CHF (Ferroresonant) Regulator. with Universal Regulator Controller (URC) Air-Cooled, 4-70kW, 6.6A / 20A. User ManualUser Manual.

Transcription

1 User ManualUser Manual CHF (Ferroresonant) Airfield L-88 / Lighting L-89 Product Constant Solutions Current Catalog Regulator with Universal Regulator Controller (URC) Air-Cooled, 4-70kW, 6.6A / 0A 96A0408, Rev. G, 0/7/6

2 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G DISCLAIMER / WARRANTY A.0 Disclaimer / Standard Warranty A. CE certification The equipment listed as CE certified means that the product complies with the essential requirements concerning safety and hygiene. The directives that have been taken into consideration in the design are available on written request to ADB. A. ETL certification The equipment listed as ETL certified means that the product complies with the essential requirements concerning safety and FAA Airfield regulations. The directives that have been taken into consideration in the design are available on written request to ADB. A.3 LED Product Guarantee A.4 Standard Product Guarantee Where applicable, per FAA EB67(applicable edition), ADB L858(L) Airfield Guidance Signs are warranted against electrical defects in design or manufacture of the LED or LED specific circuitry for a period of 4 years. ADB LED light fixtures (with the exception of obstruction lighting) are warranted against mechanical and physical defects in design or manufacture for a period of months from date of installation; and are warranted against electrical defects in design or manufacture of the LED or LED specific circuitry for a period of 4 years per FAA EB67 (applicable edition). NOTE: See your sales order contract for a complete warranty description. In some specific cases, deviations are (to be) accepted in the contract, which will supersede the standard warranty. Products of ADB manufacture are guaranteed against mechanical, electrical, and physical defects (excluding lamps) which may occur during proper and normal use for a period of one year from the date of installation or years from date of shipment and are guaranteed to be merchantable and fit for the ordinary purposes for which such products are made. ADB L858 Airfield Guidance Signs are warranted against mechanical and physical defects in design or manufacture for a period of years from date of installation per FAA AC 50/ (applicable edition). NOTE: See your sales order contract for a complete warranty description. A.5 All Products LED Products of ADB, manufactured and sold by ADB or its licensed representatives, meets the corresponding requirements of FAA, ICAO and IEC. ADB will correct by repair or replacement per the applicable guarantee above, at its option, equipment or parts which fail because of mechanical, electrical or physical defects, provided that the goods have been properly handled and stored prior to installation, properly installed and properly operated after installation, and provided further that Buyer gives ADB Airfield Solutions written notice of such defects after delivery of the goods to Buyer. Refer to the Safety section for more information on Material Handling Precautions and Storage precautions that must be followed. ADB reserves the right to examine goods upon which a claim is made. Said goods must be presented in the same condition as when the defect therein was discovered. ADB Airfield Solutions furthers reserves the right to require the return of such goods to establish any claim. ADB s obligation under this guarantee is limited to making repair or replacement within a reasonable time after receipt of such written notice and does not include any other costs such as the cost of removal of defective part, installation of repaired product, labor or consequential damages of any kind, the exclusive remedy being to require such new parts to be furnished. ADB 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 Airfield Solutions, warranty is limited to that extended by the original manufacturer. This is ADB s sole guarantee and warranty with respect to the goods; there are no express warranties or warranties of fitness for any particular purpose or any implied warranties of fitness for any particular purpose or any implied warranties other than those made expressly herein. All such warranties being expressly disclaimed. ii ADB Airfield Solutions All Rights Reserved

3 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G DISCLAIMER / WARRANTY A.6 Liability WARNING Use of the equipment in ways other than described in the catalogue leaflet and the manual may result in personal injury, death, or property and equipment damage. Use this equipment only as described in the manual. ADB cannot be held responsible for injuries or damages resulting from non-standard, unintended uses of its equipment. The equipment is designed and intended only for the purpose described in the manual. Uses not described in the manual are considered unintended uses and may result in serious personal injury, death or property damage. Unintended uses includes the following actions: Making changes to equipment that have not been recommended or described in this manual or using parts that are not genuine ADB replacement parts or accessories. Failing to make sure that auxiliary equipment complies with approval agency requirements, local codes, and all applicable safety standards if not in contradiction with the general rules. Using materials or auxiliary equipment that are inappropriate or incompatible with your ADB equipment. Allowing unskilled personnel to perform any task on or with the equipment. ADB Airfield Solutions All Rights Reserved iii

4 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G DISCLAIMER / WARRANTY A.7 ADB BVBA 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 BVBA s prior written consent. This manual could contain technical inaccuracies or typographical errors. ADB BVBA reserves the right to revise this manual from time to time in the contents thereof without obligation of ADB BVBA to notify any person of such revision or change. Details and values given in this manual are average values and have been compiled with care. They are not binding, however, and ADB BVBA disclaims any liability for damages or detriments suffered as a result of reliance on the information given herein or the use of products, processes or equipment to which this manual refers. No warranty is made that the use of the information or of the products, processes or equipment to which this manual refers will not infringe any third party s patents or rights. The information given does not release the buyer from making their own experiments and tests. iv ADB Airfield Solutions All Rights Reserved

5 TABLE OF CONTENTS CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator...i A.0: Disclaimer / Standard Warranty...II A. :CE certification... ii A. :ETL certification... ii A.3 :LED Product Guarantee... ii A.4 :Standard Product Guarantee... ii A.5 :All Products... ii A.6 :Liability...iii A.7 : ADB BVBA...iv.0: Safety.... :HAZARD Icons used in the manual..... :Qualified Personnel.... :To use this equipment safely:..... :Additional Reference Materials:..... :Intended Use :Fasteners :Operation :Storage :Material Handling Precautions :Action in the Event of a System or Component Malfunction :Maintenance :Maintenance and Repair : Introduction...5. :About this manual :How to work with the manual :Record of changes :Product Introduction :Compliance with Standards :Electrical Supply :Remote Control :Total Harmonic Distortion* (THD) :Theory of Operation Introduction :ACE Unit :Environmental Operating Conditions :Monitoring Option :Application Notes :Theory of Operation :Power Circuit :Output Measurement :Universal Regulator Controller (URC) :URC PCB Inputs/Outputs :Output Current Monitor Circuitry :Local Control Position Detection :Contactor Drive :Remote Control Position Detection :Fault Protection :L-88 CCR.... :L-89 CCR....3 :SGRS Powerpack....4 :Universal Regulator Controller :L-89 Advanced Control Equipment (ACE or ACE)... 4 ADB Airfield Solutions All Rights Reserved v

6 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G TOC.5 :L-88/L-89 CCR Monitoring Options :Optional Insulation Resistance Monitoring System :Optional Scanning Monitor Interface :Optional Scanning Monitor Ready :Optional Series Cutout Type SCO :L-88 CCRs (4-70 kw 6.6 A/ 0 A): Required Equipment :Input Wire Size :Input Power Breaker Sizing :Specifications :Efficiency :Reactive Loading :Resistive Loading :Regulation :Environmental Operating Conditions :Protection Devices :Open-Circuit Protection :Overcurrent Protection :Input Voltage :Built-In True-rms-Reading Ammeter, L-88 only :Rating and Input Voltage :Temperature Rise :Dimensions : Installation :Unpacking :Return Shipping :Installation :Wiring Connections and Startup :Stacking CCR s (Optional) :SGRS Style Powerpacks (Optional) :Frames : Operation :Introduction :CCR Control Procedures :Local Control :Remote Control :CCR Door Interlock (Optional ) :CCR Shutdown Procedure :CCR Adjustment Procedures :Output Current Adjustment :Overcurrent Adjustment :SCO Cutout Working Positions :Application Notes :Digital Power Meter Calibration (optional) :Display :Function Buttons :DPM Displays :Calibration Procedure : Maintenance and Repair :Maintenance Schedule :Short-Circuit Test :Open-Circuit Test :Troubleshooting :Preliminary Troubleshooting :L-88 General Troubleshooting :Additional L-89 General Troubleshooting Procedures :Component Replacement Procedures :Removing and Replacing URC PCB :Removing and Replacing Dual SCR Module Assembly vi ADB Airfield Solutions All Rights Reserved

7 5.4.3 :Removing and Replacing Contactor :Removing and Replacing Input Lightning Arrestors (front of Component Mounting Plate) :Removing and Replacing Output Lightning Arrestors (front of Component Mounting Plate) : CHF Parts and Mechanical Drawings :Spare Parts : Wiring Schematics...65 ADB Airfield Solutions All Rights Reserved vii

8 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G TOC viii ADB Airfield Solutions All Rights Reserved

9 .0 Safety This section contains general safety instructions for installing and using ADB Airfield Solutions equipment. Some safety instructions may not apply to the equipment in this manual. Task- and equipment-specific warnings are included in other sections of this manual where appropriate.. HAZARD Icons used in the manual For all HAZARD symbols in use, see the Safety section. All symbols must comply with ISO and ANSI standards. Carefully read and observe all safety instructions in this manual, which alert you to safety hazards and conditions that may result in personal injury, death or property and equipment damage and are accompanied by the symbol shown below. WARNING Failure to observe a warning may result in personal injury, death or equipment damage. DANGER - RISK OF ELECTRICAL SHOCK OR ARC FLASH Disconnect equipment from line voltage. Failure to observe 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... Qualified Personnel IMPORTANT INFORMATION The term qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations and have been trained to safely install, operate, maintain and repair the equipment. It is the responsibility of the company operating this equipment to ensure that its personnel meet these requirements. Always use required personal protective equipment (PPE) and follow safe electrical work practices. ADB Airfield Solutions All Rights Reserved

10 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G To use this equipment safely:. To use this equipment safely:.. Additional Reference Materials: WARNING Read installation instructions in their entirety before starting installation. Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. Make this manual available to personnel installing, operating, maintaining or repairing this equipment. Follow all applicable safety procedures required by your company, industry standards and government or other regulatory agencies. Install all electrical connections to local code. Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All wiring must meet local codes. Route electrical wiring along a protected path. Make sure they will not be damaged by moving equipment. Protect components from damage, wear, and harsh environment conditions. Allow ample room for maintenance, panel accessibility, and cover removal. 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 prior to returning power to the circuit. Failure to follow these warnings may result in serious injury or equipment damage. IMPORTANT INFORMATION IEC - International Standards and Conformity Assessment for all electrical, electronic and related technologies IEC Electrical Installations in Buildings FAA Advisory: AC 50/ (current edition) Maintenance of Airport Visual Aid Facilities ANSI/NFPA 79, Electrical Standards for Metalworking Machine Tools. National and local electrical codes and standards... Intended Use WARNING IMPROPER USE Using this equipment in ways other than described in this manual may result in personal injury, death or property and equipment damage. Use this equipment only as described in this manual. THESE WARNINGS MAY RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE...3 Fasteners WARNING FOREIGN OBJECT DAMAGE - FOD Only use fasteners of the same type as the one originally supplied with the equipment. Always tighten the fasteners to the recommended torque. Use a calibrated torque wrench and apply the recommended adhesive type. Obey the instructions of the adhesives necessary for the fasteners. Failure to follow these warnings may cause the fasteners to loosen, damage the equipment, potentially to loosen the equipment. This can lead to a highly dangerous situation of FOD, with potential lethal consequences. ADB Airfield Solutions All Rights Reserved

11 ..4 Operation CAUTION IMPROPER OPERATION 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 this instruction can result in equipment damage...5 Storage CAUTION IMPROPER STORAGE 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...6 Material Handling Precautions CAUTION ELECTROSTATIC SENSITIVE DEVICES This equipment may contain electrostatic sensitive 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 should 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 with highly insulating materials such as plastic sheets, synthetic fiber clothing. They must be laid down on conductive surfaces. The tip of the soldering iron must be grounded. Electronic modules and components must be stored and transported in conductive packing. Failure to follow this instruction can result in equipment damage. UNSTABLE LOAD WARNING 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 these instructions can result in death, serious injury, or equipment damage. ADB Airfield Solutions All Rights Reserved 3

12 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G To use this equipment safely:..7 Action in the Event of a System or Component Malfunction DANGER ARC FLASH AND ELECTRIC SHOCK HAZARD Do not operate a system that contains malfunctioning components. If a component malfunctions, turn the system OFF immediately. An open airfield current circuit is capable of generating >5000 Vac and may appear OFF to a meter. Never unplug a device from a constant current circuit while it is operating. Arc flash may result. Disconnect and lock out electrical power. Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component according to instructions provided in its manual. Failure to follow these warnings will result in death or equipment damage...8 Maintenance ELECTRIC SHOCK HAZARD WARNING..9 Maintenance and Repair Do not operate a system that contains malfunctioning components. If a component malfunctions, turn the system OFF immediately. Disconnect and lock out electrical power. Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component according to instructions provided in its manual. Failure to follow these warnings will result in death or equipment damage. DANGER ARC FLASH AND ELECTRIC SHOCK HAZARD Allow only qualified personnel to perform maintenance, troubleshooting, and repair tasks. Only persons who are properly trained and familiar with ADB Airfield Solutions equipment are permitted to service this equipment. An open airfield current circuit is capable of generating >5000 Vac and may appear OFF to a meter. Never unplug a device from a constant current circuit while it is operating. Arc flash may result. Disconnect and lock out electrical power. Always use safety devices when working on this equipment. Follow the recommended 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 Airfield Solutions replacement parts. Using unapproved parts or making unapproved modifications to equipment may void agency approvals and create safety hazards. Check the interlock systems periodically to ensure their effectiveness. Do not attempt to service electrical equipment if standing water is present. Use caution when servicing electrical equipment in a high-humidity environment. Use tools with insulated handles when working with airfield electrical equipment. Failure to follow these warnings will result in death or equipment damage. 4 ADB Airfield Solutions All Rights Reserved

13 .0 Introduction CCF (Ferroresonant) L-88 / L-89 Constant Current Regulator with Universal Regulator Controller (URC). About this manual The manual shows the information necessary to:.. How to work with the manual.. Record of changes Install Carry Out Maintenance Carry Out Troubleshooting on the CCF (Ferroresonant) L-88 / L-89 Constant Current Regulator, in the manual referred to as the equipment.. Familiarize yourself with the structure and content.. Carry out the actions completely and in the given sequence. PAGE REV DESCRIPTION CHECKED APPROVED DATE A New manual JC 0/05/09 C Full update JC /6/0 All D Updated fuses and added capacitor plate info RH JC 06/09/ All E updated entire manual RW ER 7/6/06, 4 F added shipping strap info RW ER 0/07/6 ADB Airfield Solutions All Rights Reserved 5

14 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Product Introduction. Product Introduction WARNING Read installation instructions in their entirety before starting installation. Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. Make this manual available to personnel installing, operating, maintaining or repairing this equipment. Failure to follow these warnings may result in serious injury or equipment damage..3 Compliance with Standards This section describes the ADB Airfield Solutions Signature Series Ferroresonant, L-88/L- 89, constant current regulators (CCRs). These CCRs are manufactured according FAA specification AC 50/ (latest edition). FAA: L-88/L-89 AC 50/ (Current Edition) ETL Certified ICAO: Aerodrome Design Manual Part 5, para to Military: UFC ; NAVAIR 5-50AAA- Uses Supplies three or five precision output levels to power series lighting circuits on airport runways and taxiways..4 Electrical Supply Power Input: 60Hz, single-phase, available in 08, 0, 40, 347and 480 Vac Power Factor*: 0.99 or more for 4 to 30kW 0.95 or more for 50 and 70kW NOTE: Efficiency 90% minimum for 4 to 0kW 9% minimum for 30kW 93% minimum for 50kW 94% minimum for 70kW.5 Remote Control 0V AC, 60Hz or +48V DC, ±0%.6 Total Harmonic Distortion* (THD).7 Theory of Operation Introduction Current THD: 0% maximum in highest step Voltage THD:.9% maximum in all steps * Tested with 00% resistive load according to FAA AC50/ (Latest Edition). Ferroresonant circuitry and a solid-state control system accurately regulate the output current to within the FAA-allowable range from no load to full load and with input voltage variations of -5% to +0% of nominal. For more theory of operation see: Theory of Operation on page 9. 6 ADB Airfield Solutions All Rights Reserved

15 .8 ACE Unit The ACE TM unit provides L-89 monitoring and optional megging or CCR input monitoring capability. Each unit is installed locally at each CCR that requires remote control and/or monitoring within the airfield lighting electrical vault. Optional CCR input monitoring monitors the following: CCR input current CCR input voltage CCR input volt-amps (VA) CCR input power (watts) CCR input power factor CCR % efficiency The ACE unit is also a component of ADB s distributed control and monitoring system. Each unit can be easily connected to an Airport Lighting Control & Monitoring System (ALCMS) by simply adding redundant communication wires. See ADB ACE catalog sheet 084 for additional information. ADB Airfield Solutions All Rights Reserved 7

16 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Environmental Operating Conditions.9 Environmental Operating Conditions Temperature: -40 C to +55 C (-40 F to +3 F) Humidity: 0 to 95% Altitude: 0 to 6,600 ft (,000 m).9. Monitoring Option See Order Codes Application Notes below..9. Application Notes 0 None Standard L-88 supplied with analog ammeter ALCMS Scanning Monitor Interface (SMI) The SMI option adds Primary Power and Remote/Local monitoring relays. Dry relay Interface contacts are connected to a dedicated terminal block for each monitored point. Typical application: connecting ADB L-88 CCR to ALCMS or L-87 that is manufactured by others. Note that this option does not provide dedicated output current or voltage transformers. ALCMS Scanning Monitor Ready (SMR) The SMR option adds several monitoring relays (including Primary Power and Remote/Local) and also CCR output current and voltage transformers. All monitored signals are connected to a dedicated terminal block. Application only for connecting ADB L-88 CCR to older ADB Gen I/II ALCMS scanning monitoring system. 3 L-89 Monitoring (ACE TM ) Includes FAA L-89 monitoring equipment. If application is for connection to ADB L-890 ALCMS: Add a /A to end of Ordering Code. The ACE unit will then be programmed to provide monitoring data via dual redundant communication links. If application is for a stand-alone L-89 CCR: Ordering Code is not changed. The ACE unit is programmed to activate a dry contact closure if a fault is present. The fault alarm can then be connected to any external monitoring system. 4 Insulation Resistance Monitoring System (IRMS) Ready This option adds an IRMS board in the CCR. Application: connection to externally mounted ADB ACE unit. 5 L-89 Monitoring (ACE ) Includes FAA L-89 and IRMS equipment and IRMS If application is for connection to ADB L-890 ALCMS: Add a /A to end of Ordering Code. The ACE unit will then be programmed to provide monitoring data via dualredundant communication links. If application is for a stand-alone L-89 CCR with Insulation Resistance Monitoring: Ordering Code is not changed. The ACE unit is programmed to activate a dry contact closure if a fault is present. The fault alarm can then be connected to any external monitoring system. 6 L-88 with Digital Power Meter This option replaces the analog ammeter with a Digital Power Meter. The Digital Power Meter is used on L-88 CCRs to indicate True RMS output current, voltage, VA, and watts. It can also be set to activate an alarm if there is a 0% or 5% drop in the load (Low VA). 8 ADB Airfield Solutions All Rights Reserved

