ADB Safegate RELIANCE Power CRF User Manual

Ferroresonant constant current regulator l-828/l-829, 2.5-30kw, 6.6a/20a, with reliance power ace3

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RELIANCE Power CRF - Ferroresonant Constant Current Regulator

L-828/L-829, 2.5-30kW, 6.6A/20A, with RELIANCE Power ACE3

User Manual

DM00008-000-01, Rev. F, 2024/04/17

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Page 1 RELIANCE Power CRF - Ferroresonant Constant Current Regulator L-828/L-829, 2.5-30kW, 6.6A/20A, with RELIANCE Power ACE3 User Manual DM00008-000-01, Rev. F, 2024/04/17...
Page 3 Material Handling Precautions and Storage precautions that must be followed. ADB SAFEGATE reserves the right to examine goods upon which a claim is made. Said goods must be presented in the same condition as when the defect therein was discovered. ADB SAFEGATE furthers reserves the right to require the return of such goods to establish any claim.
Page 4 Use this equipment only as described in the manual. ADB SAFEGATE cannot be held responsible for injuries or damages resulting from non-standard, unintended uses of its equipment. The equipment is designed and intended only for the purpose described in the manual. Uses not described in the manual are considered unintended uses and may result in serious personal injury, death or property damage.
Page 5: Table Of Contents
4.4 Open-Circuit Protection ....................................... 22 4.5 Overcurrent Protection ......................................22 4.6 Input Voltage ..........................................23 4.7 Built-In True-RMS Ammeter (L-828 only) ..............................23 4.8 Input Power Monitoring Option via ACE3 ™ ..............................23 DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 6 RELIANCE Power CRF - Ferroresonant Constant Current Regulator TABLE OF CONTENTS 5.0 Installation .................................... 25 5.1 Introduction to Safety ......................................25 5.2 Unpacking ..........................................26 5.2.1 Material Handling Precautions: Storage ............................26 5.3 Installation Overview ......................................26 5.3.1 Mounting Information ..................................... 27 5.3.2 Stacking Information ....................................
Page 9 Figure 33: Calibration Screen with the red X shown ..............................53 Figure 34: ACE Info Config Screen (network Config) ..............................60 Figure 35: Failsafe Config Screen ...................................... 60 Figure 36: About Screen ........................................62 DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 10 RELIANCE Power CRF - Ferroresonant Constant Current Regulator List of Figures Figure 37: About Screen Menu ......................................62 Figure 38: About Screen Disclaimer ....................................63 Figure 39: PCB URC4 Regulator Control (44A7693) ..............................67 Figure 40: Output Lightning Arrestors .................................... 71 Figure 41: Internal Wiring Schematic (Main, sheet 1/page 1) ..........................
Page 11 Table 25: Remote Input Status ......................................83 Table 26: F1-F2 Fuses ..........................................87 Table 27: F3-F4 Fuses ..........................................87 Table 28: K2 Contactor .......................................... 87 Table 29: Capacitor Banks ........................................88 DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 13: Safety
1.0 Safety Introduction to Safety This section contains general safety instructions for installing and using ADB SAFEGATE 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 14: Introduction To Safety
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Safety 1.1.1 Introduction to Safety CAUTION Unsafe Equipment Use This equipment may contain electrostatic devices, hazardous voltages and sharp edges on components • Read installation instructions in their entirety before starting installation.
Page 15: Intended Use
When removing equipment from a shipping pallet, carefully balance and secure it using a safety strap. Failure to follow this instruction can result in death, serious injury, or equipment damage DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 16: Operation Safety
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Safety 1.1.5 Operation Safety CAUTION Improper Operation Do Not Operate this equipment other than as specified by the manufacturer • Only qualified personnel, physically capable of operating the equipment and with no impairments in their judgment or reaction times, should operate this equipment.
