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Siemens L-828 Manual

Siemens L-828 Manual

Constant current regulators
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L-828 Constant Current Regulators
LC-Type
(4, 7.5, and 10 kW/6.6 A/60 Hz)
Document No. 96A0104
Issued: August 16, 1988
Rev. B: June 7, 2002
ETL Certified to FAA Specification
AC 150/5345-10E
Copyright  2002 by Siemens Airfield Solutions, Incorporated. All rights reserved.

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  • Page 1 L-828 Constant Current Regulators LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Document No. 96A0104 Issued: August 16, 1988 Rev. B: June 7, 2002 ETL Certified to FAA Specification AC 150/5345-10E Copyright  2002 by Siemens Airfield Solutions, Incorporated. All rights reserved.

  • Page 2: Record Of Changes

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Record of Changes Record of Changes Page Description EC No. Checked Approved Date Extensively revised manual to include 10 8/14/88 kW CCR. Reformatted and updated manual. 00883 6/7/02 Page ii ...

  • Page 3: Table Of Contents

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Table of Contents Table of Contents Record of Changes ..............................ii Table of Contents ..............................iii Warranties ................................vi Section 1 Safety................1-1 Safety 1. Introduction ................1-1 2. Safety Symbols ................. 1-1 3.
  • Page 4 2. Using the Illustrated Parts List ........... 7-7 3. L-828 CCR (4-10 kW/6.6 A) Part Ordering Code......7-8 4. L-828 CCR General Assembly (4-10 kW/6.6 A) Parts List ..... 7-9 5. Recommended Spare Parts............7-19 Recommended Spare Parts (4 kW/208-240 Vac) ....7-19 Recommended Spare Parts (4 kW/480 Vac) ......
  • Page 5 Figure 3-7 Control PCB..............3-9 Figure 7-1 60 Hz L-828 CCR (4-10 kW/6.6 A)......... 7-8 Figure 7-2 LC-Type L-828 CCR Component Parts (1 of 4) ..... 7-10 Figure 8-1 LC-Type L-828 CCR Internal Wiring Schematic (Part 1 of 2) ............8-3 List of Tables Table 2-1 L-828 LC-Type CCR Indicators........

  • Page 6: Warranties

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Warranties Warranties Products of Siemens Airfield Solutions manufacture are guaranteed against mechanical, electrical, and physical defects (excluding lamps) for a period of one year from the date of installation or a maximum of...
  • Page 7 Siemens Airfield Solutions reserves the right to revise this manual from time to time in the contents thereof without obligation of Siemens Airfield Solutions to notify any person of such revision or change. Details and values given in this manual are average values and have been compiled with care.

  • Page 8: Safety

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Safety Section 1 Safety This section contains general safety instructions for using your 1. Introduction Siemens 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.

  • Page 9: Qualified Personnel

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Safety Safety Symbols (contd.) WARNING: Failure to observe this warning may result in personal injury, death, or equipment damage. WARNING: Risk of electrical shock. Failure to observe this warning may result in personal injury, death, or equipment damage.

  • Page 10: Intended Use

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Safety WARNING: Use of this equipment in ways other than 4. Intended Use described in this manual may result in personal injury, death, or property and equipment damage. Use this equipment only as described in this manual.

  • Page 11: Operation

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Safety • Route electrical wiring along a protected path. Make sure they Installation (contd.) will not be damaged by moving equipment. • Protect components from damage, wear, and harsh environment conditions.

  • Page 12: Action In The Event Of A System Or Component Malfunction

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Safety Do not operate a system that contains malfunctioning components. 7. Action in the Event of a If a component malfunctions, turn the system OFF immediately. System or Component Malfunction •...

  • Page 13: Description

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Description Section 2 Description See Figure 2-1. This section describes the Siemens Airfield Solutions 1. Introduction L-828 constant current regulators (CCRs) LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz). These CCRs are manufactured according FAA specification AC 150/5345-10E.

  • Page 14: L-828 Ccr Monitoring Options

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Description The 4, 7.5, and 10 kW CCRs are designed to 1. Introduction (contd.) • supply either three or five precision output current levels (6.6 A maximum) for series lighting circuits on airport runways and taxiways.

  • Page 15: Indicators

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Description See Figure 2-2. Refer to Table 2-1 for the L-828 LC-type CCR 3. Indicators indicators. Table 2-1 L-828 LC-Type CCR Indicators Indicator Purpose True rms-reading ammeter (1) Indicates output current, voltage, and VA readings...

  • Page 16: Theory Of Operation

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Description This subsection describes the L-828 CCR theory of operation. 4. Theory of Operation Current regulation is obtained by using SCRs to switch the supply Introduction power (by varying the On duration of the AC cycle) to the power transformer and by using feedback circuitry to monitor the transformer’s output.

