Related Manuals for ADB MCR3 2.5 to 10 kVa
Summary of Contents for ADB MCR3 2.5 to 10 kVa
- Page 1 Installation manual Microprocessor controlled constant current regulator Type MCR³ 2.5 kVA to 30kVA AM.07.360e Edition 2.0...
- Page 2 ADBs prior written consent. This manual could contain technical inaccuracies or typographical errors. ADB reserves the right to revise this manual from time to time in the contents thereof without obligation of ADB to notify any person of such revision or change.
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Page 3: Table Of Contents
Table of contents About this manual 1.1. How to work with the manual ......................5 1.2. Record of changes..........................5 1.3. Icons used in the manual ........................5 1.4. Abbreviations and terms ........................6 Safety 2.1. Use..............................9 2.2. Safety symbols............................9 2.3. Signs on the equipment ........................10 2.4. - Page 4 6.10. Connect output to series circuit......................52 6.11. Connect back-indication signals ON and REG.ERR .................57 6.12. Connect remote control cables ......................58 6.13. Install panels ............................. 58 Technical data 7.1. Technical characteristics ........................59 7.2. Applicable standards.........................60 7.3. ElectroMagnetic Compatibility (EMC) ....................60 7.4.
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Page 5: About This Manual
About this manual About this manual The manual shows the information necessary to: install the MCR 2.5 to 30 kVA. 2.5 to 12.5 kVA: small cabinet; 15 to 30 kVA: big cabinet; If in the manual the term equipment is used, this refers to both the small and the big cabinet. How to work with the manual Familiarize yourself with the structure and content. -
Page 6: Abbreviations And Terms
About this manual Abbreviations and terms Table: 1.1 Terms and abbreviations Term or abbreviation Description Alternating Current AGLAS Airfield Ground Lighting Automation System American Wire Gauge Binary notation All data in the digital circuits is treated using “1” and “0”. Thus, all decimal notations are transcripted into binary notations. - Page 7 About this manual Term or abbreviation Description Power Supply Logic Root Mean Square Series CutOut Thyristor Block Module User Interface A.M.07.360e - Edition 2.0...
- Page 8 About this manual A.M.07.360e - Edition 2.0...
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Page 9: Safety
Safety Safety Read all warnings carefully. Failure to do so may result in personal injury, death, or property damage. To use the equipment safely: Refer to the International Standard IEC 61820, Electrical installation for lighting and beaconing of aerodromes - Constant current series circuits for aeronautical ground lighting - System design and installation requirements, and to the International Standard IEC 61821, Electrical installations for lighting and beaconing of aerodromes - Maintenance of aeronautical ground lighting circuits for instructions on safety precautions. -
Page 10: Signs On The Equipment
Use this equipment only as described in the manual. ADB cannot be held responsible for injuries or damages resulting from non-standard, unintended applications of its equipment. The equipment is designed and intended only for the purpose described in the manual. -
Page 11: Installation
Failure to follow these safety procedures can result in personal injury or death. Allow only qualified personnel to install ADB and auxiliary equipment. Use only approved equipment. Using unapproved equipment in an approved system may void agency approvals and will void the warranty. -
Page 12: Maintenance And Repair
All liability for consequences of any inexpert alterations or repairs carried out by the purchaser or a third party shall be waived. ADB shall in no event be liable to the purchaser for any further claims, particularly claims for damages not affecting the goods themselves. -
Page 13: Description
Description Description Series circuit system overview Input power supply Equipment Input disconnection device Output disconnection device Remote control system Series circuit The equipment is a microprocessor-controlled constant current regulator. Intended use The equipment is designed to supply airport lighting series circuits at different intensity levels. Any other or additional use will be considered not to be in conformity with the purpose. -
Page 14: Lay-Out Of The Equipment Cabinets
Description Lay-out of the equipment cabinets 3.4.1 Outside - small cabinet: 2.5 to 10 kVa Thyristor heatsink Main items Fused input switch User interface Lifting lugs (option) Series CutOut (SCO) (option) CS cabinet (option) Wheels (option) Ground stud M6 A.M.07.360e - Edition 2.0... - Page 15 Description 3.4.2 Inside - small cabinet: 2.5 to 10 kVa Input terminals (X1) Main items Earth Fault Detection module (EFD) (option) Output measurement transformers (TI2, TI3) Tap (S6 to S1) Lightning arrestors (LA1, LA2) Output terminals (X2) Series choke (L1) Multiwire control (option) J-Bus logic (option) Thyristor Block Module (TBM)
- Page 16 Description 3.4.3 Outside - big cabinet 15 to 30 kVa Thyristor heatsink Main items Fused input switch User interface Lifting lugs (option) Series CutOut (SCO) (option) CS cabinet (option) Wheels (option) Ground stud M6 A.M.07.360e - Edition 2.0...
