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Guarantee

Airport Lighting Company guarantees that the equipment manufactured by Airport Lighting

Company and covered by this manual has been manufactured to and will perform in accordance

with application specifications. Any defect in design, materials or workmanship which may occur

during proper and normal use during a period of one (1) year from date of installation or a

maximum of two (2) years from date of shipment will be corrected by repair or replacement by

Airport Lighting Company, with transportation costs borne by the purchaser. This guarantee

covers the 828HC Ferroresonant Constant Current Regulator.

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Summary of Contents for 828HC

Page 1: ...oresonant Constant Current Regulator Type 828HC Instruction Manual Revision 1 0 10 25 2019 Airport Lighting Company 108 Fairgrounds Drive Manlius New York 13104 315 682 6460 Info airportlightingcompany com ...

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Page 3: ...ovide output voltage in the magnitude of 5x nominal output before open circuit protection circuits are activated Ensure the output lines of the 828HC are always populated Always connect the male and female ends when an isolation transformer is not plugged in Output Current Warning The output current of the CCR is dangerous It is designed to work in a 6 6 Amp series loop The CCR will shut down if t...

Page 4: ...n specifications Any defect in design materials or workmanship which may occur during proper and normal use during a period of one 1 year from date of installation or a maximum of two 2 years from date of shipment will be corrected by repair or replacement by Airport Lighting Company with transportation costs borne by the purchaser This guarantee covers the 828HC Ferroresonant Constant Current Reg...

Page 5: ...Changes from last Revision First Revision ...

Page 6: ...3 1 Installation Precheck 4 3 2 Turning the CCR on for the First Time 4 3 3 Checking Current Output 5 4 0 How to Navigate the CCR Display and Keypad 6 4 1 The CCR Keypad 6 4 2 Understanding the Digital Control Monitoring Unit DCMU Display 8 4 2 1 The Main Screen 8 4 2 2 Navigating Menus 9 5 0 CCR Configuration 11 5 0 1 Accessing the Configuration Menu 12 5 0 2 Accessing the Diagnostics Menu 12 5 1...

Page 7: ...nown Good Configuration 18 7 2 2 Restoring a Known Good Calibration 18 7 3 Completing In Field Recalibrations 19 7 3 1 How to Determine if Recalibration is Needed 19 7 3 2 Calibrating Output Current 20 7 3 3 Calibrating Output Voltage 21 7 3 4 Calibrating Input Voltage 23 8 0 Additional Information 25 8 1 Replaceable Parts 25 8 2 Glossary of Terms 26 8 3 CCR Menu Navigation Flowchart 27 8 4 CCR Da...

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

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Page 11: ...will operate to Type A Class 1 specifications It will operate to both listed FAA CCR Styles in addition to a one 1 step operation as well as seven 7 step operation The brightness step selection is user selectable to accommodate for all types of fixture testing 1 3 Control Capabilities The regulator can be controlled by various means The front panel keypad display Remote control connection to inter...

Page 12: ... it is not connected in the 828HC For help setting up remote control for your 828HC please contact Airport Lighting Company 1 3 3 RS232 Serial Connection The 828HC allows for RS232 serial connection to be made at the DCMU Each DCMU comes with a RS232 connector that is used to connect directly to a PC using the DCMU Configurator software This connection is used primarily in factory setup and calibr...

Page 13: ... Shipping Sizing Information The 828HC enclosure is sized as shown below 2 1 Sizing Information kW Rating Install Weight Install Size Without Pallet 5 74 lbs 18 W x 17 D x 9 2 H Table 1 Sizing Information Figure 1 Cabinet Dimensions ...

Page 14: ...the user interface Once you are familiar with the display keypad Connect the male and female output connections With the output connections shorted plug in the 828HC The CCR display screen will turn on and show you the main screen Reference Table 3 Main Screen Information for a list of all information displayed Place a current clamp on an output wire and connect the clamp to a DMM Using the LOCAL ...

Page 15: ...al you may choose to verify the measured output current with a digital multimeter DMM and current clamp Maximum Output Current Total Step Count Step Nominal Output Current Allowable Current Range Measured Current Displayed Current 6 6 3 B10 4 8 4 7 4 9 B30 5 5 5 4 5 6 B100 6 6 6 5 6 7 6 6 5 B1 2 8 2 7 2 9 B2 3 4 3 3 3 5 B3 4 1 4 0 4 2 B4 5 2 5 1 5 3 B5 6 6 6 5 6 7 Table 2 CCR Output Currents ...