17 .0 Theory of Operation This subsection describes the L-88 CCR theory of operation..0. Power Circuit See Figure. A Ferroresonant network consisting of T, C, and the SCRs draws from the input lines. This network is capable of drawing a limited amount of power. It can be routed to one of two places. The first is the output leads to the airfield. The second is a resonant tank comprised of C and part of T. As more power is allowed to flow into the resonant tank, less is available to flow to the field. It is by regulating the current in this tank that the SCRs regulate throughput current to the airfield. It is important to note that the output of the regulator will be the smallest when the SCRs are conducting 00% of the time. This is the opposite of what is seen in simple SCR regulators where the SCRs are used to directly control the output of the regulator. NOTE: C is actually a bank of capacitors located near T. The components of the Ferroresonant network are designed to deliver an output current slightly higher than 6.6 A/0 A for the minimum input voltage, while the SCRs are fully off..0. Output Measurement.0.3 Universal Regulator Controller (URC) The output current flows through the high voltage current transformer T5. T5 provides feedback to the URC board on the actual current output to the airfield series circuit. A second current transformer, T, provides current to a true-rms-reading ammeter mounted onto the front panel to indicate output current. See Figure 5. This subsection describes the board level circuitry found on the universal regulator controller. Figure : L-88 CCR Power Circuit Block Diagram Input Voltage T C - Cx T5 T Output SCRs URC Controller RMS Current Meter.0.3. URC PCB Inputs/Outputs The URC receives the inputs listed below. See Figure 5 in this section and Wiring Schematics on page 65. Local control signals from the front panel rotary switch. Remote control signals from a remote control terminal block located in the L-88 chassis (0Vac/48Vdc) (TB). A current proportional to the output current from a current transformer (T5). Phase angle reference voltage derived from the input voltage. 4 Vac center tapped supply voltage from T4. The URC provides the outputs listed below. A contact to complete the input contactor K coil circuit. A contact to enable the Remote CCI voltage at TB. Gate drive signals to the SCR block used to regulate the output current. ADB Airfield Solutions All Rights Reserved 9

18 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Theory of Operation.0.4 Output Current Monitor Circuitry.0.5 Local Control Position Detection The system output current is sensed by a current transformer (T5) whose secondary is connected to J8-3 and J8-4 on the URC board. This current signal is passed through a 5- ohm shunt resistor (R38), located on the URC board. For the 6.6 amp regulator, T5 provides a 00: step-down of the feedback current. For 0 A regulators, this ratio is 300:. Output current steps -5 would correspond to voltage levels of 40, 50, 65, 780, and 990 millivolts respectively. Local control position detection is accomplished by using a rotary switch mounted on the front door of the CCR. See Figure..0.6 Contactor Drive The contactor drive circuit on the URC PCB pulls in the main contactor K by shorting points J4- to J Remote Control Position Detection When the local control signal to the micro-controller indicates remote the remote control circuitry is active. Relay K on the URC board closes, providing 0VAC to the CCI connection on TB. The remote control inputs incorporate surge suppression and are optically isolated from the rest of the PCB..0.8 Fault Protection This subsection describes URC fault protection. Overcurrent Protection The micro-controller detects an over current condition by comparing the output current to a preset value. If the output current exceeds this value the controller will shut the regulator down by removing drive to the input contactor. This contactor will remain de-energized until the controller is reset either by selecting the OFF position (remotely or locally) or cycling the input power off for a minimum of seconds and then back on. The control board will not recognize momentary over currents caused by load switching or other transient conditions. Open Circuit Protection The micro-controller detects an open circuit by the absence of current in the regulator output (this will also detect an open or shorted current transformer). If the output current is less than.5 amps, the controller will shut the current regulator down within one second by removing drive to the input contactor. This contactor will remain de-energized until the controller is reset either by selecting the OFF position (remotely or locally) or cycling the input power off for a minimum of seconds and then back on. 0 ADB Airfield Solutions All Rights Reserved

19 . L-88 CCR See Figure. This subsection describes the L-88 CCR. The L-88 uses a Universal Regulator Controller (URC) to provide regulator and control functions. NOTE: Figure shows a Ferroresonant 5 kw/6.6 A L-88 CCR. The other L-88 CCRs (4, 7.5, 0, 0-30 kw/6.6 A/0 A and 50/70kW) may differ in size and appearance. Figure : L-88 CCR (4-30kW/6.6 A) Ammeter (shown) or Digital Power Meter Rotary Switch The L-88 CCRs are designed to: Supply three or five precision output current levels (6.6 A/0 A maximum) to power airport series lighting circuits on runways and taxiways. Accurately regulate the output current to within ±% of the adjustable nominal levels from no load to full load and with input voltage variations of -5% to +0% of nominal. Maintain the nominal output current levels even when 30 percent of the isolation transformers in the series lighting circuit supplied by the regulator have open secondaries. ADB Airfield Solutions All Rights Reserved

20 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G L-89 CCR. L-89 CCR See Figure 3. This subsection describes the L-89 CCR. The L-89 uses a URC to provide regulator and control functions. It also uses the Advanced Control Equipment (ACE or ACE ) for control and monitoring functions. NOTE: Figure 3 shows a L-89 (5 kw/6.6 A) CCR. The other L-89 CCRs (4, 7.5, 0, 0-30 kw/6.6 A/0 A & 50/70kW) may differ in size and appearance. Figure 3: L-89 CCR with ACE ADB 3 ACE Front Panel Display L-89 CCR 3 Rotary Switch.3 SGRS Powerpack This subsection describes the Switchgear Regulator Style Powerpack. The SGRS Powerpack operates similar to the stand-alone type L-88 / L-89 and uses a URC to provide regulator and control functions. It also uses the Advanced Control Equipment (ACE or ACE ) for control and monitoring functions. The main difference is the CCR frame which is designed to insert into a SGRS line-up. NOTE: Figure 4 shows a Ferroresonant L-89 (30 kw/6.6 A) CCR. The other L-89 CCRs (4, 7.5, 0, 5, 0 kw/6.6 A/0 A and 50/70kW) may differ in size and appearance. ADB Airfield Solutions All Rights Reserved

21 Figure 4: SGRS Powerpack with ACE or ACE VR 7,8 INPUT VR 7, INPUT T4 F5 SCR BLOCK SNUBBER TB3 UBBER TB3 TOP URC PCB TB F3-F4 5 8 K. ACE not shown (Installed on inside front of SGRS door). SGRS Powerpack 3. Rotary Switch (Installed on front of SGRS door) 4. Circuit Breaker 5. Series Circuit Stab Connector 6. Input Power and control wiring stab connector 7. URC Circuit Board 8. Roller Wheels ADB Airfield Solutions All Rights Reserved 3

22 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Universal Regulator Controller.4 Universal Regulator Controller See Figure 5 below. The Universal Regulator Controller (URC) is a PC board that is designed to provide all regulator and control functions for Ferroresonant L-88/L-89 CCRs manufactured by ADB Airfield Solutions. This is accomplished with an 8-bit embedded microcontroller and interface circuitry contained on a single 8 x 8 inch (03 mm x 03 mm) through-hole type printed circuit board. The universal regulator controller PCB performs the functions listed below. Produces SCR drive signals in accordance with the desired output current setting. Detects an overcurrent, or open circuit, and switches the constant current regulator off. When in Remote mode, enables the CCI to provide 0 Vac at 50 W. The CCI is the Remote power control source. Figure 5: Universal Regulator Controller (URC).4. L-89 Advanced Control Equipment (ACE or ACE) See Figure 3 and Figure 6. The L-89 ACE TM (or ACE TM ) control and monitoring unit consists of an integrated control unit that is interfaced to each CCR either internally or within a small external enclosure. The ACE printed circuit boards are mounted inside a small and rugged environmental enclosure that is directly attached to the door of the L-89 CCR. The ACE consists of microprocessor-based module(s) that processes communication, control commands, input/output interface, and failsafe functionality for controlled elements in the airfield lighting vault. Figure 6: ACE Control Board For more information about the ACE, see: Advanced Control Equipment (ACE) manual 96A087 or the Advanced Control Equipment (ACE) manual 96A0357. ACE Programming manual 96A ADB Airfield Solutions All Rights Reserved

23 .5 L-88/L-89 CCR Monitoring Options.5. Optional Insulation Resistance Monitoring System The L-89 CCR monitoring options include the Insulation Resistance Monitoring System (IRMS), Scanning Monitor Interface (SMI), and Scanning Monitor Ready (SMR). The IRMS is used only on the L-89. It performs scheduled cable insulation resistance measurements and can also perform manually requested measurements. IRMS provides the ability for monitoring the long-term degradation of the airfield series circuit cabling and showing the results on the L-89 CCR front display panel. WARNING When servicing a regulator equipped with an IRMS module, be sure that power to the IRMS is disconnected before touching the IRMS board, or any of the high voltage components or wires..5. Optional Scanning Monitor Interface.5.3 Optional Scanning Monitor Ready.6 Optional Series Cutout Type SCO.7 L-88 CCRs (4-70 kw 6.6 A/ 0 A): Required Equipment The scanning monitor interface is a relay assembly that can be mounted internally to the front panel of the CCR. The relay assembly consists of four relays and sockets. The relay assembly is used to generate feedback signals concerning the CCRs operation to the Remote Multiplexer. The relay assembly generates feed back for the following signals: Remote/local status, commanded ON status, regulator running status, and primary power status. The scanning monitor ready includes the scanning monitor interface plus one current transformer (CT) and one potential transformer (PT). It also has resistor loads, and a fuse in the potential transformer secondary. Differential signals presenting the actual series circuit voltage and current are transmitted to the scanning monitor system two-conductor shielded cables. The series cutout Type SCO is often used at airports having a large number of series circuits to isolate the series circuit from the CCR during maintenance or testing operations. It also allows manual measurement of resistance of the series circuit to ground without disconnecting the series cable. The SCO cutout has a nominal working voltage of 5 kv and a nominal carrying current capacity of 0 amps AC. For more information refer to the SCO Cutout manual 96A094. Refer to Table for required equipment that is supplied. Refer to Table for required equipment that is not supplied. Refer to CHF Parts and Mechanical Drawings on page 5 for ordering information. Table : Required Equipment Supplied Description Quantity L-88/L-89 constant current regulator Instruction manual As Req d on Order per CCR on Order Table : Required Equipment Not Supplied Description Quantity Input power wire. Refer to Table 3. As required Remote control wire, AWG 8 minimum, AWG 4 maximum As required Ground wire, AWG 8 minimum (6.6 A); AWG 6 minimum (0 A) As required Output load wire, AWG 6 minimum, 5000 Vac, L-84 type (6.6 A); AWG 8 minimum (0 A) As required Shorting jumper wire, AWG 8 minimum As required Disconnect switch or main circuit breaker Input lightning arrestors for input voltages greater than 480 Vac. Mounted external to CCR. NOTE: lightning arrestors are standard on the power As required input for voltages 480 Vac and less for all new CCRs Voltmeter, 60 Vdc full scale ADB Airfield Solutions All Rights Reserved 5

24 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Input Wire Size Description Quantity Ammeter, true-rms-reading, 9 A maximum scale Inductive-type current probe Ohmmeter Mounting bolts, ½-3 x -/ in. long, ½ STD washers, and lockwashers 4.8 Input Wire Size Table 3 refers to recommended input power supply wire size for each regulator power rating dependent on the input voltage. This recommendation is based on 75 C rated copper wire per NEC Table Input Power Breaker Sizing Table 3: Recommended Input Wiring Rating Power Rating 08 Vac 0 Vac 40 Vac 347 Vac 480 Vac 4 kw AWG 0 AWG 0 AWG 0* AWG * AWG kw AWG 6 AWG 8 AWG 8 AWG 8 AWG 0* 0 kw AWG 4 AWG 6 AWG 6 AWG 8 AWG 0 5 kw AWG 3 AWG 3 AWG 4 AWG 6 AWG 8 0 kw AWG /0 AWG /0 AWG AWG 4 AWG 6 30 kw AWG 3/0 AWG 3/0 AWG /0 AWG AWG 4 50 kw Not applicable Not applicable Not applicable Not applicable AWG /0 Not 70 kw Not applicable Not applicable Not applicable AWG 3/0 applicable *Increased wire size to comply with small conductor limits in NEC 40.4.D. It is recommended that the circuit breaker on the input power supply lines have a rating of 5% of the CCR s input current, as given in Table 4, unless local codes require a different rating technique. Refer to the CCR s nameplate for the kw rating and input voltage to determine the actual input current from Table 4. If no standard-size circuit breaker exists at the 5% value, use the next larger standard-size circuit breaker. NOTE: The currents listed in Table 4 represent actual input currents assuming the worst case limits of AC 50/ for power factor, efficiency, and number of required lamps out. Table 4: CCR Input Voltage and Current for the CCR Power Ratings Power Rating 08 Vac 0 Vac 40 Vac 347 Vac 480 Vac 4 kw 7 A 6 A 4 A 6 A A 7.5 kw 5 A 48 A 44 A 3 A A 0 kw 68 A 65 A 59 A 4 A 30 A 5 kw 97 A 9 A 84 A 58 A 4 A 0 kw 9 A A A 78 A 56 A 30 kw 90 A 79 A 64 A 4 A 8 A 50 kw Not applicable Not applicable Not applicable 70 kw Not applicable Not applicable Not applicable Not applicable Not applicable 36 A 88 A 6 ADB Airfield Solutions All Rights Reserved

25 .0 Specifications This subsection provides specifications for L-88/L-89 CCR (4-70 kw 6.6 A/0 A). Table 5: Class Table 6: Class, Style and Power Ratings L-88/L-89 CCR Max Output Current 6.6 A Style Power Factor Brightnes s Steps 0 A 5 Nominal Output Current Power Ratings A, 5.5 A, 6.6 A 4, 7.5, 0, 5, 5.8 A, 3.4 A, 4. A, 5. A, 6.6 A 0 and 30 kw CCR Power Factor 4-0 kw 0.90 minimum 5-70 kw 0.95 minimum 8.5 A, 0.3 A,.4 A, 5.8 A, 0 A 5, 0, 30, 50 and 70 kw.0. Efficiency The efficiency of the regulator operated with rated input voltage into a full load having unity power factor is not less than the value shown in Table 7. Table 7: Efficiency CCR Efficiency 4-0 kw 0.90 minimum 30 kw 0.9 minimum 50 kw 0.93 minimum 70 kw 0.94 minimum.0. Reactive Loading The CCR maintains the output current within the limits of Table 8 for all brightness steps when the load is connected via isolating transformers, and the secondaries of 30 percent of the transformers become open-circuited. The load before opening the isolation transformer secondaries may be any value from half to full load. For regulators less than 0 kw loaded as specified above, the current remains below 6.8 amperes for the 00 percent brightness step. Table 8: Output Current and Limits Class Style Step Nominal output amperes (A) root mean square (RMS) Allowable range (A RMS) B B B B B B B B B B B B B ADB Airfield Solutions All Rights Reserved 7

26 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Specifications.0.3 Resistive Loading The regulator maintains the output current within the limits of Table 8 while powering any load between no load (or short circuit) and full load. For regulators 0 kw or larger, the regulation is maintained over the full range of environmental conditions specified in this section and for the input voltages specified in Table 4. For regulators less than 0 kw, the regulation is provided at nominal input voltage for all brightness steps..0.4 Regulation Refer to Table 8 for output current limits. Current regulation is obtained under the conditions listed in Environmental Operating Conditions..0.5 Environmental Operating Conditions The L-88 CCRs are designed for indoor use only in an area with adequate ventilation for cooling the constant current regulator. The environmental operating conditions include temperature range, relative humidity, and altitude. Table 9: Environmental Operating Conditions Temperature Range Without monitoring circuitry -40 to +55 C (-40 to +3 F) With monitoring circuitry Relative Humidity Altitude 0 to +55 C (-8 to +3 F) 0 to 95% (noncondensing) Sea level to 6,600 ft (000 m).0.6 Protection Devices L-88 CCRs have the following protection devices: Output open-circuit protection. Output overcurrent protection. Lightning arrestors on output terminals and bushings. Lightning arrestors on input terminals. Fuse protection of AC supply voltage of the URC PCB and brightness control voltage for Remote control Open-Circuit Protection.0.6. Overcurrent Protection The regulator includes an open-circuit protective device to open the primary switch within seconds after an open circuit occurs in the secondary. The device resets within seconds after the control switch is turned off and re-energized, and cannot be tripped by switching the load circuits or other transients. Regulators include an overcurrent protective device that opens the primary switch when the output current exceeds the 00 percent current (6.6 A or 0 A) by 5 percent. The device operates within 5 seconds after an overcurrent of 5 percent and within second after an overcurrent of 5 percent. The device resets within seconds after the control switch is turned off and re-energized. The overcurrent protection cannot be activated by a momentary (0.5 second) overcurrent caused by switching the load circuits and other transients..0.7 Input Voltage Input voltage is single phase 60 Hz ac. Regulators operate as required (see subsections Resistive Loading and Reactive Loading in this section) when the input voltage is anywhere between 95 and 0 percent of the nominal value. The regulator is designed to withstand momentary voltages up to 0 percent of nominal input voltage without shutting off or being damaged by such overvoltage so long as the duration of overvoltage excursions are not longer than 50 milliseconds and do not occur more than once per minute Built-In True-rms- Reading Ammeter, L-88 only.0.7. Rating and Input Voltage For the L-88 only, a flush-mounted true-rms-reading ammeter mounted on the front of the input module PCB indicates the output current. The meter accuracy is ±3.0 percent of the maximum output current. Table 0: Rating and Input Voltage Rating Input Voltage 4, 7.5, 0, 5, 0, 30 kw Vac, -5 to +0% 50, 70 kw 480 Vac, -5 to +0%.0.8 Temperature Rise The temperature rise of the transforming portion of the regulator is in accordance with ANSI C57..9 for air-cooled regulators. 8 ADB Airfield Solutions All Rights Reserved

27 . Dimensions Table : Dimensions and weights CCR Dimensions (H x W x D) Weight - lb (kg) Size 08/0V 40/347/480V 08V 0V 40V 347V 480V 4kW 7.5kW 0kW 5kW 0kW 30kW 33 x 4 x 5 - in 83.8 x 6 x cm 36 x 9 x 30 - in 9.4 x 73.7 x cm 36 x 9 x 30 - in 9.4 x 73.7 x cm 36 x 9 x 30 - in 9.4 x 73.7 x cm 33 x 4 x 5 - in 83.8 x 6 x cm 36 x 9 x 30 - in 9.4 x 73.7 x cm 36 x 9 x 30 - in 9.4 x 73.7 x cm 36 x 9 x 30 - in 9.4 x 73.7 x cm 40 x 33 x 34 - in 40 x 33 x 34 - in 0.6 x 83.8 x x 83.8 x cm cm 40 x 33 x 34 - in 40 x 33 x 34 - in 0.6 x 83.8 x x 83.8 x cm cm. Based on Input Voltage. 50kW and 70kW CCRs are only available on 480V input 434 (96.9 ) 556 (5. ) 47 (93.7) 480 (7.7) (355. (339.7) 960 (435.4 ) 90 (585.4 ) 40 (639.6 ) 87 (395.5) 50 (5.6) 350 (6.3) 467 (.8 ) 54 (33. ) 770 (349.3 ) 86 (374.7 ) 87 (538.4 ) 38 (66.4 ) 50kw NA 70 x 33 x 34 - in 77.8 x 83.8 x NA NA NA NA 70kW NA cm NA NA NA NA 50 (7.7) 600 (7.) 86 (374.7) 906 (4) 097 (497.6) 30 ( ) 50 (975.) 400 (088.6 ) W Figure 7: Ferroresonant CCR Dimensions Typical of 4-30 kw D H Top View Front View ADB Airfield Solutions All Rights Reserved 9

28 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Dimensions Figure 8: Ferroresonant CCR Dimensions Typical of kw D H Top View W 0 ADB Airfield Solutions All Rights Reserved