- Page 17 Description 3.4.4 Inside - big cabinet 15 to 30 kVa Input terminals (X1) Main items Earth Fault Detection module (EFD) (option) Output measurement transformers (TI2, TI3) Lightning arrestors (LA1, LA2) Output terminals (X2) Tap (S6 to S1) Series choke (L1) Multiwire control (option) J-Bus logic (option) Thyristor Block Module (TBM)
- Page 18 Description 3.4.5 Overview of component connections C011 C012 C013 C014 C010 UI logic Fuse (F2) EFD (option) Output power transformer (T1) Main contactor (K1) Output measurement transformer (TI2, TI3) EFD resistors (option) LFD (option) Output terminals (X2) Series choke (L1) J-Bus interface (option) Fused input switch (F1) Multiwire logic (option)
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Page 19: Components
Description Components 3.5.1 Power input Input terminals The input terminals connect the power input (X1) cables to the regulator. The size of these terminals depends on the input current rating of the regulator: Common mode The common mode choke blocks the high- choke frequency common-mode currents from the power circuitry. - Page 20 Description Fused input switch The fused input switch disconnects the (F1) equipment from the mains power supply. Fuses (F2, F3) The fuses F2 and F3 protect the wiring of the equipment from overcurrent: F2 protects the low current mains wiring; F3 protects the wiring to measure the primary voltage of the power transformer;...
- Page 21 Description Thyristors (THP1) The thyristors use phase control as a closed loop regulation system to obtain the required output current. 3.5.2 Power output Output power The transformer has a set of primary and transformer (T1) secondary taps. The primary taps can adapt to the typical input voltages of 220, 240, 380, 400 or 416 V - 50 or 60 Hz.
- Page 22 Description Output terminals The output terminals connect the equipment to (X2) the series circuit. Output terminals The output terminals connect the equipment to when you use a the series circuit. Lightning arrestors The output terminals connect the equipment to (LA1, LA2) the series circuit.
- Page 23 Description 3.5.3 Printed Circuit Boards (PCBs) Thyristor Block The TBM is the interface between the CCL and Module (TBM) the thyristor gates. The TBM PCB controls the thyristor gates to obtain the required conduction angle. The TBM also provides fast overcurrent protection and asymmetric output voltage monitoring.
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Page 24: Working Principle
Description Local Master The LMC communicates with the other modules Controller (LMC) as a master via a local bus. The LMC processes and distributes the messages it receives from the other modules. Each slave has a control line to request transmission of data to the LMC. The local bus connection uses the RS485 protocol to send isolated signals over two wires. -
Page 25: Nameplate
Description Nameplate Each equipment has a standard nameplate: CONSTANT CURRENT REGULATOR REGULATEUR A COURANT CONSTANT SINGLE PHASE TYPE : BIPHASE 2P + T INPUT : 50/60Hz ENTREE : OUTPUT : SORTIE : REMOTE CONTROL : MAN. 8STEPS TELECOM : 8BRILL. MAX. OPTIONS : SERIES NR : NUMERO DE SERIE :... -
Page 26: Options
Description Options The equipment can be controlled remotely with Multiwire, J-Bus, or a combination of the above. Remote control The system automatically detects which communication method is available. Each equipment has a maximum of three multiwire PCBs connected to the LMC: Multiwire MW1;... - Page 27 Description The LFD shows the number of defective light fittings on the UI. Lamp Fault The operation of the LFD is based on the change in the output waveforms when a series Detection (LFD) transformer saturates as a consequence of the lamp having blown at the secondary side. The LFD can be used together with a CS.
- Page 28 Description A.M.07.360e - Edition 2.0...
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Page 29: Inspection And Transport
Inspection and transport Inspection and transport Inspect equipment on delivery Each equipment comes in a crate. Check if the crate is not damaged. If the crate is damaged, tell the carrier immediately. Unpack the crates. See § 4.3. Check if the equipment corresponds to your order. Check the equipment for damage. - Page 30 Inspection and transport Lift Secure a chain or a rope (A) to the lifting lugs. Slightly lift the equipment. The cables tighten. Carefully move the equipment to the applicable location. Equipment with wheels (option) Push the equipment to the applicable location.
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Page 31: Pre-Installation
Pre-installation Pre-installation How to pre-install - general procedure Prepare the substation for the equipments. See § 5.2. Plan a power supply for each equipment. See § 5.3. Plan the cables and the lay-out of the cables. See § 5.4. Prepare substation 5.2.1 Prepare WARNING... - Page 32 Pre-installation 5.2.2 Substation specifications For details on the substation specifications below, see ICAO Aerodome Design Manual, Part 5 Electrical Systems, DOC 9157-AN/901. Table: 5.1 Substation specifications Item Description Shelter Clean and dry; Lockable; Fireproof; Separate construction with reinforced concrete floors and walls;...