Page 17: Material Handling Precautions, Esd
• Allow only qualified personnel to perform maintenance, troubleshooting, and repair tasks. • Only persons who are properly trained and familiar with ADB SAFEGATE equipment are permitted to service this equipment. • An open airfield current circuit is capable of generating >5000 Vac and may appear OFF to a meter.
Page 19: Introduction
2. Carry out the actions completely and in the given sequence. 2.3 CRF Introduction This section describes the ADB Safegate Ferroresonant, L-828/L-829, constant current regulators (CCRs). These CCRs are manufactured according to FAA specification AC 150/5345-10 (latest edition). 2.4 Constant Current Regulator...
Page 20 • CCR % efficiency The RELIANCE Power ACE3 unit is also a component of ADB SAFEGATE's distributed control and monitoring system. Each unit can be easily connected to an Airport Lighting Control & Monitoring System (ALCMS) by simply adding redundant communication wires.
Page 21: Remote Control Input
Input Circuit Breaker Option: replaces the standard input power fuses with an internally mounted thermal circuit breaker Not all Additional Options are shown in the ordering code. Please contact ADB SAFEGATE Sales for further information. In manuals cross-reference to ordering code must use scope="external".
Page 22: Ace3 Unit
• CCR % efficiency The ACE3 unit is also a component of ADB Safegate’s distributed control and monitoring system. Each unit can be easily connected to an Airport Lighting Control & Monitoring System (ALCMS) by simply adding redundant communication wires.
Page 23: Ccr Theory Of Operation
2.9.3 URC4 Control PCB See Figure 4. This subsection describes the board level circuitry found on the Control PCB. Figure 1: L-828 CCR Power Circuit Block Diagram DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 24: Urc4 Control Pcb Inputs/Outputs
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Introduction 2.9.4 URC4 Control PCB Inputs/Outputs The Control PCB receives the inputs listed below. See Figure 5 in this section and “Wiring Schematics”. • Input from the Local CCR Switch (via Ribbon Cable – J10) for local control and switching of the CCR unit •...
Page 25: Theory Of Operation
2 seconds and then back on. The control board will not recognize momentary over currents caused by load switching or other transient conditions. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 26: Open Circuit Protection
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Theory of Operation 3.6.2 Open Circuit Protection The micro-controller detects an open circuit by the absence of current in the regulator output (this will also detect an open or shorted current transformer). If the output current is less than 1 amps, the controller will shut the current regulator down within 2s by removing voltage from the input contactor.
Page 27: Urc4 Ccr Controller
When in Remote mode, enables the CCI to provide 120 Vac at 50 W. The CCI is the Remote power control source. • Provides direct, real time communication to the ACE3 control and monitoring unit via proprietary protocol Figure 4: URC4 CCR Controller DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 28: Advanced Control Equipment
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Theory of Operation 3.9.1 L-829 Advanced Control Equipment The L-829 ACE3 ™ control and monitoring unit consists of an integrated control unit that is interfaced to each CCR either internally or within a small external enclosure. The ACE3 printed circuit boards are mounted inside an environmental enclosure that is directly attached to the door of the L-829 CCR.
Page 29: Optional Series Cutout Type Sco
Regulators without an optional Series Circuit Cutout (SCO) will have a current clamp test point installed to provide a location to attach an output current clamp when used to calibrate the output of the CCR. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 30: Ccrs Required Equipment
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Theory of Operation 3.13 L-828 CCRs Required Equipment Refer to Table 1 for required equipment that is supplied. Refer to Table 2 for required equipment that is not supplied. Table 1: Required Equipment Supplied...
Page 31: Table 4: Ccr Input Voltage And Current For The Ccr Power Ratings
100 A 91 A 86 A 72 A 58 A 30 kW 195 A 185 A 177 A 169 A 117 A 107 A 102 A 85 A 68 A DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 33: Specifications
The efficiency of the regulator operated at rated input voltage running at step B5/B100 into a full load having unity power factor is not less than the value shown. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 34: Output Current Regulation
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Specifications 4.2 Output Current Regulation The CCR maintains its output current within the limits of table below as defined in FAA AC 150/5345-10 (latest edition). The FAA specification addresses resistive loads between no load (short circuit) to the full CCR rating along with reactive loads consisting of resistive loads connected via isolating transformers with the secondaries of 30 percent of the transformers open-circuited.
