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ADB Safegate CRE Series Operation And Maintenance Manual

Constant current regulator
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Operation / Maintenance Manual
Constant Current Regulator
Type CRE
A.07.370e Edition 2.1

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Summary of Contents for ADB Safegate CRE Series

  • Page 1 Operation / Maintenance Manual Constant Current Regulator Type CRE A.07.370e Edition 2.1...
  • Page 2 This manual could contain technical inaccuracies or typographical errors. ADB Safegate reserves the right to revise this manual from time to time in the contents thereof without obligation of ADB Safegate to notify any person of such revision or change.

  • Page 3: Table Of Contents

    Table of contents About this manual How to work with the manual...................... 9 Record of changes ........................9 Icons used in the manual......................9 Abbreviations and terms ......................10 Safety Use ............................11 Safety symbols ..........................11 Signs on the equipment ......................12 Skilled personnel ........................
  • Page 4 3.5.3 IGBT power bridge ......................32 3.5.4 Hall sensor, big cabinet ....................34 3.5.5 Output filter ........................34 3.5.6 Main transformer, all cabinets..................35 3.5.7 Output measure PCB (EPS422), all cabinets..............35 3.5.8 Power output ........................35 3.5.9 CPU PCB (EPS479), all cabinets ................... 36 3.5.10Remote control PCB (EPS495), all cabinets ..............
  • Page 5 Description of the configuration software tool Description of screens and menus ................... 53 CCR status screen........................55 Output/Mains screen ........................ 60 Test screen ..........................63 Configuration screen ........................ 65 EFD/LFD screen ........................67 Diag/Dsp/BUS screen....................... 69 Copy Parameters screen ......................72 Log screen ..........................
  • Page 6 First start-up..........................81 8.2.1 Procedure ........................81 8.2.2 Measure input voltage on big and small cabinets............81 8.2.3 Measure input voltage on stackable cabinet ..............82 8.2.4 Measure output current in short-circuit ................82 8.2.5 Put SCB in short-circuit ....................82 8.2.6 Put SCO in short circuit ....................
  • Page 7 10.2 Troubleshooting guide ......................102 10.2.1Fault: Equipment does not turn ON ................102 10.2.2Fault: Equipment does not go to the ON state ............. 103 10.2.3Fault: Equipment turns ON but suddenly de-energizes..........104 10.2.4Fault: equipment does not produce requested output current........105 10.3 Checks and measurements ....................
  • Page 8 11.3 Remove panels........................137 11.3.1 Generic panels ......................137 11.3.2 Remove the display / keyboard panel of the small cabinet .......... 138 11.3.3 Remove the display / keyboard panel of the big cabinet ..........138 11.3.4 Remove the display / keyboard panel of a cabinet with a CS (option CS) ....139 11.3.5 Top panel (small cabinet)....................

  • Page 9: About This Manual

    About this manual About this manual The manual shows the information necessary to: commission operate carry out maintenance on the CRE 2.5 to 30 kVA. 2.5 kVA: stackable cabinet. 2.5 to 15 kVA: small cabinet. 20 to 30 kVA: big cabinet. If in the manual the term equipment is used, this refers to the stackable cabinet, the small and the big cabinet.

  • Page 10: Abbreviations And Terms

    About this manual 1.4 Abbreviations and terms Table: 1.1 Terms and abbreviations Term or abbreviation Description Alternating Current Airfield Ground Lighting CENELEC Comitée Eruopéen de Normalisation ELECtrotechniqe (European Committee for Electrotechnical Standardization) Circuit Selector Circuit Selector Module Direct Current Digital Signal Processor Earth Fault Detection Electro Magnetic Compatibility Equipment...

  • Page 11: Safety

    Safety Safety Read all warnings carefully. Failure to do so may result in personal injury, death, or property damage. 2.1 Use 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...

  • Page 12: Signs On The Equipment

    Safety 2.3 Signs on the equipment CUTOUT TYPE SCO UNLOCK BEFORE OPENING DANGER DANGER LINE VOLTAGE : 5000 V.AC. MAX SERIES CURRENT : 20A.AC. MAX PN : 1475 92.030 HAUTE TENSION HIGH VOLTAGE HAUTE TENSION HIGH VOLTAGE COUPER L’ALIMENTATION AVANT COUPER LE REGULATEUR TOUTE VERIFICATION OU REPARATION SWITCH REGULATOR OFF...

  • Page 13: Liability

    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.

  • Page 14: Operation

    2.10 Maintenance and repair Allow only skilled personnel to perform maintenance, troubleshooting, and repair tasks. Only persons who are properly trained and familiar with ADB Safegate equipment are permitted to service the equipment. Always use safety devices when working on the equipment.

  • Page 15: Ce Certification

    ADB Safegate. 2.12 Guarantee ADB Safegate guarantees that the performance of the equipment described in this manual, when sold by ADB or its licensed representatives, meets the corresponding requirements of FAA, ICAO and IEC. Refer to the document ‘General Conditions for Deliveries and Services by ADB Safegate.
  • Page 16 Safety A.07.370e - Edition 2.1...

  • Page 17: Description

    Description Description 3.1 Series circuit system overview A Input power supply D Equipment B Manual switch E Output disconnection device (optional) C Remote control system F Series circuit The equipment is a microprocessor-controlled constant current regulator with an optional output disconnection device (circuit selector).