- Page 33 Pre-installation 5.2.3 Provide heat dissipation The equipment meets the FAA AC150/5345-10F standard for equipment efficiency. Table: 5.2 Indicative values for heat dissipation Equipment [kVA] Heat dissipation [W] 1200 1400 1750 1800 Make sure that the heat dissipation efficiency is better than 90% for an equipment less than 30kVA and at least 92% for a 30kVA equipment.
- Page 34 Pre-installation 5.2.5 Substation layout Table: 5.3 Clearance specifications Clearance specification Distance [mm] Between the rear of the machine and the wall, X Approximately 500 Between two machines (side by side), Y Minimum 50 A.M.07.360e - Edition 2.0...
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Page 35: Install Power Supply
Pre-installation 5.2.6 External fuse Install the external fuse, type gL/gG. For the specification, see the table below. Table: 5.4 External fuse specifications Equipment type [kVA] Equipment type voltage [V] External fuse [A] 208 to 240 380 to 416 208 to 240 380 to 416 208 to 240 380 to 416... -
Page 36: Plan Cables And Lay-Out Of Cables
Pre-installation Plan cables and lay-out of cables 5.4.1 Procedure Plan the layout of the cables. See § 5.4.2. Plan the cable slack. See § 5.4.3. Plan the power supply cables and earthing cables. See § 5.4.4. Plan the remote control cables (option). See § 5.4.5. Plan the cables for the series circuit. - Page 37 Pre-installation 5.4.3 Cable slack Leave enough slack for the cables. See the table below. This makes it easier to connect the equipment later. Table: 5.5 Cable slack for the different cable types Cabinet type Cable slack [mm] Big cabinet without CS: Chassis protective earth: 1000 High voltage:...
- Page 38 Pre-installation 5.4.4 Power supply cables and earthing cables Make sure the wire sections for the power supply and the earthing wire apply to the equipment. See tables 5.6 and 5.7. Table: 5.6 Input supply voltages for equipments supplied with 208 to 240 V Output Fuse in Input current...
- Page 39 Pre-installation Table: 5.9 Power input terminal sizes Input current rating of Terminal size [mm the regulator Up to 50 A Up to 100 A Above 100 A 5.4.5 Cables to remote control interface WARNING Only earth the remote control cable at one location. Only earth the local bus connection at the first equipment cabinet.
- Page 40 Pre-installation For a Tx+/Tx- and Rx+/Rx- connection plan a twisted-pairs cable. J-Bus cables Provide screened (armoured) data cable according to the selected protocol: (option) RS485 (2 wire communication). RS422 (4 wire communication). One cable for a single J-bus, two cables for a dual J-Bus. Table: 5.12 Wire sections for J-Bus cables Cable type...
- Page 41 Pre-installation 5.4.7 Install cables for substation Install the required cabling at the substation for each planned equipment. See also the figure below. Keep power cables and remote control cables separated from each other. Cables come through the ceiling. Cables come through a false room under the substation.
- Page 42 Pre-installation A.M.07.360e - Edition 2.0...
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Page 43: Installation
Installation Installation WARNING Always wear protective gloves and shoes when you do work on the equipment or the series circuit. WARNING Make sure that the power is OFF when you install the equipment. Main installation procedure Check the pre-installation. See § 6.2. Check the required tools. -
Page 44: Required Tools
Installation Required tools Protective gloves; Safety Protective shoes. True RMS Multimeter; Meters Isolating measurement transformer; CAUTION The output voltage of the 30 kVA / 6.6 A equipment can reach approximately 4600 V at full load. Insulation tester "Megger" 5000 V or 10000 V; AC True RMS measurement device, scale 10 and 30 A. -
Page 45: Remove Panels
Installation Remove panels The panels of the equipment can be removed for installation or maintenance procedures. CAUTION Do not operate the equipment with any of the panels removed. Do not mix panels from different equipments. Always connect the earthing wires before you install the panels. 6.5.1 Front and rear panel Remove panel... - Page 46 Installation 6.5.2 Top panel Remove the bolts (A) or the optional lifting lugs (B). Remove the panel (C). 6.5.3 UI panel: small cabinet Remove panel Remove the screws (A). Remove the panel (B). Disconnect wires Disconnect the power cable from connector J1 (A).
- Page 47 Installation 6.5.4 UI panel: big cabinet Remove fused input switch and complete handle (A) Open the handle (I). Move up the handle (II). Pull and remove the handle (III). Remove panel Loosen the screws (A). Remove the panel (B). Disconnect wires Disconnect the power cable from connector J1 (A).