Page 35: Input Voltage
CCR that will interface to the URC4 CCR Controller PCB. When interfaced to an ACE3 unit in ™ conjunction with an ALCMS system, real time input monitoring and alarm recording is available. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 37: Installation
Maintenance personnel must refer to the maintenance procedure described in the ICAO Airport Services Manual, Part 9. • ANSI/NFPA 79, Electrical Standards for Metalworking Machine Tools. • National and local electrical codes and standards. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 38: Unpacking
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Installation 5.2 Unpacking The equipment is shipped ready for installation. Handle equipment very carefully to prevent component damage. Unpack the carton upon receipt and check the contents and their condition. Note any exterior damage to the carton that might lead to detection of equipment damage.
Page 39: Mounting Information
5.3.2 Stacking Information CAUTION When stacking ADB Safegate regulators, the bottom regulator must be bolted to a concrete mounting pad. Stacking two CRF or CRT regulators of the same frame size: CRF and CRT regulators can be stacked to minimize floor space requirements. CRT and CRF of the same frame size can stack directly on top of each other with no need for additional supports.
Page 40: Figure 8: Side View Of Stacked Crf Or Crt Regulators
AK00033-200-01 To stack a CRF or CRT regulator on top of an ADB Safegate CSF, CCR, CHF, or CCF regulator complete the following steps: 1. Before installing anything onto the regulators, pre-build the assembly shown in the figure below with the included hardware.
Page 41 (26 n-m). 11. Torque all four (4) 3/8"-16 x 3/4" hex head bolts used to mount the upper uni-strut rail to the bottom uni-strut rail to 230 in-lbs (26 n-m). DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 42: Installation - Wiring The Ccr
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Installation 5.4 Installation - Wiring the CCR CAUTION Read installation instructions in their entirety before starting installation. Incorrect wiring can damage regulator. Double check all connections. Figure 9: Recommended Conduit interface Locations...
Page 43: Table 10: Remote Control Connections (3-Step/6.6 A)
15. Energize the regulator and re-verify that the current levels are correct in all steps. Note If the ADB Safegate Advanced Control Equipment (ACE3) is used with the CRF for remote control from an ALCMS, refer to the Advanced Control Equipment manual for wiring connections to remote control. Table 9 through Table 11 provide the necessary connections for the remote control (either 120 Vac or, +48Vdc).
Page 44: Table 13: Input/Output Connections
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Installation Table 12: Remote Vac Control Connections (5-Step/20 A) (Continued) B4 (15.8 A) CC, B4 B5 (20 A) CC, B5 Not applicable Note If more than one intensity command is connected, the CCR will activate at the highest intensity selected.
Page 45: Operation
• Never touch exposed electrical connections on equipment while the power is ON. Failure to follow these instructions can result in equipment damage DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 46: Ccr Control Procedures
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Operation 6.2 CCR Control Procedures This subsection describes the regulator operations in local and remote controls. 6.2.1 Local Control See Switch (3-Step/5-Step). Refer to Output Current Tables below for output current when using local control. The front panel rotary selector switch is used for regulator local control.
Page 47: Remote Control
Turn the rotary selector switch on the front panel of the regulator to position OFF. Remove input power before servicing control circuitry. Never service the regulator when it is in protective shutdown mode, Remote controls or power fluctuations can restart the regulator. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 48: Figure 11: Output Current Clamp
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Operation To adjust the output current, perform the following procedure: 1. Connect a clamp-on true RMS reading instrument (such as a Fluke 87 multimeter with a current clamp) around one of the output current leads.
