights Reserved ...

Page 10: ...IDM 8000 List of Figures x Copyright ADB Safegate All Rights Reserved ...

Page 11: ...List of Tables Table 1 Air conditioning relevant values 49 Table 2 Heat dissipation for air conditioning calculation 51 UM_IDM 8000 Rev 1 7 2021 05 06 xi Copyright ADB Safegate All Rights Reserved ...

Page 12: ...IDM 8000 List of Tables xii Copyright ADB Safegate All Rights Reserved ...

Page 13: ...bserve this warning may result in personal injury death or equipment damage ARC Flash may cause blindness severe burns or death WARNING Wear personal protective equipment Failure to observe may result in serious injury WARNING Do not touch Failure to observe this warning may result in personal injury death or equipment damage CAUTION Failure to observe a caution may result in equipment damage Qual...

Page 14: ...pment with safety devices as specified by applicable safety regulations If safety devices must be removed for installation install them immediately after the work is completed and check them for proper functioning prior to returning power to the circuit Failure to follow this instruction can result in serious injury or equipment damage Additional Reference Materials Important Information IEC Inter...

Page 15: ...ion will help you operate the system safely and efficiently Before starting this equipment check all safety interlocks fire detection systems and protective devices such as panels and covers Make sure all devices are fully functional Do not operate the system if these devices are not working properly Do not deactivate or bypass automatic safety interlocks or locked out electrical disconnects or pn...

Page 16: ... contain electrostatic devices Protect from electrostatic discharge Electronic modules and components should be touched only when this is unavoidable e g soldering replacement Before touching any component of the cabinet you shall bring your body to the same potential as the cabinet by touching a conductive earthed part of the cabinet Electronic modules or components must not be brought in contact...

Page 17: ...ecommended maintenance procedures in the product manuals Do not service or adjust any equipment unless another person trained in first aid and CPR is present Connect all disconnected equipment ground cables and wires after servicing equipment Ground all conductive equipment Use only approved ADB SAFEGATE replacement parts Using unapproved parts or making unapproved modifications to equipment may v...

Page 18: ...IDM 8000 Safety 6 Copyright ADB Safegate All Rights Reserved ...

Page 19: ... with focus on safety installation and maintenance procedures For more information see www adbsafegate com Note It is very important to read this document before any work is started UM_IDM 8000 Rev 1 7 2021 05 06 7 Copyright ADB Safegate All Rights Reserved ...

Page 20: ...IDM 8000 About this Manual 8 Copyright ADB Safegate All Rights Reserved ...

Page 21: ...rovides equal brightness for all lamps due equal current in the serial loop Enables low cabling costs and transmission losses due rather low current level 6 6A Because of high voltage used with larger CCRs extra precaution must be used when working with circuits Regular maintenance is also needed to maintain proper isolation levels 3 1 3 Airfield lighting power circuit AFL circuit design guideline...

Page 22: ...umidity for long time storage 60 Altitude Max 2000 m 3 2 4 Output Current I2 All CCRs 6 6A rms Accuracy 1 under following conditions Resistive load variation 0 100 Max 30 open circuited isolation transformers of total load 50 100 of CCR rating Supply voltage 0 90 Unom 1 10 Unom Environmental conditions within above given values 3 2 5 CCR Standard Sizes and Output Voltages CCR Size kVA Nominal outp...

Page 23: ...itoring Functions Lamp fault 1 lamp up to 10 lamp faults and 2 lamps up to 30 lamps at all steps from 25 load to 100 load Max 30 of total lamp power Delay and 2 levels Earth fault value 1kohm 50Mohm or 1kohm 1Gohm delay and 2 levels VA drop delay and 2 levels Cumulative operating time monitoring for lamp life 3 2 8 Display Functions All above protective and monitoring functions plus Actual power d...

Page 24: ...e control rack All electronic units E1 size plug in cards Power circuit located at the top compartment of the CCR High voltage unit located at the lower compartment of the CCR Natural cooling is provided for all compartments no fans are used All cable entries are through the bottom plate of the CCR All components are accessible from the front Rating dimensions H W D Up to 17 5kVA 1705 495 650 From...

Page 25: ...es Remote control cable entry Output Terminal block AFL cable connection Main transformer output tapping settings Parallel remote control block Thyristor element Control unit MCU Controller unit RCS Remote control Serial unit RCP Remote control parallel unit PWR Power unit Remote control cable connection WARNING HIGH VOLTAGE COMPARTMENT UM_IDM 8000 Rev 1 7 2021 05 06 13 Copyright ADB Safegate All ...

Page 26: ...ansformer Efficiency and Power Factor The dry type not oil cooled main transformer defines the rating of the CCR Because the transformer has load tapping on the output the rating of the transformer can be reduced in order to match with the connected load Optimal load matching provides following benefits Minimizes maximum output voltage in case of open circuit or thyristor failure Efficiency of the...