  • Page 17: Contactor

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Description In the event of an SCR failure, the contactor provides a means to Contactor break the current driving the primary of the power transformer T1. Under normal conditions, the contactor K1 (see Figure 8-1 in the Wiring Schematics section) has no making or breaking current across it, since the SCR is off when the contactor is opening and closing.

  • Page 18: Input Power Breaker Sizing

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Description NOTE: Table 2-4 refers to recommended input power supply wire, 6. 60 Hz LC-Type L-828 less than 100 feet, 90°C, 600 or 5000 V minimum. For 100 to 250 CCRs (4-10 kW/6.6 A):...

  • Page 19: Style

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Description Refer to Table 2-7 for Style. Style Table 2-7 Style Class Style Brightness Nominal Output Power Steps 4.8 A, 5.5 A, 6.6 A 2.8 A, 3.4 A, 4.1 A, 5.2 A, 6.6 A...

  • Page 20: Regulation

    Refer to Table 2-8 for output current limits. Current regulation is Regulation obtained under the conditions listed in Environmental Operating Conditions. The L-828 CCRs (4-10 kW/6.6 A) are designed for indoor use only in Environmental Operating an area with adequate ventilation for cooling the constant current Conditions regulator.

  • Page 21: Maximum Safe Overload

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Description Overcurrent Protection 10kW regulators include an overcurrent protective device that opens the primary switch when the output current exceeds the 100 percent current (6.6 A) by 5 percent. The device operates within 5 seconds after an overcurrent of 5 percent and within 1 second after an overcurrent of 25 percent.

  • Page 22: Weight

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Description Refer to Table 2-10. Weight Table 2-10 Weight lb (kg) 4 kW 229 (103.9) 7.5 kW 298 (135.2) 10 kW 341 (154.7) See Figure 2-3. CCR dimensions are 31 in. (788 mm) (Height) x CCR Dimensions 28 in.

  • Page 23: Installation

    3/4-inch ID eyebolts on top of the cabinet. Place the regulator inside a well ventilated room with sufficient clearance for personnel to inspect and maintain the unit. The L-828 CCR may be mounted on the floor or on a rack or shelf. Mounting CCR Floor Mounting The regulator can be placed directly on the floor without the use of bolts.

  • Page 24: Figure 3-1 Rack Mount Installation

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Rack Mounting This subsection provides recommendations for optional racking mounting. Follow the guidelines below when rack mounting the LC- type CCR. • See Figures 3-1 and 3-2. Refer to Table 3-1 for rack/shelf mounting hardware.

  • Page 25: Wiring Connections And Startup

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Rack Mounting (contd.) Figure 3-2 Rack Mount Hardware Details 1. Front of Cabinet 4. Side Rail 7. Back Rail 2. Top Back Rail Bolt 5. U-Channel Bolt 8. Bottom Back Rail Bolt 3.

  • Page 26: Figure 3-3 Location For Cables

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Wiring Connections and To install wiring, perform the following procedure: Startup (contd.) 1. Install all input and output cables. See Figure 3-3 for cable location, Figures 3-4 and 3-5 for Remote control wiring, Figure 3-6 for input/output wiring, and Figure 2-4 in the Description section for the internal parts of the CCR.

  • Page 27: Figure 3-4 Remote Control Wiring (3-Step)

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Figure 3-4 Remote Control Wiring (3-Step) Figure 3-5 Remote Control Wiring (5-Step) Page 3-5  2002 Siemens Airfield Solutions, Incorporated 96A0104B Issued 6/02 All rights reserved...

  • Page 28: Figure 3-6 Input/Output Wiring

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Wiring Connections and Startup (contd.) Figure 3-6 Input/Output Wiring 2. See Figure 2-4. Verify that the input supply voltage corresponds to the voltage rating on the name plate (8) of the regulator.

  • Page 29: Table 3-2 Remote Control Connections

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Wiring Connections and 5. Refer to Table 2-5. Install appropriate external lightning arrestors on the input power supply lines as close as possible to the CCR’s Startup (contd.) input terminal block TB3 (12).

  • Page 30: Table 3-3 Remote 120 Vac Control Connections (3-Step)

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Wiring Connections and Table 3-3 Remote 120 Vac Control Connections (3-Step) If you use 3-Step CCR Remote Intensity Connect CCI to… Startup (contd.) Step… High (6.6 A) CC, B100 Medium (5.5 A)

  • Page 31: Figure 3-7 Control Pcb

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Wiring Connections and 15. See Figure 3-7. Remove short-circuit link from the output terminals RV2 and RV3. Startup (contd.) Figure 3-7 Control PCB 1. TP7 4. Potentiometer R44 7. Potentiometer R47 10.