29 3.0 Installation L-88 / L-89 CCR Installation This section provides instructions for installing L-88/L-89 constant current regulators (CCRs) (4-70kW/6.6 A/0 A). Refer to the airport project plans and specifications for the specific installation instructions. 3. Unpacking The equipment is shipped ready for installation. Handle equipment very carefully to prevent component damage. Unpack the carton upon receipt and check the contents and their condition. Note any exterior damage to the carton that might lead to detection of equipment damage. If you note any damage to any equipment, file a claim with the carrier immediately. The carrier may need to inspect the equipment. NOTE: Take care to maintain the unit in an upright position when handling the regulator. The Core Shipping Strap (Figure 9 and top left) or the Core Restraining Bracket (Bottom Left) shall be removed after installation. Retain for future shipping. The plastic/fiberglass strap may be left installed in the CCR. 3.. Return Shipping The shipping strap that connects to the top of the CCR core to the frame must be in place for shipping. If you are returning the CCR for repair, and the shipping strap was removed after / bolt and washer () receiving, you must re-install it prior to shipment. Figure 9: IXT Core Shipping Strap SHIPPING STRAP 44A7045 IXT CORE STRAP BRACKET 60A407 /4-0 X 5/8 HX HD (for aluminum strap) /4-0 X HX H (for plastic strap) /4 FLATWASHER /4 SPLIT LOCKWASHER 0.5 HEXBOLT 3xx-N / FLATWASHER / SPLIT LOCKWASHER CHANNEL, IXT CORE STRAP 44A7045-L CHFXX0, CHFXX30 CAUTION Install the Core Shipping Strap Prior to Shipping. CORE RESTRAINT BRACKET 60A kW 0-06 /-3 HX NUT / FLATWASHER / SPLIT LOCKWASHER 44A7045-M7 CHFXX07 44A7045-M CHFXX0, CHFXX5 CORE STRAP EXTENDER PNL, IXT 44A7045-S CHFXX04 ADB Airfield Solutions All Rights Reserved

30 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Installation 3. Installation Recommend lifting for the 4 thru 70kW regulators is to use a forklift from underneath the CCR frame. Lifting points, four 3/4-inch ID eyebolts on the top corners of the CCR frame, are provided per FAA specifications. If lifting eye bolts are used, use either a portable hoist and sling(s) or sling(s) attached from forks on forklift. See Table (dimensions and weights) before lifting. WARNING Read installation instructions in their entirety before starting installation. Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. Make this manual available to personnel installing, operating, maintaining or repairing this equipment. Follow all applicable safety procedures required by your company, industry standards and government or other regulatory agencies. Install all electrical connections to local code. Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All wiring must meet local codes. Route electrical wiring along a protected path. Make sure they will not be damaged by moving equipment. Protect components from damage, wear, and harsh environment conditions. Allow ample room for maintenance, panel accessibility, and cover removal. 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 prior to returning power to the circuit. Failure to follow these warnings may result in serious injury or equipment damage. Place the regulator inside a well ventilated room with sufficient clearance for personnel to inspect and maintain the unit. 3.. Wiring Connections and Startup To install wiring, perform the following procedure: WARNING Read installation instructions in their entirety before starting installation. Installation and operation of the CCR should be performed by personnel qualified to work on high voltage equipment. The high voltage involved with the unit makes it potentially dangerous and may be lethal if contacted by operating personnel. Place wiring for output, input, and remote control only on the right side of the CCR to prevent damage to the PCB that is located on the front Left side of the enclosure. If output, input, and remote control wiring must enter from the left side of the enclosure then wiring must be then routed through conduit where it passes the PCB area. See Figure 0.. Verify the input supply voltage corresponds to the voltage rating on the nameplate of the regulator.. Make sure the front panel rotary selector switch is set to the OFF position. 3. Ground the regulator by making an adequate ground wire (AWG 6 or larger) connection to the external earth ground lug on the regulator. 4. An appropriate disconnect-type cutout or circuit breaker shall be provided outside the regulator for the input power supply lines. 5. Short-circuit the output terminals TB-, TB- using 8 AWG minimum wire to avoid lamp destruction in case of excessive current output. 6. Refer to Table 3 for the recommended input wire. Connect the power supply lines from the disconnect switch or main circuit breaker to the CCR input fuse block F/F or terminal block TB3. Tighten all connections. ADB Airfield Solutions All Rights Reserved

31 Figure 0: Wiring on Right Side of CCR. Front of CCR. Place Conduit and Wire on Right Side of CCR 7. Engage main circuit breaker or disconnect switch to energize the regulator. 8. Turn front panel rotary selector switch to all brightness steps, and verify that current values on the panel ammeter correspond to those in Table 8 for each brightness step. 9. Disengage the main current breaker or disconnect switch to de-energize the regulator. 0. Turn the rotary selector switch to OFF.. Connect remote control lines, if required, to remote control terminal block TB. Use AWG 8, 300 V wire or larger for 0 Vac signals. See Wiring Schematics on page 65 for remote control connections. NOTE: If the ADB Airfield Solutions Advanced Control Equipment (ACE) is used with the Ferroresonant L-88 CCR, refer to the Advanced Control Equipment manual (96A045) or Advanced Control Equipment (ACE) manual (96A0357) for wiring connections to remote control. Table through Table 4 provide the necessary connections for remote control. Terminal B (B0) does not need to be wired. Brightness step B (B0) occurs when the regulator is switched on. Table : Remote 0 Vac Control Connections (3-Step/6.6 A) For this remote intensity step LOW (4.8 A) MEDIUM (5.5 A) HIGH (6.6 A) OFF Connect CCI to CC CC, B30 CC, B00 Not applicable Table 3: Remote 0 Vac Control Connections (5-Step/6.6 A) For this remote intensity step Connect CCI to.8 A CC 3.4 A CC, B 4. A CC, B3 5. A CC, B4 6.6 A CC, B5 OFF Not applicable ADB Airfield Solutions All Rights Reserved 3

32 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Installation Table 4: Remote 0 Vac Control Connections (5-Step/0 A) For this remote intensity step Connect CCI to 8.5 A CC 0.3 A CC, B.4 A CC, B3 5.8 A CC, B4 0 A CC, B5 OFF Nothing. Make sure wiring connections are tight and no wires are shorting across each other. CAUTION Read installation instructions in their entirety before starting installation. Incorrect wiring can damage regulator. Double check all connections. 3. Energize regulator and set rotary selector switch to REM. Operate the CCR by remote control, and verify correct current levels are obtained on all brightness steps. 4. Turn rotary selector switch to OFF and de-energize regulator (disengage disconnect switch or main circuit breaker). Remove short-circuit link between output terminals TB-- and TB-. 5. Connect the 6.6 A or 0 A series lighting circuit to the output terminals/ bushings and tighten all connections. Table 5: Input/Output Connections CCR Size Input Location Output Location 4 thru 30kW with SCO Top of each Fuse Block front of CHF 0kW/08 V component plate right hand side CHF 30kW/08 V CHF 4, 7.5, 0 kw CHF 5,0,30 kw CHF 50, 70 kw Terminal Block (black) Front of component plate right hand side N/A Terminal Block (white) Front of component plate right hand side Top of each Fuse Block front of component plate right hand side Top of each Fuse Block front of component plate top right side Bottom of SCO Lightning Arrestors (VR and VR) on Back of component plate Lightning Arrestors (VR and VR) on Back of component plate Lightning Arrestors (VR and VR) on Back of component plate Lightning Arrestors (VR and VR) on Back of component plate Lightning Arrestors (VR and VR) on Back of component plate 6. The core shipping strap should be removed after installation. Retain for future shipping. Leave the Core Strap Bracket in place for easy re-install. See Unpacking on page. 4 ADB Airfield Solutions All Rights Reserved

33 3.3 Stacking CCR s (Optional) CAUTION Read installation instructions in their entirety before starting installation. Before stacking CCRs larger than 0 kw or stacking more than CCRs, contact the ADB Airfield Solutions Sales Department. To stack CCRs, perform the following procedure:. Remove the four ½ x 3 3/4 HILTI anchor bolts with 4 nuts and lock washers for anchoring the CCRs to concrete, and the four / 3 x ¾ hex head bolts and ½ split lock washers from the stacking kit (Part Number 94A0355).. See Table for anchor bolt template. Use the four ½ x 3.75 Lg HILTI anchor bolts with 4 nuts and lock washers to anchor the CCR to the concrete floor. NOTE: Make sure the clearance behind the CCR is far enough from the wall for easy access to the regulator. Figure : Anchor Bolt Template A B D C CCR A B C D Small.50 in 3.50 in 3.75 in 4.75 in Medium 7.50 in 8.50 in 8.75 in 9.75 in Large 3.50 in 3.50 in 3.75 in in ADB Airfield Solutions All Rights Reserved 5

34 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Stacking CCR s (Optional) Figure : Location of Bolts for Stacking CCRs. Hex Head Bolts and Split Lock washers. ½ x 3 3/4 inch HILTI Anchor Bolt Location. Remove the 4 eye bolts from the anchored CCR.. Stack the second CCR by positioning its 4 holes carefully on top of the holes of the CCR anchored to the concrete floor. 3. Install the 4 hex head bolts and split lock washers (See Figure, Item and Figure 4, Item ). 6 ADB Airfield Solutions All Rights Reserved

35 Figure 3: Stacking Bolt 3. Stacking Bolt. Bottom CCR Anchored to Concrete 3. Top CCR ADB Airfield Solutions All Rights Reserved 7

36 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G SGRS Style Powerpacks (Optional) 3.4 SGRS Style Powerpacks (Optional) CAUTION Read installation instructions in their entirety before starting installation. SGRS Style Powerpacks should be installed using Powerpack lift device. For information on installing SGRS Powerpacks refer to the SGRS Installation Manual. Document number 96A0303. Figure 4: Powerpack Installation in SGRS. Upper Bay Powerpack. Lower Bay Powerpack 8 ADB Airfield Solutions All Rights Reserved

37 3.5 Frames Figure 5: Large Frame Assembly SOUTHCO CAPTIVE SCREW FABRICATE HINGE FROM MCM / CARR #5665A5 /4-0 X / LG. COPPER COATED WELD STUD TYP 8 PLACES 44A6055 DOOR ASSEMBLY SOUTHCO SCREW RETAINER, -6-60A639 REV. B VERTICAL ANGLE INSTALL "PEM" BSO-63-0 FROM FAR SIDE PLACES (ADDED ON REV D) REV D CHANGES INCLUDE DOOR MACHINING SEE 44A6055-A FLAT LAYER FOR SPECIFIC DETAIL 44A6054 FRAME WELDMENT (5) #0-3 X.38 LONG TAPTITE SCREW PAN HEAD, PHILLIPS FOR HINGE SOUTHCO CLIP-ON RECEPTICAL (3 PLACES) 60A637 SIDE FILER 60A638 TOP FILLER 60A636 REAR FILLER SEE MO LOCATIO SIDE AN FABRIC FROM 5 60A637 SIDE FILLER (3) #0-3 X.75 LONG TAPTITE SCREW PAN HEAD, PHILLIPS (3) #0 NYLON WASHER (8) PER PANEL, () SIDE, ADB Airfield Solutions All Rights Reserved 9

38 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Frames 30 ADB Airfield Solutions All Rights Reserved

39 4.0 Operation WARNING Read installation instructions in their entirety before starting installation. Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. Make this manual available to personnel installing, operating, maintaining or repairing this equipment. Contents are static-sensitive. Must be grounded when handling PCB. Operation of a Regulator while overloaded at any step may result in equipment failure or equipment damage. 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 these warnings may result in serious injury or equipment damage. 4. Introduction This section provides the operational procedures listed below for the L-88/L-89 constant current regulator (CCR) (4-70 kw/6.6 A or 0 A). 4. CCR Control Procedures CCR control procedures CCR shutdown procedures CCR adjustment procedures SCO Cutout working positions This subsection describes the regulator operations in local and remote controls. 4.. Local Control See Figure 6. Refer to Table 6 through Table 8 for output current when using local control. The front panel rotary selector switch is used for regulator local control. The rotary switch for the 3-step CCR has five positions; the rotary switch for the 5-step has seven positions. The regulator automatically maintains the output current within ±% of the nominal value for the brightness position selected. Figure 6: Switch (3-Step/5-Step) 3-Step Switch Assembly 5-Step Switch Assembly Table 6: Output Current from Rotary Switch (3-Step/6.6A) If you set the rotary switch to the The result is... following... B0 4.8 A current output B A current output B A current output ADB Airfield Solutions All Rights Reserved 3

40 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G CCR Door Interlock (Optional ) Table 7: Output Current from Rotary Switch (5-Step/6.6 A) Table 8: Output Current from Rotary Switch (5-Step/0 A) 4.. Remote Control See Figure 6. Refer to Table 9 for instructions on how to set up and use remote control. Table 9: Remote Control If... Then CCR Door Interlock (Optional ) 4.4 CCR Shutdown Procedure If you set the rotary switch to the following... B B B3 B4 B5 If you set the rotary switch to the following... B B B3 B4 B5 The rotary switch is set to position REM and remote control wiring is connected to remote control terminal block TB on the regulator Switch is set to OFF No remote control connections exist on terminal block TB (switch is set to REM) The result is....8 A current output 3.4 A current output 4. A current output 5. A current output 6.6 A current output The result is A current output 0.3 A current output.4 A current output 5.8 A current output 0 A current output Remote control of the regulator is possible. The output current of the regulator will correspond to the brightness setting energized by remote 0 Vac or 48 Vdc control signals. Remote control signals will not operate the regulator; that is, turn the regulator on to a particular brightness setting or turn the regulator off. The position REM becomes an additional OFF position; that is, the regulator is de-energized. The optional door interlock disables remote and local control of the CCR when the door is opened. If the door is opened while the CCR is running, the CCR will shut OFF. This is to protect personnel from coming into contact with high voltage electronics. NOTE: Power to the output terminals is now off, and the regulator cannot be energized by remote control signals. Power is still present on the input power terminals and on the internal control circuitry. To bypass the interlock, pull out the plunger of the interlock switch. This will allow remote and local control of the CCR with the door open. See Figure 6. To shut down the CCR, set the rotary switch to position OFF. The door interlock removes power to the CCR when the door is opened. Pull out the plunger fully to bypass. NOTE: Power to the output terminals is now off, and the regulator cannot be energized by remote control signals. Power is still present on the input power terminals and on the internal control circuitry. To remove input power, disengage disconnect switch or external circuit breaker. 3 ADB Airfield Solutions All Rights Reserved

41 4.5 CCR Adjustment Procedures 4.5. Output Current Adjustment This subsection provides regulator adjustment procedures. NOTE: The regulator has been adjusted at the factory to provide the nominal output current levels as given in Table 6. If the current level settings need to be adjusted, read the following warning statement before proceeding. WARNING Read the instructions in their entirety before starting installation. Only personnel qualified to work on high voltage systems should attempt to make any adjustments on the constant current regulator. Turn the rotary selector switch on the front panel of the regulator to position OFF. Remove input power before servicing control circuitry. Never service the regulator when it is in protective shutdown mode, Remote controls or power fluctuations can restart the regulator. To adjust the output current, perform the following procedure:. Connect a clamp-on true rms-reading instrument (such as a Fluke 87 multimeter with a current clamp) around one of the output current leads. See Figure 7. Figure 7: Output Current Clamp TRUE RMS MULTIMETER FLUKE 87 ma Auto-Range Button CCR OUTPUT MIN MAX RANGE HOLD H V ~ V ))))) REL Hz PEAK MIN MAX ))))) Ω mv ma A ua ~ ~ Select ma OFF A ma ua COM VΩ 0A MAX FUSED 400mA MAX FUSED! 000V MAX Current Clamp To Airfield Lighting Series Circuit Red Lead ma Black Lead COM NOTE: Make sure the meter is set on the AC current scale. Because the output current waveform is not a true sine wave, the ammeter must be of the true-rms (root mean squared) type. Field instruments such as clamp-on ammeters and Simpson voltmeters will give erroneously low readings.. Energize the regulator locally, and set the rotary selector switch to the maximum brightness position B5 or B See Figure 8. Carefully adjust R40 on the universal regulator controller board until the desired current is measured on the meter. WARNING Read the instructions in their entirety before starting installation. Dangerous voltages are present on the URC PCB. It is strongly recommended that a nonconductive screwdriver be used during calibration to protect personnel and the PCB from accidental damage. ADB Airfield Solutions All Rights Reserved 33

42 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G CCR Adjustment Procedures Figure 8: R40 (URC Board) R Overcurrent Adjustment No adjustment is necessary. 34 ADB Airfield Solutions All Rights Reserved

43 4.6 SCO Cutout Working Positions See Figure 9. The SCO cutout can be plugged in three orientations. For additional information on the SCO cutout, refer to manual 96A094, SCO Cutout.. Figure 9: Handle Orientations In the operation position, the regulator is connected to the series circuit, and the microswitch is activated. NOTE: An activated microswitch means that the normally open contact is closed and that the normally closed contact is open. For interlocking with the CCR, only the normally open contact is used. When the cover is removed, the microswitch is not activated. When the microswitch is not activated local and remote control is disabled. Figure 0: SCO Cutout Operation Position Microswitch NO NC Regulator Series Circuit Ground See Figure. In the maintenance position, the regulator and the series circuit are both shorted and grounded. The microswitch is not activated. Figure : SCO Cutout Maintenance Position NO NC Microswitch Regulator Series Circuit Ground You can determine the current orientation by observing the cutoff corner of the handle. ADB Airfield Solutions All Rights Reserved 35

44 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G SCO Cutout Working Positions See Figure. In the test and measure position, the insulation resistance of the series circuit can be measured. The regulator operation can be tested under short-circuited output conditions. In the test and measure position, the regulator is shorted and grounded; the series circuit is shorted and connected to the measurement socket. The microswitch is activated. Figure : SCO Cutout Test and Measure Position NO Microswitch NC Regulator Series Circuit Measurement Socke Ground 36 ADB Airfield Solutions All Rights Reserved

45 4.7 Application Notes Monitorin g Option Description Application 0 None Standard L-88 supplied with analog ammeter ALCMS Scanning Monitor Interface (SMI) ALCMS Scanning Monitor Ready (SMR) L-89 Monitoring (ACE TM ) Insulation Resistance Monitoring System (IRMS) Ready L-89 Monitoring (ACE) and IRMS L-88 with Digital Power Meter The SMI option adds Primary Power and Remote/Local monitoring relays. Dry relay contacts are connected to a dedicated terminal block for each monitored point. Typical application: connecting ADB L-88 CCR to ALCMS or L-87 that is manufactured by others. Note that this option does not provide dedicated output current or voltage transformers. The SMR option adds several monitoring relays (including Primary Power and Remote/Local) and also CCR output current and voltage transformers. All monitored signals are connected to a dedicated terminal block. Application only for connecting ADB L- 88 CCR to ADB Gen I/II ALCMS scanning monitoring system. Includes FAA L-89 monitoring equipment. If application is for connection to ADB L-890 ALCMS: Add a /A to end of Ordering Code. The ACE unit will then be programmed to provide monitoring data via dual-redundant communication links. If application is for a stand-alone L-89 CCR: Ordering Code is not changed. The ACE unit is programmed to activate a dry contact closure if a fault is present. The fault alarm can then be connected to any external monitoring system. This option adds an IRMS board in the CCR. Application: connection to externally mounted ADB ACE unit. Includes FAA L-89 and IRMS equipment. If application is for connection to ADB L-890 ALCMS: Add a /A to end of Ordering Code. The ACE unit will then be programmed to provide monitoring data via dual-redundant communication links. If application is for a stand-alone L-89 CCR with Insulation Resistance Monitoring: Ordering Code is not changed. The ACE unit is programmed to activate a dry contact closure if a fault is present. The fault alarm can then be connected to any external monitoring system. This option replaces the analog ammeter with a Digital Power Meter. The Digital Power Meter is used on L- 88 CCRs to indicate True RMS output current, voltage, VA, and watts. It can also be set to activate an alarm if there is a 0% or 5% drop in the load (Low VA). ADB Airfield Solutions All Rights Reserved 37