Page 27: ...er is made current less in order to provide maximum lifespan for the contacts and also to avoid transients in the output circuit Note With circuit selector all circuits are connected in series and short circuited Circuits are not disconnected from the high voltage output Selection of any combination of circuits is made within the circuit selector by removing the shorts The circuit selector dielect...

Page 28: ...e cable for each CCR do not need termination Control and indication bit mode is continuous i e static Standard binary coding is used with control and indication step bits With direction changer CCRs Lamp fault LF and power drop VA alarms and displays are for the current selected direction only With circuit selector CCRs LF and VA alarms work only when all circuits are selected The CCR monitors the...

Page 29: ...0 5A 125V AC PARALLEL REMOTE CONTROL HARDWARE SETTINGS Setting Description Factor setting Allowed range Control voltage Control DC voltage selection 60V 24 48 60V DC Failsafe step One step dec Binary code bin In case of control DC voltage or cable fault failsafe control status is taken Control relays contacts are inverted with jumpers Inverted control must be given by the control system Off Any st...

Page 30: ...Control indication signals purpose depends on the Type selection See HW settings and parallel connection signal list ComF m Remote control Defines if all fault signals are summed to Com fault indication SumF or it contains only U1 f1 and T alarms SysF Parallel control interface and indication signals Appendix E Parallel control interface signal list Example connection in Appendix F Parallel remote...

Page 31: ...ote CCR in remote mode O Local CCR off 1 7 Local Step 1 7 on Direction changer control by using direction switch on the MCU unit Direction switch is enabled in the local control mode only Earth fault maintenance switch Lamp fault B reset control by using maintenance switch on the MCU unit When set to on with earth fault tripping mode is activated on level B Figure 2 Control rack with display unit ...

Page 32: ...ite text on dark background indicates that the circuit is selected and vice verse 4 1 3 Led Indicators On led on the MCU green Status Meaning Off CCR is off On CCR is on step 1 7 Fault led on the MCU red Status Meaning Off CCR is ok On CPU stopped CCR system fault Blink Fault monitoring protection operated CCR offline serial control only Monitoring protection On led green on the power unit is on w...

Page 33: ...splay window consists of header 2 function dependent data fields 2 permanent status fields and 5 function dependent soft menu texts UM_IDM 8000 Rev 1 7 2021 05 06 21 Copyright ADB Safegate All Rights Reserved ...

Page 34: ...Set Display control F1 F2 F3 F4 F5 Header Data fields 1 2 Status fields 1 2 Soft menu texts Soft menu buttons Display component Description Remarks Header Describes the function of current display IDM 8000 User Interface 22 Copyright ADB Safegate All Rights Reserved ...

Page 35: ...og Fault status text Description Ok CCR ok no faults Freq A Low frequency trip Freq B Low frequency warning Freq A High frequency trip Freq B High frequency warning U1 A Low input voltage trip U1 B Low input voltage warning U1 A High input voltage trip U1 B High input voltage warning Temp A1 High temperature trip Temp B1 High temperature warning Cur fail Current failure VAdropA VA drop alarm level...

Page 36: ...the Sys settings Factory setting for password protection is not in use Off 4 2 2 The set menu is divided into 3 sub menus Cal Calibrating functions Prot Protective functions monitoring functions which are able to trip the CCR Set Setting functions other monitoring and system configuration functions 4 2 3 Commonly used symbols in all display menus More Brings more equal level displays Up Brings you...

Page 37: ...esolution 0 01A Output voltage RMS Resolution 1V Input values Input voltage V Resolution 1V Input frequency Resolution 1Hz Lamp fault Qty of lamp faults Resolution 1 lamp Off when CCR off of total lamps Resolution 1 Lf when CCR off For correct display no of lamps must be set from system settings UM_IDM 8000 Rev 1 7 2021 05 06 25 Copyright ADB Safegate All Rights Reserved ...

Page 38: ...s Date dd mm yyyy Scroll info CCR no Circuit direction Access to scroll info displays Up to go back to main menu View scroll info displays Header function Data 1 Data 2 Remarks Fault log A acknowledged Fault number 1 10 1 oldest fault Fault text Next Next fault Prev Previous fault Ackn Acknowledge Time Fault occurrence time and date Operating hours Elapsed hours Step no 01 07 Total Cstep 01 07 Cto...

Page 39: ...e asked for a password before entering the SETTINGS display For more information see selecting password protection in the section 2 6 8 System settings 4 4 1 Output Current I2 and Voltage U2 Calibration Header function Data 1 Data 2 Remarks I2 U2 calibration I2 A U2 V I2 Cal U2 Cal Next U2 cal Next I2 cal adjust UM_IDM 8000 Rev 1 7 2021 05 06 27 Copyright ADB Safegate All Rights Reserved ...