Page 49: Adjusting Output Current (No Ace3)
8. If the reading is not in the current value range given in the Tables, adjust the appropriate step until the correct current value is obtained. 9. Repeat Step 2 for the remaining lower brightness step(s). DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 50: Adjusting Over-Current Detection Set Point (No Ace)
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Operation When the output current adjustment has been completed, turn off the CCR. 6.3.2 Adjusting Over-Current Detection Set Point (no ACE) Note Over-current set point adjustments on regulators with ACE3 must be done from the ACE3 touchscreen display (see the ACE3 manual 96A0500 in our product center at www.adbsafegate.com).
Page 51: Sco Operation
ARC FLASH AND ELECTRIC SHOCK HAZARD Allow only qualified personnel to perform maintenance, troubleshooting, and repair tasks. • Only persons who are properly trained and familiar with ADB Safegate equipment are permitted to service this equipment. • An open airfield current circuit is capable of generating >5000 Vac and may appear OFF to a meter.
Page 52: Table 18: Cutout Working Positions
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Operation WARNING Switch off the constant current regulator before manipulating the cutout. Table 18: Cutout Working Positions Position A Position B Position C The series circuit insulation versus ground can be measured...
Page 53: Graphic User Interface (Gui)
The ACE3 GUI also contains a localized event database to allow the user to view alarms/warnings for the individual device without the need to interface with the higher level control system. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 55: Figure 13: Output Current Gauge
(if enabled) and output power values arranged on an electrical diagram. If the ACE's mode is "IO" neither the Output View nor the Diagram View will be displayed. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 56: Figure 15: Io Card Cage View
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) Figure 15: IO Card Cage View This view is shown when an IO card cage is installed. It shows what type of card is installed in which slot. Blue = Regulator Interface Card, red = output card, yellow = input card.
Page 57: Menu Screen
Output VA Calibration - This displays the page used for calibrating the VA measurement of the CCR Lamps Out Calibration - This displays the page used for calibrating Lamps Out IRMS Configuration - This displays the page used for configuring IRMS schedule and parameters DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 58: Alarms View
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) Configuration – This displays the page used for configuring ACE parameters Failsafe - This displays the page used for configuring failsafe parameters Feature Enable - This displays the page used for enabling/disabling features, as well as enabling/disabling desired warnings and alarms About –...
Page 59: Status Menu - Hours/Cycle Count
7.1.4 Status Menu – Waveform Figure 21: Wave Form Screen The wave form screen displays a wave form for: • Output Current • Output Voltage DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 60: Status Menu - Miscellaneous
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) • Input Current • Input Voltage The data will be in the shape of the wave and won't give exact measurements to the user. There are buttons along the bottom to turn on and off each wave form allowing the user to select which data they wish to view.
Page 61: Figure 24: Ccr Configuration Screen 1
The CCR has five steps B1 - B5 CCR Size (W) Watts Sets open circuit voltage set point to 120% value Sets over load voltage set point to 110% value DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 62: Figure 25: Ccr Configuration Screen 1 For 20A Ccrs
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) CCR Extra IO None ACE doesn't monitor extra IO slots Standard ACE monitors for output in slot 4, input in slot 6 Extended ACE monitors for output in slots 4 & 5, input in slots 6 & 7 Figure 25: CCR Configuration Screen 1 for 20A CCRs 7.1.6.2 Screen 2...
Page 63: Figure 28: Current Set Point For 20A Ccrs
Input Channel - (only in advanced mode) The channel on the card to set for this loop • Input Polarity - (only in advanced mode) Active high or low (default high) DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 64: Figure 30: Css Loops
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) None of the changes will take effect until the "Set" button has been pressed. Figure 30: CSS Loops Note Enabled output slots must be consecutive. Note These values are read only if the "cssAdvancedConfig" is absent (default) or set to false in the ace.ini file. If the "cssAdvancedConfig"...
