

XR400 CONSTANT CURRENT REGULATOR

INSTRUCTION MANUAL

AIRFIELD LIGHT SYSTEMS UK LTD

Aviation House, Russell Gardens, Wickford Essex, SS11 8BF
Telephone: +44 (0) 1702 547562 Fax: +44 (0) 1702 533962
E-Mail: [email protected] Web: www.alsukltd.co.uk

Issue 02-04-2014 Copyright  2010 ALS UK Ltd

 XR400 CONSTANT CURRENT REGULATORS

CONTENTS

Page
Essential Reading (Safety Notice) i
Handling Precautions of Static Sensitive Devices ii

Forward 1

1. Introduction 2

2. Specifications 3

3. Installation 5
3.1 Unpacking 5
3.2 Mounting 5
3.3 Wiring 5
3.4 Connection Details 7
3.5 Remote Brightness 10

4. Initial Adjustments & Commissioning 11

4.1 A.C. Supply 11
4.2 Output Ratings 11
4.3 External Connections 11
4.4 Current Settings 12
4.5 Phase Back & Over-current Relay 13
4.6 Error Relay 13
4.7 Minimum Current Relay 13

5. Operating Instructions
6.1 Local Control
6.2 Remote Control
6.3 Emergency Operation

6. Description of Circuit
6.1 Power Circuits
6.2 Auxiliary Power Supplies
6.3 Reference Circuits
6.4 Control Circuit
6.4.1 Control Loop
6.4.2 Thyristor Drive Circuit

6.5 Protection & Indication Circuits

6.5.1 Back Indication Relay
6.5.2 Over-current Relay
6.5.3 Error Relay

7. Maintenance
7.1 General
7.2 Routine Inspection
7.3 Replacement of Tray
7.4 Replacement of Control PCB
7.5 Replacement of Thyristor Module
7.6 Replacement of Thyristor protection Fuse

Issue 02-04-2014
 8. Fault Finding
8.1 Simple Setting Up Fault Finding
8.2 Voltage Checks
8.3 Fault Location Table

9. Earth Leakage Relay

9.1 Introduction
9.2 Application
9.3 Initial Adjustments and Tests
9.4 Operation

10. Lamps Out Detector

10.1 Introduction
10.2 Principles of Operation
10.3 Adjustments
10.4 Alternative Output Regulators
105 Simultaneous Output Regulators

11. Analogue Primary Circuit Current Monitor

11.1 Introduction
11.2 Description
11.3 Commissioning
11.3.1 Equipment Required
11.3.2 Adjustments and Tests

12. Digital Primary Circuit Current Monitor

12.1 Introduction
12.2 Description
12.3 Digital PCCM Set-up

13. Multiple Output Regulators

13.1 Introduction

14. Spares List

14.1 Spares List Cabinet Assembly
14.2 Spares List Control Tray

15. List of Drawings

Issue 02-04-2014
 ESSENTIAL READING

COMPLIANCE WITH INSTRUCTIONS IN THIS MANUAL

The purchaser/user is advised to comply with the instructions and information in this
manual and ensure that all personnel to be associated with the equipment are made familiar
with the information contained therein.

SAFETY NOTICE

The purchaser/user is advised to ensure that each piece of equipment is correctly installed,
in a suitable location, by technically qualified and competent persons experienced in the
class of work involved. Operating and maintenance personnel should refer to the UK
Health and Safety at Work Act and the FAA Advisory Circular AC 150/5340-26
“Maintenance of Airport Visual Aids Facilities” for instructions on safety precautions.

While every practicable safety precaution has been incorporated in this equipment, the
following rules must be strictly observed.

KEEP AWAY FROM LIVE CIRCUITS

Operating and maintenance personnel must at all times observe all safety precautions. Do
not remove cover panels unless the power supply to the equipment has been removed. Do
not make adjustments or change components within the equipment with the incoming
power supply ON. Do not change field circuit lamps with the equipment energized.
Be aware that high voltage potentials can still exist for a period of time in the filter circuits
and the field lamp circuit after the equipment has been powered down.

RESUSCITATION

Operating and maintenance personnel should familiarise and keep up to date in the
techniques for resuscitation found in First Aid Instruction manuals.

Issue 02-04-2014 Page i

 HANDLING PRECAUTIONS FOR PRINTED CIRCUIT BOARDS
WITH STATIC SENSITIVE DEVICES

1. INTRODUCTION

A number of microelectronic devices on equipment printed circuit boards (PCB’s) are

subject to permanent damage due to electro-static potentials (static) encountered in
routine handling, testing and shipping, unless special precautions are observed. For
example, static electricity can be generated simply by an operator moving on a chair,
brushing against benches or walls or walking across the floor, so appropriate action must
be taken to discharge this personal static when handling individual PCB’s. Once the
PCB is plugged into the equipment it is protected from any static damage.

2. PROTECTION OF EQUIPMENT FROM STATIC DAMAGE

Protective measures are required when handling PCB’s containing static sensitive
devices. Such a PCB is identified by the presence of a label BEWARE STATIC
DAMAGE. These protective measures apply during arrival and handling/storage at site,
general handling and setting up.

General rules which apply are:-

a. personnel handling PCB’s shall NOT wear outer clothing which will generate
surface charge, e.g. synthetic materials like nylon; cotton is preferable,

b. personnel handling PCB’s shall put themselves in contact with a grounded

surface before removing a PCB from protective packing or from equipment, e.g.
by use of a wrist strap. The wrist strap should be kept on during all PCB
handling,

c. avoid finger contact with devices and connectors on the PCB.

d. if it is necessary to place a PCB down unprotected, place it on static shielding

bag,

e. PCB shall be protected by a static shielding bag when it is out of the equipment.

f. the system power and test equipment must be switched off before inserting or
withdrawing p.c.b.

g. dielectric strength and insulation resistance tests should not be carried out with
the p.c.b. installed in the equipment,

Issue 02-04-2014 Page ii

FOREWORD

This instruction manual has been compiled to provide a comprehensive description of this equipment
together with recommended operating and maintenance procedures. It is intended for the guidance of
persons associated with such functions and should be used to supplement local approved techniques.

Where the equipment has been engineered using standard functional units the manual may have been
compiled using standard sub-sections describing these. Any necessary supplements or revisions to
these sub-sections have been included, as necessary, to ensure that they pertain to the actual
equipment and its facilities as supplied.
(Specific Manual)

Every care has been taken to ensure the accuracy of the contents at the time of publishing.

The contents of this manual may not be reproduced, either wholly or in part, without the written
consent of the Company.
© 2010 ALS UK Ltd

ALS UK Ltd
Aviation House,
Russell Gardens,
Wickford,
Essex, SS11 8BF.

Telephone: +44 (0) 1702 547562

Fax: +44 (0) 1702 533962
Email: [email protected]

Guarantee.

Sontranic Limited guarantees to rectify any defect caused by faulty workmanship or defective
materials that occur during proper and normal use within a period of 12 months from date of
shipment. Equipment will be accepted back to base, carriage paid for rectification under warranty.
This warranty does not cover fuses, natural wear and tear or damage arising from negligent handling,
improper maintenance or installation or electrical influences.
No liability is accepted for direct or consequential damage or expenses incurred in event of such
failure of equipment.

The above constitutes the limit of our liabilities with the respect to the equipments guarantee.

Issue 02-04-2014 Page 1

 XR 400 CONSTANT CURRENT REGULATORS

1. INTRODUCTION

This Instruction Manual covers single and multiple output constant current regulators for use
on airfield lighting systems complete with earth leakage relay. The nominal output ratings
are 1.5kW up to 30kW, with a full load current of 6.6 Amps or 12 Amps r.m.s. Brilliancy
selection is controlled locally from the CCR front panel and remote control facilities are fully
available for use with a remote control console.

The XR400 series of constant current regulators provide r.m.s. current control in the load
circuit to an accuracy of + 1% of its rated full load value. A closed loop circuit automatically
adjusts the firing angle of two thyristors connected in inverse parallel in the a.c. supply to the
isolating transformer feeding the lamp load.

Protective relays are included to guard against over-current and open circuit in the external
load circuitry. The over-current circuit comprises a two-stage protection consisting of a fast
phase back circuit followed by a trip signal to the circuit breaker. The open circuit protection
gives a trip signal to the circuit breaker.

WARNING

This equipment can generate voltages up to 5000 volts. The cubicle must be isolated before
the front or rear covers are removed.

Issue 02-04-2014 Page 2

2. XR 400 CONSTANT CURRENT REGULATOR SPECIFICATION

Type : Solid State Thyristor Phase Control Single Output.

Ratings available : 1.5kW, 2.7kW, 4kW, 5kW, 7.5kW, 10kW, 12.5kW,

15kW, 20kW @ 200-250V Input.

1.5kW, 2.7kW, 4kW, 5kW, 7.5kW, 10kW, 12.5kW,

15kW, 20kW, 25kW & 30kW @ 380-450V Input.

Input Voltage : 200-250V & 380-450V at 50Hz/60Hz.

Output Current : 0-6.6A, 0-12A Other currents available on request.

Output Current Accuracy : + 1% of setting for supply variations of +6% and

-10%.
+ 2% with up to 30% lamps out.

Response Time : Less than 300ms (15 cycles)

Interference Suppression : Mains filtered to BS800 and safety standard

BS415. EN50081-2 & EN50082-2

Ventilation : Natural

Temp. Range : -20°C to +50°C

Humidity : Max 95% Non-condensing.