Page 40: ...dings are equal if necessary repeat steps 4 6 Note I2 calibration affects also to VA drop function Calibration with short circuit load U2 0 is not allowed Calibration of more than 10 from factory defaults is not allowed ERR indication in display U2 calibration 1 Connect external calibrated RMS V meter Min 30V accuracy better than 1 to the voltage transformer test outputs located on the right side ...

Page 41: ...d make in order to achieve the full accuracy of the lamp fault monitoring function 1 Go to lamp fault calibration select Set Cal Lf 1 If necessary adjust Lflim value factory setting 2 80A for typical trafos then select Next 1 Start the CCR and control from Datafield 1 the measurement value to be below 0 8 on all steps To adjust the value change the Lflim value between 1 75A and 3 50A re check the ...

Page 42: ... function Data 1 Data 2 Remarks Earth fault cal Measuring value V Open Open load circuit Next Measuring value V Shrt a Short terminal a Set Next 1G ohm range Header function Data 1 Data 2 Remarks Earth fault cal Measuring value V Short Short terminal a Set Next Measuring value V A 33M Test resistor 33M to a Set Next Measuring value V Open B Open circuit Set Next Measuring value V Open Open circuit...

Page 43: ...tarting of the CCR If failsafe steps are used remove the remote control card for calibration 1 Turn the CCR operation switch to remote position EF monitoring on but the CCR off 1 Go to Earth fault cal by selecting Set Cal Ef 1 Wait 2min until the measurement value has stabilised or the w letter from the value has disappeared The shorted value should be between 3 60V and 4 00V Select Set Next 1 Mov...

Page 44: ...ses shutdown of the CCR output hereafter called tripping and level B warning warning indication Delay Delay time after which the protection operates Nom Nominal value used for input voltage and frequency protections which are normally set with the dip switch on the mother board and are critical for correct operation and lifespan of the CCR Threshold levels A which trip the CCR are automatically se...

Page 45: ...e to hold the output current above the open circuit threshold level If the load power factor is highly capacitive the capacitive output current monitor will switch off the CCR when selected and indicate an open circuit Detection time for capacitive output current is one second Header function Data 1 Data 2 Fact set Allowed range Open circuit prot Threshold level Level 1 5A 0 6 60A in 0 05 steps De...

Page 46: ...t the threshold level below the actual output current value and make sure that the CCR trips in due time 4 5 3 Over Current Protection Fast Reset The function protects the lamps in the AFL circuit and also the CCR for fast over currents caused by load changes If the output current exceeds 125 of nominal maximum intensity the CCR will disable the output within 10ms for at least 40 ms and restores o...

Page 47: ...value is displayed select Next 1 If necessary adjust levels Lb and Lb with select Set and then select Next 1 If necessary adjust delay time as in step 3 Operational test Change the U1 calibration in order to go beyond threshold limits L a or L b and make sure that the required function operates in due time 4 5 5 Input Frequency and Temperature Protection Frequency function protects the lamps in th...

Page 48: ...Temp thresh Level T L 80 C 0 95 C in 1 C steps BTemp delay time T Delay 10s 0 1 10s in 0 1s steps Can be set from display but dipswitch settings overruns it at power up F a and F a automatically derived from nominal value Setting sequence 1 Go to freq temp protection by selecting Set Prot F T 1 If necessary adjust freq nominal value with select Set and then select Next 1 If necessary adjust thresh...

Page 49: ... and menu tree If password protection is selected from system settings you are asked for a password before entering the SETTINGS display For more information see selecting password protection in 2 6 8 System settings UM_IDM 8000 Rev 1 7 2021 05 06 37 Copyright ADB Safegate All Rights Reserved ...

Page 50: ...A 1 00 6 60A in 0 05A steps I2 Conf CF Accept current step values and recalculate current fault alarm levels Setting sequence 1 Go to output current settings by selecting Set Set Out 1 If necessary adjust step 1 level with select Set and then select Next 1 Repeat step 2 until all 7 steps are set 1 Select Set for Conf CF If you want to update the current fault monitoring values now If you want to t...

Page 51: ... earth fault maintenance switch function is enabled i e selected on from the system settings and the maintenance switch is on level B causes tripping of the CCR and is therefore a protective function Header function Data 1 Data 2 Fact set Allowed range Earth fault set Isolation level Level A 0 1M ohm 0 01 2 50Mohm in 0 01Mohm steps Isolation level Level B 1M ohm 0 1 25Mohm in 0 1Mohm steps Delay t...