Page 65: Ccr Menu - Measurement Calibration
The first page of the Output VA Calibration provides a box to adjust the settling time for each step that the ACE3 will wait before taking readings. This will allow any circuit noise that occurs during step change to settle before measuring. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 66 RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) Once the value has been set, select the button to move to the next page The second page is where the calibration can begin. Be aware that the CCR will energize and cycle through all available steps.
Page 67: Ccr Menu - Irms Configuration
Kilo-ohm using the up/down arrows or the user can touch the value bringing up a num pad. From there they can select any value within the allowable range. Note that the alarm value must be lower than or the same as the warning. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 68 RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) The controls on the scheduling page allow the user to setup the initial delay and the reoccurring interval as well as some additional options. • Enable checkbox: This is used to enable and disable each IRMS schedule independently.
Page 69: Ccr Menu - Lamps Out Calibration
Once the calibration has started, the ACE3 will command the CCR on to each brightness step, taking measurements at each step, for the duration of the configured settle time per step. After the initial measurement phase, the user will need to pull the appropriate number of lamps*. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 70 RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) CAUTION *Make sure the CCR is De-Energized Press Continue Calibration after the lamps have been pulled. Once the calibration continues, the ACE3 will command the CCR on to each brightness step, taking measurements at each step, for the duration of the configured settle time per step.
Page 71: Ace Menu - Configuration
NTP server. The ACE 3 will then use NTP to get it's time from that point on. Unchecking the box turns off the use of NTP. The network configuration views allow the user to configure both the LAN interfaces as well as the wireless interface. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 72: Ace Menu - Failsafe
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) The third view allows the user to configure the two local area network (LAN) connections. Once the user has made all desired modifications they can press the "Set" button to store the new configuration or the "Reset" button to erase all local changes and use the existing configuration.
Page 73: Ace Menu - Feature Enable
These changes take effect immediately and are stored. Disabling an alarm or warning prevents that alarm/warning from showing up on the alarm page and the corresponding event(s) will not be generated. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 74: Ace Menu - About
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Graphic User Interface (GUI) 7.1.14 ACE Menu – About The first view on the About screen displays the serial number and version info of installed modules. Using three fingers and swiping up will add a column next to the version info to display the build number for trouble shooting purposes.
Page 75: Figure 38: About Screen Disclaimer
There is no limit on the length of the text since this view's contents are scrollable. Figure 38: About Screen Disclaimer DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 77: Maintenance And Repair
Check and record output current on each tolerance. Refer to Adjustment Procedures in the Operation section. brightness step. Refer to Table 8 for the current range for the 3-Step and 5Step CCRs. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 78: Short-Circuit Test
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Maintenance and Repair Table 19: L-828/L-829 CCR (4-30 kW) Maintenance (Continued) Interval Maintenance Task Action Clean dirty or slightly pitted contactor contacts. Use a fine file for surface cleaning. Replace contacts that are excessively burned or Check relays, wiring and insulation.
Page 79: Component Replacement Procedures
7. Remove the 4 screws at the 4 corners of the PCB. Retain the standoffs. Figure 39: PCB URC4 Regulator Control (44A7693) DIP Switches 8. Ensure that the DIP switches of the new board match exactly to those of the board being replaced. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 80: Table 20: Dip Switch Bank 1
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Maintenance and Repair 9. Mount the new PCB by replacing the 4 screws and the standoffs at the corners of the PCB. 10. Plug the ribbon cable back into J10 by pressing it in. It is keyed and will only go in one way. Also verify the tabs on the side have locked into place.
Page 81: Table 21: Dip Switch Bank 2
It is very important when replacing the URC4 to match the Regulator type. Class (6.6/20 amp) OFF = 6.6 amp ON = 20 amp Output Voltage Sensing OFF = Core Winding ON = External Transformer Reserved for Manufacturer (Default to OFF) DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 82: Removing And Replacing Input Lightning Arrestors
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Maintenance and Repair Table 22: DIP Switch Bank 3 Bank Position Purpose Input Volts 1 = ON, 0 = OFF 120 VAC = 0000 208 VAC = 1000 220 VAC = 0100...