Page 16: ...n that will come up when the CCR is powered on Refer to Section 4 2 Understanding the Digital Control Monitoring Unit DCMU Display for additional information 4 1 The CCR Keypad The OFF button will turn the CCR off from any brightness step in Local or Remote The ON button will turn the CCR on to the most previous brightness step There is an LED on the button that will illuminate when the CCR is on ...

Page 17: ...nings The CCR will still operate even if there are warnings It is recommended to identify the cause of the warning and fix them as prolonged runtime with warning conditions may cause damage to the CCR See Section 6 1 Warnings and Alarms for information about warnings and alarms and how to remediate them The CONFIG button is used to access multiple screens and menus If equipped pressing the CONFIG ...

Page 18: ...te the command 4 2 Understanding the Digital Control Monitoring Unit DCMU Display As stated in Sections 4 0 and 4 1 the CCR display is controlled by pushing the UP DOWN and DOT buttons that are located below the screen Each screen that is displayed will scroll continuously as if on a rolling drum Once you attempt to navigate past the last line of information you will be returned to the first line ...

Page 19: ...f the output Lamps Out Current count of lamps out must be configured enabled and calibrated If not equipped this line will show Lamps Out Hz The configured AC voltage frequency Temperature Displays the current temperature reading at the DCMU in centigrade Mgr Displays the current megger reading if equipped Until a megger test is run this line will show Mgr HwVer Hardware version of the DCMU SwVr S...

Page 20: ...ourth line are commands that can be executed by the corresponding DOT button As you can see the second and third lines have arrows The down arrow on the third line is showing you that there are additional options to look at Pressing the DOWN button will scroll through the options The right arrow is a cursor for the menu Upon scrolling up or down the option next to the cursor will change When you h...

Page 21: ...enu is set up in a nested folder setup like a file cabinet or the files on your computer To understand the method of navigating referenced in this manual see the below example of a block flow diagram that navigates to the option for brightness step count The established way to designate the above navigation in plain text is Push the CONFIG button Enter Password CCR Config Number of Steps This manu...

Page 22: ...ults and Warnings as well as a run time log The Run time log can be found by navigating to Diagnostics Menu Operations The Fault and Warning logs can be found respectably by navigating to Diagnostics Menu Faults Warnings 5 1 Common CCR Configuration Changes This section will go over the most common CCR changes that may be warranted in field Note that configuration beyond the options covered in thi...

Page 23: ...ect the accurate step count nomenclature 3 step CCRs identify the step counts as B10 B30 and B100 while 5 step CCRs identify the step counts as B1 B2 B3 B4 and B5 5 1 2 Calibrate Zeros This command will have the CCR find a zero threshold in the input AC voltage It is required when making equipment changes to the CCR or when a part is replaced Before completing this calibration put the CCR in Local...

Page 24: ...larms When the CCR determines a warning or setpoint alarm it will engage the indicator light and the warning will be shown on line 1 of the CCR display The CCR will continue to operate in the event of a warning Although the CCR will continue operation warning conditions must still be noted and fixed Allowing the CCR to operate in a warning state may cause problems for efficiency general safety and...

Page 25: ...pany Problem Likely Cause s Steps to Fix The CCR will not turn on CCR supply voltage feeder is not on Blown fuses within the CCR The control transformer is not providing 12VAC Faulty DCMU Check to see if the CCR feeder supply breaker has tripped Verify the supply voltage with a DMM With all power off verify the integrity of the electrical connections Check the CCR fuses With power on check the con...

Page 26: ...rmine if this is true complete the following steps Turn off power to the CCR Wait for power to completely discharge by monitoring the LEDs Once they are all off power is no longer present Unplug the serial cable connected to the left side of the DCMU and the firing card The thumbscrews need to be loosened before removal Reapply power to the CCR If the issue persists replace the DCMU if a spare is ...

Page 27: ...e SSR contact it should be normally open If it isn t the SSR was damaged Contact Airport Lighting Company Output current is too low for the selected brightness step The output current needs to be recalibrated The CCR is overloaded Using a DMM verify the output current If the current measured on the DMM does not match the CCR displayed current refer to Section 7 3 1 To see if the CCR is overloaded ...

Page 28: ...ort Lighting Company setup settings navigate to the following menu option Configuration Menu System Commands Known Good Settings Restore Config Execute This will have the CCR return to the most recent saved configuration The CCR will ship with a factory saved configuration that may be overwritten in field Note this will not affect the CCR calibration This is useful for instances where an option wa...

Page 29: ...turn it on to the first brightness step Check the DMM measured value against the CCR measured value Due to a difference in the fidelity of measuring in the different equipment you may see a slight difference Log the measured numbers Put the CCR on the highest brightness step Log the measured numbers If the numbers are consistently more than 5 amps different you may want to consider recalibration T...