Page 52: ... drop and lamp fault alarms required when the CCR is used with addressable light control monitoring system Setting sequence 1 Go to VA drop setting by selecting Set Set VAd 1 If necessary select operation mode with select Set and then select Next 1 If necessary adjust levels A and B as in step 2 These levels are used for both directions if the CCR is with direction changer 1 If necessary adjust de...

Page 53: ... the output current step setting e g step 3 to be out of the current fault tolerance e g 0 2A and do not update current fault limits see paragraph output current step setting update CF Make sure that the alarm is generated in due time Finally set the output current level back to its original setting 4 6 6 Time and date setting Time and date settings are used as time labels in the fault log and als...

Page 54: ... board whenever the CCR is powered up Dec code 0 enables setting from display e g for protection testing purposes These factory settings enable the MCU card to automatically detect the basic settings of the CCR and need only to be changed checked when modifying the CCR type or replacing a new mother board IDM 8000 User Interface 42 Copyright ADB Safegate All Rights Reserved ...

Page 55: ... 0 0 1 CCR with circuit selector CS 3 4 1 0 1 CCR with circuit selector CS 4 5 0 1 1 CCR with circuit selector CS 5 6 1 1 1 CCR with circuit selector CS 6 7 7 8 Remote control Sw7 Sw8 Setting View value D 0 0 Parallel serial auto detection 0 1 0 Serial 1 0 1 Parallel start in use 2 1 1 Redundant serial 3 Defines A protection levels No auto detection on redundant or start in use The settings are ma...

Page 56: ... output voltage calibration and scaling size dependent measurement data for remote monitoring CCR type display only normally set from HW system settings Can be set only if dip switch code enables setting from display M switch defines if the maintenance switch is used for earth fault maintenance or Lamp fault B reset FAA monitor reset function or is not used at all Monitor defines the indication op...

Page 57: ... value an alarm LAMP_AGE will be given to local indication Also the ComF indication is given if selected as SumF indication For more information see 2 6 9 Remote control settings The indication is reset by resetting the operating hours counter from the View Hrs menu Also the indication is reset automatically if the lamp life parameter is increased is this menu Service date Used to memorize date of...

Page 58: ... control status is Off else continues with selected control stat ContHB Continues with selected control status Heart beat signal is used for bus failure detection Fs HB Selects the failsafe step 0 7 failsafe Heart beat signal is used for bus failure detection Fs of HB Selects the failsafe step only if control status is Off else continues with selected control stat Heart beat signal is used for bus...

Page 59: ...imal setting causes minimum flickering of lights without overshooting the output current when disconnecting loads with the circuit selector Note Factory setting is minimum current with short circuit load If more than one circuit is active ERR indication is displayed Header function Data 1 Data 2 Fact set Allowed range Set Cs min current I2 A CS MIN Short Loads CS1 CS4 only one Set Min Setting sequ...

Page 60: ...ust contrast value with and select Set to confirm 1 If setting is not enough to make the contrast visible see concepts IDM 8000_troubleshooting dita 4 6 12 Language setting Display language for the header and soft key texts can be selected between Standard English characters are used Header function Data 1 Data 2 Fact set Allowed range Language set Eng Language eng Eng fin swe pol spa fra Setting ...

Page 61: ...nditioning relevant values Power Rating Heat Dissipation W 3 kVA 300 4 kVA 400 5 kVA 500 7 5 kVA 750 10 kVA 1000 12 5 kVA 1250 15 kVA 1400 17 5 kVA 1500 20 kVA 1600 25 kVA 2000 30 kVA 2400 5 1 2 Transportation Unpacking and Storage Transportation Make sure to do the following regarding transportation NOTICE Keep the CCR always in upright position during transportation and storage Protect the CCR f...

Page 62: ...1 Unpack and inspect the equipment immediately 2 Check the packing and equipment itself for damage Remember Notify the carrier if of any damages Storage Restriction Do not store the equipment for a prolonged period in its packaging Do not store the equipment in an environment which does not comply with the environmental conditions defined for its use in Environmental section NOTICE For long term s...

Page 63: ...sufficient clearances to walls and other objects This way you ensure proper ventilation and smooth workflows in case of operation maintenance tasks Table 2 Heat dissipation for air conditioning calculation Version Value W 3 kVA 300 W 4 kVA 400 W 5 kVA 500 W 7 5 kVA 750 W 10 kVA 1000 W 12 5 kVA 1250 W 15 kVA 1400 W 17 5 kVA 1500 W 20 kVA 1600 W 25 kVA 2000 W 30 kVA 2400 W 5 2 Mechanical Installatio...

Page 64: ...nded minimum cross section of supply copper wire from LV board to CCR Recommended minimum cross section of earth copper wire from LV board to CCR 3 kVA 230 VAC 2 pole 20 A c curve 2 pole 25 A c curve 6 mm2 4 mm2 4 kVA 230 VAC 2 pole 25 A c curve 2 pole 35 A c curve 10 mm2 6 mm2 5 kVA 230 VAC 2 pole 40 A c curve 2 pole 50 A c curve 10 mm2 6 mm2 400 VAC 2 pole 20 A c curve 2 pole 25 A c curve 6mm2 4...

