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Universal Regulator Controller (URC) Air-Cooled, 4-70kW, 6.6A / 20A ETL Certified to FAA Specification AC 150/5345-10F Document No. 96A0288 Issued: January 21, 2007 Rev. U: May 28, 2010 Copyright 2009 by ADB Airfield Solutions, LLC All rights reserved.
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Corrected Title Page of Manual 9/22/04 Added detailed info about 50/70Kw 01414 WT/JG/JR 6/3/05 4-8 thru 4- Added Digital Power Meter 01443 9/8/05 12, 3-4 Added I/O Table 3-4 01364 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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Updated Name 5/29/09 2-15, 3-6, Reference ECO 2200. Changed size of 10KW 02349 6/25/09 7-2, 7-3 240/480 VAC CCF to medium frame ADB update 12/17/09 MCO update 05/28/10 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
4. Stacking CCR’s (Optional) ..............3-5 5. SGRS Style Powerpacks (Optional) ............3-8 Section 4 Operation ................... 4-1 1. Introduction ................... 4-1 2. CCR Control Procedures ............... 4-1 Local Control ..................4-1 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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6. Universal Regulator Controller Parts List ........... 7-11 7. Recommended Spare Parts ..............7-11 Section 8 Wiring Schematics ..............8-1 1. Introduction ................... 8-1 2. Wiring Schematics ................8-1 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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(a) on the date of shipment the goods are of the kind and quality described herein and are free of non-conformities in workmanship and material, (b) the 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04...
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This manual could contain technical inaccuracies or typographical errors. Disclaimers ADB Airfield Solutions reserves the right to revise this manual from time to time in the contents thereof without obligation of ADB Airfield Solutions to notify any person of such revision or change.
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Table of Contents Details and values given in this manual are average values and have been compiled with care. They are not binding, however, and ADB Airfield Solutions 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.
Ferroresonant L-828/L-829 CCR Safety Section 1 Safety This section contains general safety instructions for using your ADB 1. Introduction 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. Note all warnings and follow all instructions carefully.
It is the responsibility of the company operating this equipment to see that its personnel meet these requirements. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
Unintended uses may result from taking 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 Airfield Solutions replacement parts • Failing to make sure that auxiliary equipment complies with approval agency requirements, local codes, and all applicable safety standards •...
• Never touch exposed electrical connections on equipment while the power is ON. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
Allow only qualified personnel to perform maintenance, troubleshooting, 8. Maintenance and Repair and repair tasks. Only persons who are properly trained and familiar with ADB Airfield Solutions equipment are permitted to service this equipment. • Always use safety devices when working on this equipment.
1. Introduction Ferroresonant, L-828/L-829, constant current regulators (CCRs). These CCRs are manufactured according FAA specification AC 150/5345-10F. NOTE: Signature Series is a trademark of ADB Airfield Solutions. See Figure 2-1. This subsection describes the L-828 CCR. The L-828 2. L-828 CCR uses a Universal Regulator Controller (URC) to provide regulator and control functions.
The other L-829 CCRs (4, 7.5, 10, 20-30 kW/6.6 A/20 A & 50/70kW) may differ in size and appearance. Figure 2-2 L-829 CCR with ACE2 1. ACE2 Front Panel Display 2. L-829 CCR 3. Rotary Switch 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
Item 3 (Installed on door) front of SGRS door) 5. Series Circuit Stab 6. Input Power and control 7. URC Circuit Board 8. Roller Wheels Connector wiring stab connector 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
Controller ferroresonant L-828/L-829 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 through-hole type printed circuit board.
For more information about the ACE, See: Advanced Control Equipment (ACE) manual 96A0287 or the Advanced Control Equipment (ACE2) manual 96A0357. See manual 96A0348 for the ACE Programming Manual. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
The SCO cutout has a nominal working voltage of 5 kV and a nominal carrying current capacity of 20 amps AC. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04...
See Figure 2-4. This subsection describes the board level circuitry found Universal Regulator on the universal regulator controller. Controller Figure 2-5 L-828 CCR Power Circuit Block Diagram 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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This subsection describes URC failure protection. VERCURRENT ROTECTION The micro-controller detects an over current condition by comparing the output current to a preset value. If the output current exceeds this value 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
Voltmeter, 60 Vdc full scale Ammeter, true rms-reading, 9 A maximum scale Inductive-type current probe Ohmmeter Mounting bolts, ½-13 x 1-1/2 in. long, ½ STD washers, and lockwashers 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
114 A 82 A 50 kW Not applicable Not applicable Not applicable Not applicable 136 A 70 kW Not applicable Not applicable Not applicable Not applicable 188 A 2009 ADB Airfield Solutions, Incorporated 2-10 96A0288T Issued 9/04 All rights reserved...