  • Page 18: Working Principle

    Description 3.3 Working principle ENTER CANCEL REMOTE LOCAL A Line input. B Input filter. See § 3.5.1. C Diode bridge and sensing PCB, components of the IGBT power bridge. See § 3.5.3. D IGBT module and IGBT PCB, components of the IGBT power bridge. See § 3.5.3. E Output filter.

  • Page 19: Lay-Out Of The Equipment Cabinet

    Description 3.4 Lay-out of the equipment cabinet 3.4.1 Outside - stackable cabinet 2.5 kVA B C D A Ventilation grids B HMI C Serial communication port D Manual switch E Remote control connector F Series output connection. The illustration shows the SCB. G Output to Series Circuit H Power supply connector A.07.370e - Edition 2.1...

  • Page 20: Inside - Stackable Cabinet 2.5 Kva

    Description 3.4.2 Inside - stackable cabinet 2.5 kVa A Lightning arrestors B Input filter C Output filter D Manual switch E Sensing transformer F Power supply transformer G IGBTs H IGBT-PCBs (EPS477) Diode bridge + sensing PCB (EPS476) J CPU PCB (EPS479) K Power supply PCB (EPS480) L Remote control PCB (EPS495) M Line filter...

  • Page 21: Outside - Small Cabinet: 2.5 To 15 Kva

    Description 3.4.3 Outside - small cabinet: 2.5 to 15 kVA A Ventilation grids B HMI C Serial communication port D Manual switch E Remote control connector F Series output connection. The illustration shows the SCO. G Output to Series Circuit H Ethernet connector Power supply cable entry A.07.370e - Edition 2.1...

  • Page 22: Inside - Small Cabinet: 2.5 To 15 Kva

    Description 3.4.4 Inside - small cabinet: 2.5 to 15 kVA Note The illustrations show the 10 kVA cabinet. A Output filter B CPU PCB C Main fuses D Main contactor E Sensing transformer F IGBT G IGBT PCB (EPS477) H Diode bridge and sensing PCB (EPS476 / EPS507) Power supply PCB (EPS480) J Input filter K Remote control PCB (EPS495)

  • Page 23: Outside - Small Cabinet: 2.5 To 15 Kva With Cs (Option Cs)

    Description 3.4.5 Outside - small cabinet: 2.5 to 15 kVA with CS (option CS) A Ventilation grids B HMI C Serial communication port D Manual switch with lockable cover A.07.370e - Edition 2.1...

  • Page 24: Inside - Small Cabinet: 2.5 To 15 Kva With Cs (Option Cs)

    Description 3.4.6 Inside - small cabinet: 2.5 to 15 kVA with CS (option CS) Note The illustration shows only the items of the CS. For all other items, see § 3.4.4. A Interface PCB (PCB1702) B Power supply convertors for multiwire remote control C Input terminals D Lightning arrestors E CS PCB (PCB1619)

  • Page 25: Outside - Big Cabinet 20 To 30 Kva

    Description 3.4.7 Outside - big cabinet 20 to 30 kVA A Ventilation grids B HMI C Serial communication port D Manual switch E Remote control connector F Series output connection. The illustration shows the SCO. G Output to Series Circuit H Ethernet connector Power supply cable entry A.07.370e - Edition 2.1...

  • Page 26: Inside - Big Cabinet 20 To 30 Kva

    Description 3.4.8 Inside - big cabinet 20 to 30 kVa A Line filter B Input filter C Power supply PCB (EPS480) D Power supply transformer E CPU PCB (EPS479) F Sensing PCB (EPS476) G Diode Bridge H Main fuses Main contactor J IGBT-PCBs (EPS496) K IGBTs L Sensing transformer...

  • Page 27: Outside - Big Cabinet: 20 To 30 Kva With Cs (Option Cs)

    Description 3.4.9 Outside - big cabinet: 20 to 30 kVA with CS (option CS) A Ventilation grids B HMI C Serial communication port D Manual switch A.07.370e - Edition 2.1...

  • Page 28: 10Inside - Big Cabinet: 20 To 30 Kva With Cs (Option Cs)

    Description 3.4.10 Inside - big cabinet: 20 to 30 kVA with CS (option CS) Note The illustration shows only the items of the CS. For all other items, see § 3.4.4. A Interface PCB (PCB1702) B Power supply convertors for multiwire remote control C Input terminals D Lightning arrestors E CS PCB (PCB1619)

  • Page 29: Line Input

    Description 3.5.1 Line input Input terminal, all cabinets The input terminal connects the power input cables to the equipment. Line filter, all cabinets The line filter blocks the noise the equipment generates to the line input and filters out voltage pulses from the input voltage. Manual switch, all cabinets The manual switch is a magneto-thermal switch that connects the mains power supply to the equipment.
  • Page 30 Description Main fuses, all cabinets The main fuses disconnect the equipment from the mains power supply if the input current is above a given value. Main contactor, stackable cabinet and small cabinet The main contactor allows the power supply PCB to automatically interrupt the power.