Page 65: ... there are termination switches on the serial control cards too It is recommended to use the termination in the cable connector to be able to replace any unit without affecting the bus operation Make sure that the node address setting conforms to the bus configuration 5 3 4 Parallel Remote Control Connection Connect the parallel control cable directly on the D37 connector located on the face of th...

Page 66: ...ing the CCR in local mode at step 7 with maximum load for circuit selector CCRs all circuits must be switched on The main transformer is then tapped to more accurately match the load See table on next page for instructions IDM 8000 Installation 54 Copyright ADB Safegate All Rights Reserved ...

Page 67: ...ad for the specific circuit all fixtures should be ON In the case of circuit selector CCRs all circuits should be connected and ON 1 Go to System Info press Next until TAP menu is reached 1 Make a note of the Tap info value 1 Turn the CCR OFF at main switch 1 Open the CCR door and de energize by setting the terminal outputs to either Safety Mode or Maintenance mode as described in Appendix M Outpu...

Page 68: ...ff position Open the CCR doors and set the output terminals in operating mode Safety Appendix M Output Terminals Measure continuity of the circuit between output connectors A a 2 Check the supply cable and supply circuit breaker coming to the CCR Measure the supply voltage 3 Check that the system setting on the mother board are correct Supply voltage DIP 1 2 Supply frequency DIP 3 CCR type DIP 4 6...

Page 69: ...mote control settings 5 Start the CCR with local control Check all current steps and adjust if needed 2 6 1 Output current step setting 6 Switch the CCR off and connect the output terminals to operating mode I2 cal Use RMS ammeter with accuracy of 1 or better 1 3 4 High voltage circuit Check input voltage calibration 2 4 2 Input voltage U1 calibration Check output current calibration Check output ...

Page 70: ...2 6 5 Current fault setting Check and adjust test if desired the VA drop alarm settings 2 6 4 VA Drop setting Calibrate lamp fault monitor Write down LF lim 1 74 3 50A 2 4 3 Lamp fault and VA Drop calibration 10 Check and test if desired the remote control function according to remote control manual 11 Fill up the commissioning test report in Appendix I and sign all sheets Store the diary and all ...

Page 71: ...s Check protections at least open circuit 2 5 Protective functions CT 8000 LC CT 8000 RC CT 8000 PR Calibration Output current calibration check 2 4 1 Output current I2 and voltage U2 calibration CT 8000 CA Other calibration check if desired 2 4 x Appendix I Commissioning test report form The front doors can be only opened when the main switch is in off position When the door is opened the main sw...

Page 72: ...contactors and circuit breakers Slotted 8x1 2 door and main transformer connections Pozidriv No 1 plug in units Pozidriv No 2 length 160mm mounting screws on installation plate Hexagon socket drivers 10mm for output connectors 8mm for housing Hex Key set metric for supply and main transformer in larger CCRs Torque wrench Clean compressed air for cleaning dust or dirt CCR manual for correct operati...

Page 73: ...if contrast not visible Replace MCU unit if contrast visible 2 6 11 LCD contrast setting After change of MCU control unit or LCD display unit LCD display appears shifted Press F1 and F5 simultaneously for 5 seconds Replace MCU control unit if shift does not go away U1 A or U1 A on display Check mains voltage level Check U1 calibration 2 4 2 Input voltage U1 calibration Check U1 nom setting 2 5 4 I...

Page 74: ...U2 calibration OverCu A or B on display Check over current levels and delay times 2 5 2 Over current protection Check output current calibration 2 4 1 Output current I2 and voltage U2 calibration Check thyristor controller and module Check passive filter components 1 3 2 Power circuit Temp A1 on display Check temperature values from View E T Protection level is fixed 100 C 2 3 View functions Check...

Page 75: ...orking e g by checking that other units are online Check node address and bus termination settings 1 3 6 Serial control interface Parallel interface Check remote mode settings View RCS Check control system voltage Check that control system voltage selector setting conforms to the cont syst voltage Check that failsafe step setting conforms with the control system failsafe step Check that signal mod...

Page 76: ...IDM 8000 Troubleshooting 64 Copyright ADB Safegate All Rights Reserved ...

Page 77: ... the 1st and Last units Termination can be done in following ways 1 Active terminators with guaranteed power supply are recommended to use protects against power loss of a CCR at the end of the bus 2 If active terminators are not available use the terminators in the fieldbus connectors disconnecting the connector will not affect the bus status 3 As last a resort use the termination switches on the...

