Airport 828HC Instruction Manual
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Airport 828HC Instruction Manual

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Ferroresonant Constant Current Regulator
Airport Lighting Company
108 Fairgrounds Drive
Manlius, New York 13104
(315) 682-6460
Info@airportlightingcompany.com
Type 828HC
Instruction Manual
Revision 1.0
10/25/2019

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Summary of Contents for Airport 828HC

  • Page 1 Ferroresonant Constant Current Regulator Type 828HC Instruction Manual Revision 1.0 10/25/2019 Airport Lighting Company 108 Fairgrounds Drive Manlius, New York 13104 (315) 682-6460 Info@airportlightingcompany.com...
  • Page 3 Input Current Warning While the input current of the 828HC is low enough to run without issue on a 15A circuit, it may be high enough to cause a hazard to personal safety. Ensure proper safety measures are taken before servicing input power.
  • Page 4 (1) year from date of installation or a maximum of two (2) years from date of shipment will be corrected by repair or replacement by Airport Lighting Company, with transportation costs borne by the purchaser. This guarantee covers the 828HC Ferroresonant Constant Current Regulator.
  • Page 5 Changes from last Revision • First Revision...

  • Page 6: Table Of Contents

    Table of Contents 1.0 Introduction ..........................1 1.1 Scope ............................. 1 1.2 Equipment Description ......................1 1.3 Control Capabilities ....................... 1 1.3.1 Front Panel Display Control ................... 1 1.3.2 Remote Control ......................2 1.3.3 RS232 Serial Connection ....................2 2.0 Shipping & Sizing Information ....................3 2.1 Sizing Information .........................
  • Page 7 5.1.2 Calibrate Zeros ......................13 6.0 Warnings, Alarms, and Faults ....................14 6.1 Warnings and Alarms ......................14 6.2 Faults ........................... 14 7.0 Troubleshooting ........................15 7.1 Troubleshooting Chart ......................15 7.2 Restoring Known Good Settings ..................18 7.2.1 Restoring a Known Good Configuration ..............18 7.2.2 Restoring a Known Good Calibration ................
  • Page 9 List of Figures Figure 1: Cabinet Dimensions ......................3 Figure 2: Keypad and Display of a 240V input CCR ................. 6 Figure 3: The Configuration Menu ....................10 Figure 4: Block Flow of Menu Navigation ..................11 List of Tables Table 1: Sizing Information ......................

  • Page 11: Introduction

    Regulator manufactured by Airport Lighting Company, Manlius, NY, USA. 1.2 Equipment Description The 828HC is a 500W Ferroresonant Constant Current Regulator that is intended to test small circuits, isolation transformers, and fixtures. It is powered by a 120VAC service, and draws 6A nominal full load, meaning it can operate on a standard 15A circuit without issue.

  • Page 12: Remote Control

    Company. 1.3.3 RS232 Serial Connection The 828HC allows for RS232 serial connection to be made at the DCMU. Each DCMU comes with a RS232 connector that is used to connect directly to a PC using the DCMU Configurator software. This connection is used primarily in factory setup and calibration of the CCR.

  • Page 13: Shipping & Sizing Information

    2.0 Shipping & Sizing Information The 828HC enclosure is sized as shown below: Figure 1: Cabinet Dimensions 2.1 Sizing Information Install Size kW Rating Install Weight (Without Pallet) 74 lbs 18”W x 17”D x 9.2”H Table 1: Sizing Information ©...

  • Page 14: Installing The Ccr

    3.2 Turning the CCR on for the First Time Exercise caution at all times It is recommended to do an initial startup of the 828HC to ensure familiarity with the controls and operation. Before starting, review Section 4.0 How to Navigate the CCR Display and Keypad for information about the user interface.

  • Page 15: Checking Current Output

    Current Current Current Count Current Range 4.7 – 4.9 5.4 – 5.6 B100 6.5 – 6.7 2.7 – 2.9 3.3 – 3.5 4.0 – 4.2 5.1 – 5.3 6.5 – 6.7 Table 2: CCR Output Currents © Airport Lighting Company...