46 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Digital Power Meter Calibration (optional) 4.8 Digital Power Meter Calibration (optional) 4.8. Display Figure 3: Meter Display Function Buttons Display 4.8. Function Buttons Figure 4: Function Buttons Scroll Up Scroll Down Enter (Save) DPM Displays NOTE: Scroll through displays using the Scroll Up and Scroll Down buttons. After 30 seconds the display will revert to the default setting of A rms. 38 ADB Airfield Solutions All Rights Reserved

47 4.8.4 Calibration Procedure NOTE: The following is needed to calibrate the DPM: Calibrated true-rms AC multimeter with current clamp. High Voltage probe capable of reading 5,000V true-rms. Ability to apply a shorted load to CCR. Ability to apply a field load or equivalent resistive load to CCR. WARNING Read the instructions in their entirety before starting installation. The CCR must be operating during calibration. Risk of electrical shock. Failure to observe this warning may result in personal injury, death, or equipment damage. Proceed as follows to calibrate the DPM. Depress and hold the top SCROLL button and the bottom ENTER button simultaneously for 3 seconds (See Figure 4) to enter the calibration menu. Figure 5: Calibration Menu Menu The SCROLL buttons are used to select items on the calibration menu. Scroll to the desired selection and then press the ENTER button. See the following steps to calibrate the DPM. Current Calibration During calibration you will be asked to wait until displayed cnt values settle. These cnt values are internal A/D values as measured by the power meter s microprocessor. These values will always vary slightly while the meter is measuring voltage and current. They are displayed to give feedback that the load has settled and the meter is obtaining a steady reading. NOTE: TIP: At each calibration step, wait until the thousands digit has settled before proceeding. A. Irms High Step (6.6 amps) Using the SCROLL buttons, select Irms and follow the prompts to calibrate the Irms. Short the CCR output and then turn the CCR to the highest step. Measure the CCR output current with a true-rms current meter and adjust the current value on the meter display to match. NOTE: If the CCR output needs to be adjusted follow the procedure in CCR Adjustment Procedures on page 33. Wait until the Icnt and V Cnt values settle and select the ENTER button. Figure 6: Irms High Step Calibration B. Irms Low Step (.8 amps) ADB Airfield Solutions All Rights Reserved 39

48 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Digital Power Meter Calibration (optional) Repeat the previous steps and follow the prompts for the Low CCR step. C. Press ENTER button to save. Figure 7: Irms Low Step Calibration Voltage Calibration At the calibration screen, scroll to Vrms on the menu and press the ENTER button. The next screen (Figure 8) shows the last calibration voltage set points and internal A/D numbers. Select Y (yes) to enter the Vrms calibration. Figure 8: Vrms Calibration A. Vrms High Step Loaded WARNING Read the instructions in their entirety before starting installation. Use proper safety procedures when adjusting the meter display. Following screen prompts, apply the field load or equivalent resistive load to the CCR at the high step. Measure the Vrms at the CCR output terminals with the High Voltage probe. Adjust the meter display to match the measured voltage. Wait for the cnt-number to settle (this may take a couple minutes while the load heats up) and then press the ENTER button. Figure 9: Vrms High Step Loaded B. Vrms - Off Follow the prompts to turn off the CCR. When the Cnt has settled press the ENTER button. (Cnt may not go to zero) Figure 30: Save Vrms Calibration 40 ADB Airfield Solutions All Rights Reserved

49 5.0 Maintenance and Repair 5. Maintenance Schedule This section provides maintenance and repair instructions for the L-88 and L-89 CHF Aircooled CCRs. WARNING Read installation instructions in their entirety before starting maintenance procedures. Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. Follow all applicable safety procedures required by your company, industry standards and government or other regulatory agencies. Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All wiring must meet local codes. Protect components from damage, wear, and harsh environment conditions. Allow ample room for maintenance, panel accessibility, and cover removal. 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 prior to returning power to the circuit. Failure to follow these warnings may result in serious injury or equipment damage. This section provides preventive maintenance for L-88 /L-89 constant current regulators (CCRs) (4-70 kw 6.6 A or 0 A). To keep the L-88/L-89 CCRs operating efficiently, follow a preventive maintenance schedule.refer to Table 0. Table 0: L-88/L-89 CCR (4-70 kw/6.6 A/0 A) Maintenance Interval Maintenance Task Action Daily Monthly Annually Unscheduled Check all control equipment for proper operation. Check input voltage. Check and record output current on each brightness step. Check relays, wiring and insulation. Check local and remote control (if used) on each brightness step. If input voltage is not within -5% to +0% of the nominal value specified on the nameplate of the regulator, notify power company to correct voltage. Use a true-rms reading instrument. Adjust current levels if out of tolerance. Refer to Adjustment Procedures in the Operation section. Refer to Output Current and Limits on page for the current range for the 3- Step and 5-Step CCRs. Replace contacts that are excessively burned or pitted. Operate the local control switch to check for proper operation of relays and contactors. Make sure input and output connections are tight and that no damaged wires or damaged insulation exists. Inspect housing for rust spots. Clean and touch-up rust spots with paint. Inspect lightning arrestor connections. Perform a short-circuit test. Perform an open-circuit test. Check load on regulator. Tighten any loose connections. Replace charred or burnt wiring or broken arrestors. Refer to Short-Circuit Test in this section. Refer to Open-Circuit Test in this section. At installation and subsequent load changes make sure that the output rms-voltage times the output true-rms current does not exceed the rated load on the nameplate of the regulator. ADB Airfield Solutions All Rights Reserved 4

50 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Maintenance Schedule 5.. Short-Circuit Test WARNING Read the instructions in their entirety before starting installation. Only personnel authorized to work on high-voltage equipment should perform maintenance on the regulator. Since high open-circuit voltages may result by opening the primary of a series lighting circuit, only personnel authorized to work on high-voltage equipment should be allowed to perform the short-circuit test. To perform the short-circuit test, perform the following procedure:. Remove input power to the regulator (turn off disconnect switch or main circuit breaker) and turn the rotary switch to OFF.. Remove leads from output terminals and bushings. Use AWG 8 or larger wire to short output bushings. 3. Energize the regulator and turn the rotary selector switch to the lowest brightness step () and then to the remaining brightness steps. Check the output current on the ammeter at each step. NOTE: The output current should be within the tolerance given in Output Current and Limits on page. The panel meter is intended to indicate function. Any calibrations should be performed with a calibrated true-rms current meter. 5.. Open-Circuit Test 4. If the output current is not within the limits specified in Output Current and Limits on page check the input voltage to the regulator. The supply voltage should be within 5% to +0% of the nominal input voltage given on the regulator nameplate. Refer to Adjustment Procedures in the Operation section. 5. Turn off disconnect switch or main circuit breaker to remove input power to regulator. 6. Disconnect the shorting jumper and reconnect output cables. 7. Close input-power disconnect switch or main circuit breaker. WARNING Read the instructions in their entirety before starting installation. Only personnel authorized to work on high-voltage equipment should perform maintenance on the regulator. Since high open-circuit voltages may result by opening the primary of a series lighting circuit, only personnel authorized to work on high-voltage equipment should be allowed to perform the open-circuit test. To perform the open-circuit test, perform the following procedure:. Remove input power to regulator (turn off disconnect switch or main circuit breaker) and turn the rotary switch to OFF.. Disconnect cables from the output terminals and bushings. 3. Turn on input power to the regulator. 4. Turn the rotary switch to the lowest brightness position (). The open-circuit protective device should automatically de-energize the regulator in less than seconds. 5. Turn the rotary switch to OFF. The open-circuit protective device should reset. 6. Turn the rotary switch to position. The regulator should turn on and then de-energize in less than seconds. 7. If regulator operation is satisfactory, turn rotary switch to OFF, and turn off disconnect switch or main circuit breaker before reconnecting the load. 8. After the load has been reconnected, turn on input power to the regulator. 4 ADB Airfield Solutions All Rights Reserved

51 5. Troubleshooting 5.. Preliminary Troubleshooting WARNING Read the instructions in their entirety before starting installation. Only personnel authorized to work on high-voltage equipment should perform maintenance on the regulator. Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Since high open-circuit voltages may result by opening the primary of a series lighting circuit, only personnel authorized to work on high-voltage equipment should be allowed to perform the open-circuit test. De-energize regulator by turning rotary switch S to OFF, and remove input power to regulator by turning off disconnect switch or main circuit breaker. Discharge capacitors and ground output terminals bushings by using a grounding rod prior to touching any parts. If the regulator de-energizes, the output circuit could be interrupted by an overcurrent, open-circuit, or undervoltage condition. Before inspecting the output circuit. Place rotary selector switch S in the OFF position and turn off disconnect switch or main circuit breaker. Without this precaution, a dip in the power line may reset the regulator and turn it on, resulting in an output voltage of thousands of volts which can cause serious injury or death. Contents are static-sensitive. Must be grounded when handling PCB. Short the output terminals before switching the regulator on. The wire should be AWG 8 or larger. The following is a check list of initial steps to perform. Visually examine all areas of the CCR. Do burnt or loose connections/parts exist? Is the input voltage present and within +0 to 5% of nominal? Check all the fuses. Are the wire harness connectors to the control board fully seated? Have the PCBs been adjusted in accordance with the instruction manual? If the CCR works in local but not Remote, check the voltage on the Remote control lines. Can the CCR be re-energized by turning the rotary switch from OFF to Step B (B0)? Short the output of the CCR with an AWG 8 wire, and turn on the CCR. If the regulator operates normally, the problem is probably load related. If the CCR turns on and then shuts off after a few seconds and the ammeter has a high current reading, the problem is overcurrent. Adjust the output current accordingly. If the output current is not adjustable, replace the control board restart the regulator. If the CCR still fails in overcurrent, replace the SCR and restart. ADB Airfield Solutions All Rights Reserved 43

52 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Troubleshooting 5.. L-88 General Troubleshooting This subsection provides general troubleshooting procedures for the L-88 CCR. WARNING Read the instructions in their entirety before starting installation. Only personnel authorized to work on high-voltage equipment should perform maintenance on the regulator. Since high open-circuit voltages may result by opening the primary of a series lighting circuit, only personnel authorized to work on high-voltage equipment should be allowed to perform the open-circuit test. Operating a regulator for long periods of time while seriously overloaded may cause the regulator to overheat. Table : Problem Possible Cause Corrective Action. Regulator not turning on. Regulator turns on but de-energizes suddenly 3. Output Current always 6.6 A/0 A or more 4. Output Current always 4.8 A or less for 3-Step CCR or.8 A or less for 5- Step CCR or 8.5 or less on 0 A Main power supply off Switched off due to overcurrent Incorrect external wiring Blown fuse Defective URC PCB Output circuit interrupted Defective printed circuit board Overcurrent condition Universal regulator controller not calibrated Overcurrent condition Defective control board SCRs always conducting Defective Ferroresonant resonant circuit (transformer or capacitor) CCR overload Verify presence of input voltage. Switch regulator off in local. Wait for seconds and check to see if the regulator now operates correctly. If the regulator works correctly in local but not in Remote, check the Remote control signals. Replace any blown fuse. Check the input supply voltage and make sure that it is between 5% and +0% of the nominal value listed on the CCR nameplate. Replace URC PCB. Apply a short to the regulator output. Turn the regulator on. If the regulator works correctly, repair the lighting circuit. Follow all safety precautions in this manual. Replace regulator controller. Verify that SCR is triggering by replacing the PCB. Check feedback transformer T5 for damage and proper connections. Polarity does not affect operation. Compare input voltages across J8-4 to J8-3 with those in Output Current Monitor Circuitry on page 5. If the voltage at the terminals is correct for the selected step and the output is not correct, and the difference cannot be corrected by calibrating the regulator as specified in Output Current Adjustment in the Operation section. Check SCRs and wiring. Replace SCR. Refer to Problem # in this table. With regulator set on Step B00 (B5), adjust R40 until a current reading of 6.6 A or 0 A is measured. Check remaining steps to verify the values from Output Current and Limits on page. Refer to problem # in this table, Regulator turns on but de-energizes suddenly. If problem exists in Remote and local control, replace universal regulator controller. Verify SCR is triggering by replacing PCB. Check SCRs and wiring for shorts in SCR circuitry. Replace SCR snubber assembly. Replace SCR. Visually inspect capacitors for damaged housing or wire connections. Visually inspect transformer for damaged coils, connections, and/or wiring. Faulty capacitors will exhibit a bulging case. Remove section of load. 44 ADB Airfield Solutions All Rights Reserved

53 Problem Possible Cause Corrective Action 5. More than seconds required for CCR to deenergize on open-circuit load 6. Short lamp life and/or high output current reading on panel ammeter 7. Regulator not indicating proper current Faulty overcurrent protection Replace URC PCB. Incorrect output current adjustment Refer to Output Current Adjustment on page 33. Faulty overcurrent protection Incorrect output current adjustment Current meter not calibrated or faulty Replace URC PCB. Refer to Output Current Adjustment in the Operation section. Refer to Problem # in this table. Turn the regulator to the top step (6.6 A/0 A). Verify the current with a true-rms current meter. If the meter is not accurate, adjust the meter with the screw on the front cover. For systems equipped with ACE, refer to: Advanced Control Equipment (ACE) manual 96A087 or Advanced Control Equipment (ACE) manual 96A0357 for display calibration procedures. 8. Regulator operates by the local control switch but not by Remote control 9. Ammeter on CCR oscillates and loud noise occurs Refer to Problem # in this table. The rotary switch on the input module not set to REM Set the rotary switch to REM. Blown fuse Check fuse F5. Check connections on Remote terminal block TB. If 0 Vac Remote control signals are used, use an AC Loose or broken Remote control wires voltmeter (300 Vac scale) to verify correct signals are received at the CCR. Incorrect wire connections Refer to Table through Table 4. SCR drive not working properly Check connections at SCR module. Replace URC PCB. Refer to Problem # in this table. Either reduce the load or replace the regulator with a larger kw CCR. 0. Output current not able to be adjusted up to 6.6 A/0 A Regulator load too large When overloaded, the regulator may make a faint bouncing sound as the controller bounces against the upper control limits. NOTE: This problem can also be verified by shorting the output of the CCR and verifying output current can be adjusted correctly in each step. Increase load on regulator.. 5-Step regulator (in Steps or ) emitting loud hum, not indicating proper current, and operating erratically Light inductive load (for example, signs) If you cannot increase the load, verify that you are dealing with the right problem by placing a current clamp on the output of the regulator and measuring the frequency of the output. Investigate to see if the problem occurs in Highest Step 5.3 Additional L-89 General Troubleshooting Procedures For additional L-89 CCR general troubleshooting procedures, refer to the Troubleshooting section in manuals: 96A087, Advanced Control Equipment (ACE ) or ADB Airfield Solutions All Rights Reserved 45

54 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Component Replacement Procedures 5.4 Component Replacement Procedures 96A0357, Advanced Control Equipment (ACE ) Removing and Replacing URC PCB. Turn CCR local switch to the OFF position. Figure 3: URC PCB 5.4. Removing and Replacing Dual SCR Module Assembly. Remove and lock out/tag out primary power to the CCR at the breaker panel. 3. Lock out/tag out the SCO in the maintenance position. 4. Loosen the door latch screws and open the CCR door. 5. Unplug green connectors J8, J, J, J3, J4, and J5 from the PCB. 6. Disconnect the ribbon cable from J6 by pressing out on the tabs at both sides of the ribbon connection and pull the cable away from the board. 7. Remove the 4 screws at the 4 corners of the PCB. Remove the ground wire from the top right corner. Remove and label the ground wire from the top left corner of the PCB. 8. Mount the new PCB by replacing the 4 screws at the corners of the PCB including the ground wire on the top right corner. 9. Plug the ribbon cable back into J6 by pressing it in. It is keyed and will only go in one way. Also verify the tabs on the side have locked into place. 0. Plug in all of the green connectors to the board. J8, J, J, J3, J4, and J5.. Close the CCR door and loosen the door latch screws.. Restore the SCO to the ON position. 3. Restore primary power to the CCR at the breaker panel. 4. Turn the CCR local switch to the REM position. See Internal Wiring Schematic, 43A5.dwg in Wiring Schematics on page ADB Airfield Solutions All Rights Reserved

55 Figure 3: Dual SCR Module Assembly #0 Split Lock Washer ( or 4 each) and ¼-0 X / Hex Head Screw ( or 4 each). Turn CCR local switch to the OFF position.. Remove and lock out/tag out primary power to the CCR at the breaker panel. 3. Lock out/tag out the SCO in the maintenance position. 4. Open the CCR front door by loosening the 3 door screws. 5. Remove wire 300 and the ground wire from the top lug of the SCR using a /6-inch socket. *note: There are different versions of this SCR so hardware may vary. 6. Remove wire 30 from the bottom lug of the SCR using a /6-inch socket. 7. Pull the 4 colored gate wires from the bottom of the SCR. 8. Remove the SCR from the regulator by removing the () 5/3-hex mounting screws. Clean the heat-sink surface with a dry rag. 9. The replacement SCR will arrive mounted to a rectangular metal plate. 0. Remove the SCR from the attached plate by removing the () 5/3-hex mounting screws from the new SCR and the mounting it to the existing plate in the front of the regulator. Place a thin layer of thermal paste on the heat-sink prior to attaching the SCR.. Once the SCR is mounted in the CCR, connect wire 300 and the ground wire to the top lug of the SCR.. Connect wire 30 to the bottom lug of the SCR. 3. Connect the colored gate wires according to the documentation supplied with the replacement SCR. Different versions of the SCR require these gate wires to be connected in a different order, refer to the documentation shipped with the replacement SCR. 4. Close all doors and replace all panels. 5. Restore the SCO to the ON position. 6. Restore primary power to the CCR at the breaker panel. 7. Turn the CCR local switch to the REM position. ADB Airfield Solutions All Rights Reserved 47

56 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Component Replacement Procedures Removing and Replacing Contactor. Turn CCR local switch to the OFF position. Figure 33: CCR Power Contactor Contactor #40/0 #400/03 Retaining Screw #04 #05 #50 # Removing and Replacing Input Lightning Arrestors (front of Component Mounting Plate). Label the wires. 3. Remove and lock out/tag out primary power to the CCR at the breaker panel. 4. Lock out/tag out the SCO in the maintenance position. 5. Open the CCR front door by loosening the 3 door screws. 6. Loosen the wire retaining lugs for 0, 03, 04 and 05 and disconnect. See Internal Wiring Schematic, 43A5.dwg in Wiring Schematics on page Label any wires not labeled prior to disconnecting them. 8. Remove wires 400 and 40 from the top connectors of the contactor. 9. Remove the wires 53 and 50 from the contactor coil connections at the bottom of the contactor. 0. Remove the 3 mounting screws until the contactor is free.. Replace the contactor. Tighten the contactor retaining screws on the contactor plate.. Connect wires 53 and 50 to the contactor coil connections at the bottom of the contactor. 3. Connect wires 400 and 40 to the top connectors of the contactor. 4. Connect the wires for 0, 03, 04 and 05 and tighten retaining lugs. 5. Close the CCR front door by tightening the 3 door screws. 6. Restore the SCO to the ON position. 7. Restore primary power to the CCR at the breaker panel. 8. Turn the CCR local switch to the REM position.. Turn CCR local switch to the OFF position.. Remove and lock out/tag out primary power to the CCR at the breaker panel. 3. Lock out/tag out the SCO in the maintenance position. 4. Open the CCR front door by loosening the 3 door screws. 48 ADB Airfield Solutions All Rights Reserved