Page 78: ...ine N A N A N A 3 Offline Red Offline Online N A N A N A 4 Diagnostics Red N A Ok Conf err Parm err Init err IDM 8000 Appendix A Serial communication interface Profibus DP connection 66 Copyright ADB Safegate All Rights Reserved ...

Page 79: ... binary coded with 8 dip switches on the front plate of the communication interface Note Addresses 0 and 127 cannot be used Subnet mask 255 255 255 0 default Default gateway 0 0 0 0 default no gateway set It is possible to change the default IP address 192 168 0 IAONA standard for private networks the subnet mask and default gateway address if necessary by performing the following steps Connect a ...

Page 80: ...ime data packet is transmitted Power breaks IDM 8000 equipped with single modbus TCP serial interface can manage 1s power breaks without any break on the control status When returning from longer power breaks the failsafe setting will be taken and hold until the serial interface is in online mode and starts following the control system commands The start up time varies depending on the network sta...

Page 81: ...R powered 56 8 U2 0 U2 Output voltage resol 0 8 125 U2n acc CCR size U2n Pn 6 6A digit U2n 125 eg 3 63V 3kVA CCR Lsb U2 0 9 Oc Over current alarm fast I2 1 57 U2 1 10 Uc Open circuit alarm SCO 2 58 U2 2 11 U1 A Input voltage alarm 59 U2 3 12 U1 B Input voltage warning 60 U2 4 13 Freq A Input frequency alarm 61 U2 5 14 Freq B Input freq Warning 62 U2 6 15 Temp A Thyrist temp alarm 63 U2 7 16 3 Temp...

Page 82: ...s 7 bits byte 4 and the display value can be calculated by multiplying it with the scale factor Value 127 means that the monitoring function is off Local control switch off No of lamp faults LF Byte 5 No of lamps faults 0 62 is coded with 6 bits in byte 5 Value 63 indicates that the LF monitor is off CCR off not all circuits selected I2 output current Byte 7 The range is always from 0 to 8A regard...

Page 83: ...ary coded format 1 2 5kVA 2 3kVA 3 4kVA 4 5kVA 5 7 5kVA 6 10kVA 7 12 5kVA 8 15kVA 9 17 5kVA 10 20kVA 11 25kVA and 12 30kVA Dec values Redundant duplicated interface other interface control bit status Byte 12 This information is provided for the control system to facilitate control channel interface monitoring Displays which can be calculated from the above values in the control system S2 I2 U2 App...

Page 84: ...IDM 8000 Appendix C Serial control interface signal list Profibus DP 72 Copyright ADB Safegate All Rights Reserved ...

Page 85: ... current 8A 160 digit 0 05A resol 0 6 Lsb I2 0 1 On ind b 49 I2 1 2 On ind c 50 I2 2 3 Dir 2 Circ 1 0 dir 1 1 dir 2 Circ 1 on 51 I2 3 4 Circ 2 52 I2 4 5 Circ 3 53 I2 5 6 Circ 4 54 I2 6 7 Remote Local Remote 1 55 I2 7 8 2 Pwr on CCR powered 56 8 U2 0 U2 Output voltage resol 0 8 125 U2n acc CCR size U2n Pn 6 6A digit U2n 125 eg 3 63V 3kVA CCR Lsb U2 0 9 Oc Over current alarm fast I2 1 57 U2 1 10 Uc ...

Page 86: ...rved 1 Fast I2 fast over current detection 2 SCO Optional series cut out device which opens the circuit for safe maintenance works Detailed descriptions of the numeric values EF earth fault isolation resistance Bytes 4 5 The isolation resistance value has two scaling bits code 0 1k 1 10k and 2 100k or 10M ohms in byte 5 to reduce the bits required to indicate the large scale of 1kohm 50Mohm and 1k...

Page 87: ...and can be used to automatically update these parameters in the control system Three first bits 80 82 Lsb 80 define the CCR type in binary coded format 0 normal CCR 1 direction changer 2 6 2 6 circuit selectors Dec values Four last bits 84 87 Lsb 84 define the CCR size in binary coded format 1 2 5kVA 2 3kVA 3 4kVA 4 5kVA 5 7 5kVA 6 10kVA 7 12 5kVA 8 15kVA 9 17 5kVA 10 20kVA 11 25kVA and 12 30kVA D...

Page 88: ...IDM 8000 Appendix D Serial control interface signal list Modbus TCP 76 Copyright ADB Safegate All Rights Reserved ...

Page 89: ...p ind b1 Step 2 ind Step ind b1 15 PI I3 Step3 on indication Step ind b2 Step3 ind Step ind b2 16 PI I4 Step4 on indication N A Circuit 1 on indication 17 PI I5 Step5 on indication N A Circuit 2 on indication 18 PI I6 Step6 on indication N A Circuit 3 on indication 19 PI I7 Step7 on indication N A Circuit 4 on indication Pin Group Abbrev Normal dir CCR Circuit selector CCR Dec Bin Dec Bin 20 PI I8...