Refer to Table 2-9 for output current limits. Current regulation is obtained Regulation under the conditions listed in Environmental Operating Conditions. 2009 ADB Airfield Solutions, Incorporated 2-12 96A0288T Issued 9/04...
2 seconds after an open circuit occurs in the secondary. The device resets within 2 seconds after the control switch is turned off and re-energized, and cannot be tripped by switching the load circuits or other transients. 2009 ADB Airfield Solutions, Incorporated 2-13 96A0288T Issued 9/04...
50, 70 kW 480 Vac, -5 to +10% The temperature rise of the transforming portion of the regulator is in Temperature Rise accordance with ANSI C57.12.91 for air-cooled regulators. 2009 ADB Airfield Solutions, Incorporated 2-14 96A0288T Issued 9/04 All rights reserved...
70 x 33 x 34 in (177.8 x 83.8 x 86.4 cm) 70kW Not applicable 70 x 33 x 34 in (177.8 x 83.8 x 86.4 cm) 2009 ADB Airfield Solutions, Incorporated 2-15 96A0288T Issued 9/04 All rights reserved...
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Ferroresonant L-828/L-829 CCR Description Ferroresonant CCR Dimensions – Typical of 4-30 kW 50kW 70kW Ferroresonant CCR Dimensions – Typical of 50-70 kW NOTE: For Dimensions see Table 2-12 2009 ADB Airfield Solutions, Incorporated 2-16 96A0288T Issued 9/04 All rights reserved...
Startup equipment. The high voltage involved with the unit makes it potentially dangerous and may be lethal if contacted by operating personnel. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
PCB area. See Figure 3-1. Figure 3-1 Wiring on Right Side of CCR 1. Front of CCR 2. Place Conduit and Wire on Right Side of CCR 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
3-3 for 120 Vac signals. See Figure 8-1 in the Wiring Schematics section for remote control connections. NOTE: If the ADB Airfield Solutions Advanced Control Equipment is used with the ferroresonant L-828 CCR, refer to the Advanced Control Equipment manual (96A0245) for wiring connections to remote control.
CCF 50, 70kW Top of each Fuse Block – CCF 50, 70kW Lightning Arrestors (VR1 front of component plate and VR2) on Back of top right side component plate 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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Installation CAUTION: Before stacking CCRs larger than 10 kW or 4. Stacking CCR’s (Optional) stacking more than 2 CCRs, contact the ADB Airfield Solutions Sales Department. To stack CCRs, perform the following procedure: 1. 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 1/2−13 x ¾...
For information on installing SGRS Powerpacks refer to the SGRS Installation Manual. Document number 96A0303. Figure 3-4 Powerpack Installation in SGRS 1. Upper Bay Powerpack 2. Lower Bay Powerpack 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
5-step has seven positions. The regulator automatically maintains the output current within ±1% of the nominal value for the brightness position selected. Figure 4-1 Switch (3-Step/5-Step) 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
No remote control connections The position REM becomes an exist on terminal block TB1 additional OFF position; that is, the (switch is set to REM) regulator is de-energized. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
1. Connect a clamp-on true rms-reading instrument (such as a Fluke 87 multimeter with Y8101A current clamp or equivalent) around one of the output current leads. See 2. Figure 4-3. Figure 4-3 Output Current Clamp 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
It is strongly recommended that a nonconductive screwdriver be used during calibration to protect personnel as we as the card from accidentally shorting. Figure 4-4 R40 (URC Board) 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
Figure 4-6 S1 Cutout Operation Position See Figure 4-7. In the maintenance position, the regulator and the series circuit are both shorted and grounded. The microswitch is not activated. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
The microswitch is activated. Regulator Series Circuit Measurement Socket Ground Figure 4-8 S1 Cutout Test and Measure Position 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
Ferroresonant L-828/L-829 CCR Operation 7. Digital Power Meter Calibration Display Display Function Buttons Figure 4-9 Meter Display Function Buttons Scroll Up Scroll Down Enter (Save) Figure 4-10 Function Buttons 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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CCR. WARNING: 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. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
NOTE: If the CCR output needs to be adjusted follow procedure in the CCR manual. • Wait until the Icnt and Vcnt values settle and select the ENTER button 2009 ADB Airfield Solutions, Incorporated 4-10 96A0288T Issued 9/04 All rights reserved...