  • Page 32: Calibrating Regulator

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Wiring Connections and 16. Connect the 6.6 A series lighting circuit to the output terminals and tighten all connections. Startup (contd.) NOTE: Do not route output cable in the vicinity of other wiring sensitive to EMI or RFI.
  • Page 33 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Setting Up Regulator for Calibration To set up the regulator for calibration, perform the following procedure: 1. See Figure 2-4. Check to make sure the proper input voltage is supplied to the CCR at terminal block TB3 (12).

  • Page 34: Table 3-5 Setting 3-Step Output Current Levels

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Adjusting Output Current (contd.) 2. See Figure 2-4. Set switch S1 to next to the lowest brightness step, and verify that the true-rms ammeter reading corresponds to Tables 3-5 and 3-6. If the reading is not in the current value...
  • Page 35 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Installation Adjusting Overcurrent (contd.) 2. See Figure 2-4. Turn switch S1 (6) to the highest brightness step, 5 for 5-step CCR or 100 for a 3-step CCR. Ammeter should read 6.6 amps.

  • Page 36: Operation

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Operation Section 4 Operation WARNING: Contents are static-sensitive. Must be grounded when handling PCB. This section provides the operational procedures for the L-828 style 1. Introduction constant current regulators (CCRs) listed below.

  • Page 37: Remote Control

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Operation Table 4-2 Rotary Switch S1 Position for 5-Step CCRs 2. Local Control Procedures If you set switch S1 The result is... (contd.) to the following... Operation of CCR by remote control signals.

  • Page 38: Maintenance

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Maintenance Section 5 Maintenance WARNING: Only personnel authorized to work on high- voltage equipment should perform maintenance on the regulator. WARNING: Operate regulator under local control (using rotary switch) when performing maintenance tasks on the regulator.

  • Page 39: Maintenance Schedule

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Maintenance To keep the L-828 CCRs operating efficiently, follow a preventive 2. Maintenance Schedule maintenance schedule. Refer to Table 5-1. Table 5-1 L-828 CCR (4-10 kW/6.6 A) Maintenance Interval Maintenance Task...

  • Page 40: Short-Circuit Test

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Maintenance 2. Maintenance Schedule (contd.) WARNING: Since high open-circuit voltages may result by Short-Circuit Test opening the primary of a series lighting circuit, only personnel authorized to work on high-voltage equipment should be allowed to perform the short-circuit test.
  • Page 41 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Maintenance Open-Circuit Test 3. Turn on input power to the regulator. (contd.) 4. Turn the rotary switch to the lowest brightness position (B1 for 5- Step, B10 for 3-Step). The open-circuit protective device should automatically de-energize the regulator in less than 2 seconds.

  • Page 42: Troubleshooting

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Troubleshooting Section 6 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. WARNING: De-energize regulator by turning rotary switch S1 to OFF, and remove input power to regulator by turning off disconnect switch or main circuit breaker.

  • Page 43: Preliminary Troubleshooting

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Troubleshooting The following is a check list of initial steps to perform. 2. Preliminary Troubleshooting • Check all LED indicators, fuses and circuit breakers. Refer to Table 6-1. • Visually examine all areas of the CCR. Do burnt or loose connections/parts exist? •...
  • Page 44 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Troubleshooting This subsection provides general troubleshooting procedures. 3. General Troubleshooting Procedures Problem Possible Cause Corrective Action 1. Regulator not Circuit breaker tripped Turn off CCR using local control switch turning on using S1.

  • Page 45: General Troubleshooting Procedures

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Troubleshooting 4. General Troubleshooting Procedures (contd.) Problem Possible Cause Corrective Action 3. Regulator Feedback transformer T2 or main Turn control switch S1 to the OFF repeatedly trips transformer T1 failed position.
  • Page 46 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Troubleshooting 4. General Troubleshooting Procedures (contd.) Problem Possible Cause Corrective Action 5. Regulator shuts Open-circuit protection fails Test the load for open-circuit condition. down from open- Then short the CCR’s output TB1 and circuit protection check for normal operation.
  • Page 47 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Troubleshooting 4. General Troubleshooting Procedures (contd.) Problem Possible Cause Corrective Action 7. W VA-Indicator red CCR’s output current not properly Refer to calibration instruction in LED light lit (contd.) calibrated Calibrating Regulators in the Installation section.

  • Page 48: Parts

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts Section 7 Parts To order parts, call Siemens Airfield Solutions Customer Service or 1. Introduction your local representative. Use this four-column parts list, and the accompanying illustration, to describe and locate parts correctly.