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Page 48: Switch Off Power Supply
Installation Switch OFF power supply Switch OFF the fused input switch (A). Small cabinet Switch OFF the main power supply at the disconnection device. Open the main switch on the main distribution board. Disconnect the equipment from the series circuit. Switch OFF the fused input switch (A). -
Page 49: Install Additional Earthing
Installation Route cables CAUTION Keep the power cables separated from other cables. Do not let the series circuit cables touch the transformer winding. The transformer winding becomes extremely hot during operation. Use gland plates and correctly sized glands to route the cabling. Tie the cables to the shaft walls with a cable tie. -
Page 50: Connect Power Input Supply
Installation Connect power input supply Strip the input supply cables and earthing wires. See the tables below. Strip cables Table: 6.5 Input supply cables earthing wires for equipments 208 / 220 / 230 / 240 V Output power Section supply Strip length Section ground Strip length... - Page 51 Installation The connection is based on screw terminals. Connect: wire sections up to 35 mm Connect - 1 Put the cables through the stress-relief clamp (A) Connect the input supply cables to the terminals (B). Connect the earthing wire to the terminal (C).
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Page 52: Connect Output To Series Circuit
Installation Connect - 2 Connect the earthing wire to the earthing network (A) of the substation. 6.10 Connect output to series circuit CAUTION If the series circuit cable is screened, you must connect the screen to an earthing network either inside or outside the equipment. The procedures show how to connect the integrated output connections: Standard, small cabinet. - Page 53 Installation Connect - 1 Lead the series circuit cables and the earthing cable through the stress relief clamps (A). Install the the series circuit cables in the connectors (B), labeled OUT 1 and OUT 2. Install the the earthing wire in the connector (C), labeled GRND.
- Page 54 Installation Connect Connect the series circuit cables to the lightning arrestors (A). Connect the earthing wire to the earthing terminal (B). Connect the earthing wire to the earthing network of the substation. With cable ties, tighten the cables to the rail (C).
- Page 55 Installation 6.10.4 With Circuit Selector (CS) (option), big cabinet The number of terminals available for series circuit connections depends on your order. CAUTION Make sure you connect all terminals. If you do not want to use all terminals, put the free terminals into short-circuit. Strip the cables at the end.
- Page 56 Installation Connect Put the output cablies through the stress relief clamps (A). Connect the output cables to the to the terminals labeled OUT3 and OUT4 (B). If you use a screened cable, connect the screen to the GRND (C). Tighten the screw of the stress relief clamp. 6.10.6 With built-on Series CutOut (SCO), big cabinet (option) Remove cover...
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Page 57: Connect Back-Indication Signals On And Reg.err
Installation Connect Connect the output cables to the red connectors (A). If you use a screened cable, connect the screen to an earthing ponit at the bottom (B). Use a 6 mm socket wrench. Connect the output cables tightly to the rail (C). -
Page 58: Connect Remote Control Cables
Installation 6.12 Connect remote control cables 6.12.1 Earth remote control cabling Carry out the procedure when an earthing feeder is present in the remote control cable harness. Attach the cable harness to the earthing and stress relief bar (A). Use the clamp (B) provided with the equipment. -
Page 59: Technical Data
25 and 30 kVA, only for 380/ 400/ 415 V. Some readjustments are possible in the ranges 220 - 240 V and 380 - 415 (420 V). For readjustments, contact ADB. The net weights depend on the chosen configuration. A.M.07.360e - Edition 2.0... -
Page 60: Applicable Standards
Technical data Applicable standards The equipment is in accordance with these standards: Table: 7.2 Applicable standards Standard Description ICAO Aerodrome Design Manual, Part 5 paragraphs 3.2.1.4/5/6 AC 150/5345-10F and L829 IEC 61822 ElectroMagnetic Compatibility (EMC) The equipment is designed to operate in an industrial electro-magnetic environment. The regulator complies with IEC 61822, in accordance with IEC 61000-6-4 and IEC 6-6-2 (generic standard for industrial environment). -
Page 61: Dimensions
Technical data Dimensions The small cabinet (A) and the big cabinet (B): Table: 7.4 Dimensions Item A - 2.5 to 10 kVa B - 15 to 30 kVA X [mm] Y [mm] Z1 [mm] Z2 [mm] 1280 Dimensions with options [mm] Wheels Height + 100 Lifting lugs... -
Page 62: J-Bus Pcb: Slave Connections
Technical data J-Bus PCB: Slave connections The figures show the wire connections for the slave side. The connections for the master side depend on the used hardware. J-bus type Single J-bus: Bus A P1 Dual J-bus: Bus A P1 and Bus B P3 Two wire RS485 Tx +... - Page 63 Technical data A.M.07.360e - Edition 2.0...
- Page 64 Tel: +86 10 8476 0106 P.O. Box 341218 Fax: +86 10 8476 0090 United Arab Emirates Tel: +971 4372 4970 ADB Airfield Solutions GmbH & Co. KG Fax: +971 4372 4975 Von-der-Tannstr. 31 90439 Nürnberg Germany Unit 44 Business Innovation Centre...
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