57 5.4.5 Removing and Replacing Output Lightning Arrestors (front of Component Mounting Plate) 5. Loosen the wire retaining screws for 00, 40, 0, 403, 80 and 803 and disconnect. See Internal Wiring Schematic, 43A5.dwg in Wiring Schematics on page Remove the top two of (4) #0 x 3 pan-head screws and loosen the bottom two screws until the arrestors are free. 7. Replace the Input Lightning Arrestor assembly. Replace the two top screws on the assembly plate and tighten all four until the arrestors are secure. 8. Connect the wires for 00, 40, 0, 403, 80 and 803 and tighten retaining screws. 9. Close the CCR front door by tightening the 3 door screws. 0. Restore the SCO to the ON position.. Restore primary power to the CCR at the breaker panel.. Turn the CCR local switch to the REM position.. Turn CCR local switch to the OFF position.. Remove and lock out/tag out primary power to the CCR at the breaker panel. 3. Lock out/tag out the SCO in the maintenance position. 4. Remove the side panel of the CCR, by removing the 8 mounting screws. Be careful as you will also need to disconnect the ground wire attached from the frame to the panel. Figure 34: Output Lightning Arrestors 5. Loosen the /6-inch wire retaining nuts for 00, 0, 03, ST, ST and 0 and disconnect. 6. Remove the (4) #0 x 3 pan-head screws and retain until later. 7. Replace the Input Lightning Arrestor assembly. Replace and tighten the screws on the assembly plate. 8. Connect the wires for 00, 0, 03, ST, ST and 0 and tighten retaining nuts. 9. Connect the ground wire from the frame to the side panel. 0. Put the side panel back on the CCR with the 8 screws.. Restore the SCO to the ON position.. Restore primary power to the CCR at the breaker panel. 3. Turn the CCR local switch to the REM position. ADB Airfield Solutions All Rights Reserved 49

58 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Component Replacement Procedures 50 ADB Airfield Solutions All Rights Reserved

59 6.0 CHF Parts and Mechanical Drawings Figure 35: Ordering Code Amperage 66 = 6.6A output 0 = 0A output Size 04 = 4kW, 6.6A only 07 = 7.5kW, 6.6A only 0 = 0kW, 6.6A only 5 = 5kW 0 = 0kW 30 = 30kW 50 = 50kW, 0A only 70 = 70kW, 0A only Ordering Codes Output Range 3 = 3-step without Series Cutout 4 = 3-step with Series Cutout 5 = 5-step without Series Cutout 6 = 5-step with Series Cutout Input Voltage = 08, 4-30kW only = 40, 4-30kW only 3 = = 347, 4-30kW only 5 = 0, 4-30kW only CHFXXXX-XXXX Monitoring Options (See Application Notes) 0 = None (Standard L-88) = ALCMS Scanning Monitor Interface = ALCMS Scanning Monitor Ready 3 = L-89 Monitoring (ACE) 4 = Insulation Resistance Monitoring System (IRMS) Ready 5 = L-89 Monitoring (ACE) and IRMS 6 = L-88 with Digital Power Meter CCR Input/Output Monitoring 0 = No optional CCR input or output circuit monitoring A = With L-89 or IRMS monitoring; without optional input CCR monitoring 3 G = With L-89 or IRMS monitoring; with optional input CCR monitoring 3 Notes A ferroresonant CCR is preferred for airports that require low output harmonic content (EMI) or that have varying loads, such as Runway Guard Lights using incandescent (tungsten-halogen) lamps, L-849 REILs using xenon flash lamps, or Runway Status Lights (RWSL) Runway Guard Lights using incandescent (tungstenhalogen) lamps should be powered with ferroresonant type CCRs and not with thyristor type CCRs 3-step, 0A is not standard FAA operation. ADB Airfi eld Solutions can offer a non-etl Certifi ed Style, Class CCR for dedicated 5.5A sign circuits or other needs. Please contact the ADB Sales Department for more details. Used only with Monitoring Options 0,,, and 6. 3 Used only with Monitoring Options 3 and 5. ADB Airfield Solutions All Rights Reserved 5

60 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G CHF Parts and Mechanical Drawings Figure 36: CHF 4 kw CHF6604-XXXX SURGE ARRESTOR MTG BRACKET 60A34 CAPACITOR PLATE ASSEM., CHF SMALL FRAME 44A CORE LIST: 08 PWR TX, IXT, 4KW, 480V, 6.6A 0 PWR TX, IXT, 4KW, 347/480V, 6.6A 3 PWR TX, IXT, 4KW 08/0/40V 6.6A L-88 METER KIT, SIG SRS REGULATORS 44A7050-F66 ACE II INTERNAL LCD DISPLAY WITH LOM 44A K COMP PLT (IXT) 3/5S, 40V, 6.6A, L-88 44A K COMP PLT (IXT) 3/5S, 40V, 6.6A, L-89 44A K COMP PLT (IXT) 3/5S, 40V, 6.6A, L-88+ IRMS 44A K COMP PLT (IXT) 3/5S, 40V, 6.6A, L-89+ IRMS 44A K COMP PLT (IXT) 3/5S, 40V, 6.6A, L-88 + DPM 44A K COMP PLT (IXT) 3/5S, 480V, 6.6A, L-88 44A K COMP PLT (IXT) 3/5S, 08V, 6.6A, L-89 44A K COMP PLT (IXT) 3/5S, 480V, 6.6A, L-88+ IRMS 44A K COMP PLT (IXT) 3/5S, 480V, 6.6A, L-89+ IRMS 44A SIDE VIEW 4KW L-88 SHOWN 5 ADB Airfield Solutions All Rights Reserved

61 Figure 37: CHF 4KW Component Plate Parts KIT# 94A034 FOR S CUTOUT VERSIONS KIT# 94A0335 FOR SMI (/XX) VERSIONS. KIT# 94A0334 FOR SMR VERSIONS (/XX). (TERMINAL BLOCK LOC. HERE) See FUSE Table 3 FUSEBLOCK see table CIRCUIT VOLTAGE MONITOR ASSY,6.6 AMP 44A636-0 HARN ASSY, CCF, COMP. PLT, SM FRM 44A636- FUSE BLOCK 47A006 FUSE /A 50V SLO-BLO 47A09 47A008 FUSE A 500V 47A03 FUSE A 50V SB FUSEHOLDER 49A0084 DISCONNECT ADAPTER M-M-F IRMS ONLY FUSE BLOCK 47A006 FUSE /A 50V SLO-BLO 47A09 INPUT VARISTORASSEM 94B00 CONT P 5 FLA 0VAC COIL 53A04-5 MOUNTING CLIP, SIRIUS SZ0 CONTACTOR 63A53? PCB ASSY URC-II FERRO REGULATOR, IXT 44A7075-4KW L-89 SHOWN PCB ASSY, ACE II IRMS-LI (LOW IMPEPANCE) 44A6397 ALTERNATE LOCATION FOR IRMS PCB IF USED WITH PT 35A A590 LOCATION (SMR ONLY) SEE NOTE 7 NOTE: See ALN74 to replace the F and F fuse block with a circuit breaker. ADB Airfield Solutions All Rights Reserved 53

62 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G CHF Parts and Mechanical Drawings Figure 38: CHF kw CHF665-XXXX 44A658 FROM DPM KIT# 94A045 L-88 METER KIT, CHF REGULATORS 44A7050-F66 ACE II LCD DISPLAY WITH LOM 44A ACE II LCD DISPLAY WITH LOM 44A6508- RIBBON CABLE ASSY,34-POS W/CONNS,4" 89A009-4 PCB ASSY 34-PIN HDR/SW ADAPTOR 3-STEP 44A678 CAP PLTASSY 0-5KW IXT 44A703-XX KW IXT PWR TX, V, 6.6A/0A CHF Core See Table 30 CURRENT TX 6.6/6.6 L88 35A063 SURGE ARR. KIT, SIG. SRS. REGULATOR, 6KV 94A Component Plate Assembly 44A KVA, 40V, 6.6A IXT 44A KW 3/5S L89 40V A KW 3/5S L88 40V 6.6A IRMS ONLY 44A KW 3/5S L89+ IRMS 40V 6.6A IRMS 44A KVA, 40V, 6.6A L-88 W/DPM 44A KVA, 480V, 6.6A IXT 44A KW 3/5S L88 480V 6.6A SMI ONLY 44A KW 3/5S L88 480V 6.6A SMR 44A KW 3/5S L89 480V 6.6 IXT 44A KW 3/5S L88 480V 6.6A IRMS ONLY 44A KW 3/5S L89+ IRMS 480V 6.6A 44A A A A A A A A A A A A A A A A KVA, 6.6A, V 0 KVA, 6.6A, V 0 KVA, 6.6A, V 0 KVA, 6.6A, VS 0 KVA, 6.6A, V 0 KVA, 6.6A, V 0 KVA, 6.6A, V 0 KVA, 6.6A, V 7.5 KVA, 6.6A, V 7.5 KVA, 6.6A, V 7.5 KVA, 6.6A, V 7.5 KVA, 6.6A, V 7.5 KVA, 6.6A, V 7.5 KVA, 6.6A, V 7.5 KVA, 6.6A, V 7.5 KVA, 6.6A, V 54 ADB Airfield Solutions All Rights Reserved

63 Figure 39: CHF kw CHF665-XXXX DUAL SCR MOD. ASSY, 4-0KW IXT 8A0056 CIRCUIT VOLTAGE MONITOR ASSY,6.6 AMP 44A636-0 USE 44A636/ FOR 0A VERSION, HOSE CLAMP,/"WIDE BAND, RG. 77A076-9 FERRO RESONANT CCR FCS MTG PL 60A59 FUSE ASSEM., F5-F9 RWSL, CHF 44A770 FUSE ASSEM., F5-F9 RWSL, CHF 44A770/L-88 TX 40/347/480-0/4CT 0.5A 35A0546 TX 40/347/480-0/4CT 0.5A 35A0539 KIT# 94A034 FOR S CUTOUT VERSIONS A A /4" PUSH MOUNT WIRE TIE 6A045 FUSE 3A 500V SLO-BLO MIDGET 47A087 FUSE A 500V 47A008 FUSE A 50V SB 47A03 47A007 47A A A A A07 47A093 47A009 47A A0094 FUSE 60A 50V FUSE 80A 50V FUSE 50A 50V FUSE 50A 600V FUSE 45A 50V FUSE 80A 600V FUSE 35A 600V FUSE 5A 600V FUSE 30A 600V FUSE 70A 50V FUSEBLOCK 3-60A 600V 49A008 FUSE BLOCK 6-00A 50V 49A009 FUSEBLOCK /0-30A 600V 49A008 FUSE BLOCK 3-60A 50V 7A0098 COMP PLATE HARN ASSY, CCF, COMP. PLT, KW 44A636- PCB ASSY, ACE II IRMS-LI (LOW IMPEPANCE) 44A6397 FRONT VIEW GROUND LUG 7A000 VARISTORS ARE PART OF KIT 94B00. 53A04-40 CONT P 40 FLA 0VAC COIL 53A04/50 CONT P 50 FLA 0VAC COIL 53A04/90 CONT P 90 FLA 0VAC COIL 53A04-75 CONT P 75 FLA 0VAC COIL 53A04/60 CONT P 60 FLA 0VAC COIL 44A7046/535 { 5KW } SHOWN 44A7047/XXX { 0KW } 44A7069/XXX { 7.5KW } NOTE: See ALN74 to replace the F and F fuse block with a circuit breaker. ADB Airfield Solutions All Rights Reserved 55

64 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G CHF Parts and Mechanical Drawings Figure 40: CHF 0-30 kw CHF6630-XXXX RIBBON CABLE ASSY,34-POS W/CONNS,4" 89A009-4 PCB ASSY 34-PIN HDR/SW ADAPTOR 3-STEP 44A SURGE ARR. KIT, SIG. SRS. REGULATOR, 6KV 94A CHF SEE CORE Core LIST See Table 30 L-88 METER KIT, SIG SRS REGULATORS 44A7050-F66 ACE II LCD DISPLAY WITH LOM 44A ACE II LCD DISPLAY WITH LOM 44A6508- CAP PLTASSY 0-5KW IXT 44A A COMP PNL ASSEMBLY, 30KW, 6.6A, 480V, L-89 + IRMS 44A COMP PNL ASSEMBLY, 30KW, 6.6A, 40V, L-88 44A COMP PNL ASSEMBLY, 30KW, 6.6A, 40V, L-89 44A COMP PNL ASSEMBLY, 30KW, 6.6A, 40V, L-88 + IRMS 44A COMP PNL ASSEMBLY, 30KW, 6.6A, 40V, L-89 + IRMS 44A COMP PNL ASSEMBLY, 30KW, 6.6A, 480V, L-88 44A COMP PNL ASSEMBLY, 30KW, 6.6A, 480V, L-89 44A COMP PNL ASSEMBLY, 30KW, 6.6A, 480V, L-88 + IRMS 56 ADB Airfield Solutions All Rights Reserved

65 Figure 4: CHF 0-30 kw Component Plate Assembly FUSE ASSEM., F5-F9 RWSL, CHF 44A770 FUSE ASSEM., F5-F9 RWSL, CHF 44A770/L-88 See Table SCR 8 Block 49A0084 FUSE HOLDER IS REF. IT IS IN BOM FOR 44A WIRING HARNESS PCB ASSY, ACE II IRMS-LI (LOW IMPEPANCE) 44A6397 TX 40/347/480-0/4CT 0.5A 35A0546 See FUSE 90A 600V Table 47A CVM/FCS RPLCMNT KIT, 6.6A 30KW CHF, 8Ft LEAD 94A0395-5P-8 FERRO RESONANT CCR FCS MTG PL 60A59 PCBASSY CHF 44A7075- HARN ASSY, CCF, COMP. PLT, KW 44A636- FUSE 3A 500V SLO-BLO MIDGET 47A087 VARISTORS - INPUT PROTECTION KIT 94B00. CONT P 75 FLA 0VAC COIL 53A04-75 KIT# 94A034 GROUND LUG 7A000 GROMMET " 63A0436 FRONT KIT# 94A0335 FOR SMI (/Xx) VERSIONS.. KIT# 94A0334 FOR SMR VERSIONS (/XX). ADB Airfield Solutions All Rights Reserved 57

66 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Spare Parts 6. Spare Parts This subsection provides information for fuses and other components. Table : L-88/L-89 Input Power Fuses F and F. Amp rating as a function of input voltage and CCR kw rating for input power fuses F and F on the L-88 and L-89 CCRs. Input Power Fuses, F and F, per CCR Input Voltage and CCR kw Rating CHF/XXXX INPUT FUSES (F, F) SIZE 08 V 0 V 40 V 347 V 480 V 4kW 47A009 47A A A09 47A kW 47A A A A093 47A009 0kW 47A A007 47A007 47A A0085 5kW 47A A A A07 47A0088 0kW 47A007 47A007 47A A A kW 47A00 47A00 47A00 47A006 47A kW N/A N/A N/A N/A 47A006 70kW N/A N/A N/A N/A 47A04 47A A A007 47A007 47A A A A A009 47A009 47A A A A A A00 47A00 47A006 47A00 47A04 Fuse 5A 50V Time Delay Fuse 45A 50V Fuse 60A 50V Fuse 5A 50V Fuse 30A 600V Fuse 60A 600V Fuse 50A 600V Fuse A 600V Fuse 5A 600V Fuse 30A 50V Fuse 50A 50V Fuse 70A 50V Fuse 80A 50V Fuse 90A 600V Fuse 0A 50V Fuse 75A 50V Fuse 00A 50V Fuse 5A 600V Fuse 400V Fuse 00A 600V 58 ADB Airfield Solutions All Rights Reserved

67 Table 3: Input Fuse Blocks CHF/XXXX INPUT FUSE BLOCK (Item ) SIZE 08 V 0 V 40 V 347 V 480 V 4kW 7A009 7A009 7A009 49A008 49A kW 7A0098 7A0098 7A A008 49A008 0kW 7A009 7A0098 7A A008 49A008 5kW 7A009 49A009 49A009 49A A008 0kW 7A0099 7A0099 7A A A008 30kW 7A0099 7A0099 7A A A kW N/A N/A N/A N/A 49A kW N/A N/A N/A N/A 49A A008 49A008 49A A0097 7A009 7A0098 7A0099 Fuse Block, 0-30A, 600V Fuse Block, 3-60A, 600V Fuse Block, 6-00A, 600V Fuse Block, 00-00A, 50V Fuse Block, P, 30A, 50V Fuse Block, 3-60A, 50V Fuse Block, 00-00A, 50V Table 4: L-88 / L-89 Step-Down T4 Transformer Fuses F3 and F4 Fuses F3 and F4 on the L-88/L-89 CCRs protect transformer T4, which supplies 0 Vac and 4 Vac to the universal regulator control card. Transformer T3 Fuses F3 and F4 Ratings CHF/XXXX T4 Fuses (F3, F4) SIZE 08 V 0 V 40 V 347 V 480 V 4kW 47A03 47A03 47A03 47A03 47A kW 47A03 47A03 47A03 47A03 47A008 0kW 47A03 47A03 47A03 47A03 47A008 5kW 47A087 47A087 47A087 47A087 47A087 0kW 47A087 47A087 47A087 47A087 47A087 30kW 47A087 47A087 47A087 47A087 47A087 50kW N/A N/A N/A N/A 47A087 70kW N/A N/A N/A N/A 47A087 47A008 47A03 47A087 49A0084 Fuse A 500V Fuse A 50V Fuse 3A 500V Fuse Holder (double) (4, 0-30 kw) Table 5: L-89 Power Supply Transformer Fuse F5 and ACE Power Supply Fuse F6 Universal regulator power supply transformer fuse F5 protects the remote control circuitry on the URC. Fuse F6 protects the 0 Vac power supply to the ACE. Fuses F5 and F6 Ratings CHF/XXXX ACE Fuses F5, F6 47A09 47A006 Fuse.5A 50V Fuse Block (single) ADB Airfield Solutions All Rights Reserved 59

68 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Spare Parts Table 6: Current Transformer T CHF/XXXX Current Transformer T SIZE 6.6 A 0 A 4kW 35A063 N/A 7.5kW 35A063 N/A 0kW 35A063 N/A 5kW 35A063 35A0308 0kW 35A063 35A kW 35A063 35A kW N/A 35A kW N/A 35A A063 Current Transformer 6.6/6.6A (Only required if analog current meter used) 35A0308 Current Transformer 0/6.6A (Only required if analog current meter used) Table 7: CHF CCR Contactors CHF/XXXX CONTACTORS SIZE V 347 V 480 V 4kW 53A04/5 53A04/5 53A04/5 7.5kW 53A04/50 53A04/40 53A04/40 0kW 53A04/60 53A04/50 53A04/40 5kW 53A04/90 53A04/75 53A04/40 0kW 53A04/0 53A04/90 53A04/50 30kW 53A033 53A04/50 53A04/75 50kW N/A N/A 53A04/50 70kW N/A N/A 53A033 53A033 Contactor 3P 00A 70A 0VAC Coil 53A04/50 Contactor P 50 FLA 53A04/5 Contactor P 5 FLA 53A04/40 Contactor P 40 FLA 53A04/50 Contactor P 50 FLA 53A04/60 Contactor P 60 FLA 53A04/75 Contactor P 75 FLA 53A04/90 Contactor P 90 FLA 53A043 Contactor P 60A V 60 ADB Airfield Solutions All Rights Reserved