  • Page 31: Input Filter

    Description Sensing transformer, all cabinets The sensing transformer measures the input voltage level of the line input. Power supply transformer, all cabinets The power supply transformer: Supplies the zero crossing signal determined from the input voltage. Provides the correct current and voltage to power all the electronic components such as PCBs and to power the fans (for 15 to 30kVA equipment).

  • Page 32: Igbt Power Bridge

    Description Input filter, 15 kVA small cabinet and big cabinet The input filter is a 12.5 kHz filter that blocks the noise the equipment produces from the line input at a different frequency than the line filter. 3.5.3 IGBT power bridge The IGBT power bridge has the components that follow: Diode bridge + sensing PCB IGBT PCB...
  • Page 33 Description Sensing PCB (EPS476), big cabinet The sensing PCB measures the AC input line and controls the diode bridge. Note In the big cabinet, the sensing PCB and the diode bridge are separate parts. IGBT, all cabinets An IGBT controls a high power via a low power electronic signal. The IGBT can switch at high frequency.

  • Page 34: Hall Sensor, Big Cabinet

    Description 3.5.4 Hall sensor, big cabinet The Hall sensor measures the current between the IGBT and the output filter. 3.5.5 Output filter Output filter, stackable cabinets and small cabinet (except 15 kVA) The output filter is a Pulse Width Modulation (PWM) filter that builds the pure sine wave signal that comes from the H-bridge.

  • Page 35: Main Transformer, All Cabinets

    Description 3.5.6 Main transformer, all cabinets The main transformer converts the pure sine wave to the correct output voltage and current. 3.5.7 Output measure PCB (EPS422), all cabinets The output measure PCB measures the output voltage and current and sends these measurements to the CPU PCB. The EFD (See §...

  • Page 36: Cpu Pcb (Eps479), All Cabinets

    Description Connection to the series circuit There are mutual exclusive options possible. See §3.6. 3.5.9 CPU PCB (EPS479), all cabinets The CPU PCB Receives the measurement data of the output current and voltage from the output measure PCB via an optical fibre and compares these values with the required values.

  • Page 37: 12Lamp Fault Detection (Lfd)

    Description 3.5.12Lamp Fault Detection (LFD) The equipment analyses the output current and the voltage pattern to calculate, on a linear load, the number of open circuited lamps, in compliance with IEC 61822. The accuracy is ± 1 lamp with a range from 1 to 15 broken lamps. The HMI shows the actual LFD value.

  • Page 38: Circuit Selector (Cs)

    Description 3.6.3 Circuit selector (CS) With a CS you can connect several (up to eight) series circuits to a single equipment. The CS has two modes: Simultaneous: the equipment can connect to a number of the available circuits at the same time; Alternate: the equipment can connect to only one circuit at a time.

  • Page 39: Hmi Sin Pcb (Pcb1703) (Option Cs)

    Description 3.6.7 HMI SIN PCB (PCB1703) (option CS) Note This item is installed on the CS when the CS option is chosen. The HMI SIN BCB provides the indication of the state of the different series circuits (selected or not selected). 3.6.8 Remote control SIN PCB (PCB1694) (option CS) Note...

  • Page 40: 10Current Sensor (Option Cs)

    Description 3.6.10 Current sensor (option CS) Note This item is installed on the CS when the CS option is chosen. The current sensors sense if there runs current through the series circuits. 3.6.11 Series Connector Box (SCB), all cabinets The SCB connects the equipment to the series circuit with two medium voltage cables of the primary circuit.

  • Page 41: 13Rolling Castors

    Description 3.6.13 Rolling castors The equipment can be supplied with two fixed and two pivoting rolling castors to facilitate the movement of the equipment. The option is not available for stackable equipments or for an equipment with a CS. 3.7 HMI You can operate the equipment with the HMI.

  • Page 42: Nameplate

    Description 3.9 Nameplate Each equipment has a standard nameplate: SAFEGATE Constant Current Regulator DESCRIPTION: INPUT: OUTPUT: Remote CTRL: STEPS: OPTIONS: SERIAL NO: www.adbsafegate.com A.07.370e - Edition 2.1...

  • Page 43: Description Of The Hmi

    Description of the HMI Description of the HMI 4.1 HMI overview RUNWAY V :0.00KV I :0.00A HOURS:68 STATE: H _ TOT :256 ENTER EFD: 5.8 Mohm LOCAL LFD: - - - OPTIONS ALARMS MAINT CANCEL REMOTE LOCAL A Display B Function buttons C Keypad D ON, OFF, ENTER, CANCEL REMOTE and LOCAL buttons 4.2 HMI overview for an equipment with a CS (option CS)
  • Page 44 Description of the HMI LED colour Description CS ON Green The equipment and the CS are active. EVENT An alarm is active. LOCAL The equipment and the CS are in local mode REMOTE Green The equipment and the CS are in local mode You can only select local or remote control on the equipment A.07.370e - Edition 2.1...

  • Page 45: Display Overview: Main Screen

    Description of the HMI 4.3 Display overview: Main screen RUNWAY V :0.00KV I :0.00A HOURS:68 STATE: H _ TOT :256 EFD: 5.8 Mohm LOCAL LFD: - - - MENU 5KVA - Rel. 4.00 Table: 4.1 Display description: Main screen Name Description A Menu Push the corresponding function button to go to the Main menu.