Altitude : Zero to 2000m A.S.L.

Standard Features : a. Soft Start

b. Open Circuit Trip (Manual Reset)
c. Over Current Trip (Manual Reset)
d. Over Current (Phase Back)
e. Power On Remote Indication
f. Local/Standby Selected Remote Indication
g. Current Flowing Remote Indication
h. Earth Leakage Detector with Local and
Remote Indication
i. 7 Stage Local and Remote Brilliance
Settings
j. Hours Run Counter

Optional Features a. 2 Stage Lamp Out Detector

b. Analogue Primary Current Monitor.
c. Digital Primary Current Monitor
d. Integral Circuit Selectors.
e. Internal 48V DC Remote Supply.
f. 100% Hours Run Counter.
g. Lightning Arrestors.

NB. All remote indications supplied via normally open volt free contacts.

Issue 02-04-2014 Page 3

 Standard Front Panel Controls and Indicators :

a. MCCB Isolator
b. Power On Indicator
c. Ammeter
d. Earth Leakage Fault Indicator
e. Earth Leakage Reset & Test Switch
f. 3 Position Local/Standby/Remote Selector Switch
g. 7 Position Brilliance Selector Switch
h. Set Max. Current Control
i. Hours Run Counter

Optional Front Panel Controls and Indicators :

a. Lamp Filament Failure Indicators.

b. Lamp Filament Failure Test Pushbutton.
c. 100% Hours Run Counter.

CCR Cabinet :

All steel construction with removable front and rear panels. Cable access via removable
gland plate mounted at the front of the cabinet.

Standard Size :

Height = 1250 mm
Width = 575 mm
Depth = 645 mm

Lifting Lugs supplied as standard. Add 60mm to height.

Issue 02-04-2014 Page 4

3. INSTALLATION

CAUTION
The regulator and associated equipment must not be subjected to a flash test. The load
insulation resistance may be checked with a 1000 volt Megger by disconnecting the load
from the cubicle.

3.1 UNPACKING

Unless Castors have been fitted, the cubicles are shipped with the cubicle base mounted on a
wooden pallet. In order to facilitate the removal of the pallet, the front and rear base supports
are split and each can be separated by the removal of two bolts. Once these bolts and the
cubicle base fixing bolts have been removed the cubicle can be tilted from one side and one
section of the wooden pallet removed; then by tilting the other side the remaining section can
be pulled clear.

3.2 MOUNTING

The cubicle is designed to be lifted by means of a forklift truck. It should be sited above its
cable duct with sufficient front access to enable the control tray to be pulled out and
removed. It is also necessary to be able to adjust preset potentiometers and check voltages
during commissioning or fault finding and to operate controls on the front panel of the
control tray as normal operating procedure when local control is selected.

At least 500mm. clearance should be provided at the rear of the cubicle to enable the
ventilation system to function correctly and to provide access for initial setting up of the
transformer secondary taps.

If castors are fitted the front castors may be locked to prevent the cubicle moving from the
selected location

3.3 WIRING

All external connections are taken through a gland plate in the base of the cubicle to
conveniently placed terminals as shown on the outline drawing. The cubicle must be soundly
earthed.

The a.c. supply leads to terminals L1 and L2 should be fused in accordance with the
following table. Moulded case circuit breakers may be used in place of fuses so long as the
protection provided is not worse than that provided by these fuses. The maximum cable size
that the regulator terminals can accommodate is also given.

200-250V Inputs: -

Regulator Full Load 200V Fuse Max Cable

Rating (kW) Current (Amperes) Rating (Amperes) Size (mm2)

1.5 9 10 6
2.7 16 20 6
4 23 25 6
5 29 32 6
7.5 44 50 35
10 58 63 35
12.5 72 80 70
15 88 100 70
20 110 150 70

Issue 02-04-2014 Page 5

 380-450V Inputs: -

Regulator Full Load 440V Fuse Max Cable

Rating (kW) Current (Amperes) Rating (Amperes) Size (mm2)

1.5 5 10 6
2.7 8 10 6
4 12 16 6
5 15 20 6
7.5 23 25 6
10 30 32 6
12.5 38 40 6
15 46 50 35
20 61 63 35
25 76 80 70
30 92 100 70

Issue 02-04-2014 Page 6

3.4 CONNECTION DETAILS

The incoming a.c. power supply is connected across connectors L1 and L2 with the earth on
E.

Variations in the mains supply can be accommodated by altering the taps provided on the
primary of the main transformer TX1.

The lighting circuit is connected between the terminals L3 & L4 on a single output regulator.
On multiple output units, terminals L3 & L4 are for output 1, L5 & L6 are for output 2 etc.

Taps are provided on TX1 for selection of the appropriate loads. The load rating must be
equal or lower than the tap selected. All regulators are pre-set to their maximum rating.
Each tap will accommodate 10% of its load rating before requiring a change down to the next
tapping but for optimum efficiency the load and tap should be matched as closely as possible.
All output transformers are clearly marked in kW rating.

Table 1 (Refer Figs. 2 and 3 for Terminal Layouts.)

Connector Function

L1 } Incoming Supply
L2
E Incoming Earth

L3 } Output Circuit to Lampload 1

L4

L5 } Output Circuit to Lampload 2

L6

PC } Power Indicator
P1 (Indicates power is applied and isolator is on)

AC } Local Indication
A1 (Indicates that CCR is in Local or Standby mode)

EC } Earth Leakage Fault Indication

E1 (Indicates Earth Fault on Lamp Load Circuit)

BC } Back Indication Common

B1 Lamp Load 1
B2 Lamp Load 2
(Indicates that the current in load is greater than 2.3A)

CC Multiple Output Common (48V d.c. -ve)

C1 Output Circuit 1 Select (48V d.c. +ve)
C2 Output Circuit 2 Select (48V d.c. +ve)

Issue 02-04-2014 Page 7

 RA } Two Wire Brightness Control (If fitted)
RB }

RC Remote Brightness Common (48V d.c. -VE)

R1 " " Position Min (48V d.c. +VE) Not used
R2 " "Position 2 " if 2- Wire
R3 " "Position 3 " Control
R4 " "Position 4 " is fitted
R5 " "Position 5 "
R6 " "Position 6 "
R7 " "Position Max "

DC Lamps Out Detector Common

D1 5% Lamps Out (N/O Contact)
D2 5% Lamps Out (N/C Contact)
D3 10% Lamps Out (N/O Contact)

I+ } P.C.C.M. Analogue Output (If fitted)

I- }

+ } Output of Internal 48 Volt DC Supply (If fitted)

- }

Issue 02-04-2014 Page 8

Issue 02-04-2014 Page 9
3.5 REMOTE BRIGHTNESS

A typical remote brightness control system is shown in Fig 4.

It should be noted that an external supply, normally 48V DC is necessary for operation of the
remote control system, although 24V DC system may be used if required. (See section 6.3).

The ON/OFF and BRIGHTNESS SELECTOR switches should be rated at 100mA at 60V
DC.

FIG 4 TYPICAL CONNECTIONS FOR REMOTE BRIGHTNESS CONTROL

Issue 02-04-2014 Page 10

4. INITIAL ADJUSTMENTS AND COMMISSIONING

4.1 A.C. SUPPLY

Three taps are provided on the primary side of transformer TX1 suitable for supply voltages
rated at 200, 220 and 240 volts or 380, 415 and 440 volts. A 10 volt tap is provided where by
transferring the cable from the 0 stud to the 10 volt stud, input supply voltages of 210, 230
and 250 volts or 390, 425 and 450 volt are catered for. The tap selected should be nearest to
the voltage of the local supply.

A higher voltage tap may be used if the full output rating of the regulator is not required: i.e.
the 440 volt tap could be used on a 415 volt supply if a 6% reduction in the output rating is
acceptable and the use of this tap would give better power factor and efficiency when
working into the lower impedance load.

The auxiliary transformer TX2 and if fitted TX3 have similar voltage taps, which must be
adjusted to match the correct supply voltage.

4.2 OUTPUT RATINGS

Select the secondary tap required to suit the load rating via the appropriate terminals located
on transformer TX1. The secondary taps provided are as follows: -

Regulator Minimum Middle Maximum

Rating (kW) Tap (kW) Tap (kW) Tap (kW)

1.5 0.75 1.1 1.5

2.7 1.35 2 2.7
4 2 3 4
5 2.5 3.75 5
7.5 3.75 5.6 7.5
10 5 7.5 10
12.5 6.25 9.4 12.5
15 7.5 11.25 15
20 10 15 20
25 12.5 18.75 25
30 15 22.5 30

The tap selected should be equal to or higher than the rating of the load. The lowest possible
tap should be used in order to operate at the best possible efficiency and power factor. The
CCR output may be connected between taps by changing the C.T. link. It is important that
the C.T. is in circuit. Terminal P1 must always be connected to the output circuit. P2-0 link
can be replaced by a link from P2 to the required kW tap. The regulators are all rated above
their nominal kW rating to allow for all normal operating conditions.

Ensure that the load circuit is connected correctly.

4.3 EXTERNAL CONNECTIONS

Ensure that all external connections are made in accordance with the appropriate interface
drawing, and that the correct fuses are fitted in the a.c. supply leads L1, L2 to the regulator
(see section 3.3).