69 Table 8: Dual SCR Blocks CHF/XXXX Dual SCR Block (SCR) SIZE 08 V 0 V 40 V 347 V 480 V 4kW 8A0056 8A0056 8A0056 8A0056 8A kW 8A0056 8A0056 8A0056 8A0056 8A0056 0kW 8A0056 8A0056 8A0056 8A0056 8A0056 5kW 8A0057 8A0057 8A0057 8A0057 8A0057 0kW 8A0055 8A0055 8A0055 8A0055 8A kW 8A0054 8A0054 8A0054 8A0054 8A kW N/A N/A N/A N/A 8A kW N/A N/A N/A N/A 8A0037 8A0037 8A0054 8A0055 8A0056 8A0057 Dual SCR Module (50, 70 kw) Dual SCR Module (30 kw) Dual SCR Module (0 kw) Dual SCR Module (4, 7.5, 0 kw) Dual SCR Module (5 kw) Table 9: Power Transformer T CHF/XXXX Power Transformer T (Core) SIZE 4kW 7.5kW 0kW 5kW 0kW 30kW 08 V 6.6A V 0A V 6.6A V 0A V 6.6A V 0A V 6.6A V 0A V 6.6A kW N/A N/A N/A N/A N/A N/A N/A N/A N/A 70kW N/A N/A N/A N/A N/A N/A N/A N/A N/A 480 V 0A A A060 4 ADB Airfield Solutions All Rights Reserved 6

70 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Spare Parts Table 30: Table 3: Power Core List Power Core List 35A kW High Efficiency Power Transformer, 480V, 0A 35A kW High Efficiency Power Transformer, 480V, 0A 03 30kW High Efficiency Power Transformer, 480V, 6.6A 04 0kW High Efficiency Power Transformer, 480V, 6.6A 05 5kW High Efficiency Power Transformer, 480V, 6.6A 06 0kW High Efficiency Power Transformer, 480V, 6.6A kW High Efficiency Power Transformer, 480V, 6.6A 08 4kW High Efficiency Power Transformer, 480V, 6.6A 09 30kW High Efficiency Power Transformer, 480V, 0A 0 0kW High Efficiency Power Transformer, 480V, 0A 5kW High Efficiency Power Transformer, 480V, 0A 0kW High Efficiency Power Transformer, 480V, 0A 5 30kW High Efficiency Power Transformer, 480/347V, 6.6A 6 0kW High Efficiency Power Transformer, 480/347V, 6.6A 7 5kW High Efficiency Power Transformer, 480/347V, 6.6A 8 0kW High Efficiency Power Transformer, 480/347V, 6.6A 9 7.5kW High Efficiency Power Transformer, 480/347V, 6.6A 0 4kW High Efficiency Power Transformer, 480/347V, 6.6A 30kW High Efficiency Power Transformer, 480/347V, 0A 0kW High Efficiency Power Transformer, 480/347V, 0A 3 5kW High Efficiency Power Transformer, 480/347V, 0A 4 0kW High Efficiency Power Transformer, 480/347V, 0A 7 30kW High Efficiency Power Transformer, 08/0/40V, 6.6A 8 0kW High Efficiency Power Transformer, 08/0/40V, 6.6A 9 5kW High Efficiency Power Transformer, 08/0/40V, 6.6A 30 0kW High Efficiency Power Transformer, 08/0/40V, 6.6A 3 7.5kW High Efficiency Power Transformer, 08/0/40V, 6.6A 3 4kW High Efficiency Power Transformer, 08/0/40V, 6.6A 33 30kW High Efficiency Power Transformer, 08/0/40V, 0A 34 0kW High Efficiency Power Transformer, 08/0/40V, 0A 35 5kW High Efficiency Power Transformer, 08/0/40V, 0A 36 0kW High Efficiency Power Transformer, 08/0/40V, 0A Input Lightning Arrestor VR7, VR8 CHF/XXXX Input Lightning Arrestor VR7, VR8 3A008 Input Power Lightning Assestor (All sizes and input voltages) (Kit used is 94B00) 6 ADB Airfield Solutions All Rights Reserved

71 Table 3: Output Lightning Arrestor CHF/XXXX Output Lightning Arrestor VR, VR3, VR4, VR5 SIZE 4kW 7.5kW 0kW 5kW 0kW 30kW 08 V 6.6A 3A0 5 3A0 5 3A0 5 3A0 4 3A0 4 3A V 0A N/A N/A N/A 3A0 5 3A0 5 3A0 4 0 V 6.6A 3A0 5 3A0 5 3A0 5 3A0 4 3A0 4 3A0 4 0 V 0A N/A N/A N/A 3A0 5 3A0 5 3A V 6.6A 3A0 5 3A0 5 3A0 5 3A0 4 3A0 4 3A V 0A N/A N/A N/A 3A0 5 3A0 5 3A V 6.6A 3A0 5 3A0 5 3A0 5 3A0 4 3A0 4 3A V 0A N/A N/A N/A 3A0 5 3A0 5 3A V 6.6A 3A0 5 3A0 5 3A0 5 3A0 4 3A0 4 3A0 4 50kW N/A N/A N/A N/A N/A N/A N/A N/A N/A 70kW N/A N/A N/A N/A N/A N/A N/A N/A N/A 480 V 0A 3A0 5 3A0 5 3A0 4 3A0 4 3A0 4 3A0 4 3A0 5 Surge Arrestor 6kV Surge Arrestor 6kV Table 33: T5 Current Sensing Transformer CHF/XXXX Current Sensing Transformer (T5) SIZE 6.6A 35A0548 Transformer, Current Sensing, 6.6A to 66mA 0A 35A058 Transformer, Current Sensing, 0A to 66mA Table 34: T4 Power Transformer CHF/XXXX Power Transformer (T4) 35A A /347/480 V to 0/4 V.5A (4, 7.5, 0 kw) 40/347/480 V to 0/4 V.5A (5, 0, 30, 50, 70 kw) Table 35: CHF/XXXX Other parts CHF/XXXX Other parts 44A7075/ URC PC Assembly 44A6397 IRMS-LI Board (Option) 44A678 Rotary Switch (3 Step) 44A678/5 Rotary Switch (5 Step) SCO Series Circuit Cutout (Option) Table 36: Current / Voltage Monitor Assembly (CVM) CHF/XXXX Current / Voltage Monitor Assembly (CVM) (Option) 44A636/0 Current / Voltage Monitor Assembly (6.6A) 44A636/ Current / Voltage Monitor Assembly (0A) ADB Airfield Solutions All Rights Reserved 63

72 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Spare Parts Table 37: Ammeters CHF/XXXX Ammeter 5A0099 5A0098 Analog Ammeter (6.6A) Analog Ammeter (0A) Note: Refer to ACE Manuals for Optional L-89 Monitoring and Control Table 38: CCF/XXXX Capacitor Plate 44A607/ 30kW (6.6A and 0A) 44A607/ 0kW (6.6A) V 44A607/ 0kW (0A) V 44A607/3 5kW (6.6A and 0A) V 44A608/3 0kW V 44A608/ 7.5kW 08V 44A67 4kW V 44A639/07 7.5kW 0-480V 44A6483/09 0kW and 30kW 400V 44A6483/3 50kW (0A) 480V 44A6483/8 0kW 400V 44A6483/6 50 kw (0A) and 70kW (0A) 480V 64 ADB Airfield Solutions All Rights Reserved

73 DRAWING NUMBER: REV. 9 L L ASSOCIATED DRAWINGS: DRAWN BY: DRAWN DATE: All information contained herein, including illustrations, specifications, and dimensions, is believed to be reliable as of the date of this publication, but is subject to change without notice. ADB reserves the right to make changes and improvements to its products and assumes no responsibility for these modifications. Any disclosure of this information is strictly prohibited except as ADB Airfield Solutions may otherwise agree to in writing. Copyright 009 ADB Airfield Solutions L 8 4 INITIAL & DATE: J ST ST Wiring Schematics This section provides wiring schematics for the ADB L-88/L-89 Ferroresonant constant current regulators (CCRs) (4-70 kw/6.6 A/0 A) with universal regulator controller (URC) cards. NOTE: For the ACE to URC PCB internal wiring diagram for Ferroresonant CCRs (3 and 5 Step), refer to the Wiring Schematics section in Advanced Control Equipment (ACE ) manual 96A087 or Advanced Control Equipment (ACE ) manual 96A0357. For Powerpack internal wiring diagram for Ferroresonant CCRs (3 and 5 Step), refer to the Wiring Schematics drawing 43A3736 Sheet &. Figure 4: Ferroresonant L88/L89, 4-30kW, 6.6A - 0A Internal Wiring Schematic (43A3736 of ) - VARIATIONS - OPTIONS COPPER BAR JUMPER COPPER BAR JUMPER DRAWING TITLE: ORG (G) NO GND! NO GND! (+) (-) 43A3736 PUR PUR (K) (+) (-) BLU YEL ORG G K G K (3 STEP CONN'S IN ( )'s) S S CCI CC B (B0) B (B30) B3 (B00) B4 B5 NEU XCP N GND PCFS PCFS 5 STEP WIRING TB TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKER: AS LISTED ON COMPONENT LABEL. 7A007 TERM. BLK. : 35 in-lb.s 7A007 TERM. BLK. : 50 in-lb.s BLU (G) YEL (K) N/C N/C 5 N/C F A0055 SCR ASSY. (0KW) & 8A0057 SCR ASSY. (5KW) 8A0056 SCR ASSY. (4-0KW) WIRING DIAGRAM, L-88 W/URC, 4 TO 30KW, "CHF" REGULATOR WITH "IXT" CORE, 6.6A & 0A, SIGNATURE SERIES 58 G 8A0054 SCR ASSY. (30KW) SHOWN 56 - T4 TO IRMS DPM T8 REV LEVEL 30 0 ORG G PUR K NO GND! 534-ACE PS 535-ACE PS 903-ACE PS 904-IRMS SEE GND'ING NOTES ABOVE A0539/ YEL BLU K G RED BLU L 04 COPPER BAR JUMPER ACE/CVM CONNECTIONS -SEE WIRING DIAGRAM #43A550 or 43A38 FOR ACE F6 =.5A, 50V, SLO-BLO (47A09) 56 TO TB-NEU BLU YEL PUR 54 ORG J3 J J C SEE ECO-79; CORRECTED TYPO IN NOTE 4 BE AUG0 B SEE ECO-79; WIRE GA. & FB WIRE CHG'S SR/BE 0JUL0 A SEE ECO-56: PRODUCTION RELEASE BE 3FEB0 BLK BRN D SEE ECO's 868 & 869 BE/SR 0SEP0 508 E ECO-868; 4KW 00 WIRE NOW AWG BE/SR 6SEP0 REVISION DESCRIPTION RED VIO 507 L L3 305 RED/BLK GRN/YEL 53 NOTE 6 50 BLK T4 GRY 506 T: 4-30KW, 480V ONLY DRAWN BY T4: 480VAC INPUT REV DATE SEE GND'ING NOTES ABOVE. 50/50A 30 ASSY. NOTE #, PG. 35A0539/546 0 J RED BLU REV LEVEL CAUTION: INPUT SIDE FEEDBACK L 04 (347V) BLK BRN STEP JUMPER 04 (480V) USE FIRMWARE #90A0083C or higher (U9). RED VIO 507 J5 50 RED/BLK GRN/YEL 53 L L3 0 AMP JUMPER 44A7075/ PCB ADD 7A009 FORK TERM. 50 BLK T4 GRY NOTE 6 IF "KEYED" MATING CONN. IS USED, PIN #/RED STRIPE IS ON THE RIGHT SIDE (SAME FOR ROTARY SWITCH CONN.). DANGER: LETHAL VOLTAGES ARE PRESENT REPLACE FORK TERM. ON HARNESS W/FEM. FASTON TERM. 70A079 T4: 347VAC INPUT T: 4-30KW, 347 & 480V CVM J6 ATTACH TO FOOT OF T4 ( PLACES) WIRE #53 MUST BE TIED TO BLU WIRE - NOT TO ANOTHER GND. 57 TO IRMS TO DPM T8 IF "UN-KEYED" MATING CONN. WAS USED, PIN #/RED STRIPE IS ON THE LEFT SIDE (SAME FOR ROTARY SWITCH CONN.). ST4 ST3 ST ST 50C - TO K-A 70A0596; MALE FASTON TERM. 50B REVISION DESCRIPTION 538 ST4 ST3 ST ST 70A079 TERM. ( PLC.S) J7 J8 ST ST4 ST3 35A0539/546 ROTARY SWITCH CONNECTION A0308 (0:6.6A) S S ST MICROSWITCH NC NO COM F5 =.5A, 50V, SLO-BLO (47A09) TO AIRFIELD DRAWN BY 3 RED BLU P P T9 08 OPTIONAL SCO G SEE ECO-973: CORRECTED T TAP WIRING BE 09NOV0 F ECO-9: Removed "ALWAYS USED" J5 Jumper BE 4OCT0 REV DATE BE RED BLK BRN 508 0ACVM WIRING DETAIL"A" FEEDBACK JUMPER (8AWG) 3 FEB 0 F3 503 VIO 507 RED/BLK GRN/YEL 53 FOR PREVIOUS FB WINDING CONNECTIONS, SEE PG /0/40 VAC INPUT F4 50 T4 BLK GRY L VR6 VR5 IF VARISTORS ARE PLATE MOUNTED, GND PLATE TO EARTH GND (NOTE 3, PG. : PROD. ONLY) Cx METER OPTION VR7 VR POS. CURRENT FEEDBACK SENSOR OPTION (#53A083) A K A 50/50C C P T S S VR4 VR3 6.6A = 35A0548 0A = 35A058 NO GND REQ'D DIGITAL POWER METER OPTION - SEE PG C 50B SEE DETAIL"A" 94A0358 KIT 04 (0V) 04 (08V) MICROSWITCH WIRING - SEE DETAIL "A" 4 0 T5 P VR 04 50C 50B 50 NO SCO OPTION OPT. DOOR-SW COM 50A (40V) 4 (0) C 0A SHUNT POS. IS "MID" (DO NOT USE SHUNT FOR 6.6A) 03 ST F L VR #4 TO VR W/O MTR #4 TO T W/MTR L3 40 TB DANGER: LETHAL VOLTAGES ARE PRESENT ST 04 F OPTIONAL SCO TO AIRFIELD 305 ST NOTE 5 0 TB NOTE: LAND ALL CAP BANK WIRES AS CLOSE AS POSSIBLE TO THE CENTER OF THE CAP BANK; ALSO, NOTE 4. T CVM 6.6A WIRING: SEE BELOW FOR 0A 5 ATTACH "OUTPUT" TAG - PLC.S FOR 30KW, 08V & 40V, USE F & F FOR INPUT, DO NOT USE TB3. LAND 40 & 403 ON SIDE OF FUSE BLOCKS. ST4 ST3 ST ST J4 4-30KW; V #5 TO VR W/O CVM ST4 TO #5 W/6.6A CVM #5 TO T9 W/0A CVM F5 TB-NEU TB-GND ST4 J3 IRMS ST 00 OUTPUT NOTE: OUTPUT CONNECTIONS ON VR AND VR UNLESS TERMINAL BLOCKS OR "SCO" IS USED. CONTROLLED COPY Unauthorized duplication of this document in whole or part is prohibited. Initialed in RED ink below indicates authorized copy. ADB Airfield Solutions 977 Gahanna Parkway, Columbus, Ohio 4330 Telephone: , Fax: ST ADB Airfield Solutions All Rights Reserved 65

74 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Wiring Schematics Figure 43: Ferroresonant L88/L89, 4-30kW, 6.6A - 0A, Internal Wiring Schematic (43A3736 of ) DIGITAL POWER METER OPTION OUTPUT NOTE: OUTPUT CONNECTIONS ON VRAND VR UNLESS TERMINAL BLOCKS OR "SCO" IS USED. 00 VR TO AIRFIELD VR MICROSWITCH WIRING - SEE DETAIL "A"; PG. VR4 VR3 (NOTE 3, PG. : PROD. ONLY) VR6 VR5 IF VARISTORS ARE PLATE MOUNTED, GND PLATE TO EARTH GND. OPTIONAL SCO 00 SEC. 536 T7 T6 6.6A = 35A0493 0A = 35A058 PRIM. ATTACH "OUTPUT" TAG - PLC.S 44A636/-/ FERRO CNTRL. PNL. WIRE HARNESS, SM. & MED./LG. FRAME 44A639/-/ FERRO/ACE WIRE HARNESS, SM. & MED./LG. FRAME 94A056/XXXX POWER WIRE KIT, "IXT" FERRO CCR 43A38 WIRING DIAGRAM, ACE TO URCII/ PCB DOC. NO. DESCRIPTION RELATED DOCUMENTS 4 V Sig V Sig l Sig lsig Sig Amp Raw V+ Raw V- GND GND GND 538 (F5) TB RELAY/LOAD_SELECT CONNECTIONS TO DPM TB DIGITAL POWER METER 44A K-COM K-NO K-NO K-COM K3-COM K3-NO K4-COM K4-NO >.5A.8A (S) 3.4A (S) 4.A (S3) K5-COM 5.A (S4) K5-NO K6-COM 6.6A (S5) K6-NO K7-COM K7-NO LOAD-SELECT-AC LOAD-SELECT-AC 5VAC 5VAC LVA (LOW VA) +V Out -V Out +l Out -l Out GND LOAD SELECT (0V) V EARTH GND TB3 539 (TB-NEU) A0346 TB C 50B DRAWING TITLE: WIRING DIAGRAM, L-88 W/URC, 4 TO 30KW, "CHF" REGULATOR WITH "IXT" CORE, 6.6A & 0A, SIGNATURE SERIES 43A3736 G E ECO-868; 4KW "00" WIRE NOW AWG BE/SR 6SEP0 D SEE ECO's 868 & 869 BE 0SEP0 C SEE ECO-79; CORRECTED TYPO IN NOTE 4 BE AUG0 B SEE ECO-79; WIRE GA. & FB WIRE CHG'S SR/BE 0JUL0 A SEE ECO-56 BE 3FEB0 REV REVISION DESCRIPTION LEVEL DRAWN REV BY DATE LEVEL BE 3 FEB 0 All information contained herein, including illustrations, specifications, and dimensions, is believed to be reliable as of the date of this publication, but is subject to change without notice. ADB reserves the right to make changes and improvements to its products and assumes no responsibility for these modifications. Any disclosure of this information is strictly prohibited except as ADB Airfield Solutions may otherwise agree to in writing. Copyright 009 ADB Airfield Solutions. CONTROLLED COPY Unauthorized duplication of this document in whole or part is prohibited. Initialed in RED ink below indicates authorized copy. INITIAL & DATE: ADB Airfield Solutions 977 Gahanna Parkway, Columbus, Ohio 4330 Telephone: , Fax: G SEE ECO-973: CORRECTED T TAP WIRING BE 09NOV0 F ECO-9: Removed "ALWAYS USED" J5 Jumper BE 4OCT0 REV REVISION DESCRIPTION DRAWN BY REV DATE DRAWING NUMBER: REV. ASSOCIATED DRAWINGS: DRAWN BY: DRAWN DATE: PREVIOUS FEED BACK WINDING CONNECTIONS 305 T NOTE 5 L3 FB L 04 (40V) SEE NOTE BELOW 04 (0V) 04 (08V) SERIES WIRES: PRIMARY POWER, 600V, 05 C WIRE & ASSEMBLY NOTES: POWER 4 kw 7.5 kw 0 kw 5 kw 0 kw 30 kw 08 V AWG 89A084/9 8 AWG 89A096/9 8 AWG 89A096/9 4 AWG 89A098/9 /0 AWG 89A00/9 /0 AWG 89A00/9 0 V 40 V 347V 480 V AWG AWG AWG 89A084/9 89A084/9 89A084/9 8 AWG 8 AWG 8 AWG 89A096/9 89A096/9 89A096/9 8 AWG 8 AWG 8 AWG 89A096/9 89A096/9 89A096/9 6 AWG 6 AWG 6 AWG 89A097/9 89A097/9 89A097/9 AWG AWG 6 AWG 89A099/9 89A098/9 89A097/9 AWG AWG 6 AWG 89A099/9 89A098/9 89A097/9 xi-,l;. ADD APPROPRIATE JUMPER WHERE REQUIRED (NO JUMPER IS 6.6A, 5-STEP). TIEALL JUMPERS INTO CABLE HARNESS SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB. i0,l0;. WIRE SIZES: 00-05: PRIMARY POWER, SEE TABLE. 00-3: HIGH VOLTAGE, AWG, 5KV, 50 C, 89A0086/ : TANK LOOP, SEE TABLE : MEDIUM CURRENT, AWG, 600V, 05 C, 89A085/ : STD CONTROL, 8AWG, 600V, 05 C, 89A08/ : GROUND, AWG, 600V, GN/YL, 89A63/5. i-,l; : GROUND, 8AWG, 600V, GN/YL, 89A063/7. 3. SEE BILL OF MATERIALS FOR NUMBER OF MOV's OR SURGE SUPPRESSORS IN EACH LEG. 300 SERIES WIRES: TANK LOOP; 600V, 05 C POWER ALL 4 kw 7.5 kw 0 kw 0 AWG 89A095/9 0 AWG 89A095/9 6 AWG 89A097/9 i0,l0;4. USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK. i-,l;5. IF A JUMPER WIRE IS REQUIRED FOR ANY CORE LEAD, USE HIGH VOLTAGE 89A0086/ WIRE. 6. GROUNDING NOTES: - GND EACH PANEL TO THE FRAME. - JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG. 7. USES POWER WIRE KIT # 94A056/XXXX. 5 kw 6 AWG 89A097/9 0 kw AWG 89A099/9 30 kw AWG 89A099/9 SCR PART NO.S PER CCR KW RATING 4 KW 7.5 KW 0 KW 5 KW 0 KW 30 KW 8A0056 8A0056 8A0056 8A0057 8A0055 8A0054 INPUT PWR FUSES, F & F, PER CCR INPUT VOLTAGE & CCR KW RATING TX. T4 FUSES, F3 & F4 RATINGS CCR INPUT VOLTAGE 4 KW 7.5 KW 0 KW 5 KW 0 KW 30 KW 4-0 KW 5-40 KW 08/0V 30A, 50V 50A, 50V 70A, 50V 0A, 50V 5A, 50V 00A, 50V A, 50V NA 40V 5A, 50V 45A, 50V 60A, 50V 80A, 50V 0A, 50V 75A, 50V A, 50V NA 347/480V A, 600V 5A, 600V 30A, 600V 50A, 600V 60A, 600V 90A, 600V A, 500V 3A, 500V J7 J NOTE: USES "44A6035/" PCB WITH FIRMWARE # 90A004D L L 5 4 S F 66 ADB Airfield Solutions All Rights Reserved