  • Page 46: Description Of General Functions

    Description of the HMI 4.4 Description of general functions The function buttons can have different functions. The display description show the dedicated functions. This section shows the general functions, which are available in several menus. Table: 4.2 General function buttons Button Description →...

  • Page 47: Options Menu

    Description of the HMI 4.6 Options menu Table: 4.4 Buttons Button Description RS232/485 To activate or deactivate the RS232 or RS485 port. MODE To select the correct equipment work mode (see § 9.9): NORMAL (for linear loads) INDUCTIVE (for non-linear loads (e.g. LED loads)) To change the name of the field circuit that the equipment powers.

  • Page 48: Maintenance Menu

    Description of the HMI 4.8 Maintenance menu Before you can access the maintenance menu, you must fill in a password. Table: 4.6 General function buttons Button Description TEST Shows the DSP microcontroller operating parameters. These parameters show the state of the software process that controls the equipment. These parameters are only for an advanced user.

  • Page 49: How To Enter An Alphanumeric String

    Description of the HMI 4.10 How to enter an alphanumeric string 1. The display shows an alphanumerical matrix (B). 2. Push the LEFT and RIGHT buttons to select the character. 3. Push the ENTER button. The HMI adds the character to the string (A).

  • Page 50: Alarm Texts And Messages On The Hmi

    Description of the HMI 4.11 Alarm texts and messages on the HMI There are four types of alarms: Equipment alarms The equipment automatically switches OFF. Restart the equipment only after you have found the cause of the alarm. The red light goes on but the equipment still operates. Find the cause of the alarm. Field alarms The equipment automatically switches OFF.
  • Page 51 Description of the HMI Alarm text / message Possible cause LFD LEVEL 1 FAULT Minimum 3 broken lamps. LFD LEVEL level 2 fault Minimum 5 broken lamps. MAIN CONTACTOR The main contactor is broken. FAILED (OFF) MAIN CONTACTOR The main contactor is broken. FAILED (ON) MAIN DC <95% The rectified 560 V DC voltage is too low.
  • Page 52 Description of the HMI Alarm text / message Possible cause PRE-CHARGE The pre-charge contactor is broken (VIS CONTACTOR ON only). PRE-CHARGE The pre-charge contactor is broken (VIS CONTACTOR OFF only). SCO / DOOR OPENED A front, rear and or field connection panel is open.

  • Page 53: Description Of The Configuration Software Tool

    When you activate the configuration tool, you transfer all control of the equipment to the configuration software tool. In this situation, remote or local control of the equipment is not possible. To update the software version, contact ADB Safegate. 5.1 Description of screens and menus 5.1.1 General A.07.370e - Edition 2.1...
  • Page 54 Description of the configuration software tool Description Slave To select the slave number of the equipment you want to connect to. Connection To open and close the port to the selected slave number. Rem Reset To reset the alarm. See also § 9.7. Restore To restore a saved configuration from the PC to the equipment.

  • Page 55: Ccr Status Screen

    Description of the configuration software tool 5.2 CCR status screen Description Active step Shows the active brightness step of the selected equipment. Burnt lamps Shows the number of burnt lamps in the series circuit. CCR Status See § 5.2.1. EFD Errors See §...
  • Page 56 Description of the configuration software tool 5.2.1 CCR Status Item Description Event An error event occurred. DB Chgd A change was made to the database. DB Valid The data in the database is up to date. CCR Master LOCAL SELECTOR: the master is in LOCAL mode PC: the RS232 port of the master is active.
  • Page 57 Description of the configuration software tool 5.2.4 Regulation Errors Possible cause Alarm type CCR switched OFF for The output current is more than The equipment OVERCURRENT Imax +5% for minimum 4s. automatically switches OFF. The output current is more than Restart the equipment only Imax + 20% for minimum 0.4s.
  • Page 58 Description of the configuration software tool 5.2.5 CCR Errors Possible cause Alarm type DC BUS Voltage too low Only for a three-phase equipment. The equipment The voltage on the DC bus does not automatically switches OFF. reach the nominal value. Restart the equipment only after you have found the Possible root causes:...
  • Page 59 Description of the configuration software tool 5.2.6 Mains Voltage Errors Possible cause Alarm type Mains Voltage too Low The input voltage is too low. This can The equipment lead to an over current situation. automatically switches OFF. Restart the equipment only Mains Voltage too high The input voltage is too high.

  • Page 60: Output/Mains Screen

    Description of the configuration software tool 5.3 Output/Mains screen Description Output screen See items B to F. part Output currents See § 5.3.1. Imax Shows the maximum output current. Overcurrent See § 5.3.3. Off if overload See § 5.3.2. Step See §...
  • Page 61 Description of the configuration software tool 5.3.1 Output currents Item Description Number of Steps To select the number of brightness steps. Brightness 1 to 8 To adjust the current for each brightness step, accurate up to 25 mA. Change To activate the values and to send them to the equipment. Note When you select less than 8 brightness steps, the steps higher than the highest step automatically get the current of the highest brightness step.
  • Page 62 Description of the configuration software tool 5.3.5 Mains Item Description V_in_Scale Shows the scale used to calculate the nominal voltage. V_in_Nom Shows the nominal supply voltage. V_in_High To adjust the supply voltage threshold above which the equipment restarts when it switched OFF due to a too low supply voltage.