Issue 02-04-2014 Page 11

4.4 CURRENT SETTINGS

IMPORTANT

The "Ammeter" fitted to the tray of XR400 CCR's is a DC Voltmeter (Scaled to read Amps)
monitoring the output of the CCR's RMS-DC converter.

Should either the main p.c.b. or the "Ammeter" movement be replaced, then the meter MUST
be recalibrated against a "TRUE RMS" ammeter as follows:-

i) With the CCR switched off, check that the meter movement reads ZERO. Adjust
movement if necessary.

ii) Connect "TRUE RMS" Ammeter into output circuit fed by CCR. Select STANDBY
on the front panel, energise CCR and switch BRIGHTNESS switch to position 7.
Adjust output current using front panel ‘SET MAX CURRENT’ until "TRUE RMS"
meter reads exactly rated full load current of CCR i.e. 6.6 Amps.

iii) Using potentiometer RV12, (located on main p.c.b., below and to the right of Relay
RL2), adjust tray Ammeter to also read rated full load current of CCR.
(i.e. to red line on meter).

This adjustment should be carried out BEFORE any other adjustments are made to either of
the intermediate output current levels, or the trip setting levels.

iv) Check that readings of tray meter and TRUE RMS meter agree to within +-0.15
Amps at all intermediate brightness levels.

NOTE : Always ensure that the CCR is operating under the correct input and output
conditions when SET MAX CURRENT is adjusted. In particular SET MAX
CURRENT must be set when the actual maximum obtainable output current
is being drawn. If SET MAX CURRENT is set with the input voltage wrong
or with the output incorrectly loaded then the CCR may trip when the faulty
conditions are subsequently removed.

WARNING - The maximum output current (i.e. 6.6A or 12A) should not be exceeded except
for checking the over current relay when it is necessary to run at 105% FLC in order to check
the relay operation. The time taken to complete this test should be kept to a minimum so as
to avoid stressing the lamps.

a) On the front panel select STANDBY and set the BRIGHTNESS switch to position 1.
Close the main isolator: the red indicator POWER ON should light. Then select LOCAL
and note that load current rises. Do not attempt to trim the current level to an exact value
at this stage.

b) Turn the BRIGHTNESS switch to positions 1-2-3-4-5-6-7 in turn, noting a rise of current
at each step. The currents corresponding to each position for a 7 stage regulator are
factory set as follows:-

Position Brightness R.M.S. Current R.M.S. Current

(6.6A Range) (12A Range)
1 0.3% 2.9 A 5.28A
2 1% 3.4 A 6.12A
3 3% 3.9 A 7.08A
4 10% 4.6 A 8.28A
5 30% 5.4 A 9.72A
6 80% 6.3 A 11.52A
7 100% 6.6 A 12.0A

If any of the current settings require trimming proceed as follows:-

Issue 02-04-2014 Page 12

 1. The maximum setting potentiometer RVM (SET MAX CURRENT) on the front panel
must be adjusted first as this control also changes the other current settings. It may be
adjusted using a screwdriver via the hole provided in the front panel. Adjust to give rated
full load current with the brightness switch SW2 on position 7.

2. The remaining positions may then be adjusted by partially withdrawing the tray (up to the
first stop) to allow access to the main printed circuit board. RV1 may then be adjusted
with the brightness switch on position 6, RV2 on position 5, etc.

WARNING

To prevent unwanted surges it is advisable to have the CCR in standby when applying mains
and when operating the circuit breaker.

4.5 PHASE BACK & OVERCURRENT RELAY

Check the setting of the over current trips. With the regulator in LOCAL, select position 7 on
the front panel BRIGHTNESS Switch, run at FLC and slowly increase the output current by
means of the front panel SET MAX CURRENT. The over current trip should cause the CCR
to phase back and hunt at 102%. This setting can be adjusted by means of RV9 on the
Control printed circuit board. If LK1 on the Control printed circuit board is moved to the
"OUT" position the error relay will cause the circuit breaker to trip at 105%. This setting can
be adjusted by means of RV7 on the Control printed circuit board.

If phase back is required then move LK1 to "IN" position.

4.6 ERROR RELAY

The error relay also trips the circuit breaker if the output voltage is high with no output
current. This means that it will detect and trip if the load circuit is open circuit. It will also
trip if the RMS-DC converter used for the over current circuit falls to zero output.

To check the operation of the error relay, switch off the a.c. supply to the cubicle, remove the
output leads to the load circuit, and refit the covers. Re-energise the cubicle and switch to
LOCAL control with the brightness selector switch set to position 1. The circuit breaker
should trip out. Reconnect the output leads.

4.7 MINIMUM CURRENT RELAY

Check that the minimum current relay RL8 on the control board operates when the regulator
is set to deliver minimum output current. With the LOCAL/REMOTE switch to ‘STANDBY’
switch the BRIGHTNESS selector switch to position 1. Set the LOCAL/REMOTE switch to
‘LOCAL’ and note that the relay operates. Check that the relay de-energises when the
regulator is switched to "STANDBY".

The relay has been set up in the factory to operate at 2.3 Amps for 6.6A and 4.2 Amps for a
12A CCR by adjustment of potentiometer RV8. To check the relay setting switch the
Local/Remote switch to Local and the BRIGHTNESS Selector to position 1. Note the output
current on the meter, and then reduce the current slowly by adjustment of potentiometer RV6.
The relay RL8 should de-energise just below the above currents. If the setting has to be
adjusted, set to the desired current by means of RV6, then slowly adjust RV8 until RL8 just
energises.

Re-adjust RV6 to give the original current setting.

Issue 02-04-2014 Page 13

5. OPERATING INSTRUCTIONS

5.1 LOCAL CONTROL

To operate the regulator on local control, first check that the front panel LOCAL/REMOTE
switch is in the STANDBY position. Check that a.c. supply to the cubicle is switched on by
means of the remote isolator. Then proceed as follows:-

1. Close the regulator circuit breaker (note that the RED power indicator lights, indicating
that the circuit breaker has closed).

2. Select the level of brightness required by means of the front panel BRIGHTNESS Selector
switch.

3. Turn the LOCAL/REMOTE switch to the LOCAL position. The current should rise to the
required level as indicated on the meter.

4. To change the brilliancy level, adjust the BRIGHTNESS switch to the required position.

5. To turn the equipment off, switch the LOCAL/REMOTE switch to the STANDBY
position. If the equipment is to be left out of use for long periods the circuit breaker
should be switched off.

5.2 REMOTE CONTROL

Select the REMOTE position on the front panel LOCAL/REMOTE switch and follow
instructions provided for central control station.

5.3 EMERGENCY OPERATION

To maintain the lighting supply in the event of a major fault it is possible to energise the
lamp circuits through the regulator transformer, bypassing the control circuits.

Emergency operation is only possible on CCR’s that are connected across two phases of the
incoming supply. Where a CCR is connected between phase and neutral this procedure must
not be used.

To do this proceed as follows:-

1. Remove the incoming cable from terminal L2 and replace it by the neutral of the supply so
that the voltage across L1-L2 is 240 volts i.e. approximately half the original supply voltage.

2. Short circuit the secondary of current transformer CTX1 by putting a link between
terminals S1 and S2 located on the main transformer terminal panel (refer to cabinet
wiring diagrams).

3. Remove incoming cables to tray terminals CON1/1 and CON1/2 and join cables together
using suitable connector block.

This method of operation is only permissible if the load is reasonably well matched to the
CCR output tap.

It should be noted that current control and back indication are lost and the ammeter on the
tray will cease to function.

Issue 02-04-2014 Page 14

6. DESCRIPTION OF CIRCUIT

The function of the CCR is to maintain a constant current in an external series (lamp) circuit
so as to maintain a constant brightness in the lamps, even when load or the input voltage
varies.

The r.m.s. (root-means- square or 'effective') current flowing in the series circuit is detected
by an accurate transducer. This enables a dc voltage to be produced which is directly
proportional to the current flowing in the lamp circuit. This voltage is the brightness
analogue. The brightness analogue is compared to a dc brightness reference signal. This
signal is a dc voltage, which is proportional to the brightness selected at the front panel or
control tower. Any difference between the brightness analogue and the brightness reference
indicates that the lamp current is not the required value. The current is then restored to the
correct value by a regulator in series with the primary of the output transformer.

The essential element in the regulator is a pair of thyristors in inverse parallel. The CCR
provides gate-firing pulses at the correct time in each mains half-cycle so as to trigger the
appropriate thyristor and cause it to conduct for the remainder of that half cycle.

Fig.1 is a block diagram of the regulator. The circuit may be divided into the power circuit,
auxiliary power supplies, control circuit, reference circuit and protection circuits.

6.1 POWER CIRCUITS

(Refer to cubicle circuit diagram specified in Section 15).

The incoming single phase supply to the regulator is applied via an MCB isolator, a radio
interference filter, and two thyristors connected in inverse parallel to the primary of a step-up
isolating transformer TX1. The secondary of transformer TX1 feeds the airfield lighting
circuit via a current transformer CTX.

The voltage across the primary of the transformer is adjusted to the required level by phase
control of the thyristors.

The MCB isolator is used to switch the regulator on and off locally and to trip the regulator
off in the event of faults detected by the protection circuits. Transformer TX2 mounted in
the rear of the control tray provides the low voltage supplies for the Control Electronics. A
red indicator lamp on the front panel lights when the MCB is closed with power applied.