  • Page 16: How To Navigate The Ccr Display And Keypad

    The LOCAL UP and LOCAL DOWN buttons change the brightness step of the CCR when it is in Local mode. If LOCAL DOWN is pressed when the CCR is at Step B10 (3 step configuration) or B1 (5 step configuration), the CCR will turn off. © Airport Lighting Company...
  • Page 17 The UP and DOWN buttons are the buttons that navigate the screen. If on the main screen, the information will cycle through as if on a rolling drum. If navigating the menus, you will see an arrow-cursor on © Airport Lighting Company...

  • Page 18: Understanding The Digital Control Monitoring Unit (Dcmu) Display

    4.2.1 The Main Screen The main screen of the display shows the most important, at-a-glance information. The following table shows all the available information on the main screen: [Table on next page] © Airport Lighting Company...

  • Page 19: Navigating Menus

    The menus of the CCR are set up as a collection of folders within folders, similar to a file cabinet. By using the UP, DOWN, and DOT buttons, it is possible to scroll through folder selections, and open a folder with its own options and sub-folders. © Airport Lighting Company...

  • Page 20: Figure 3: The Configuration Menu

    The → (right arrow) is a cursor for the menu. Upon scrolling up or down, the option next to the → cursor will change. When you have reached the menu you’d like to open, use the Enter button to navigate to the next sub-folder. © Airport Lighting Company...

  • Page 21: Ccr Configuration

    The Airport Lighting Company CCR has multiple field-configurable options. While these options may be changed during initial setup, generally with the advice of an Airport Lighting Company representative or with the help of this manual, the day-to-day use of the configuration menu is not anticipated.

  • Page 22: Accessing The Configuration Menu

    From the CCR main screen, press the CONFIG button once. You will be prompted for a password. The password on all Airport Lighting Company CCRs is “9999”. Use the UP and DOWN buttons to change the number above the ↑ up arrow cursor.

  • Page 23: Calibrate Zeros

    CCR, or when a part is replaced. Before completing this calibration: put the CCR in Local Mode and turn the output off. Configuration Menu > CCR Config > Calibrate > Zeros > [Execute] © Airport Lighting Company...

  • Page 24: Warnings, Alarms, And Faults

    Allowing the CCR to operate in a warning state may cause problems for efficiency, general safety, and longevity of equipment. Due to the test-bench nature of the 828HC, an “Output Shorted” or “Low VA” warning may be anticipated depending upon equipment being powered by the CCR.

  • Page 25: Troubleshooting

    Airport Lighting Company. 7.1 Troubleshooting Chart Fully read the description and steps to fix thoroughly before completing work. Complete all steps to ensure a proper fix. For more information, contact Airport Lighting Company. Problem Likely Cause(s)
  • Page 26 DCMU if a spare is available. If the issue is resolved with the serial cable disconnected, replace the serial cable, firing card, and megger card (if installed) one at a time to determine the cause of the problem. © Airport Lighting Company...
  • Page 27 SSR. Use a DMM to check the SSR contact – it should be normally open. If it isn’t, the SSR was damaged. Contact Airport Lighting Company. Output current is The output current Using a DMM, verify the output...

  • Page 28: Restoring Known Good Settings

    The “Known Good” setting will restore the CCR to the configuration that is saved by Airport Lighting Company during the factory setup and testing procedure. Please note that unless saved, field-made changes will not be retained if “Known Good”...

  • Page 29: Completing In-Field Recalibrations

    V2 on the 11-pin firing card terminal block by probing the screw heads. Multiply the measured voltage by the “V1-V2 Output Voltage Measurement Factor” provided on the CCR Datasheet at the end of this manual. If the factor is not available, contact Airport Lighting Company.