  • Page 63: Test Screen

    Description of the configuration software tool 5.4 Test screen Description Read To read the actual Analogue Data parameters (AD0 to AD7) from the selected equipment. Brightness See § 5.4.1. Ctrl Hardware See § 5.4.2. Iprim Switch on To enable the J-Bus serial port an to disable the RS232 serial port. JBUS Test To start the overcurrent alarm test.
  • Page 64 Description of the configuration software tool 5.4.2 Ctrl Hardware Iprim Item Description I primary hardware Shows if the primary current hardware protection is released. This is a read-only protection parameter. Reset To reset the primary current hardware protection. Read To read the actual primary current protection parameter from the selected equipment.

  • Page 65: Configuration Screen

    Description of the configuration software tool 5.5 Configuration screen C D E F G H I J Description CCR ID See § 5.5.1. Change Slave See § 5.5.2. Number Firmware Shows the firmware version of the selected equipment. version Firmware Shows a description on the firmware version of the selected equipment.
  • Page 66 Description of the configuration software tool 5.5.1 CCR ID Item Description Blank field To change the name of the field circuit that the equipment delivers power to. This name shows in the HMI. Change To activate the value and to send it to the equipment. 5.5.2 Change Slave Number Item...

  • Page 67: Efd/Lfd Screen

    Description of the configuration software tool 5.6 EFD/LFD screen Description EFD Enable See § 5.6.1. EFD Levels See § 5.6.2. Reset error To reset the EFD error. Read To read the actual EFD parameters from the selected equipment. LFD Calibrated Shows if the LFD is calibrated. LFD not Shows if the LFD is not calibrated.
  • Page 68 Description of the configuration software tool 5.6.1 EFD Enable Item Description State To select if the EFD measurement is enabled or disabled. Measure If the EFD measurement is enabled, you can choose between these values: Interval: the interval between measurements is indicated in the Min-Sec field. Continuous: the equipment measure continuously.

  • Page 69: Diag/Dsp/Bus Screen

    Description of the configuration software tool 5.6.5 VA Drop + delay Item Description VA Drop1 and Drop2 To adjust the threshold above which the equipment gives the VA Drop 1 and Drop 2 alarm. LFD Delay To adjust the minimum time span after the error before the equipment gives the LFD Level 1 or Level 2 alarm.
  • Page 70 Description of the configuration software tool Description Imp Test See § 5.7.4. Hours_Meter See § 5.7.5. Arbiter: To set the signal source for remote control. To set a priority for different Parameters systems. If you set this parameter to disabled, remote control is not possible. BF Mode: Use normal or stop bar.
  • Page 71 Description of the configuration software tool 5.7.2 Rem Reset Item Description Rem Reset To enable or disable the Rem Reset button. 1: the Rem Reset button is enabled. 0: the Rem Reset button is disabled. Change To activate the value and to send it to the equipment. Read To read the actual Rem Reset parameter from the selected equipment.

  • Page 72: Copy Parameters Screen

    Description of the configuration software tool 5.7.6 Rem Reset Circuit selector Item Description Circuit selector When the boxed is checked, the circuit selector will be reset. Change To activate the value and to send it to the equipment. Read To read the actual Circuit selector parameter from the selected equipment. 5.7.7 Speed Item...

  • Page 73: Log Screen

    Description of the configuration software tool 5.8.1 Load parameters from ccr Item Description Hours meter To select if you want to load/save the hours meter values of the equipment. Lfd calibration To select if you want to load/save the LFD calibration parameters of the equipment. all parameters To select if you want to load/save the all parameters of the equipment.

  • Page 74: Test Jbus Screen

    Description of the configuration software tool 5.10 Test JBus screen Description Start Test To start the test. Stop To stop the test. No. of slaves Shows the number of slaves. Reg. start No. of reg A.07.370e - Edition 2.1...

  • Page 75: Circuit Selector Web Interface (Option Cs)

    Circuit selector web interface (option CS) Circuit selector web interface (option CS) 6.1 Description of settings A Configuration settings B Series circuits data Table: 6.1 Configuration settings Setting Description Mode Simultaneous: free circuit selection Alternate: only 1 circuit selection is possible (only for 2 way CS) Key local/remote enabled Set to: DISABLE Circuits number...
  • Page 76 Circuit selector web interface (option CS) Table: 6.2 Series circuits data Item Description Presence YES for detected relays NO for undetected relays 3.3V OK for all connected CS PCBs KO for all not connected CS PCBs Input voltage measured by the CS PCB Status relay To check the correction functioning of the relay, push the buttons RELAY ON and RELAY OFF...

  • Page 77: Install And Operate The Configuration Software Tool

    Install and operate the configuration software tool Install and operate the configuration software tool 7.1 Install the configuration tool software Requirements System requirements: PC with Microsoft Windows 2000, XP operation system, or later; At least 50 Mbytes free disk space; 1 free serial communication (COM) port, or a virtual serial communication port over a USB bridge or a PCMCIA card;...
  • Page 78 Install and operate the configuration software tool Connect ethernet cable, if applicable 1. Switch OFF the equipment. See § 9.2. 2. Connect the ethernet cable (B) to the equipment (A) and to the PC (C). Configure the remote control ethernet connection 1.