6.2 AUXILIARY POWER SUPPLIES

All internal control voltages are derived from a mains transformer TX2 mounted in the rear
of the control tray protected by a fuse FS101 mounted on the tray bulkhead. The control
circuitry operates from a ±24V DC and a stabilised +15 volts DC supply, components of
which are integral on the main control board. Transformer TX2 also supplies the 72 volts
required by the Earth Leakage Detector.

Issue 02-04-2014 Page 15

6.3 REFERENCE CIRCUITS

The XR400 regulator is provided with seven pre-settable reference levels selected locally by
the front panel rotary Brightness switch (SW2) when the Local/Standby/Remote switch
(SW1) is in the local position. When ‘Remote’ is selected on the front panel an 8-wire
remote scheme is used for brilliancy control.

In local and remote the maximum brilliancy stage is set by the ‘Set Max Current’
potentiometer ‘RVM’ which is adjustable by means of a screwdriver through a hole in the
front panel of the control tray. This may be used for checking the setting of the over current
relay or to provide a proportional reduction in the level of all the reference settings.
Potentiometers (RV1-6) mounted on the main control board are used for individual stage
brilliancy control of stages 1 to 6 and can be adjusted by withdrawing the control tray up to
the first stop.

The brightness reference signal voltage required for each brilliancy stage is selected by any
one of seven relays RL1-7 by either via the front panel brightness switch or remotely from
the control tower.

The selector voltage is 24V DC supplied by the CCR in local mode. In remote mode an
external 48V DC source is applied for the brightness selection. Provision for 24V DC remote
control is provided by strapping link LK2 on the main control board.
As an option the CCR can be provided with an integral 24V or 48V DC supply for remote
control.

6.4 CONTROL CIRCUIT

The control circuit may be divided into:-

1. Control Loop.
2. Thyristor Drive Circuit.
3. Phaseback circuit.

6.4.1 Control Loop

The CCR employs two RMS-DC converters, one for the current control and a second
converter for the protection and monitoring circuits. In the event that if one of the converters
should fail the other converter will shut down the CCR.
The brightness analogue is produced from a current transformer mounted on the main output
transformer, which is fed to RMS-DC converters RD1 & RD2, which provide a dc output
proportionate to the current flowing in the lamp load. Converter RD1 is used for current
control and its output is adjustable via the front panel SET MAX CURRENT potentiometer.

The positive output from ‘RD1’ is then summed with the brightness reference negative output
of AMP1 and integrated by AMP2, any difference between the brightness reference and the
brightness analogue will produce an output from AMP2. The closed loop of the system will
try to keep those two signals equal and maintain current regulation.

AMP2 produces a positive output the level of which will vary with the current flowing, the
higher the voltage the earlier the gate pulses to the thyristors and therefore more output
current will be supplied.

Within the starting and phaseback block, circuitry is provided to monitor the incoming mains
supply for short and long breaks. If the break in the supply is greater than 100mS on resumption
of the supply the CCR will soft start. Also provided within this block is a minimum demand
circuit, which will suppress the output current until at least 1 amp has been demanded.

Issue 02-04-2014 Page 16

6.4.2 Thyristor Drive Circuit

The thyristor drive circuit consists of a free running oscillator mounted on a plug-in daughter
board located on the main control board assembly, which is stopped and started by the firing
control circuit.

The drive control circuit consists of a constant current sourced timer controlled by a zero
crossing detector so that when the mains voltage passes through zero the timer is reset.
The output of the timer is applied to a variable threshold comparator that is controlled by the
output from AMP2. The output of the comparator is then applied to a fast acting switch to
start and stop the drive oscillator. Thyristor trigger pulses are produced from the secondary of
a pulse transformer that forms part of the oscillator circuitry.

6.5 Protection and Indication Circuits

The protection circuits are made up of comparators comparing a DC voltage proportional to

the current flowing to a preset reference source. The reference source is via potentiometers
RV7-RV9 connected across a constant voltage supply. The DC proportional voltage is
derived from a second RMS-DC converter ‘RD2’. Should the DC voltage exceed the preset
reference voltage a logic 1 will be produced on the output of the comparators.

6.5.1 Back Indication Relay

Comparator ‘COMP2’ provides back indication of minimum current flowing, Potentiometer

RV8 on the main control board is adjusted for an output current of 2.1-2.3 amps and at this
current its output will energise relay RL8. Relay RL8 also switches the hours run counter so
that the counter only runs when current is flowing in the lamp load.

6.5.2 Over current Relay

When Link LK1 on the main control board is in the "IN" position, over current is detected at
the level set by potentiometer RV9 to comparator ‘COMP4’ to produce a phase back of the
output current in a fault condition. The output current will be phased back to zero and then
will ramp up to the previously set level, if the fault is still there then the CCR will continue to
phase back until the fault is rectified.

The phase-back facility can be disabled by moving Link LK1 from the "IN" to "OUT"
position. With the link in the "OUT" position over current is detected at the level set by
potentiometer RV7 setting the comparator ‘COMP3’. The output of the comparator energises
error relay RL1 mounted on the fuse panel in the cabinet, which will energise the trip coil in
the isolator.

6.5.3 Error Relay

Comparator ‘COMP1’ detects an open circuit in the lamp load by comparing the output of the
drive amplifier ‘AMP1’ with the output of the RMS-DC converter RD2. A discrepancy will
result in the energising of the error relay RL1 mounted on the fuse panel in the cabinet,
which in turn will energise the trip coil in the isolator.

Issue 02-04-2014 Page 17

Issue 02-04-2014 Page 18
7. MAINTENANCE

7.1 GENERAL

Little maintenance is required on this type of equipment. However, regular inspection is the
best assurance against serious faults. It is not permissible to lay down a strict routine, as this
must depend on operating conditions and personnel available. As a rough guide, it is
recommended that equipment operating under normal duty should be inspected at three or
four monthly intervals.

7.2 ROUTINE INSPECTION

The following checks are suggested:-

Check that all external connections are secure, especially in the terminal blocks. Examine
internal connections for looseness or fraying. The SCR cooling fins should be blown out to
remove any accumulation of dirt, check that the fuses are of correct rating and secure fit.
Check that there is no restriction to air circulation.

7.3 REPLACEMENT OF TRAY

To remove the control tray:-

1. Ensure that the supply to the cubicle is dead.

2. Release the eight fixing screws and remove the rear panel.

3 . Unplug the 2 x 12 way Fanning strips from the rear of the tray (CON2) and the 25
way 'D' type plug CON3. Unplug CON4 on the side of the tray if fitted.

4. Remove the two heavy duty connections CON1/1 & CON1/2 to the thyristor stack.
Remove the earth lead and Connections CON1/3 & CON1/4.

5. Release the four fixing screws and withdraw the tray to the first stop. Depress the
stop mechanism on the left hand under side of the tray and withdraw the tray
completely.

6. Fit the replacement tray. Check that all connectors are correctly positioned and tight
and refit rear panel.

7. Check the operation of the replacement tray.

8. Check that the over current relay is set to 105% FLC as specified in Section 5.5 and
readjust if necessary.

Issue 02-04-2014 Page 19

7.4 REPLACEMENT OF CONTROL PCB
To change the printed circuit board: -
1. Unplug all Molex connectors, and the ribbon connector.

2. Disconnect the four "Faston" connectors wired with Red and White twisted pairs.

3. Unscrew the two fixing screws at the top of the board. Lift the board out of the
slotted stand offs.

4. Fit the replacement PCB. Check that the Molex connectors and ribbon cable are
correctly positioned and that the two Red and White twisted pair ‘Faston’ connectors
are reconnected to the daughter board in the correct order.

5. Check the operation of the replacement PCB.

6. Re-calibrate Tray Ammeter against True RMS Ammeter as specified in Section 5.4
and adjust current settings for all brilliancy levels.

7. Check that the over current relay is set to 105% FLC as specified in Section 5.5 and
re-adjust if necessary.

7.5 REPLACEMENT OF THYRISTOR MODULE

a) Remove Perspex cover from top of thyristor stack (2 nuts, washers)

b) Remove R/H Perspex cover retaining pillar: slacken pillar and slide out of heatsink
complete with retaining nut.

c) Remove heavy-duty wire [60] from thyristor module and wire from snubber p.c.b.

d) Remove snubber p.c.b. (1 screw, washers).

e) Remove screw from centre terminal of module retaining fuse plate.

f) Unplug wires from module terminals 4,5.6 & 7.

g) Slacken two screws retaining module and slide out of the heatsink complete with the
retaining nuts.

h) Transfer module retaining screws and nuts to new module then slide nuts into
heatsink and when in position tighten retaining screws to 5Nm for IRKT type module
or 2.5Nm for MCC type modules.

i) Reassembly is a reversal of a – f.

Issue 02-04-2014 Page 20

7.6 REPLACEMENT OF THYRISTOR PROTECTION FUSE

a) Remove Perspex cover from top of thyristor stack (2 nuts, washers)

b) Remove retaining nut and washers from insulated stud on R/H side of fuse and lift
off heavy-duty wire [61].

c) Remove retaining nut and washers from L/H side leaving fixing bolt in place, then
lift off fuse.

d) Place new fuse on insulated R/H stud and L/H bolt.

e) Replace washers and nut on L/H bolt and tighten.

f) Replace heavy-duty wire on R/H stud and refit washers and nut then tighten.

g) Replace Perspex cover.