ENTER button. The next screen (Fig 5) shows the last calibration voltage set points and internal A/D numbers. Select Y (yes) to enter the Vrms calibration. Figure 4-14 Vrms Calibration 2009 ADB Airfield Solutions, Incorporated 4-11 96A0288T Issued 9/04...
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 4-16 Save Vrms Calibration 2009 ADB Airfield Solutions, Incorporated 4-12 96A0288T Issued 9/04...
This section provides preventive maintenance for L-828 /L-829 constant 1. Introduction current regulators (CCRs) (4-70 kW 6.6 A or 20 A). 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
1. Remove input power to regulator (turn off disconnect switch or main circuit breaker) and turn the rotary switch to OFF. 2. Disconnect cables from the output terminals and bushings. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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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. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
The wire should be AWG 8 or larger. This section provides a preliminary troubleshooting check list and 1. Introduction troubleshooting procedures for the ferroresonant L-828/L-829 CCR (4-70 kW/6.6 A or 20 A): 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
15-70 kW (Fuse Part Number) (Fuse Part Number) 208-240 Vac 2A, 250 V Not applicable (47A0113) 480 Vac 1 A, 500 V 3 A, 500 V (47A0108) (47A0187) 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
ACE Power Supply Fuse F6 Table 6-3 Fuses F5 and F6 Ratings CCR kW Rating CCR Input Voltage 4-70 kW (Fuse Part Number) 208-480 Vac ½ A, 250 V (47A0119) 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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Output Current Adjustment in the Operation section. Check SCRs and wiring. Replace SCR. Refer to Problem #11 in this table. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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6. Short lamp life Incorrect output current adjustment Refer to Output Current Adjustment in the and/or high output Operation section. current reading on panel ammeter Faulty overcurrent protection Replace URC PCB. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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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. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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Step 5, refer to Feedback Wiring Modification Procedure in this section to modify wiring. WARNING: Operating a regulator for long periods of time while seriously overloaded may cause the regulator to overheat. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
9. Remove input power from the regulator. Remove the output short circuit. Reconnect the field circuit. 10. Apply input power to the regulator. Verify all steps output the correct current level. Modification complete. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
Ferroresonant L-828/L-829 CCR Parts Section 7 Parts To order parts, call ADB Airfield Solutions Customer Service or your local 1. Introduction representative. Use this four-column parts list, and the accompanying illustration, to describe and locate parts correctly. This subsection describes how to use the illustrated parts list covered later 2.
6 = 5 Step with KIRK Key 3 = L-829 4 = IRMS Only 5 = L-829 and IRMS 6 = L-828 with Digital Meter INPUT VOLTAGE 3 = 480 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
NOTE: On Figure 7-3, the exact location of parts may vary according to regulator size. NOTE: Where a part applies only to the L-828 or L-829, it is so noted in the description of the part. NOTE: Contact ADB Technical Service for 2,400 VAC applications. Part Number Description Quantity...
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NOTE B: Quantity is 1 for L-828, SMI, IRMS with 208-480 V input. Quantity is 2 for ACE and SMR with 208-480 V input. Continued on next page 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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Ammeter, 0-25 amps, L-828, 20 A Ammeter regulators 53A0331 Cont 3P, 200A, 170A 120Vac Coil 70kW 53A0412-40 Contactor, 2-pole, single-phase, Class 42, 600 Vac maximum, 110-120 V coil (for 480 V input only) 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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1475.92.030 Optional S1 cutout NOTE A: Quantity is 1 for L-828, SMI, IRMS with 208-480 V input. Quantity is 2 for L-829 and SMR with 208-480 V input. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
Figure 7-3 CCF-828/L-829 CCR Component Mounting Plate Parts (Part 1 of 3) NOTE: Location of components may vary depending upon the size of the regulator. See Numerical Parts Listing Tables for component part numbers and complete description for a specific size ccr. 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04...
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Core Figure 7-3 CCF L-828/L-829 CCR Component Parts – Side View (Part 2 of 3) NOTE: See Numerical Parts Listing Tables for component part numbers and complete description 2009 ADB Airfield Solutions, Incorporated 96A0288T Issued 9/04 All rights reserved...
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Mounting Plate Figure 7-3 Ferroresonant L-828 CCR Component Parts – Front Access Door (Part 3 of 3) NOTE: See Numerical Parts Listing Tables for component part numbers and complete description 2009 ADB Airfield Solutions, Incorporated 7-10 96A0288T Issued 9/04...
20 A ferroresonant and Thryristor controlled regulators. No user Controller Parts List serviceable parts exist on the URC. If a card fails, return it to ADB Airfield Solutions for repair or replacement. This subsection provides recommended spare parts. See L-828/L-829 CCR 7.
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