  • Page 79: Monitor The Data Of An Equipment

    Install and operate the configuration software tool Setup the serial port, if applicable 1. Select the menu Communication. 2. Select the applicable serial communication port (COM). Note The baud rate and parity settings for the communication between the PC and the equipment must be the same.
  • Page 80 Install and operate the configuration software tool A.07.370e - Edition 2.1...

  • Page 81: Commissioning

    Commissioning Commissioning 8.1 Main commissioning procedure 1. Do the first start-up. See § 8.2. 2. Calibrate the Lamp Fault Detection (LFD) module. See § 8.3. 3. Adjust the number of available brightness steps. See § 9.6. 4. Configure the remote control interface (option). See § 8.4, § 8.5 and/or § 8.6 dependent upon the hardware.

  • Page 82: Measure Input Voltage On Stackable Cabinet

    Commissioning 8.2.3 Measure input voltage on stackable cabinet Prepare 1. Set the manual switch to the ON position. 2. On the HMI, push the Local button. The screen now shows the state LOCAL. 3. Push the OFF button. The equipment goes to the mode OFF. Measure 1.

  • Page 83: Put Sco In Short Circuit

    Commissioning Remove the box panel of the SCB 1. Loosen the screws (A). 2. Remove the box panel (B). Short circuit SCB with separate piece of output cable 1. Disconnect the series circuit cables. 2. With the separate piece of output cable (B), short-circuit the output terminals (A).

  • Page 84: Test Cs In Short-Circuit (Option Cs)

    Commissioning Connect AC True RMS multimeter (SCO) 1. Connect the current clamp of an AC True RMS multimeter (B) to the output cable (A). Measure output current 1. Switch ON the equipment and set it to LOCAL mode. See § 9.1. 2.
  • Page 85 Commissioning Short-circuit 1. With the separate piece of output cable, short-circuit the series circuit terminals (A). Note The illustration shows an equipment with connections to two series circuits, both in short-circuit. The procedure for more or less series circuits is similar. Connect AC True RMS multimeter 1.

  • Page 86: Measure Output Current Series Circuit (Option Cs)

    Commissioning Measure 1. Adjust the brightness step until the HMI shows 6.6 A for True RMS output current (A). See § 9.5. 2. If the output current on the AC True RMS multimeter does not reach 6.6 A, change the series circuit configuration before you proceed.

  • Page 87: 10Measure Resistance And The Insulation Resistance Of Series Circuit

    Commissioning Finish 1. Disable each circuit one by one menu (the indicators must be OFF). After you disable a circuit, check that the lights in that circuit go OFF. 2. Set the equipment to OFF. See § 9.2. 8.2.10 Measure resistance and the insulation resistance of series circuit 1.

  • Page 88: 12Prepare With Sco

    Commissioning 8.2.12 Prepare with SCO Set power to OFF 1. Make sure that all power to the equipment is OFF. See § 9.3. 2. Set the SCO to mode C. See § 9.8. The output terminals are now discharged. Remove cover 1.

  • Page 89: 15Calculate Minimum Insulation Resistance Of Series Circuit

    Commissioning 8.2.15 Calculate minimum insulation resistance of series circuit Table: 8.1 Theoretical insulation resistance for the series circuit Item Maximum insulation resistance current (standard: ICAO, part 5, § 3.9.4.7) [µA] Series transformer 100 m of cable with standard number of connectors Example: a runway centre-line circuit with 133 light fixtures with a total length of the series circuit of 8 km.

  • Page 90: Calibrate Lamp Fault Detection (Lfd)

    Commissioning Measure 1. Switch ON the equipment and set it to LOCAL mode. See § 9.1. 2. Select the step 6.6 A. 3. If the output current does not reach 6.6 A, change the series circuit configuration before you proceed. This indicates that the equipment is too small for the load.

  • Page 91: Remote Control Configuration: Multiwire (Option)

    Commissioning Remove lamps 1. Make sure that all power to the equipment is OFF. See § 9.3. 2. Earth the series circuit. With the SCO. See § 9.8. With an earthing wire on the SCB. 3. Remove a number of lamps in the field. Note Choose the number of lamps in function of the alarm level you use.

  • Page 92: Remote Control Configuration: J-Bus (Option)

    Commissioning 8.5 Remote control configuration: J-Bus (option) Configure the slave number 1. On the HMI, push the MENU button to go to the Main menu. 2. Push the OPTIONS button to go to the Options menu. 3. Push the SLVNUM button to set the slave number of the equipment. 4.
  • Page 93 Commissioning Select a ‘useable IP address’ Unidentified network Public network 192 168 255 255 255 0 1. Select a ‘useable’ IP address. Refer to the screenshots above. Examine the ethernet configuration and adjust if necessary 1. Simultaneously press button C2 on the HMI and switch ON the equipment. See § 9.1. 2.
  • Page 94 Commissioning Configure the HMI 1. Switch ON the equipment. See § 9.1. 2. On the HMI, go to the maintenance menu. 3. Push the MORE button. 4. Push the → or ← buttons until the HMI shows the CSE mode screen. 5.

  • Page 95: Operation

    Operation Operation 9.1 Switch ON the equipment When you switch ON the equipment, it starts to produce the same output current that was valid before the equipment was switched OFF. To set a different output current, select another brightness step. See § 9.5. For more information on the produced output currents, see §...