Page 83: Removing And Replacing Output Lightning Arrestors
11. Restore the SCO to the "In Service" position. 12. Restore primary power to the CCR at the breaker panel. 13. Turn the CCR local switch to the REM position. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 84: Wiring Schematics
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Maintenance and Repair 8.4 Wiring Schematics Figure 41: Internal Wiring Schematic (Main, sheet 1/page 1) INPUT MONITOR OPTION OPTION DETAIL "B" INPUT SHEET 2 ACE / IRMS SEE PAGE 2 B1,B10 B2,B30...
Page 85: Figure 42: Internal Wiring Schematic (Main, Sheet
FOR SCO (DETAIL "A") OPTION WIRING SEE SHEET 2 3. GROUNDING NOTES: -24VDC+, 18AWG, RED, UL1015 -24VDC-, 18AWG, BLACK, UL1015 7. CONNECT PRIMARY SIDE TO CAP ASSEMBLY LUGS (600V)(RED AND BLACK). DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 86: Figure 43: Internal Wiring Schematic (Details A-D)
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Maintenance and Repair Figure 43: Internal Wiring Schematic (Details A–D) DETAIL "B" DETAIL "A": SERIES CUT OUT (SCO) OPTION SEE INPUT MONITOR OPTION "CUTOUT OPTION" ON SHEET 1 FOR LOCATION OUTPUT LEADS (INDICATED BY HEAVY BLACK LINE), TO BE COVERED BY 1/2"...
Page 87: Figure 44: Internal Wiring Schematic (Details E-F)
Figure 44: Internal Wiring Schematic (Details E–F) " " E " " . P I DETAIL "F" DIRECT CURRENT CONTROL VOLTAGE 24VDC RELAYS SHOWN. USE TERMINAL BLOCKS ON 120V AND 48VDC. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 88: Figure 45: Internal Wiring Schematic (Detail G - Ace3)
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Maintenance and Repair Figure 45: Internal Wiring Schematic (Detail G - ACE3) 3 2 1 Copyright © ADB Safegate, All Rights Reserved...
Page 89: Figure 46: Internal Wiring Schematic (T1)
T1: 2.5-30KW; 240/480V, T1: 2.5-30KW; 380/400V, 60HZ (480V SHOWN) 50HZ (MULTI-TAP) OUT1 OUT1 OUT2 OUT2 CAP2 CAP2 400V CAP1 CAP1 380V CAP1 SCR1 CAP1 SCR1 SCR2 CAP2 SCR2 CAP2 DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 90: Figure 47: Internal Wiring Schematic (T4)
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Maintenance and Repair Figure 47: Internal Wiring Schematic (T4) T4 WIRING CONNECTIONS "T4" CONTROL TX: "T4" CONTROL TX: 208/220/240V, 50/60HZ INPUT 347/380V, 60HZ INPUT RED/BLK GRN/YEL RED/BLK GRN/YEL 35A0539/546 35A0539/546 "T4" CONTROL TX: "T4"...
Page 91: Troubleshooting
Short the output terminals before switching the regulator on. The wire should be AWG 6 or larger. You may also use the SCO cutout to short the regulator output. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 92: General Troubleshooting Chart
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Troubleshooting 9.1 General Troubleshooting Chart CAUTION Read the instructions in their entirety before starting installation. Only personnel authorized to work on high-voltage equipment should perform maintenance on the regulator. Since high open-circuit voltages may result by opening the primary of a series lighting circuit, only personnel authorized to work on high-voltage equipment should be allowed to perform the open-circuit test.
Page 93 9. Ammeter on CCR SCR drive not working properly Check connections at SCR module. Replace Control PCB . oscillates and loud Refer to Problem #11 in this table. noise occurs DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 94: Preliminary Troubleshooting
RELIANCE Power CRF - Ferroresonant Constant Current Regulator Troubleshooting Table 23: CCR Troubleshooting (Continued) Problem Possible Cause Corrective Action Problem Possible Cause Corrective Action 10. Output current Regulator load too large Either reduce the load or replace the regulator with a larger kW CCR.