Issue 02-04-2014 Page 21

The thyristor protection fuse mounted on the thyristor assemble is a special fast acting semi-
conductor fuse and MUST NOT be replaced with any other type or rating.

Fuse FS201 for 1.5 – 20kW 200-250V Input SIBA Type Order Code
100 Amp Thyristor Protection Fuse for 1.5 – 7.5kW 50 053 06/100 FL093
125 Amp Thyristor Protection Fuse for 10 - 12.5kW 52 053 06/125 FL094
160 Amp Thyristor Protection Fuse for 15kW 54 053 06/160 FL095
180 Amp Thyristor Protection Fuse for 20kW 56 053 06/180 FL096

Fuse FS201 for 1.5 – 30kW 380-450V Input Bussman Type Order Code
71 Amp Thyristor Protection Fuse for 1.5 – 7.5kW 71FE FL088
100 Amp Thyristor Protection Fuse for 10 – 12.5kW 100FE FL089
140 Amp Thyristor Protection Fuse for 15kW 140FEE FL090
180 Amp Thyristor Protection Fuse for 20kW 180FEE FL091
200 Amp Thyristor Protection Fuse for 25 –30kW 200FEE FL092

Issue 02-04-2014 Page 22

8. FAULT FINDING

DANGER - This cubicle produces very high output voltages. Up to 5000 volts r.m.s. can be
generated in the case of a 30 kW, 6.6 A regulator.

The 440V r.m.s. circuitry on the control tray, including the high voltage section of the PCB is
kept separate as an additional safeguard against accidental contact with the 440V circuits.
When the tray is withdrawn to its first stop, the voltage on the exposed part of the PCB is
limited to approximately 80 volts, although voltages on the daughter board may be higher

Faults relating to component failure are best resolved by substitution of the suspected
part or printed wiring board. It is not recommended that repairs are attempted on the
printed wiring boards as further damage can be caused. If after substitution the fault is
cured then return the faulty board to the factory for repair.

Blown fuses usually have an underlying cause, which should be investigated.

The following table of faults should help to trace the cause of any incorrect operation of the
regulator.

8.1 SIMPLE SETTING UP FAULT FINDING.

Symptom Possible Fault

1. Lights pulse at approximately 2- "Adjust Max" set to above 102% of rated output
second intervals, when max. current: - reduce current setting by turning RVM
brightness is selected anti-clockwise
2. Circuit breaker trips when Max. "Adjust Max" set to above 105% of rated output
brightness selected and ammeter current: - reduce current setting by turning RVM
indicates current above rated output anti-clockwise. (Control PCB link 1 in "out"
current. position or phase back trip level set higher than
105%).
3. Circuit breaker trips with current Supply volts very low or load greater than
below maximum rated output current. regulator can supply: - Recalculate load and re-
check load tap setting, check if lamps out above
30%. Check 105% trip level is not set below
maximum rated output current.
4. Circuit breaker closes correctly, but Either open circuit in airfield circuit. (Could also
trips as soon as any brightness stage be severely over-loaded or under-loaded
selected or switched on. producing the same effect.)
Thyristor protection fuse FS201 blown.
5. One or more brightness levels not Check incoming remote cables.
obtainable Select Local mode, if levels still missing suspect
faulty relay(s) on control board.

***************************************************

WARNING : 440V AC IS PRESENT ON THE

DAUGHTER BOARD AND THYRISTORS

***************************************************

Issue 02-04-2014 Page 23

8.2 VOLTAGE CHECKS

Test points on the main control PCB are provided to check the DC supply voltages. These
are accessible by withdrawing the control tray to its first stop, and voltage measurements
should be taken using a high impedance digital multi-range meter.

PROCEDURE:-

a. Isolator on

b. Selector switch in local

c. Brightness switch set to max.

d. Check DC voltages on control PCB. TP1 = +15V, TP2 = -15V

WRT TP3 = 0V

If both not present check AC voltages on tray transformer TX2 19-0-19. If not present check
tray fuse and cabinet fuses. If AC voltages are present suspect control printed wiring board.

8.3 FAULT LOCATION TABLE

Symptom Possible Fault Notes

Circuit breaker closes but red a) Loss of supply. Check volts on terminals L1,
LED does not light (or LED L2
dim for failure of one supply b) Failure of supply fuses Failure of one fuse could be a
fuse). faulty fuse or an earth fault.
Failure of both fuses - check
equipment for short circuit.
Check fuse rating
c) Failure of control fuse Replace fuse
FS101

d) Faulty circuit breaker Check circuit breaker

Circuit breaker again trips. Error Trip
No kick on output ammeter a) Fuse FS201 blown Check and replace FS201 with
on switching on. correct fuse for CCR rating.

Remove external leads to L3,

b) Open circuit on load L4 (single output) and check
load with resistance meter
c) Control fault on PCB Replace main control PCB.
d) No output from CTX or Check connector PL5 pushed
O/C secondary. fully home on main PCB.

e) Too many lamps out on Replace lamps on field circuit.

field circuit

Issue 02-04-2014 Page 24

 Circuit breaker trips with Overcurrent Trip Replace main control PCB
kick on ammeter when a) Fault on main PCB.
switching on.
b) Short circuit on thyristor Check thyristors with
stack resistance meter.
Replace faulty thyristor
module.
Thyristor fuse FS201 blown Fault in field lamp circuit Repair lamp circuit.
Replace fuse.
Output current oscillating a) Over current phase back Switch to a lower brilliancy
when Brightness selector setting has been disturbed setting. Current should be
SW1 is at max. but stable on stable. Reset over current
lower settings. Phase back as in 5.5
b) Max. current setting pot. Switch to a lower brilliancy
set too high setting. Current should be
stable. Reset current levels as
in 5.4.

9. EARTH LEAKAGE RELAY

9.1 INTRODUCTION

The ELR relay continuously monitors and indicates the existence of earth faults in Airfield
Lighting circuits and other similar circuits at high potential by detecting earth fault resistances
and ignoring normal capacitive leakage’s. The relay is effective throughout the whole loop
without affecting the normal circuit performance, as highly recommended by International Civil
Aviation Organisation in their Aerodrome Design Manual: Part 4: Visual Aids - 1st Edition
1976.

9.2 APPLICATION

The ELR relay provides an indication of earth faults, which may occur in airfield lighting
circuits. It is capable of detecting earth fault resistances from approx. 100K ohms down to zero.

A potentiometer (RV1) is provided on the ELR printed wiring board to adjust the fault tripping
level current from 1mA up to 5mA. The relay operates on earth currents produced by an
internally generated 110V d.c. voltage injected into the circuit being monitored. The relay, with
LED indication is electrically latched. Pushbuttons are provided on the control front panel to
reset the relay and to test that it functions correctly.
A N/O contact on the relay is provided for remote indication of earth faults.

The earth leakage reactor (ELC) is mounted at the rear of the right hand filter panel within the
cabinet. On the top of the ELC is a link bar, which can be used to disconnect the Earth Leakage
Detector from the lighting circuit. This link must be removed before any insulation resistance
testing is undertaken on the lighting circuit.
The ELR printed wiring board is located in the control tray mounted along side of the main
control board.

Issue 02-04-2014 Page 25

 DANGER

1. Very high voltages may be present on the a.c. reactor ELC. The a.c. supply to the cubicle
must be isolated before any work on the earth leakage relay is attempted.

2. A link is provided on reactor ELC to isolate the earth leakage relay from the lighting circuit.
This link must be removed before any insulation resistance testing is undertaken on the
lighting circuit.

9.3 INITIAL ADJUSTMENT AND TESTS

1.Remove the link on reactor ELC. Switch on the a.c. supply to the regulator with switch
SW1 in the STANDBY position. Note that the fault LED does NOT light, indicating
healthy conditions.

2. A confidence test may be performed by pressing the TEST pushbutton, which injects a
leakage current of 5mA, into the relay. Note that the FAULT LED lights.

3. Note that once the relay has operated, an electrical hold-in circuit ensures that the relay
remains energised until the RESET pushbutton is pressed or the a.c. supply to the cubicle is
switched off.

4. The relay has been set in the factory to operate at 1mA. The relay maybe checked and re-set
to comply with CAP168 by linking the two small terminals on reactor ELC (the PCB Input
and Earth terminals marked ELR & E) with a 100kΩ ¼ watt resistor and then adjusting
potentiometer RV1 so that the relay just operates and the FAULT LED lights.

REMOVE THE RESISTOR before replacing the link on the reactor!

5. Replace the link on reactor ELC. Operate the regulator into the lighting load and check that
the fault LED does NOT light, indicating an earth free system.

9.4 OPERATION

1. With the earth leakage relay adjusted as above, all that is necessary is to occasionally check
the relay by pressing the TEST pushbutton and noting that the FAULT alarm lights. The
relay should then be reset by pressing the RESET pushbutton.

2. If, in the course of time, the lighting circuit leakage current rises to the pre-set value, this
will be indicated by the operation of the alarm relay. To reset the relay 5mA above the
leakage current, adjust the potentiometer RV1 with the earth leakage TEST pushbutton
pressed, so that a trip just takes place. This will reset the relay to the sum of the 5mA
current through the TEST pushbutton plus the lighting circuit leakage.

Issue 02-04-2014 Page 26

10. LAMPS OUT DETECTOR (Optional Feature)

10.1 INTRODUCTION

All XR400 CCR’s are pre-wired for the Lamps Out Detector facility and have the local test
pushbutton and status indicators fitted as standard. The Lamps Out Detector printed wiring
board can either be fitted when the CCR is ordered or fitted by the user at a later date if
required.