  • Page 96: Switch Between Local And Remote Mode

    Operation 9.4 Switch between local and remote mode To control the equipment through the HMI switch to the local mode. To control the equipment with the remote control system, switch to the remote mode. 1. For Local mode, push the LOCAL button on the HMI. The HMI now shows the mode LOCAL. Note The keypad keys on the HMI only operate when the equipment is in Local mode.

  • Page 97: Use Series Cutout (Sco)

    Operation 9.8 Use Series CutOut (SCO) 9.8.1 Operation mode WARNING Always wear protective gloves and shoes when working with the equipment or series circuit. The SCO has three operation modes: Description Mode A Mode B Mode C Purpose Normal operation. Maintenance operation.

  • Page 98: Adjust Operation Mode

    Operation 9.8.2 Adjust operation mode Remove cover 1. Open the lock (A). 2. Remove the cover (B). Use the handle. Set operation mode 1. Install the cover (B). See the cover placement in § 9.8.1. 2. Close the lock (A). A.07.370e - Edition 2.1...

  • Page 99: Operation Mode

    Operation 9.9 Operation mode A series circuit with non-linear loads can be unstable. If the system is unstable, do the procedure below. Note The equipment automatically detects if the inductive mode is required. The alarm message ‘DC BUS VOLTAGE TOO HIGH’ means that the series circuit is unstable. 1.
  • Page 100 Operation A.07.370e - Edition 2.1...

  • Page 101: Troubleshooting

    Troubleshooting 10 Troubleshooting WARNING Do not troubleshoot unless you have read and understood all the information in chapter 2 and you are qualified to work on high-voltage systems. Set the equipment to Local mode. Set the equipment to the brightness step OFF before you examine the series circuit. Switch OFF the main switch of the equipment;...

  • Page 102: Troubleshooting Guide

    Troubleshooting 10.2 Troubleshooting guide Note For a list of errors, see § 5.2. 10.2.1 Fault: Equipment does not turn ON Table: 10.1 Equipment does not turn ON Problem Possible cause Possible solution No display indications. A problem with the power Examine the transformer on the diode supply on the diode bridge bridge.

  • Page 103: 2Fault: Equipment Does Not Go To The On State

    Troubleshooting 10.2.2 Fault: Equipment does not go to the ON state Table: 10.2 Equipment does not turn ON Problem Possible cause Possible solution Local mode: One of the panels is opened. Close the panel. The display shows an Examine the fuses on power supply PCB. alarm.

  • Page 104: 3Fault: Equipment Turns On But Suddenly De-Energizes

    Troubleshooting 10.2.3 Fault: Equipment turns ON but suddenly de-energizes Table: 10.3 Equipment turns ON but suddenly de-energizes Problem Possible cause Solution (See) After you pressed the ON The input AC line is delivers Examine the input VAC line. button you record these less than 360 VAC.

  • Page 105: 4Fault: Equipment Does Not Produce Requested Output Current

    Troubleshooting 10.2.4 Fault: equipment does not produce requested output current Table: 10.4 Equipment does not produce the requested output current Problem Possible cause Solution (See) The red lamp on top of The equipment does not Examine the IGBT modules. the equipment goes on. operate correctly.

  • Page 106: 6Measure Cable Capacitance

    Troubleshooting 10.3.6 Measure cable capacitance Measure the cable capacitance towards the ground as follows: 1. Make sure that the main switch is OFF. 2. Connect a multimeter to the regulator output cable. Use a Multimeter that has an internal resistance of 10 MOhm.

  • Page 107: Maintenance

    Maintenance Maintenance WARNING Only personnel authorized to work on high-voltage equipment can do maintenance work on the equipment. Operate the equipment under local control when you do maintenance work on the equipment to prevent the equipment from being accidentally switched ON. Obey all local safety procedures.

  • Page 108: Part Replacement

    Maintenance 11.2 Part replacement WARNING Make sure you have read and understood all safety procedures and standards related to this equipment. See chapter 2. Make sure you switch OFF the power to the equipment. See § 9.3. Make sure you switch OFF the manual switch to remove all power to the equipment. CAUTION While you carry out maintenance, make sure that: You do not drop any screws or nuts inside the equipment cabinet.

  • Page 109: Cpu Pcb (Eps479) Replacement

    Maintenance 11.2.2 CPU PCB (EPS479) replacement CAUTION If you install an OVP version of the CPU PCB, make sure that the diode bridge PCB is also an OVP version. If you install an non-OVP version of the CPU PCB, make sure that the diode bridge PCB is also an non-OVP version.

  • Page 110: Cs Pcb (Pcb1619) Replacement (Option Cs)

    Maintenance 11.2.3 CS PCB (PCB1619) replacement (option CS) Parts: see § 13.8. CS PCB 1. Switch OFF the power supply. See § 9.2. 2. Remove the rear panel. See § 11.3. 3. Disconnect the cables from the CS PCB that you need to replace (A).

  • Page 111: Diode Bridge + Sensing Pcb (Eps476 / Eps507) Replacement, Small And Stackable Cabi

    Maintenance 11.2.5 Diode bridge + sensing PCB (EPS476 / EPS507) replacement, small and stackable cabinet CAUTION If you install an OVP version of the CPU PCB, make sure that the diode bridge + sensing PCB is also an OVP version. If you install an non-OVP version of the CPU PCB, make sure that the diode bridge + sensing PCB is also an non-OVP version.