Page 90: ...switch on indication or optional SCO indication 35 PI Icom1 Common for positive PI indications 36 FI Icom2 Common for alarm FI indications 37 DC Internal DC out IDM 8000 Appendix E Parallel control interface signal list 78 Copyright ADB Safegate All Rights Reserved ...

Page 91: ...lel remote control example Example of remote control with parallel interface refer to signal chart on Appendix E Parallel control interface signal list UM_IDM 8000 Rev 1 7 2021 05 06 79 Copyright ADB Safegate All Rights Reserved ...

Page 92: ...IDM 8000 Appendix F Parallel remote control example 80 Copyright ADB Safegate All Rights Reserved ...

Page 93: ...pecification 4 RTS Request to send 5 GND BUS Isolated GND for the BUS termination 6 5V BUS Isolated 5V for the bus termination 7 Not connected 8 A line Negative RxD TxD according to RS 485 specification 9 Not connected PROFIBUS DP CONFIGURATION NOTES Configuration tools Profibus DP bus must be configured with a special configuration SW tool e g Hilscher Sycon PB Gsd file A GSD file which defines p...

Page 94: ...s DP busmaster is running without connection to the host computer The failsafe Hb heartbeat bit function can be used to check the host computer connection Hb bit changes it state in max 1s intervals this functionality must be included in the control system which the CCR checks to define its online status IDM 8000 Appendix G Profibus DP design notes AFL control system designers 82 Copyright ADB Saf...

Page 95: ...e g fast normal slow of which the desired level can be selected for each slave If more than one level is used then the bandwidth calculation must be done for each scan level Unit IP address Each slave has its own unique IP address The same address which is set to the slave unit must be declared to master unit Read ref In area 0 dec 000 h This setting defines where the read data is located in the M...

Page 96: ...IDM 8000 Appendix H Modbus TCP design notes AFL control system designers 84 Copyright ADB Safegate All Rights Reserved ...

Page 97: ...TTINGS HARDWARE CT 8000 SE System motherboard settings Dip switch setting Remote control Parallel Jumper setting 1 U1 nom dip sw 2 1 7 Control voltage 24V 48V 60V DC 2 F1 nom dip sw 3 8 Failsafe step 0 7 and circuit 3 CCR type dip sw 6 4 9 Ind grouping C PI FI C D 4 Parallel Serial dip sw 7 Remote control Serial 1 2 Front panel setting 5 S redundant P start dip sw 8 DIP POS 8 7 6 5 4 3 2 1 10 Fiel...

Page 98: ... setting 7 REGULATION CT 8000 RU U1 V Load Step I2ccr A I2ext A Accept U2ccr V P2ccr W Remarks 1 2 3 4 5 6 7 IDM 8000 COMMISSIONING Serial number Sign Date 8 PROTECTIVE FUNCTIONS CT 8000 PR Input and temp Limit Delay Func Output Limit Delay Reset m Cap_m Func 1 U1 B 6 Open circuit 2 U1 B 7 Over current A NA 3 F1 B 8 Over current B NA 4 F1 B 9 SCO NA NA NA 5 Temperature B 9 MONITORING FUNCTIONS AND...

Page 99: ...urrent fault 4 P 4 P Remote control ComF P 5 P 5 P EF A LF A 6 P 6 P EF B LF B 7 P 7 P Maint sw ON or SCO VA drop A Dir 2 CS 1 Dir 2 CS 1 U1 A S VA drop B S CS 2 CS 2 U1 B S EF Ω S CS 3 CS 3 F1 A S SCO S CS 4 CS 4 F1 B S CCR size S CS 5 CS 5 T1 A S LF S CS 6 CS 6 T1 B S I2 A S DIR 1 P Redundant control S U2 V S Only P Parallel S Serial P2 W S Failsafe function 11 UPDATES CT 8000 UD Description Ver...

Page 100: ...IDM 8000 Appendix I Commissioning test report form 88 Copyright ADB Safegate All Rights Reserved ...

Page 101: ...nterface 1 30 kVA SG11479 A3 Serial control interface PROFIBUS DP 1 30 kVA SG11488 A3 Serial control interface MODBUS TCP 1 30 kVA SG11487 A4 Power unit 1 30 kVA SG11480 A5 LCD display unit 2 1 30 kVA SG11476 A6 Thyristor controller for CCRs manufactured before 2003 3 4 kVA SG15268 5 30 kVA SG15269 A6 Thyristor controller Trigger unit 1 30 kVA SG11489 A7 Earth fault module LV 50 MΩ range 1 30 kVA ...