Page 95: Troubleshooting Control Board
Indicates the Local Switch is in Remote D20_12 (On) CC is active D20_13 (B5) B5 is active D20_14 (B4) B4 is active D20_15 (B3) B3/B100 is active D20_16 (B2) B2/B30 is active DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 97: Crf Parts
08 = Input Circuit Breaker Notes Not ETL Certified in Sizes 20 - 30 kW with 6.6 A Output Not ETL Certified when combined with 20 A Output Amperage Not ETL Certified. DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 98: Ccr Options And Kits
CCR when ordered, please see the Additional Options section of the CCR ordering code. If a kit or kit combination you desire is not listed on the ordering code, please contact the ADB Safegate sales department. Some kits can be ordered separately and installed by the customer or by ADB Safegate Technical Service.
Page 99: Table 26: F1-F2 Fuses
53A0412/50 53A0412/40 53A0412/40 53A0412/40 53A0412/25 10KW 53A0412/75 53A0412/40 53A0412/40 53A0412/40 53A0412/25 15KW 53A0412/120 53A0412/60 53A0412/60 53A0412/50 53A0412/40 20KW 53A0412/150 53A0412/90 53A0412/90 53A0412/60 53A0412/50 30KW 53A0331 53A0412/150 53A0412/150 53A0412/90 53A0412/75 DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 100: Table 29: Capacitor Banks
RELIANCE Power CRF - Ferroresonant Constant Current Regulator CRF Parts Table 29: Capacitor Banks CCR Size 60Hz Input 50Hz Input 2.5 kW AS00034-100-01 AS00034-100-01 4 kW AS00034-150-01 AS00034-200-01 5 kW AS00034-150-01 AS00034-200-01 7.5 kW AS00034-250-01 AS00034-300-01 10 kW AS00034-300-01 AS00034-350-01...
Page 101: Assembly Views
10.3 Assembly Views Figure 49: Component Plate (Front View) INPUT URC3 F5-6 Current Clamp Test Point (If no SCO) DM00008-000-01, Rev. F, 2024/04/17 Copyright ADB Safegate, All Rights Reserved ©...
Page 102: Figure 50: Component Plate (Rear View)
RELIANCE Power CRF - Ferroresonant Constant Current Regulator CRF Parts Figure 50: Component Plate (Rear View) OUTPUT(VR1 VR2) IRMS Current Clamp Test Point (If no SCO) Copyright © ADB Safegate, All Rights Reserved...
Page 104: Figure 52: Assembly View (Door Open, Side Removed)
RELIANCE Power CRF - Ferroresonant Constant Current Regulator CRF Parts Figure 52: Assembly View (Door Open, Side Removed) GND1 Copyright © ADB Safegate, All Rights Reserved...
Page 105: Support
ADB SAFEGATE Support Live Technical Support – Americas If at any time you have a question or concern about your product, just contact ADB SAFEGATE’s technical service department. Trained in all areas of system issues, troubleshooting, quality control and technical assistance, our highly experienced Technical support specialists are available 24 hours a day, seven days a week to provide assistance over the phone.
Page 106: Recycling
A.2.1 Local Authority Recycling The disposal of ADB SAFEGATE products is to be made at an applicable collection point for the recycling of electrical and electronic equipment. The correct disposal of equipment prevents any potential negative consequences for the environment and human health, which could otherwise be caused by inappropriate waste handling.
Page 107 Tel.: +46 (0)40 699 17 00 Internet: www.adbsafegate.com Fax: +46 (0)40 699 17 30 ADB SAFEGATE, China ADB SAFEGATE Airfield Technologies Ltd. China Unit 603, D Block, CAMIC International Convention Center, No 3, Hua Jia Di East road, ChaoYang district, Beijing 100102 P.R.

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