75 A J Figure 44: Ferroresonant L88/L89, 50-70kW, Internal Wiring Schematic (43A3736/5070 of ) DESCRIPTION RELATED DOCUMENTS 43A38 WIRING DIAGRAM, ACE TO URCII/ PCB 5-WHT DOC. NO. 53-RED (3 STEP CONN'S IN ( )'s) 5 STEP WIRING TB S S CCI CC B (B0) B (B30) B3 (B00) B4 B5 NEU XCP N GND PCFS PCFS 43A550 WIRING DIAGRAM, ACE TO URCII/ PCB 94A0338/X48X POWER WIRE KIT, FERRO CCR A6504/ WIRE HARNESS, CCF 50/70, W/ACE A6504/ WIRE HARNESS, CCF 50/70, W/O ACE 54-RED 55-WHT N/C N/C N/C F6 905 TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKER - AS LISTED ON COMPONENT LABEL. 7A007 TERM. BLK.: 35 in-lb.s 7A007 TERM. BLK.: 50 in-lb.s PREVIOUS 8A008 COLOR CODING: 56 - T4 COPPER BAR JUMPER 58 - IRMS 534-ACE PS 535-ACE PS 903-ACE PS 904-IRMS YEL BLU K G 3 K G ASSEMBLY NOTES: ) WIRE NO.S REASSIGNED AT THE CREATION OF THIS DOC. ) GROUND TO FOOT OF TRANSFORMER. 3) ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING. 4) WIRE #53 MUST BE TIED TO BLU WIRE - NOT TO ANOTHER GND. 5) DELETED. 6) DELETED. 7) ADD APPROPRIATE JUMPER WHERE REQ'D (TIE ALL JUMPERS INTO CABLE HARNESS SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB. 8) GROUNDING NOTES: - GND EACH PANEL TO THE FRAME - JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG. 9) ROUTE THESE WIRES ALONG TOP SIDE & LEFT SIDE OF PCB TO CONNECT TO J3. 0) IF A JUMPER IS NEEDED FOR ANY CORE LEAD, USE HIGH VOLTAGE 89A0086/ WIRE. ) SEE BILL OF MATERIALS FOR NUMBER OF MOV'S OR SURGE SUPPRESSORS IN EA. LEG. ) USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK. SCR # 8A PUR ORG 56 TO TB-NEU U( = RUNS EACH AS SHOWN) 5 50 BLU YEL PUR ORG J3 J J /50A 0 L T J4 CAUTION: INPUT SIDE FEEDBACK 309 & & 308 NOTE 0 &6 L ASSY. NOTE # & 30 3-STEP JUMPER 70KW CORE 8 7 L4 CONTROL WINDING J5 USE FIRMWARE #90A0083D or higher (U9). NOT YET APPROVED FOR 70KW 306 & 3 L 3 L3 0 ALWAYS USED 44A7075/ PCB 304 & () IF "KEYED" MATING CONN. IS USED, PIN #/RED STRIPE IS ON THE RIGHT SIDE (SAME FOR ROTARY SWITCH CONN.). 57 TO IRMS J6 509 =.5A, 50V, SLO-BLO (47A09) 50 IF "UN-KEYED" MATING CONN. WAS USED, PIN #/RED STRIPE IS ON THE LEFT SIDE (SAME FOR ROTARY SWITCH CONN.). F5 NOTE # J8 F7 =.5A, 50V, SLO-BLO (47A09) 504 NOTE # ROTARY SWITCH CONNECTION RED BLU NOTE #3 NOTE #5 BLK BRN (.5A, 50V, SLO-BLO; 47A09) RED VIO 507 ( = RUNS EACH AS SHOWN) FEEDBACK JUMPER (8AWG) VR7 VR8 F RED/BLK GRN/YEL F F4 480 VAC INPUT T4 BLK GRY NOTE # A0308 P P METER S OPTION S SEE NOTE KW, 480VAC (3 BANKS) T5-35A058 F A 403 K A 50/50C SCO OPTION OPT. DOOR-SW 50C 50B 50 NO COM 50A SEE DETAIL"A" 94A0358 KIT L T (30) &7 L L4 SEE NOTE # 0 35A0308 (0:6.6A) F NOTE: LAND ALL CAP BANK WIRES AS CLOSE AS POSSIBLE TO THE CENTER OF THE CAP BANK DANGER: LETHAL VOLTAGES ARE PRESENT B4 T9 B3 B B 3 INPUT L ST3 P S ST4 ST3 ST ST CVM 70KW, 480VAC (4 BANKS) () 4 L3 5 0 IRMS-OUT(FIBER CABLE) IRMS-IN (FIBER CABLE) 305 ST4 ST3 ST ST KW CORE P S (3) ST4 IMPORTANT! KEEP WIRES (00's & 300's) AWAY FROM CORE! R. SCHWEDER 8MAR Information contained on this drawing is to be used expressly in accord with purpose for which it was submitted. Any disclosure of this information is strictly prohibited except as ADB Airfield Solutions, Ilc. may otherwise agree in writing. Copyright Ó 0 ADB Airfield Solutions, Ilc. N/A DRAWING NUMBER: 43A3736/5070 REV. A SCALE: SHEET NUMBER: OF ASSOCIATED DRAWINGS: ENG. BY: REV LEVEL ECO NUMBER REVISION DESCRIPTION 3040 PRODUCTION RELEASE DRAWING TITLE: WIRING DIAGRAM, L-88 W/URC, BE 8MAR 50 & 70KW FERRO CHF, REV DRAWN BY DATE DRAWN DATE: 0 AMP, SIGNATURE SERIES NOT APPROVED FOR 70KW ADB Airfield Solutions 977 Gahanna Parkway, Columbus, Ohio 4330 Telephone: , Fax: APPROVED BY: DATE: Unauthorized duplication of this document in whole or part is prohibited. Initialed in RED ink below indicatesauthorized copy. CONTROLLED COPY ACE/CVM CONNECTIONS -SEE WIRING DIAGRAMS: #43A550 FOR ACE #43A38 FOR ACE F6 =.5A, 50V, SLO-BLO (47A09) ADD 7A009 FORK TERM. 50 REPLACE FORK TERM. ON HARNESS W/FEM. FASTON TERM. 70A079 50C - TO K-A 70A0596; MALE FASTON TERM. 50B 70A079 TERM. ( PLC.S) kw /0 AWG 89A03 MICROSWITCH NC NO COM TO AIRFIELD 50 kw /0 AWG 89A00/9 08 POWER 480V OPTIONAL SCO 00 SERIES WIRES PRIMARY POWER 600V - 05 C DETAIL"A" : GROUND, 8AWG, 600V, GN/YL, 89A063/ : STD CONTROL, 8AWG, 600V, 89A08/ : GROUND, AWG, 600V, GN/YL, 89A63/ : MEDIUM CURRENT, AWG, 600V, 05C, 89A085/9. ( = RUNS EACH AS SHOWN) : TANK LOOP & CAPS, AWG, 600V, 05C, 89A099/9, 00-3: HIGH VOLTAGE, AWG, 5KV, 50C, 89A0086/. WIRE SIZES: 0-03: PRIMARY POWER, SEE TABLE VR6 VR VR4 VR3 (NOTE - PROD. ONLY) MICROSWITCH WIRING - SEE DETAIL "A"; BELOW 06 50C 50B POS. CURRENT FEEDBACK SENSOR OPTION (#53A083) 0 (0) VR ST 0A SHUNT POS. IS "MID" 00 VR ST 05 TB OPTIONAL SCO TO AIRFIELD -3 GRY BLU 03 J4 J5 - F5 TB-NEU TB-GND ATTACH "OUTPUT" TAG - PLC.S IRMS 00 OUTPUT NOTE: OUTPUT CONNECTIONS ON VR AND VR UNLESS TERMINAL BLOCKS OR "SCO" IS USED. ADB Airfield Solutions All Rights Reserved 67

76 ST J A B C B C ST CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Wiring Schematics Figure 45: Powerpack 5-30kW 43A66 of 4-30 KW, 40V ACE CVM & IRMS Options T 04 X 05 H 305 SC- A B C (COMP. PANEL) IMPORTANT! SEE NOTE FOR SC- & INPUT WIRE LUG ASSEMBLY. ST4 TO H W/ CVM ST ST4 *DPM OPTION 00 TORQUE = 5-6 NM ( PLC.S) SEC. PRIM. T7 6.6A WIRING: SEE ST ST4 ST3 ST IRMS X BELOW FOR 0A CVM NOTE 0 C NOTE H X3 NOTE: LAND ALL CAP BANK WIRES AS CLOSE AS POSSIBLE TO THE CENTER OF THE CAP BANK. 35A0346 OR 6A037 (/30) F5 TB-NEU ICVM OPTION: SEE NOTE 3 J4 J5 - C CB TB3 904 TB-GND X4 Cx H W/O CVM GRY BLU (FIBER CABLE) (FIBER CABLE) IRMS-OUT IRMS-IN DANGER: LETHAL VOLTAGES ARE PRESENT NOTE 40 (NOTE 4) SC5- SC A A ST *INSULATORS REQ'D FOR 30KW, 6.6ACVM ONLY CVM- GRY WINDINGS CONTROL HV-SC 0 (FIBER CABLE) X X SEE PG. FOR "DOOR NOT CLOSED" INDICATOR WIRING 00 SC- SC-6 DOOR SWITCH A K VR T5 TO SM. INDUCTOR (L3) X 30 NO A A = 35A0548 0A = 35A058 NO GND REQ'D HV-SC SC- H(60) LG. INDUCTOR (L) 35A0539/546; REV. C, SAME COLORS (SEE PG. FOR PREVIOUS REV.S) 08/40 VAC INPUT 04 VR H 0 P P T S 90 S ANALOG METER OPTION (L-88) X COM 534 T6 6.6A = 35A0493 T4 F NOTE 9 NOTE A = 35A GRY A 50 BLK X 400 B *DPM OPTION Z VR7 VR8 Y VR3 K VR4 A 53 X GRN/YEL Z RED/BLK Y F3 B COMP. PANEL GND LUG BOLT ON BACK SIDE SC5-5 SC5-6 (TO STAB CONN) NOTE 4 SC5-54 SC J Z 503 Y DRAWING TITLE: 6.6 & 0A, 4-30KW FERRO SGRS POWER PACK WIRING DIAGRAM PG. OF 43A66 V Q VAR & DPM UPDATES (ECO-767) BE 0MAR07 P UPDATED TERM. BLK. WIRING (ECO-67) BE 9AUG06 O TITLEBLOCK UPDATE CMS 08AUG06 N REVISED DPM OPTION WIRING (ECO-057) BE APR06 M MOVED SC3-8 WIRE TO F5 (ECO-0546) BE FEB06 REV REVISION DESCRIPTION LEVEL DRAWN REV BY DATE LEVEL V TITLEBLOCK UPDATE BAR 3APR09 U SEE ECO's 85, 947 AND 968 BE JUN08 T 300 SERIES TABLE CLARIFICATION BE 0NOV07 S SEE ECO's - 83/833. BE 7SEP07 R ECO-88: ADDED SCO OPTION BE 0AUG07 REV REVISION DESCRIPTION DRAWN BY REV DATE BE 06 AUG 0 All information contained herein, including illustrations, specifications, and dimensions, is believed to be reliable as of the date of this publication, but is subject to change without notice. ADB reserves the right to make changes and improvements to its products and assumes no responsibility for these modifications. Any disclosure of this information is strictly prohibited except as ADB Airfield Solutions may otherwise agree to in writing. Copyright 009 ADB Airfield Solutions. 05 CONTROLLED COPY Unauthorized duplication of this document in whole or part is prohibited. Initialed in RED ink below indicates authorized copy. INITIAL & DATE: ADB Airfield Solutions 977 Gahanna Parkway, Columbus, Ohio 4330 Telephone: , Fax: DRAWING NUMBER: REV. ASSOCIATED DRAWINGS: DRAWN BY: 07 DRAWN DATE: (NOTE 4) 507 VIO RED NOTE 8 VR5 508 BRN VR6 *DIGITAL PWR METER OPTION BLK NOTE NOTE 8 0ACVM WIRING BLU 53 RED P P OPTIONAL SCO WIRING: T9 H ROTARY SWITCH CONNECTION J7 J8 IF "UN-KEYED" MATING CONN. WAS USED, PIN #/RED STRIPE IS ON THE LEFT SIDE J6 (SAME FOR ROTARY SWITCH CONN.) A0308 (0:6.6A) F5 =.5A, 50V, SLO-BLO (47A09) TO IRMS 509 NOTE 5 NOTE 4 ST3 S S ST4 HV-SC 08 OPTIONAL SCO 0 ST 508S SC3-8 ST VR ST ST ST3 ST4 HV-SC ST ST4 ST3 ST IF "KEYED" MATING CONN. IS USED, PIN #/RED STRIPE IS ON THE RIGHT SIDE (SAME FOR ROTARY SWITCH CONN.). (T4) VAC INPUT NOTE VR CVM T4 F GRY BLK 50 0 AMP JUMPER DANGER: LETHAL VOLTAGES ARE PRESENT (T) KW, 08V 04 T X H 05 X 44A6035/ URC II PCB ASSY. 53 RED/BLK GRN/YEL GND TO FRAME USING 6AWG G/Y WIRE F3 J5 FERRO JUMPER ALWAYS USED RED VIO 507 H 3 STEP JUMPER 508 BLK BRN 509 NOTE ASSEMBLY NOTES: ) ADD APPROPRIATE JUMPER WHERE REQUIRED (ONLY JUMPER REQ'D FOR A 6.6A, 5-STEP). TIE ALL JUMPERS INTO CABLE HARNESS SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB. ) USE INDIVIDUAL WIRES TO EACH CAPACITOR BANK. 3) ROUTE THESE WIRES SEPARATE FROM ALL OTHER WIRING. 4) WIRE #53 MUST BE TIED TO BLU WIRE - NOT TO ANOTHER GND. 5) ATTACH TO FOOT OF T4. 6) ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES. **WIRE 400 & 40 TO TOP SIDE OF F3 & F4. 7) REMOVED - REV. U. 8) SEE BILL OF MATERIALS FOR NUMBER OF MOV's OR SURGE SUPPRESSORS REQ'D IN EACH LEG. 9) GROUNDING NOTES : - GND EACH PANEL TO THE FRAME - JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG. 0) IF A JUMPER IS NEEDED FOR ANY CORE LEAD, USE HIGH VOLTAGE 89A0086/ WIRE. ) IF OUTPUT GOES THRU SGRS BAYS, USE 89A0087/. ) REFERENCE ASSY. DWG. 44A69/ FOR WIRE LUG ASSY. 3) FOR ICVM WIRING - SEE DWG. # 44A6687-XXX. 4) SEE "SYSTEM PACKAGE" FOR WIRING OF 44A6007/X HARTING "STAB" CONNECTOR WINDINGS CONTROL RED BLU J4 50 BNC J J3 J COMPONENT PANEL PUR ORG YEL BLU TO TB-NEU : (T) KW, 480V 04 T 05 X H X (T4) VAC INPUT T4 506 GRY BLK 50 LOCATE ON FRONT SIDE OF PANEL 53 RED/BLK GRN/YEL F4 F3 503 H 507 VIO RED 300 T3 X3 508 BLK BRN COPPER BAR JUMPER 05 X YEL TO IRMS BLU 30 WINDINGS CONTROL RED BLU T PUR ORG (T): 4-30KW, 480V, CCF-004 CORE (T): 4-30KW, 40V, CCF-004 CORE NOT USED, INSULATE W TO VR 04 N/C 5 N/C N/C W 56 SNUBBER ASSY. #44A A008 SCR: KW (B0) (B30) (B00) N GND XCP NEU B B B3 B4 B5 CCI CC S S TB 5 STEP WIRING (3 STEP CONN'S IN ( )'s) (FOR 8A00 (4KW) SEE PG. ) 04 X L X3 X C (ST4 TO "C" W/6.6ACVM) ("C" TO T9 W/0ACVM) ("C" TO VR W/O CVM) X3 (FOR PREVIOUS SCR COLOR CODING SEE PG. ) L TO X NOTE:LAND ALLCAPBANK WIRES ASCLOSE POSSIBLE TOTHECENTER OFTHECAP BANK. FAN 537 SC NS XCPS C 56S 58S 59S 50S 5S 57S 5S T X4 C C Cx X C X W H SC4-7 SC4-8 TO IRMS 05 SC3-7 SC3-0 SC3-9 W H SC3-6 SC3-5 SC3-4 SC3-3 SC3- SC3- K L C Z 300 H3 H3 (SMALL) T FAN NEUTRAL (NOTE 4) J8- FB H SC (HARTING GND. PIN) J8- FB H TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKER- AS LISTED ON COMPONENT LABEL. 7A007 TERM. BLK.: 35 in-lbs 7A007 TERM. BLK.: 50 in-lbs J8- FB J8- L SCR G (LARGE) 30 FB 30 H4 H CHASIS GND. USE EXT. WASHER FIRST OR GRIND PAINT OFF IN CONNECTION AREA. SEE 43A66/5070 FOR 50 & 70KW WIRING. H4 7A0306/ & / HARTING CONN'S: 48 in-lbs 68 ADB Airfield Solutions All Rights Reserved