The Lamps Out Detector raises an alarm at two levels of lamp failures, each of which may be
independently adjusted by means of pre-set potentiometers. The more sensitive setting is
capable of detecting 1% to 5% lamp failures. The second alarm level may be set to detect from
2% to 10% lamp failures.

The detector PCB is mounted within the tray by the L/H side of the regulator control PCB. The
LED's and test pushbutton are mounted on the front panel of the tray.

Three LED's provide local indication that the lamps are healthy or that the first or second level
of lamp failures have been reached. Corresponding volt-free relay contacts are provided for
remote indication. A local pushbutton is included to check the operation of the detector.

10.2 PRINCIPLES OF OPERATION

Under healthy conditions the impedance of the load circuit is predominantly resistive and the
voltage and current waveforms are in phase. When a lamp fails, its supply transformer
saturates, and the power factor of the circuit becomes more lagging. This change in power
factor is sensed by the Lamps Out Detector and used to indicate a lamp failure.

Because the lamps have to operate over a wide current range the current and voltage signals
must pass through an automatic gain control circuit so that the amplitude of the voltage and
current signals are equal and constant. The instantaneous values of the processed voltage and
current signals are then compared and any phase error detected. This phase error is amplified,
converted to a smoothed d.c. voltage and compared with an adjustable reference voltage. When
the d.c. voltage derived from the phase error exceeds the reference then a relay operates. A
second reference voltage and relay is used for the second stage alarm.

Issue 02-04-2014 Page 27

10.3 ADJUSTMENTS

SINGLE OUTPUT REGULATORS

Withdraw the control tray to its first stop and operate the CCR at "MAX" brilliancy either under
LOCAL or REMOTE control. Check that all the airfield lights supplied by the CCR are
operating correctly. Under this condition adjust the preset controls on the top edge of the PCB
as listed below. The voltage checks should be made with an a.c./d.c. digital voltmeter using the
test points provided on the PCB. The common test point for all tests is TP1.

1. Check that all lamps in the series circuits are healthy.

2. Voltage Input. Adjust potentiometer RV1 & RV3 to give 87mV a.c. on TP2. *

3. Current Input. Adjust potentiometer RV2 to give 2.0V a.c. on TP3. *

* These values are only obtained by using a true RMS reading meter, slightly
lower values will be obtained using a mean reading instrument. It should also
be noted that the values given are for a CCR with full load connected. The
maximum reading obtainable on TP2 will be lower for a reduced load, and in
this condition RV2 should be adjusted to maintain the ratio (87mV to 2V)
between TP2 and TP3 as closely as possible.

4. Balance Control. Check that the voltages on TP6 and TP7 are equal. If necessary,
adjust balance control RV4 to obtain as low a difference as possible. (Measure TP7,
then adjust RV4 to bring TP6 to same value.)

5. Starting Circuit. Potentiometer RV5 is included to prevent transient operation of the

lamp failure detector under starting conditions. These tests must be carried out at
minimum brilliancy setting or the minimum brilliancy step that the detector is required
to operate at. Connect a DC voltmeter to TP10. With the CCR in Standby the voltage
on TP10 should be approximately 14 volts negative. Switch the CCR from Standby to
Local control and adjust potentiometer RV5 until voltage on TP10 moves positive.
Check that the voltage goes to approx. 14 volts negative when CCR is in ‘Standby’
and on lower unwanted brightness stages.

6. Note the voltage on the TP9 for each brilliancy stage. Re-adjust the balance control
(RV4) and current input control (RV2) so as to keep the voltage on TP9 as near
consistent as possible. The actual voltage on TP9 will be 5 volts +3 volts depending on
the characteristics of the lighting circuit, but the voltage should not change by more
than 1.0 volt over the full brilliancy range.

7. Sensitivity Controls. Note that the green "LAMPS HEALTHY" LED lights, and that
the first and second level fault LED’s are extinguished. If either alarm lights, slowly
decrease the sensitivity controls (RV6 for level 1 and RV7 for level 2) until the warning
lamp goes out. Set potentiometer RV6 so that the level 1 warning just fails to operate.
Switch through the range of brilliancy settings to ensure that no alarm comes up under
any operating conditions, making further adjustments of RV6 and RV7 as necessary.

8. Remove one or more lamps (depending on the sensitivity required) from the CCR
output circuit, switch to MAX brilliancy, and check that level 1 alarm comes up and
that level 2 alarm does not operate. Adjust RV7 so that the alarm just fails to operate.

9. Check through all the brightness stages as in previous test.

Issue 02-04-2014 Page 28

 10. Remove a second lamp (or more lamps depending on the sensitivity required) and
check that both alarms come up.

11. Replace the lamps and re-check operation. Note that when the test button is pressed
both alarm lamps are energised.

10.4 ALTERNATIVE OUTPUT REGULATORS

If loads are approximately equal, follow the above setting-up sequence. For two unequal loads,
adjust the voltage input setting (RV1 & RV3) with the lower impedance load connected to the
regulator.

10.5 SIMULTANEOUS OUTPUT REGULATORS

Follow the instructions laid down in Section 10.3 with the lowest impedance load in circuit. .
Special instructions are issued when more than two loads are supplied from one CCR.

Issue 02-04-2014 Page 29

11. ANALOGUE PRIMARY CIRCUIT CURRENT MONITOR (Optional Feature)

11.1. INTRODUCTION

The ‘Analogue’ Primary Circuit Current Monitoring (PCCM) System continually monitors
CCR output/AGL series circuit current, (independently of the CCR Control circuitry) and
provides an ‘industrial standard’ current loop signal of 4-20mA for comparison with the
brilliancy level selected in ATC for that CCR.

The PCCM System enables monitoring of AGL series circuit currents in accordance with
CAP168 Chapter 6 (March 1994) Section 11 Paragraph 11.1.2 (b).

11.2. DESCRIPTION

The ‘Analogue’ Primary Circuit Current Monitoring (PCCM) facility consists of a printed
wiring board mounted on the right hand side plate within the control tray.
All power supplies and inputs are derived from the main control board.
The output from the Analogue PCCM board when installed on its own is available at the
cabinet main remote terminal block and marked I- and I+.

The current loop output is suitable for direct input to external "Analogue Input" devices
having an input impedance up to 270 ohms. (Or into the XR400 Digital PCCM optional
feature)

For "Analogue Input" modules having input impedance higher than 270 ohms - contact
Alstom Power Ltd, Airport Division, Rugby, for further advice.

It should be noted that a current loop output of < 4mA represents ZERO Amps in the field
circuit, while a current loop output of 20mA represents FLC +10% field current, to enable
over current conditions to be monitored.

11.3 COMMISSIONING

11.3.1 EQUIPMENT REQUIRED

1 off Digital Multimeter

1 off TRUE RMS Ammeter (In-Line Ammeter)

1 off 270R ¼ Watt Resistor

11.3.2 ADJUSTMENTS AND TESTS

The following commissioning procedures assume that the associated CCR has already been
commissioned in accordance with the manufacturers instructions and that the output current
levels have been set to approximately the correct values specified in CAP168 Chapter 6
(March 1994) Table 6.6.

a) Connect the CCR to its field circuit with the TRUE RMS Ammeter inserted into one of
the CCR output cables. (It is assumed that the CCR load tappings have already been
adjusted to match the CCR output to the circuit load as closely as possible. If not this task
should be completed before proceeding).

b) Unlock the 4 retaining fasteners and pull out to the control tray to the stop position.

c) Connect the Digital Multimeter (DMM) (Set to "DC Volts") across Test Points TP3 &
TP4 of the PCCM Analogue Card (TP3 is positive).

Issue 02-04-2014 Page 30

 d) Switch on and run the CCR at exactly 6.6 Amps or 12 Amps (Note - All CCR current
measurements must be with respect to the TRUE RMS ammeter and not the CCR
ammeter).

Adjust Analogue Card RV1 (CAL) potentiometer to obtain 6.60 Volts 0.01 on the DMM

e) Select ‘Standby’ on the CCR front panel, switch off CCR isolator and disconnect the
DMM from TP3 and TP4.

f) Connect associated external Analogue input device to CCR Cabinet terminals I+ and I-
Connect the DMM (Set to "DC mA") across Test Points TP1 & TP2 of the PCCM
Analogue Card (TP2 is positive) and remove jumper Link LK1.

(If the external analogue input module is not available then connect a 270R resistor across
CCR cabinet terminals I+ and I- to demonstrate commissioning procedure).

g) Switch on CCR isolator and if necessary adjust potentiometer RV3 (4mA) to obtain
4mA 0.1mA on the DMM.

h) Run CCR at exactly 6.60 or 12 Amps. Adjust Analogue Card RV2 (SPAN) potentiometer
to obtain 18.54mA + 0.01mA on the DMM#

Note: 20mA in the current loop represents FLC +10% in the AGL field circuit, to
enable over currents to be monitored.