  • Page 49: Figure 7-1 60 Hz L-828 Ccr (4-10 Kw/6.6 A)

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts See Figure 7-1. Refer to Table 7-1 for the LC-type L-828 CCR 3. L-828 CCR (4-10 kW/6.6 (4-10 kW) part numbers. A) Part Ordering Code 44D13XX - X X X 0...
  • Page 50 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts This subsection provides part numbers for the L-828 LC-Type CCR (4- 4. L-828 CCR General 10 kW/6.6 A/60 Hz). Assembly (4-10 kW/6.6 A) Parts List NOTE: Substitution of electronic components may be done only if...

  • Page 51: L-828 Ccr General Assembly (4-10 Kw/6.6 A) Parts List

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts 4. L-828 CCR General Assembly (4-10 kW/6.6 A) Parts List (contd.) Part Number Description Quantity Note 35A0343 Ratio transformer, 6:1 32A0025 Varistor, 750 V 28A0011 SCR block, 95 amp, 1200VRRM...
  • Page 52 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts 4. L-828 CCR General Assembly (4-10 kW/6.6 A) Parts List (contd.) 44D1475 47A0113 47A0108 49A0084 35A0438 53A0198 53A0212 53A0412-60 47A0117 Figure 7-2 LC-Type L-828 CCR Component Parts (2 of 4) Page 7-11 ...
  • Page 53 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts 4. L-828 CCR General Assembly (4-10 kW/6.6 A) Parts List (contd.) 35A0290 35A0343 44D1476-1 44D1476-2 32A0025 35B0462 35B0462-480 35B0463 35B0463-480 35B0464 35B0464-480 Figure 7-2 LC-Type L-828 CCR Component Parts (3 of 4) Page 7-12 ...
  • Page 54 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts 4. L-828 CCR General Assembly (4-10 kW/6.6 A) Parts List (contd.) 33A0013 44B1712P 28A0011 28A0015 44A4824-1 Figure 7-2 LC-Type L-828 CCR Component Parts (4of 4) Page 7-13  2002 Siemens Airfield Solutions, Incorporated...
  • Page 55 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts See Figure 7-2. Refer below for the part numbers for the 4 kW 4. L-828 CCR General (480 Vac) L-828 CCR. Assembly (4-10 kW/6.6 A) Parts List (contd.) Part Number...
  • Page 56 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts Refer below for the part numbers for the 7.5 kW (208-240 Vac) 4. L-828 CCR General L-828 CCR. Assembly (4-10 kW/6.6 A) Parts List (contd.) Part Number Description Quantity...
  • Page 57 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts 4. L-828 CCR General See Figure 7-2. Refer below for the part numbers for the 7.5 kW (480 Vac) L-828 CCR. Assembly (4-10 kW/6.6 A) Parts List (contd.) Part Number...
  • Page 58 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts See Figure 7-2. Refer below for the part numbers for the 10 kW (208- 4. L-828 CCR General 240 Vac) L-828 CCR. Assembly (4-10 kW/6.6 A) Parts List (contd.)
  • Page 59 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts See Figure 7-2. Refer below for the part numbers for the 10 kW (480 4. L-828 CCR General Vac) L-828 CCR. Assembly (4-10 kW/6.6 A) Parts List (contd.) Part Number...

  • Page 60: Recommended Spare Parts

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts This subsection provides recommended spare parts for the LC-Type 5. Recommended Spare CCR. Parts See Figure 7-2. This subsection provides spare part for the 4 kW Recommended Spare Parts (208-240 Vac) L-828 CCR.

  • Page 61: Recommended Spare Parts (7.5 Kw/480 Vac)

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Parts See Figure 7-2. This subsection provides part numbers for the 7.5 kW Recommended Spare Parts (480 Vac) L-828 CCR. (7.5 kW/480 Vac) Part Number Description 47A0108 Fuse, 2 A, 250 V, SLO-BLO, 3-Step...

  • Page 62: Wiring Schematics

    L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Wiring Schematics Section 8 Wiring Schematics This section provides wiring schematics for LC-Type L-828 constant 1. Introduction current regulators (CCRs) (4-10 kW/6.6 A). See Figure 8-1 for internal wiring schematics.

  • Page 63: Figure 8-1 Lc-Type L-828 Ccr Internal Wiring Schematic

    REM OTE COM M AND > >SAM PLING 12VDC SAM PLE > GATE 120VAC Figure 8-1 LC-Type L-828 CCR Internal Wiring Schematic (Part 1 of 2) Page 8-2  2002 Siemens Airfield Solutions, Incorporated 96A0104B Issued 6/02 All rights reserved...
  • Page 64 L-828 CCRs LC-Type (4, 7.5, and 10 kW/6.6 A/60 Hz) Wiring Schematics Figure 8-1 LC-Type L-828 CCR Internal Wiring Schematic (Part 2 of 2) Page 8-3  2002 Siemens Airfield Solutions, Incorporated 96A0104B Issued 6/02 All rights reserved...

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