77 DRAWING NUMBER: REV J J7-57 ASSOCIATED DRAWINGS: DRAWN BY: DRAWN DATE: Figure 46: Powerpack 5-30kW 43A66 page of ADD WIRES 54 & 54. NO A K A 534 COM 536 NC DOOR SWITCH SC SC3- (PPF STAB CONN.) SC3- (PPF STAB CONN.) (NOTE 4) (NOTE 4) POWER PAK WIRING FOR 94A0399 "DOOR NOT CLOSED" INDICATOR 35A0539 COLORS SHOWN, SEE 40V INPUT FOR 35A0546 COLORS BLK VIO WHT/BLK VIO/WHT 508 BRN RED 507 F3 503 RED/WHT WHT/BRN RED 506 F4 T4 (T4) VAC INPUT ATTACH TO FOOT OF T4 ( PLACES) WIRE #53 MUST BE TIED TO VIO (OR RED) WIRE - NOT TO ANOTHER GND. 56 (BLK)BLK VIO 53 (RED) (WHT) VIO/WHT 508 WHT/BLK 509 (BRN) (BLK)BRN RED 507 (BLU) 503 F3 RED/WHT 53 (ORG) 40 VAC INPUT F4 50 (WHT) WHT/BRN RED 506 (BLU) T4 35A0546 COLORS (XXX) 35A0539 COLORS REV'S A & B - SUPPLY TX LEAD COLORS WHT 55 RED WHT 53-RED PREVIOUS SCR WIRE COLOR CODING CVM- (FIBER CABLE) 00/0 GRY TB-L (T/T3 and meter not used) 530 CVM attaching wires F6 59 H 600 ACE Potted CVM/IRMS Options Use wrench to hold RES when 600 PREVIOUS "MOLDED" STYLE CVM WIRING Use wrench to hold RES when attaching wires 00 IRMS-IN IRMS-OUT TB-GND (FIBER CABLE) GRY (FIBER CABLE) BLU F5 IRMS TB-N PREVIOUS IRMS W/RES WIRING SEE 43A66/5070 FOR 50 & 70KW WIRING. 30 kw 6AWG 89A097/9 30 kw AWG 89A099/9 30kW TBD 0 kw 6AWG 89A097/9 0 kw AWG 89A099/9 0kW TBD 5 kw 0AWG 89A095/9 5 kw AWG 89A099/9 5 kw 6AWG 89A097/9 0 kw 0AWG 89A095/9 0 kw 8AWG 89A096/9 0 kw 8AWG 89A096/9 7.5 kw 0AWG 89A095/9 7.5 kw 8AWG 89A096/9 7.5 kw 8AWG 89A096/9 4 kw 0AWG 89A095/9 4 kw 0AWG 89A095/9 POWER 480 V POWER ALL V's POWER ALL V's ALL REGULATORS 300 SERIES WIRES: TANK LOOP, 600V, 05 C 00 SERIES WIRES - PRIMARY POWER, 600V, 05 C USTD. REGULATORS UCCF-004 REGULATORS BLK BLU A00 SCR (4KW) DOC. NO. DESCRIPTION RELATED DOCUMENTS 94A0368/4 POWER WIRE KIT, FERRO SGRS, 0 & 30KW 94A0368/3 POWER WIRE KIT, FERRO SGRS, 5KW 94A0368/ POWER WIRE KIT, FERRO SGRS, 7.5 & 0KW 94A0368/ POWER WIRE KIT, FERRO SGRS, 4KW 44A693 FERRO SGRS WIRE HARNESS, 4-30KW, 6.6 & 0A 43A66/5070 WIRING DIAGRAM, SGRS 50 & 70KW 43A38 WIRING DIAGRAM, ACE TO URCII/ PCB 43A550 WIRING DIAGRAM, ACE TO URCII/ PCB 000-0: GROUND, 6AWG, 600V, GRN/YEL, 89A068/ : GROUND, AWG, 600V, GRN/YEL, 89A63/ : GROUND, 8AWG, 600V, GRN/YEL, 89A063/ : PRIMARY POWER, 6AWG, 600V, 05C, 89A HIGH VOLTAGE 8AWG, 7.5KV, SIL, 89A00: OBSOLETE - USE "00" SERIES WIRE : MEDIUM CURRENT, AWG, 600V, 05C, 89A085/ : STD CONTROL, 8AWG, 600V, 89A08/ : PRIMARY POWER, SEE TABLE. 00-0: HIGH VOLTAGE, AWG, 5KV, 50C, 89A0086/ : TANK LOOP, SEE TABLE.. WIRE SIZES: NOTES:. WIRE NUMBERS REASSIGNED AT THE CREATION OF THIS DOCUMENT. DRAWING TITLE: 6.6 & 0A, 4-30KW FERRO SGRS POWER PACK WIRING DIAGRAM PG. OF 43A66 V Q VAR & DPM UPDATES (ECO-767) BE 0MAR07 V TITLEBLOCK UPDATE BAR 3APR09 U SEE ECO's 85, 947 BE JUN08 P UPDATED TERM. BLK. WIRING (ECO-67) BE 9AUG06 AND 968 O TITLEBLOCK UPDATE CMS 08AUG06 T 300 SERIES TABLE CLARIFICATION BE 0NOV07 S SEE ECO's - 83/833. BE 7SEP07 N REVISED DPM OPTION WIRING (ECO-057) BE APR06 M MOVED SC3-8 WIRE TO F5 (ECO-0546) BE FEB06 R ECO-88: ADDED SCO OPTION BE 0AUG07 REV REVISION DESCRIPTION DRAWN REV REV REVISION DESCRIPTION DRAWN REV LEVEL BY DATE LEVEL BY DATE BE 06 AUG 0 All information contained herein, including illustrations, specifications, and dimensions, is believed to be reliable as of the date of this publication, but is subject to change without notice. ADB reserves the right to make changes and improvements to its products and assumes no responsibility for these modifications. Any disclosure of this information is strictly prohibited except as ADB Airfield Solutions may otherwise agree to in writing. Copyright 009 ADB Airfield Solutions. CONTROLLED COPY Unauthorized duplication of this document in whole or part is prohibited. Initialed in RED ink below indicates authorized copy. INITIAL & DATE: ADB Airfield Solutions 977 Gahanna Parkway, Columbus, Ohio 4330 Telephone: , Fax: ADB Airfield Solutions All Rights Reserved 69

78 L 4 J3 5 J (COMP. PANEL) CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Wiring Schematics Figure 47: Powerpack 50-70kW 43A66/5070 page 0f IMPORTANT! KEEP WIRES (00's & 300's) AWAY FROM CORE! ST H TO P FOR CVM 50KW CORE *DPM OPTION 00 H P P T9 L3 35A0308 SEE NOTE #3 T7 SEC. PRIM. (0:6.6A) IRMS 04 0 HV-SC S S ST F5 35A0346 OR 0ACVM WIRING TB-NEU IRMS-OUT 6A037 (/30) VR CONTROL (FIBER CABLE) GRY WINDINGS ST TB-GND (FIBER CABLE) BLU IRMS-IN J4 NOTE 4 SC5- SC5- ST4 ST3 ST ST NOTE NOTE 00 T CVM ST H (W/O CVM) KW, 480VAC (4 BANKS) IMPORTANT! SEE NOTE 9 FOR SC- & INPUT WIRE LUG ASSEMBLY. (3) COMP. PANEL GND LUG BOLT ON BACK SIDE (COMP. PANEL) DRAWING TITLE: 50 & 70KW, 0A, 480VAC SIESMIC FERRO SGRS POWER PACK WIRING DIAGRAM PG. OF 43A66/5070 W U TITLEBLOCK UPDATE BE 3APR09 T SEE ECO's 85, 947 & 968 BE JUN08 S ECO-83; ADD COMP. PLATE GND. BE SEP07 REV REVISION DESCRIPTION LEVEL DRAWN REV BY DATE LEVEL REV REVISION DESCRIPTION DRAWING NUMBER: REV. ASSOCIATED DRAWINGS: DRAWN BY: DRAWN DATE: 00 R ECO-83: UPDATED FOR URCII/ PCB BE 8SEP07 Q ECO-88: ADDED SCO OPTION & PG. BE 0AUG07 BE 0 MAR 03 All information contained herein, including illustrations, specifications, and dimensions, is believed to be reliable as of the date of this publication, but is subject to change without notice. ADB reserves the right to make changes and improvements to its products and assumes no responsibility for these modifications. Any disclosure of this information is strictly prohibited except as ADB Airfield Solutions may otherwise agree to in writing. Copyright 009 ADB Airfield Solutions. CONTROLLED COPY Unauthorized duplication of this document in whole or part is prohibited. Initialed in RED ink below indicates authorized copy. INITIAL & DATE: ADB Airfield Solutions 977 Gahanna Parkway, Columbus, Ohio 4330 Telephone: , Fax: W ECO-54, CHNGS FOR SHORTER GNDS DTR 0OCT0 V ECO-449: CTRL WIRE CONN. CORRECTION BE 09OCT09 DRAWN BY REV DATE 05 L B B B3 ST3 ST4 04 B4-55 SEE NOTE 0 K CB L4 & & ST ST3 ST4 40 L NOTE: LAND ALL CAP BANK WIRES AS CLOSE AS POSSIBLE TO THE CENTER OF THE CAP BANK (30) SC- SC- ICVM OPTION: SEE NOTE KW, 480VAC (3 BANKS) 400 A VAC INPUT TO 50 SC-6 SC DOOR SW NO COM A HV-SC ACE CVM & IRMS OPTIONS: 0 DANGER: LETHAL VOLTAGES ARE PRESENT VR T6 CVM- (FIBER CABLE) GRY VAC INPUT F4 50 BLK T4 GRY 506 RED/BLK GRN/YEL 53 F3 503 RED VIO A = 35A *DPM OPTION NOTE 4 VR8 VR7 T SC5-6 SC A058 NO GND REQ'D NOTE # 40 OPTIONAL SCO WIRING: NOTE #3 *DIGITAL PWR METER OPTION 508 BRN BLK 509 NOTE #5 56 HV-SC OPTIONAL SCO BLU RED VR NOTE # 06 HV-SC NOTE #4 NOTE VR ROTARY SWITCH CONNECTION GND TO FRAME USING 6AWG G/Y WIRE J7 J8 IF "UN-KEYED" MATING CONN. WAS USED, PIN #/RED STRIPE IS ON THE LEFT SIDE (SAME FOR ROTARY SWITCH CONN.). F5 =.5A, 50V, SLO-BLO (47A09) TO IRMS 55 J6 SC S IF "KEYED" MATING CONN. IS USED, PIN #/RED STRIPE IS ON THE RIGHT SIDE (SAME FOR ROTARY SWITCH CONN.). 70KW CORE 44A6035/ URC II PCB ASSY. SNUBBER ASSY. #44A649 H J5 TO L3 0 5 CONTROL WINDING 5 L NOTE SC FAN L SC J4 300 & &6 SC4-8 L CHASIS GND. J3 J J 307 & 308 NOTE 44A678 SWITCH ADAPT. PCB ASSY & 309 L T 0 FAN NEUTRAL POS./STOP BLADE INSTALLATION: BNC 5000: REMOVE NUT & WASHERS, TURN UPSIDE DOWN AND TAP SHAFT TO REMOVE BLADES. SHAFT "FLAT" MUST BE IN THE POSITION SHOWN WHEN RE-INSTALLING THE BLADES. CAUTION: BLADES ARE VERY SMALL! PUR ORG BLU YEL TO TB-NEU YEL 58 BLU STOP BLADES () Twisted awg. wires ORG 50 PUR TO IRMS 56 - T4 (FOR PREVIOUS SCR COLOR CODING SEE PG. ) COPPER BAR JUMPER SC-3 ASSEMBLY NOTES: ) ADD JUMPERS TO J5 AS SHOWN. TIE JUMPERS INTO CABLE HARNESS SO CONNECTOR HAS TO BE PULLED FROM PCB WHEN REPLACING PCB. ) GROUND TO FOOT OF TRANSFORMER. 3) ROUTE THESE WIRES SEPARATE FROMALL OTHER WIRING. 4) WIRE #53 MUST BE TIED TO BLU WIRE - NOT TOANOTHER GND. 5) ROUTE THESE WIRES SEPARATE FROM CONTROL WIRES. 6) SNUBBER MAY BE SUPPLIED WITH SCR. 7) (REMOVED: REV. B) 8) GROUNDING NOTES: - GND EACH PANEL TO THE FRAME - JUMPER INTERNAL GND LUG TO EXTERNAL GND LUG.BE PULLED FROM PCB 9) REFERENCE ASSY. DWG. 44A69/ FOR WIRE LUG ASSY. 0) TORQUE SPEC.'S OF #53A04/50 CONTACTOR: 0 LB-IN. ) IF A JUMPER IS NEEDED FOR ANY CORE LEAD, USE HIGH VOLTAGE 89A0086/ WIRE. ) IF OUTPUT GOES THRU SGRS BAYS, USE 40KV 89A0087/ WIRE. 3) FOR ICVM WIRING, SEE DWG. # 44A6687/XXX STEP REG. 3-STEP REG. N/C 540 N/C N/C SC- SC CHASIS GND. (5 STEP WIRING) STB RUN UNDER CAP BANK GND N XCP NEU B5 B4 B3 CCI CC B B CHASIS GND. IF 4AWG GRN/YEL WIRE IS NOT AVAILABLE, USE 89A03 & WRAP WITH GREEN ELECTRICAL TAPE AS SHOWN. S GRIND PAINT OFF IN CONNECTION AREA ) SEE "SYSTEM PACKAGE" FOR WIRING OF 44A6007/X HARTING "STAB" CONNECTOR. NS XCPS 539S 538S 537S 59S 530S 533S 540S USE EXT. WASHER FIRST OR GRIND PAINT OFF IN CONNECTION AREA. 43A66 WIRING DIAGRAM, SGRS 4-30KW, 6.6 & 0A 44A6796 SGRS WIRE HARNESS, 50/70KW W/CCT PCB 94A0368/5 POWER WIRE KIT, FERRO SGRS, 50KW 94A0368/6 POWER WIRE KIT, FERRO SGRS, 70KW DOC. NO. DESCRIPTION RELATED DOCUMENTS SC3-9 SC3-0 SC3-7 SC3-6 SC3-5 SC3-4 SC3-3 SC3- SC3- TO IRMS (NOTE 4) 70 ADB Airfield Solutions All Rights Reserved

79 DRAWING NUMBER: REV. J ASSOCIATED DRAWINGS: DRAWN BY: DRAWN DATE: Figure 48: Powerpack 50-70kW 43A66/5070 page of : GROUND, 4 AWG, 600V, 05C, GN/YL, 89A : GROUND, 6 AWG, 600V, 05C, GN/YL, 89A068/ : GROUND, AWG, 600V, GN/YL, 89A63/ : GROUND, 8AWG, 600V, GN/YL, 89A063/7. 70 kw /0 AWG 89A : INPUT POWER, /0 AWG, 600V, 05C, 89A kw /0 AWG 89A00/ : HIGH VOLTAGE, 8AWG, 7.5KV, 89A00: OBSOLETE - USE "00" SERIES WIRE. POWER 480V : MEDIUM CURRENT, AWG, 600V, 05C, 89A085/ : STD CONTROL, 8AWG, 600V, 89A08/9. 00 SERIES WIRES PRIMARY POWER 600V - 05 C 300-3: TANK LOOP & CAPS, AWG, 600V, 05C, 89A099/9 ( = RUNS AS SHOWN) : HIGH VOLTAGE, AWG, 5KV, 50C, 89A0086/. WIRE SIZES: 0-05: PRIMARY POWER, SEE TABLE. 7A0306/ & / HARTING CONN'S: 48 in-lbs 7A007 TERM. BLK.: 50 in-lbs TORQUE SPEC.S: CONTACTOR, FUSE BLOCK, BREAKER - AS LISTED ON COMPONENT LABEL. 7A007 TERM. BLK.: 35 in-lbs ADD WIRES 54 & 54. NO 53 A 534 COM A K NC DOOR SWITCH SC SC3- (PPF STAB CONN.) SC3- (PPF STAB CONN.) (NOTE 4) (NOTE 4) POWER PAK WIRING FOR 94A0399 "DOOR NOT CLOSED" INDICATOR 43A66 44A A0368/5 94A0368/6 DOC. NO. WIRING DIAGRAM, SGRS 4-30KW, 6.6 & 0A FERRO SGRS WIRE HARNESS, 50 & 70KW SEISMIC POWER WIRE KIT, FERRO SGRS, 50KW POWER WIRE KIT, FERRO SGRS, 70KW DESCRIPTION RELATED DOCUMENTS WHT 55 RED WHT 53-RED PREVIOUS SCR WIRE COLOR CODING Use wrench to hold RES when attaching wires 00 IRMS-IN (FIBER CABLE) BLU IRMS IRMS-OUT (FIBER CABLE) GRY TB-GND TB-N J7 F5 PREVIOUS IRMS W/RES WIRING CVM- (FIBER CABLE) 00/0 GRY (T/T3 and meter not used) TB-L 530 CVM 59 F6 ACE Potted CVM/IRMS Options Use wrench to hold RES when attaching wires H PREVIOUS "MOLDED" STYLE CVM WIRING DRAWING TITLE: 50 & 70KW, 0A, 480VAC SIESMIC FERRO SGRS POWER PACK WIRING DIAGRAM PG. OF 43A66/5070 W U TITLEBLOCK UPDATE BAR 3APR09 T SEE ECO's 85, 947 & 968 BE JUN08 S ECO-83; ADD COMP. PLATE GND. BE SEP07 R ECO-83: UPDATED FOR URCII/ PCB BE 8SEP07 W ECO-54, CHNGS FOR SHORTER GNDS DTR 0OCT0 V ECO-449: CTRL WIRE CONN. CORRECTION BE 09OCT09 Q ECO-88: ADDED SCO OPTION & PG. BE 0AUG07 REV REVISION DESCRIPTION DRAWN REV REV REVISION DESCRIPTION DRAWN REV LEVEL BY DATE LEVEL BY DATE BE 0 MAR 03 All information contained herein, including illustrations, specifications, and dimensions, is believed to be reliable as of the date of this publication, but is subject to change without notice. ADB reserves the right to make changes and improvements to its products and assumes no responsibility for these modifications. Any disclosure of this information is strictly prohibited except as ADB Airfield Solutions may otherwise agree to in writing. Copyright 009 ADB Airfield Solutions. CONTROLLED COPY Unauthorized duplication of this document in whole or part is prohibited. Initialed in RED ink below indicates authorized copy. INITIAL & DATE: ADB Airfield Solutions 977 Gahanna Parkway, Columbus, Ohio 4330 Telephone: , Fax: ADB Airfield Solutions All Rights Reserved 7

80 CHF (Ferroresonant) L-88 / L-89 Constant Current Regulator 96A0408 Rev. G Wiring Schematics 7 ADB Airfield Solutions All Rights Reserved

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