# At this time the Panel Ammeter on the XR400 CCR should be adjusted (if necessary) to
read exactly FLC (Red line) using RV12 on the CCR's main p.c.b.

i) Adjust CCR output currents for "standard" brilliancy levels and check scaling of
Analogue card as follows: -

CCR O/P Current 2.30A 2.90A 3.37A 3.89A 4.55A 5.35A 6.34A 6.60A

Target mA 9.07 10.39 11.43 12.57 14.03 15.79 17.97 18.54

CCR O/P Current 4.68A 5.28A 6.12A 7.08A 8.28A 9.72A 11.52A 12.0A

Target mA 9.67 10.4 11.42 12.58 14.03 15.78 17.96 18.54

j) Select ‘Standby’ on the CCR front panel, switch off CCR isolator and disconnect the
DMM and replace the jumper link LK1.

k) Push the control tray back into the cabinet and lock the 4 retaining fasteners.

l) Disconnect the TRUE RMS Ammeter from the CCR and field cable and reconnect the
field cable to the CCR output.

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 LAYOUT OF ANALOGUE PWB.

Issue 02-04-2014 Page 32

12. DIGITAL PRIMARY CIRCUIT CURRENT MONITOR (Optional Feature)

12.1. INTRODUCTION

The ‘Digital’ Primary Circuit Current Monitoring (PCCM) System continually monitors CCR
output/AGL series circuit current, (independently of the CCR Control circuitry) and provides
depending on configuration either upto 8 individual stages of In-band/out-of band signals or
as fitted as standard a common error signal when any brightness stage goes out of the
permissible current band.

The PCCM System enables monitoring of AGL series circuit currents in accordance with
CAP168 Chapter 6 (March 1994) Section 11 Paragraph 11.1.2 (b).

12.2. DESCRIPTION

The ‘Digital’ Primary Circuit Current Monitoring (PCCM) facility consists of a printed
wiring board mounted on the CCR’s lower front isolator panel. Access to the setup
potentiometers on the p.w.b. is gained through an aperture in the panel.

The Digital PCCM board takes its input from the 4-20mA current loop output derived from
the Analogue PCCM system, (the Analogue board must be setup before any adjustments are
made to the Digital board, see section 11) the analogue input is then converted to 10 discrete
digital outputs.

9 of these outputs relate to the 8 CCR current bands as specified in CAP168 Chapter 6
(March 1994) Table 6.6, plus ‘OFF’ and the 10th output relates to the CCR output current
being outside of the specified bands (out of correspondence signal’).

The current ranges for each digital output are individually adjustable across the total current
range, to widen or reduce the ‘compliant’ bands.

Associated with each digital output is a p.c.b. mounted LED. These illuminate to indicate the
band in use.

Note:
Two connection options are available for the Digital PCCM outputs.

Option A

The digital outputs are compared with the brilliancy control signals received at the CCR and
are connected within the CCR to provide a simple remote indication of either ‘Brilliancy
Level Correct’ or ‘Brilliancy Error’.

This information is provided via a set of volt-free relay changeover contacts, wired down to 3
terminals, CMC, CM1 & CM2. The output relay incorporates a time delay to avoid spurious
alarms being generated during switching operations.

Option B

The digital outputs are relay based providing volt-free contacts that are individually wired down
to terminals for direct connection to the AGLCS.

This section covers the setting up of Option ‘A’ only.

The setting up procedure for the Digital PCCM is identical for Option ‘B’, but the final
comparison with brilliancy level selected by ATC is carried out within the AGLCS itself.

Issue 02-04-2014 Page 33

 Details would therefore be included in the AGLCS Instruction Manual.
12.3 DIGITAL PCCM SET-UP

a) Connect the CCR to its field circuit with the TRUE RMS Ammeter inserted into one
of the CCR output cables.

b) Remove the Perspex cover from PCCM aperture on the lower front panel.

c) For the initial set-up adjust all potentiometers on the Digital PWB fully clockwise.

d) Set CCR front panel control switches to ‘Standby’ and minimum brilliancy step.

e) Switch on the CCR isolator and then set front panel control switch to ‘Local’.

f) Adjust CCR front panel ‘Set Max Current’ to obtain about 1.5 Amp output current,
then adjust PCCM board potentiometer RV1 anti-clockwise until the ‘OFF’ LED just
goes off.
Switch the CCR to ‘Standby’ and check that the ‘OFF’ LED comes on.

g) Switch the CCR back to ‘Local’ and check that the ‘OFF’ LED goes off.

h) The Digital PCCM board has been factory set to the values shown in Table 1.
If adjustments are required, proceed as follows: -

i) Adjust the CCR front panel ‘Set Max Current’ potentiometer to the desired
current lower limit, then with reference to drawing 141-6310-11/POTS adjust
the low level potentiometer anti-clockwise until the associated LED just
comes on.

ii) Adjust the CCR front panel ‘Set Max Current’ potentiometer to the desired
current upper limit, then with reference to drawing 141-6310-11/POTS adjust
the high level potentiometer anti-clockwise until the associated LED just
goes off.

iii) Adjust the CCR front panel ‘Set Max Current’ potentiometer slowly above
and below the desired current band and check that the associated LED comes
on when in the band and goes off when out of band.

i) Repeat the above (h i-iii) for the remaining brilliancy steps. If any levels are not
required, leave the associated high & low potentiometers turned fully clockwise.

j) When all levels have been adjusted, adjust the CCR front panel ‘Set Max Current’
potentiometer to bring a level out of band, check that the ‘ERR’ error LED comes on
and when the output current is brought back in band the error LED goes off.

k) Check that when the ‘ERR’ error LED comes on, the output timer relay contacts on
the terminals CMC, CM1 & CM2 change over after a delay of 5 seconds. The output
timer relay is mounted on the CCR’s R/H filter panel and can be adjusted if
necessary.

l) When the set-up of the Digital PCCM has been completed, disconnect the TRUE
RMS Ammeter from the CCR and field cable and reconnect the field cable to
the CCR output. Refit the CCR front cover and fit the Perspex cover with 2
screws over the PCCM aperture on the lower front isolator panel.

Issue 02-04-2014 Page 34

 CCR DIGITAL HIGH LIMIT LOW LIMIT
BRILLIANCY PCCM
LEVEL LEVEL
(A) ADJUST (A) ADJUST
- 8 (NOT USED) >7.0 RV16 >7.0 RV17
MAX 100% 7 6.70 RV14 6.40 RV15
6 80% 6 6.36 RV12 6.20 RV13
5 30% 5 5.76 RV10 5.26 RV11
4 10% 4 4.80 RV8 4.20 RV9
3 3% 3 4.05 RV6 3.70 RV7
2 1% 2 3.58 RV4 3.26 RV5
1 0.3% 1 3.18 RV2 2.76 RV3
OFF OFF 2.30 RV1 - -

TABLE 1. DIGITAL OUTPUT CURRENT SETTINGS

Issue 02-04-2014 Page 35

13. MULTIPLE OUTPUT REGULATORS (Optional Feature)

13.1 INTRODUCTION

The XR400 CCR can be supplied with internally fitted output circuit selectors for
applications requiring two or more outputs from one constant current regulator.
The standard output configurations are: -
2 Alternate Outputs
2-5 Simultaneous Outputs

The 2 Alternate output version is electrical and mechanically configured so that only one
output can be selected at a time whilst the 2-5 Simultaneous versions allow for any
combination of outputs to be selected ON or OFF.

Local or Remote switches operate a pilot relay which in turn operates a contactor with two
N/O poles which are used to isolate the circuit when the contactor opens. In addition, some
applications also require a N/C pole to bypass the CCR output current

The CCR control thyristors are phased back and the firing circuit inhibited before a contactor
is opened or closed to prevent unwanted surges in the lamp load. This feature is provided by
the logic circuitry of the multiple output printed wiring board mounted on the contactor
panel.
A single board can handle up to five output circuits. This circuit also provides a continuous
suppression pulse if no output circuit is selected.

Each circuit can be selected either on LOCAL or REMOTE control depending on the
position of the CCR’s LOCAL/STANDBY/REMOTE switch. With the switch set to LOCAL
or STANDBY circuit selection is via the switches mounted on the CCR’s lower front isolator
panel. Also mounted on this panel is an indicator lamp, one for each circuit, which
illuminates when that circuit has been selected.

Remote control operation requires an external 48V DC supply (unless the internal 48V DC
supply option has been installed). The remote control switches should have a minimum rating
of 60 volts at 50mA per switch.

The circuit select control inputs are marked CC and C1 to C5 on the main cabinet remote
terminals. +48V DC is applied to C1-C5 to select a circuit with the common of the 48V
supply connected to terminal CC.

Simplified Remote Connections

Issue 02-04-2014 Page 36

14. SPARES LIST

14.1. SPARES LIST CABINET ASSEMBLY

14.1.1. GENERAL

CIRCUIT REF. DESCRIPTION ORDERING REFERENCE

TX1 6.6 AMP OUTPUT TRANSFORMER 200-250V INPUT

1.5kW TX056
2.7kW TX054
4kW TX059
5kW TX060
7.5kW TX061
10kW TX062
12.5kW TX063
15kW TX064
20kW TX082

TX1 6.6 AMP OUTPUT TRANSFORMER 380-450V INPUT

1.5kW TX058
2.7kW TX046
4kW TX002
5kW TX048
7.5kW TX033
10kW TX005
12.5kW TX042
15kW TX003
20kW TX004
25kW TX040
30kW TX045

TX1 12 AMP OUTPUT TRANSFORMER 380-450V INPUT

2.7kW TX091
4kW TX092
5kW TX093
7.5kW TX094
10kW TX095
12.5kW TX096
15kW TX097
20kW TX098
25kW TX099
30kW TX100

CTX CURRENT TRANSFORMER 6.6 AMP TX050

CTX CURRENT TRANSFORMER 12 AMP TX117

Note that Current Transformer CTX is part of output transformer assembly.