Page 30: ...w to Determine if Recalibration is Needed If it is determined that recalibration is required complete the following steps fully to ensure the most accurate results Read all steps before beginning Contact Airport Lighting Company for additional information as needed Note a resistor load bank such as can be provided by Airport Lighting Company is recommended to provide a purely resistive load to the...

Page 31: ...h you need to execute Yes If the calibration needs additional fine tuning complete the calibration procedure again If the calibration procedure does not yield acceptable results you may want to restore a known good calibration Refer to Section 7 2 2 Restoring a Known Good Calibration for more information 7 3 3 Calibrating Output Voltage Before continuing refer to Section 7 3 1 How to Determine if ...

Page 32: ... the measured voltage by the V1 V2 Output Voltage Measurement Factor provided on the CCR Datasheet at the end of this manual If the factor is not available contact Airport Lighting Company Use the UP and DOWN arrows below the screen to adjust the calibration value to the calculated value Once the values match push the left DOT button to accept Put the CCR on the highest brightness step while stayi...

Page 33: ...R into Local mode Open the CCR door and pull the door switch plunger toward you laterally to bypass the safety interlock Navigate to the following menu but do not enter the Input Voltage screen yet Configuration Menu CCR Config Calibrate Input Voltage The LOCAL Up and LOCAL Down arrows will still operate while in the menu allowing for easier calibration Put the CCR on the lowest brightness step On...

Page 34: ...DOT button until you re asked to Record Changes to which you need to execute Yes If the calibration needs additional fine tuning complete the calibration procedure again If the calibration procedure does not yield acceptable results you may want to restore a known good calibration Refer to Section 7 2 2 Restoring a Known Good Calibration for more information ...

Page 35: ... Switch 82 45 Display Cable 82 46 Current Transformer 100 1 82 60 DCMU WBC 910 03 82 61 DCMU Firing Card Cable 82 72 Firing Card 82 76 Glass Fuse 1 x 5A 250V 82 93 Solid State Relay 50A 82 87 12V Control Transformer 82 92 20A Contactor 82 508 Input Power Cord 99 00203 828HC Rubber Foot 82 505 Fan 24VDC 92mm 82 506 Fan Guard Wire Frame 92mm 82 401m 8AWG Male Primary Cable 82 401f 8AWG Female Primar...

Page 36: ...nt Transformer DC Direct Current DCMU Digital Control Monitoring Unit DMM Digital multimeter FAA Federal Aviation Administration FLA Full Load Amperage FR Ferroresonant Hz Hertz IRMS Insulation Resistance Monitoring System kv kilovolt kW kilowatt LED Light Emitting Diode LO Lamp Out PF Power Factor PLC Programmable Logic Controller PM Preventative Maintenance SSR Solid State Relay V v Voltage VA V...

Page 37: ... Flowchart The included flowchart is designed to accompany a user when navigating the CCR menus For information about accessing and using the menu refer to Section 4 0 How to Navigate the CCR Display and Keypad and Section 5 0 CCR Configuration Attached ...

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Page 39: ...CONTACTOR DELAY FAULT RELAY USE CALIBRATE NUMBER OF CSS CSS STATE MONITOR CSS FAULT MONITOR CSS REMOTE MONITOR FAILSAFE TEMPERATURE CURRENT MONITOR MAX OFF CURRENT INPUT VOLTAGE VA CHANGES LAMP OUTAGE OUTPUT VOLTAGE FUSE MONITOR FUSE MONITOR AUTO MEGGER HEARTBEAT FAILSAFE SETTING FAILSAFE DELAY ADDRESS REMOTE SWITCH PORT A PORT B LANGUAGE FACTORY SETTINGS KNOWN GOOD SETTINGS CLEAR SUPRS D WARN CLE...

Page 40: ... CAP VOLTAGE FLIP DAMPING ADJUST VALUE ADJUST VALUE DISABLE ENABLE ADJUST VALUE MIN DELAY MAX DELAY LOW TAP DELAY PICKET WIDTH ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE DAMPING ADJUST VALUE MIN DELAY MAX DELAY PICKET WIDTH DAMPING ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE 50 60 DISABLE ENABLE CONFIGURATION MENU CCR CONFIG PG 1 ...

Page 41: ...E STEP PERIOD ADJUST VALUE STEP CURRENTS B1 CURRENT B3 CURRENT B2 CURRENT B4 CURRENT B5 CURRENT ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE OPEN CIRCUIT TRIP THRESHOLD DURATION ADJUST VALUE ADJUST VALUE 1 2 4 5 7 5 10 15 20 25 30 50 70 Other OUTPUT POWER PARALLEL INPUTS 24V 120V ENABLE DISABLE INPUT TYPE STANDARD BCD INPUT VOLTAGE CONFIGURATION MENU CCR CONFIG PG 2 DISABLE ENA...