  • Page 30: Calibrating Output Current

    Read all steps before beginning. Contact Airport Lighting Company for additional information as needed. Note: a resistor load bank, such as can be provided by Airport Lighting Company, is recommended to provide a purely-resistive load to the CCR during calibration. Ideally, the CCR should be loaded at 100% of its kW rating for the most accurate calibration.

  • Page 31: Calibrating Output Voltage

    Read all steps before beginning. Contact Airport Lighting Company for additional information as needed. Note: a resistor load bank, such as can be provided by Airport Lighting Company, is recommended to provide a purely-resistive load to the CCR during calibration. Ideally, the CCR should be loaded at 100% of its kW rating for the most accurate calibration.
  • Page 32 “V1-V2 Output Voltage Measurement Factor” provided on the CCR Datasheet at the end of this manual. If the factor is not available, contact Airport Lighting Company. □ Use the UP and DOWN arrows below the screen to adjust the calibration value to the calculated value.

  • Page 33: Calibrating Input Voltage

    Read all steps before beginning. Contact Airport Lighting Company for additional information as needed. Note: a resistor load bank, such as can be provided by Airport Lighting Company, is recommended provide a purely-resistive load to the CCR during calibration. Ideally, the CCR should be loaded at 100% of its kW rating for the most accurate calibration.
  • Page 34 □ If the calibration needs additional fine-tuning, complete the calibration procedure again. □ If the calibration procedure does not yield acceptable results, you may want to restore a known good calibration. Refer to Section 7.2.2 Restoring a Known Good Calibration for more information. © Airport Lighting Company...

  • Page 35: Additional Information

    82-93 Solid State Relay, 50A 82-87 12V Control Transformer 82-92 20A Contactor 82-508 Input Power Cord 99-00203 828HC Rubber Foot 82-505 Fan, 24VDC, 92mm 82-506 Fan Guard, Wire Frame, 92mm 82-401m 8AWG Male Primary Cable 82-401f 8AWG Female Primary Cable ©...

  • Page 36: Glossary Of Terms

    8.2 Glossary of Terms A, a – Ampere AC – Alternating Current (power), Advisory Circular (standards) ALC – Airport Lighting Company BCD – Binary Coded Decimal C – Celsius CCR – Constant Current Regulator CS – Current Sensor CSS – Circuit Selector Switch CT –...