Issue 02-04-2014 Page 37

CIRCUIT REF. DESCRIPTION ORDERING REFERENCE

FTR1 MAINS FILTER 200-250V INPUT

15A FOR 1.5kW & 2.7kW FM007

40A FOR 4kW & 5kW FM006
60A FOR 7.5kW & 10kW FM005
85A FOR 12.5kW & 15kW
Assembly comprising:-
L1,2 2 x AIR CORED INDUCTOR CH009
2 x INDUCTOR INSERTS PA044
C1,2
POLYPROPYLENE CAPACITORS CR004

120A FOR 20kW

Assembly comprising:-
L1,2 2 x AIR CORED INDUCTOR CH035
2 x INDUCTOR INSERTS PA044
C1,2
POLYPROPYLENE CAPACITORS CR004

FTR1 MAINS FILTER 380-450V INPUT

15A FOR 1.5kW, 2.7kW & 4kW FM001

25A FOR 5kW & 7.5kW FM004
40A FOR 10kW & 12.5kW FM002
60A FOR 15kW & 20kW FM003
85A FOR 25kW & 30kW
Assembly comprising:-
L1,2 2 x AIR CORED INDUCTOR CH009
2 x INDUCTOR INSERTS PA044
C1,2
POLYPROPYLENE CAPACITORS CR004

FS1,2 FUSE HOLDERS FH018

4 A FUSES FL039

ELC EARTH LEAKAGE CHOKE CH023

VDR VARISTOR RN011

RL1 24V d.c. 2 POLE C/O 8 PIN RELAY RL044

8 PIN RELAY BASE PA087

ISOLATOR SW065

14.1.2. ADDITIONAL CABINET MOUNTED ITEMS FOR CCR FITTED WITH INTERNAL
48V DC SUPPLY FOR BRILLIANCY CONTROL

TX3 42V TRANSFORMER 200-240V INPUT TX052/A

TX3 42V TRANSFORMER 380-440V INPUT TX043/A

FS3, FS4 1 AMP FUSE FL060

Issue 02-04-2014 Page 38

14.1.3. ADDITIONAL CABINET MOUNTED ITEMS FOR CCR FITTED WITH MULTIPLE
OUTPUT CIRCUIT SELECTORS

CIRCUIT REF. DESCRIPTION ORDERING REFERENCE

TX3 42V TRANSFORMER 200-240V INPUT TX052/A

TX3 42V TRANSFORMER 380-440V INPUT TX043/A

SW1-5 SWITCH TOGGLE SW066

LP2-6 LED INDICATOR & RESISTOR ASSEMBLY LH006/A

RL2,3 48V d.c. 3 POLE C/O 11 PIN RELAY RL043

11 PIN RELAY BASE PA086
RL4-8 24V d.c. 2 POLE C/O 8 PIN RELAY RL044
8 PIN RELAY BASE PA087

CN1-5 CONTACTORS 220V AC COIL SW072

CONTACTORS 440V AC COIL SW073
AUXILLIARY CONTACT BLOCKS SW071

MULTIPLE OUTPUT PCB ASSEMBLY 141-6125-11

14.1.4. ADDITIONAL CABINET MOUNTED ITEMS FOR CCR FITTED WITH P.C.C.M.

TMR TIMER RELAY RL078

DIGITAL PCCM PWB ASSEMBLY 141-6310-11

14.1.5. MISC. ADDITIONAL CABINET MOUNTED ITEMS

LIGHTNING ARRESTOR 1.5 – 15KW RN019A

LIGHTNING ARRESTOR 20KW RN019B
LIGHTNING ARRESTOR 25 – 30KW RN019C

Issue 02-04-2014 Page 39

14.2. SPARES LIST CONTROL TRAY

14.2.1 GENERAL

CIRCUIT REF. DESCRIPTION ORDERING REFERENCE

TX2 LV TRANSFORMER 200-240V INPUT TX053

TX2 LV TRANSFORMER 380-440V INPUT TX010

SCR1 & 2 THYRISTOR STACK ASSEMBLY 200-250V INPUT: -

THYRISTOR STACK ASSEMBLY 1.5 - 7.5KW TY033
THYRISTOR STACK ASSEMBLY 10 - 12.5KW TY034
THYRISTOR STACK ASSEMBLY 15KW TY035
THYRISTOR STACK ASSEMBLY 20KW TY036

SCR1 B& 2 THYRISTOR STACK ASSEMBLY 380-450V INPUT: -

THYRISTOR STACK ASSEMBLY 1.5 - 7.5KW TY026
THYRISTOR STACK ASSEMBLY 10 - 12.5KW TY027
THYRISTOR STACK ASSEMBLY 15KW TY028
THYRISTOR STACK ASSEMBLY 20KW TY029
THYRISTOR STACK ASSEMBLY 25 - 30K TY030

SCR1 & 2 THYRISTOR MODULE BLOCK 200-250V INPUT: -

THYRISTOR MODULE 1.5 - 7.5KW TY041
THYRISTOR MODULE 10 - 12.5KW TY042
THYRISTOR MODULE 15KW TY043
THYRISTOR MODULE 20KW TY044

SCR1 & 2 THYRISTOR MODULE BLOCK 380-450V INPUT: -

THYRISTOR MODULE 1.5 - 7.5KW TY037
THYRISTOR MODULE 10 - 15KW TY038
THYRISTOR MODULE 15KW TY039
THYRISTOR MODULE 20KW TY040

FS201 FOR 1.5 – 20KW 200-250V INPUT: -

100 Amp Thyristor Protection Fuse for 1.5 – 7.5kW FL093
125 Amp Thyristor Protection Fuse for 10 - 12.5kW FL094
160 Amp Thyristor Protection Fuse for 15kW FL095
180 Amp Thyristor Protection Fuse for 20kW FL096

FS201 FOR 1.5 – 30KW 380-450V INPUT: -

71 Amp Thyristor Protection Fuse for 1.5 – 7.5kW FL088
100 Amp Thyristor Protection Fuse for 10 - 12.5kW FL089
140 Amp Thyristor Protection Fuse for 15kW FL090
180 Amp Thyristor Protection Fuse for 20kW FL091
200 Amp Thyristor Protection Fuse for 25 - 30kW FL092

Issue 02-04-2014 Page 40

CIRCUIT REF. DESCRIPTION ORDERING REFERENCE

MINIATURE SWITCH MECHANISM SW084

SW2 1 POLE 12 WAY ROTARY SWITCH SW085
SW1 4 POLE 3 WAY ROTARY SWITCH SW086
SWITCH KNOB KC013
PB1 MINIATURE PUSHBUTTON SWITCH SW040

RVM 5K 0.75" POTENTIOMETER RV018

PANEL MOUNT BUSH FOR POT BB014

LED1 LED INDICATOR RED 24V DC DL032

LED2 LED INDICATOR GREEN DL034

(LAMPS HEALTHY)

LED3, 4 LED INDICATOR RED DLO35

(LAMPS FAILURE)

LED101 LED INDICATOR RED 12V AC LP027

POWER ON INDICATOR

FS101 FUSE 1 A ANTI-SURGE FL020

M1 AMMETER MT014
MINIATURE HOUR METER MT004

CONTROL PCB ASSEMBLY 141-6317-11

CONTROL DAUGHTER BOARD ASSY 141-6317-11
EARTH LEAKAGE PCB ASSEMBLY 141-6123-11

14.2.2 ADDITIONAL COMPONENTS FITTED IF LAMPS-OUT-DETECTOR SUPPLIED

LAMPS-OUT DETECTOR PCB ASSY 141-6140-11

14.2.3 ADDITIONAL COMPONENTS FITTED PCCM SUPPLIED

ANALOGUE PCCM PWB ASSEMBLY 141-6493-11

Issue 02-04-2014 Page 41

 15. LIST OF DRAWINGS.

Title Drawing No. Rev.

GENERAL ARRANGEMENTS

G.A. SINGLE OUTPUT 141-3014/AG 1

G.A. SIMULTANEOUS OUTPUT 141-3013/AG 1
G.A. ALTERNATE OUTPUT 141-3015/AG 1

CABINET WIRING DIAGRAMS

SINGLE OUTPUT 141-1046-31/AM 1

2 SIMULTANEOUS OUTPUTS 141-1006-31/AM 1
5 SIMULTANEOUS OUTPUTS 141-1009-31/AM 1
2 ALTERNATE OUTPUTS 141-1012-31/AM
1

CONTROL TRAY WIRING

TRAY WIRING DIA 141-2091-31/AM 1

TRAY WIRING WITH PCCM ANALOGUE 141-2185-31/AM 1

PRINTED WIRING BOARDS

CONTROL PCB (MULTI-WIRE REMOTE) ASSEMBLY 141-6317-11 1

CONTROL DAUGHTER PCB ASSEMBLY 141-6318-11 1

EARTH LEAKAGE RELAY ASSEMBLY 141-6123-11 3

LAMPS OUT DETECTOR ASSEMBLY 141-6140-11

2

ANALOGUE PRIMARY CURRENT MONITOR ASSEMBLY 141-6493-11 1

DIGITAL PRIMARY CURRENT MONITOR ASSEMBLY 141-6310-11 4

MULTI-OUTPUT BOARD ASSEMBLY 141-6125-11

1

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