Page 42: ...BLE DISABLE WARNING LOCAL REMOTE PROGRAMMED ENABLE DISABLE ENABLE DISABLE ENABLE DISABLE CALIBRATE ZEROS CAP SYNC OUTPUT CURRENT OUTPUT VOLTAGE INPUT CURRENT INPUT VOLTAGE CAP VOLTAGE OUTPUT VOLT SPAN EXECUTE EXIT ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE CONFIGURATION MENU CCR CONFIG PG 3 SELECT EXIT ...

Page 43: ... CSS STATE MONITOR DISABLE ENABLE CSS FAULT MONITOR CSS REMOTE MONITOR FAILSAFE DISABLE ENABLE DISABLE ENABLE CIRCUIT 1 LAST STATE OFF ON CIRCUIT 2 LAST STATE OFF ON CIRCUIT 3 LAST STATE OFF ON CIRCUIT 4 LAST STATE OFF ON CIRCUIT 5 LAST STATE OFF ON CIRCUIT 6 LAST STATE OFF ON ...

Page 44: ...BLE LOW LEVEL HIGH LEVEL ADJUST VALUE ADJUST VALUE DISABLE ENABLE VA CHANGES VA LOW ALARM ADJUST VALUE VA HIGH ALARM CALIBRATE LO VA ADJUST VALUE LAMP OUTAGE DISABLE ENABLE NUMBER OF LAMPS ADJUST VALUE WARNING LEVEL ALARM LEVEL CALIBRATE LO VA ADJUST LO ADJUST VALUE ADJUST VALUE EXECUTE EXIT ACTUAL LAMPS OUT ADJUST VALUE CONFIGURATION MENU MONITOR CONFIG PG 1 EXECUTE EXIT EXECUTE EXIT ...

Page 45: ...MEGGER DISABLE ENABLE MEASURE NOW MEGGER RESISTOR READING DURATION AUTO MEASURE WARNING LEVEL ALARM LEVEL CALIBRATE OPEN CALIBRATE SHORT ADJUST VALUE ADJUST VALUE ADJUST VALUE ADJUST VALUE DISABLED WHEN ON WHEN OFF DAILY CONFIGURATION MENU MONITOR CONFIG PG 2 EXECUTE EXIT EXECUTE EXIT EXECUTE EXIT ...

Page 46: ...T A PROTOCOL MODBUS DF1 HDX DF1 FDX BAUD RATE OFF 9600 19200 38400 57600 115200 ADJUST VALUE IP ADDRESS SUBNET 255 255 255 0 255 255 0 0 255 0 0 0 EDIT BYTE 4 GATEWAY PORT B PROTOCOL MODBUS DF1 HDX DF1 FDX BAUD RATE OFF 9600 19200 38400 57600 115200 ADJUST VALUE IP ADDRESS SUBNET 255 255 255 0 255 255 0 0 255 0 0 0 EDIT BYTE 4 GATEWAY CONFIGURATION MENU COMMS CONFIG DEFAULT DISABLE DISABLE ENABLE ...

Page 47: ...Y SETTINGS RESTORE CONFIG RESTORE CALIB KNOWN GOOD SETTINGS RESTORE CONFIG SAVE CONFIG RESTORE CALIB SAVE CALIB CLEAR SUPRS D WARN CLEAR COUNTERS RESET BOOT BLOCK CONFIGURATION MENU SYSTEM COMMANDS EXECUTE EXIT EXECUTE EXIT EXECUTE EXIT EXECUTE EXIT ...

Page 48: ...CHAR READS WRITE OTHER CMD CRC ERRORS TIME OUTS OVER RUNS RX ERRORS STATUS RX CHAR TX CHAR READS WRITE OTHER CMD CRC ERRORS TIME OUTS OVER RUNS RX ERRORS VIN IOUT VOUT VCAP IIN MEGGER PHASE PERIOD ANGLE INDUCT 1 MOST RECENT UP TO 10 1 MOST RECENT UP TO 10 FIRING PERIOD TOP HALF BOTTOM SYNC CNT SPIKES HIGH TAP LOW TAP DISPLAY STATUS VERSION RX ERRORS TX ERRORS CALIBRATION VIN IOUT VOUT VCAP IIN MEG...

Page 49: ...irport Lighting Company 39 8 4 CCR Datasheet The included datasheet contains CCR specific information that is gathered during testing It also has the model and serial numbers of various equipment Attached ...

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