  • Page 37: Ccr Menu Navigation Flowchart

    The included flowchart is designed to accompany a user when navigating the CCR menus. For information about accessing and using the menu, refer to Section 4.0 How to Navigate the CCR Display and Keypad and Section 5.0 CCR Configuration. [Attached] © Airport Lighting Company...
  • Page 39 CONFIGURATION MENU OVERVIEW CONFIGURATION MENU MONITOR COMMS SYSTEM CCR CONFIG CSS CONFIG CONFIG CONFIG COMMANDS NUMBER LAMP AC INPUT ADDRESS LANGUAGE OF CSS OUTAGE CSS STATE REMOTE FACTORY CCR TYPE MONITOR SWITCH SETTINGS CHANGES CSS FAULT KNOWN GOOD NUMBER CURRENT PORT A MONITOR SETTINGS...
  • Page 40 CONFIGURATION MENU CCR CONFIG – PG 1 120, 208, 220, 230, 240, AC INPUT INPUT VOLTAGE 277, 347, 380, 400, 415, 480, 600, 2400 ADJUST ON THRESHOLD VALUE (##) ADJUST OFF THRESHOLD VALUE (##) INPUT 50, 60 FREQUENCY DISABLE / INPUT CT ENABLE ADJUST...
  • Page 41 CONFIGURATION MENU CCR CONFIG – PG 2 NUMBER 1, 3, 5, 7 OF STEPS OUTPUT MAXIMUM 2.2A, 6.6A, CURRENT CURRENT ASYMMETRY ADJUST THRESHOLD TRIP VALUE (##) ADJUST DURATION VALUE (##) TEMPERATURE ADJUST ADJUST VALUE (##) TOLERATE DISABLE / SURGES ENABLE B1 DWELL ADJUST TIME...
  • Page 42 CONFIGURATION MENU CCR CONFIG – PG 3 DISABLE, RELAY ENABLE, FEEDBACK WITH CC AND REMOTE, PROGRAMMED OUTPUT DISABLE / VOLTAGE FLIP ENABLE CONTACTOR ADJUST DELAY VALUE (##) FAULT ENABLE / FAULT RELAY USE DISABLE ENABLE / WARNING DISABLE ENABLE / LOCAL DISABLE ENABLE /...
  • Page 43 CONFIGURATION MENU CSS CONFIG – DEFAULT DISABLE NUMBER NONE, OF CSS 1, 2, 3, 4, 5, 6 CSS STATE DISABLE / MONITOR ENABLE CSS FAULT DISABLE / MONITOR ENABLE CSS REMOTE DISABLE / MONITOR ENABLE LAST STATE, FAILSAFE CIRCUIT 1 OFF, ON LAST STATE, CIRCUIT 2...
  • Page 44 CONFIGURATION MENU MONITOR CONFIG – PG 1 LAMP DISABLE, NUMBER OF ADJUST OUTAGE ENABLE LAMPS VALUE (##) WARNING ADJUST LEVEL VALUE (##) ALARM ADJUST LEVEL VALUE (##) CALIBRATE EXECUTE / (LO & VA) EXIT ACTUAL LAMPS EXECUTE / ADJUST (LO) OUT, EXIT ADJUST...
  • Page 45 CONFIGURATION MENU MONITOR CONFIG – PG 2 AUTO DISABLE, MEASURE EXECUTE / MEGGER ENABLE EXIT MEGGER ADJUST RESISTOR VALUE (##) READING ADJUST DURATION VALUE (##) DISABLED, AUTO WHEN ON, MEASURE WHEN OFF, DAILY WARNING ADJUST LEVEL VALUE (##) ALARM ADJUST LEVEL VALUE (##) CALIBRATE...
  • Page 46 CONFIGURATION MENU COMMS CONFIG – DEFAULT DISABLE ADJUST ADDRESS VALUE (##) REMOTE DISABLE / SWITCH ENABLE MODBUS, PORT A PROTOCOL DF1-HDX, DF1-FDX OFF, 9600, BAUD RATE 19200, 38400, 57600, 115200 ADJUST IP ADDRESS VALUE (##) 255.255.255.0 SUBNET 255.255.0.0 255.0.0.0 EDIT BYTE 4 GATEWAY (##) MODBUS,...
  • Page 47 CONFIGURATION MENU SYSTEM COMMANDS SYSTEM ENGLISH LANGUAGE COMMANDS FRANCAIS FACTORY RESTORE SETTINGS CONFIG RESTORE CALIB. KNOWN GOOD RESTORE SETTINGS CONFIG SAVE CONFIG RESTORE CALIB. SAVE CALIB. CLEAR SUPRS’D EXECUTE / WARN EXIT CLEAR EXECUTE / COUNTERS EXIT EXECUTE / RESET EXIT BOOT EXECUTE /...
  • Page 48 DIAGNOSTICS MENU OVERVIEW DIAGNOSTICS MENU OPERATIONS FAULTS WARNINGS COMMANDS PORT A PORT B RAW VALUES FIRING DISPLAY CALIBRATION #1 MOST #1 MOST #1 MOST OPERATIONS STATUS STATUS PERIOD STATUS RECENT RECENT RECENT UP TO 10 UP TO 10 UP TO 10 RX CHAR RX CHAR IOUT...

  • Page 49: Ccr Datasheet

    8.4 CCR Datasheet The included datasheet contains CCR-specific information that is gathered during testing. It also has the model and serial numbers of various equipment. [Attached] © Airport Lighting Company...

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