Page 102: ...Synchronizing transformer 1 4 kVA SG11521 5 30 kVA SG11522 T3 U2 Output voltage transformer 1 3 kVA SG19234 4 kVA SG19235 5 kVA SG19236 7 5 kVA SG19237 10 kVA SG19238 12 5 kVA SG19239 15 kVA SG19240 17 5 kVA SG19241 20 kVA SG19242 25 kVA SG15429 30 kVA SG19243 T4 I2 Output current transformer 1 30 kVA SG11524 V1 incl RC Thyristor pack Thyristor Unit and RC 3 4 kVA SG11491 5 17 5 kVA SG11492 20 30 ...

Page 103: ...n the LCD display causing only half the screen to be displayed properly If this is the case press the F1 and F5 buttons simultaneously for more than 5 seconds to correct the problem This is due to a generation shift in the LCD display units 2 When ordering a new LCD display unit please check the software version of the MCU control unit If it is version 2 30c or earlier then the MCU control unit mu...

Page 104: ...IDM 8000 Appendix J Spare part list 92 Copyright ADB Safegate All Rights Reserved ...

Page 105: ...Components of electronics Component ID Description A1 Mother board A2 MCU control unit A3 Control interface card A4 Power unit A5 LCD display unit UM_IDM 8000 Rev 1 7 2021 05 06 93 Copyright ADB Safegate All Rights Reserved ...

Page 106: ...IDM 8000 Appendix K Components of electronics 94 Copyright ADB Safegate All Rights Reserved ...

Page 107: ...Appendix L Appendix L CCR components UM_IDM 8000 Rev 1 7 2021 05 06 95 Copyright ADB Safegate All Rights Reserved ...

Page 108: ...current transformer F1 F3 Circuit breakers T5 T6 Earth fault measurement supply transformers K1 Main contactor V1 Thyristor unit L1 Choke Inductor NTC Temperature sensor RC Snubber S1 Main switch SA 1 2 Surge arrester pair supply SA 3 4 Surge arrester pair output IDM 8000 Appendix L CCR components 96 Copyright ADB Safegate All Rights Reserved ...

Page 109: ...ng modes Commissioning mode A meter for calibration can be easily connected by turning the slide switch in off position in one of the terminals and by connecting the meter with test leads supplied with the CCR into the meter output return of the terminal Safety mode Grounding and output shorting can be achieved by turning off both slide switches and short circuiting the meter outputs of both termi...

Page 110: ...ecking and calibration use the TRMS current probe meter Safety mode Grounding and output shorting can be achieved by opening both terminal taps connection plates and short circuiting the meter outputs of both terminals and connecting the meter return to the ground with the test leads Cable discharge mode Use cable discharge to remove capacitive voltage from the cable Note Check that the terminal t...

Page 111: ...SCO to connect the cables to the terminals marked with S Use the tension relief to hold the cables in position Connection for the cable shield can be made by using the earthing rod E S S E SW connections Figure 15 SCO installation UM_IDM 8000 Rev 1 7 2021 05 06 99 Copyright ADB Safegate All Rights Reserved ...

Page 112: ... When the CCR is off from the main switch open the locking screw in the middle of the cover remove gently the cover and insert the cover back to one of the following modes and tighten the locking screw Be careful when inserting the cover that all connections are made properly For more information see the SCO manual or www adbsafegate com E Operation mode Maintenance mode Figure 16 SCO with differe...

Page 113: ...UM_IDM 8000 Rev 1 7 2021 05 06 101 Copyright ADB Safegate All Rights Reserved ...

Page 114: ...IDM 8000 Appendix M Output Terminals 102 Copyright ADB Safegate All Rights Reserved ...

Page 115: ... you have an airfield lighting or system control system problem it is our goal to support airfield maintenance staff as quickly as possible To support this effort we ask that you have the following information ready before calling The airport code If not with an airport then company name prefer customer id number Contact phone number and email address Product with part number preferable or product...

Page 116: ...sses as well as supplier components and sub contractor operations ADB SAFEGATE offers a recycling program for our products to all customers worldwide whether or not the products were sold within the EU ADB SAFEGATE products and or specific electrical and electronic component parts which are fully removed separated from any customer equipment and returned will be accepted for our recycling program ...

Page 117: ... 0 40 699 17 00 Fax 46 0 40 699 17 30 Email marketing adbsafegate com Internet www adbsafegate com ADB SAFEGATE Airfield Technologies Ltd China ADB SAFEGATE China Unit 603 D Block CAMIC International Convention Center No 3 Hua Jia Di East road ChaoYang district Beijing 100102 P R China Contact Tel 86 10 8476 0106 Fax 86 10 8476 0090 Email china safegate com Internet www adbsafegate com ADB SAFEGAT...

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