  • Page 112: Diode Bridge And Sensing Pcb (Eps476) Replacement, Big Cabinet

    Maintenance Install 1. Wipe clean the copper plate (A). 2. Apply an even layer of conductive paste on the copper plate. 3. Install the new diode bridge on the new sensing PCB. 4. Make sure that the diode bridge makes good contact with the heatsink.
  • Page 113 Maintenance Remove sensing PCB 1. Disconnect the wires and connectors (A). 2. Remove the fasteners (B). 3. Remove the sensing PCB (C). Remove diode bridge 1. Remove the fasteners (A). 2. Disconnect the wires (B). 3. Remove the fasteners (C). 4.

  • Page 114: Display And Keyboard Replacement

    Maintenance 11.2.7 Display and keyboard replacement Parts: see § 13.8. Display/keyboard panel 1. Remove the display/keyboard panel. See § 11.3. 2. Install the new display/keyboard panel. See § 11.3. 11.2.8 Fuses on the power supply PCB (EPS480) replacement Parts: see § 13.8. Fuses.

  • Page 115: 10Igbt Replacement, Stackable And Small Cabinet

    Maintenance 11.2.10 IGBT replacement, stackable and small cabinet Parts: see § 13.8. IGBT Note The IGBT PCB, IGBT module, and the diode bridge and sensing PCB together are the IGBT power bridge. If one component breaks, replace the entire IGBT power bridge. The illustrations for this procedure show the situation for the 2.5 kVA and 10 kVA cabinets.
  • Page 116 Maintenance Prepare the IGBT 1. Make sure that spring number 7 (A) of the IGBT is removed. Once a spring has been removed, it cannot be installed back. Install - 1 1. Wipe clean the heat sink below the IGBT (A). 2.

  • Page 117: 11Igbt Replacement, Big Cabinet

    Maintenance 11.2.11 IGBT replacement, big cabinet Parts: see § 13.8. IGBT Note The IGBT PCB, IGBT module, and the diode bridge and sensing PCB together are the IGBT power bridge. If one component breaks, replace the entire IGBT power bridge. The procedure shows the IGBT at the right-hand side.

  • Page 118: 12Igbt Pcb (Eps477 / Eps 478) Replacement, Small Cabinet

    Maintenance 11.2.12 IGBT PCB (EPS477 / EPS 478) replacement, small cabinet Parts: see § 13.8. IGBT PCB Note The IGBT PCB, IGBT module, and the diode bridge and sensing PCB together are the IGBT power bridge. If one component breaks, replace the entire IGBT power bridge. The illustrations for this procedure show the situation for the 2.5 kVA and 10 kVA cabinets.

  • Page 119: 13Igbt Pcb (Eps496) Replacement, Big Cabinet

    Maintenance 11.2.13 IGBT PCB (EPS496) replacement, big cabinet Parts: see § 13.8. IGBT PCB Note The IGBT PCB, IGBT module, and the diode bridge and sensing PCB together are the IGBT power bridge. If one component breaks, replace the entire IGBT power bridge. The procedure shows the IGBT PCB at the right-hand side.

  • Page 120: 14Input Filter Replacement, Stackable Cabinet

    Maintenance Install CAUTION when you tighten the fasteners, only apply force vertically. Use an allen key screwdriver or an allen key handle instead of a socket wrench or a ratchet. Sideways force can cause the components to get damaged. 1. Install the new IGBT PCB (A) on the IGBT. 2.

  • Page 121: 15Input Filter Replacement, Small (Up To 10 Kva) Cabinet

    Maintenance Install 1. Install the new parts of the input filter (A). 2. Tighten the fasteners (B). Apply a torque of 3 Nm. 3. Connect the wires. 4. Tighten the fasteners (C). Apply a torque of 6 Nm. 5. Install the top panel. See § 11.3. 11.2.15 Input filter replacement, small (up to 10 kVA) cabinet Parts: see §...

  • Page 122: 16Input Filter Replacement, Small Cabinet (15 Kva) And Big Cabinet

    Maintenance Install 1. Install the new input filter plate (A). 2. Tighten the fasteners (B). 3. Install the wires. 4. Tighten the fasteners (C). Apply a torque of 6 Nm. 5. Install the side panels. See § 11.3. 11.2.16 Input filter replacement, small cabinet (15 kVA) and big cabinet Parts: see §...

  • Page 123: 17Interface Pcb (Pcb1702) Replacement (Option Cs)

    Maintenance Install 1. Install the new complete input filter (A). 2. Tighten the fasteners (B). 3. Install the wires. 4. Tighten the fasteners (C). Apply a torque of 6 Nm. 5. Install the side panels. See § 11.3. 11.2.17 Interface PCB (PCB1702) replacement (option CS) Parts: see §...

  • Page 124: Lightning Arrestors Replacement, Equipment With Sco Or Scb

    Maintenance 11.2.18 Lightning arrestors replacement, equipment with SCO or SCB Note The number of lightning arrestors can be different from the illustrations, depending on the output power. Parts: see § 13.8. Lightning arrestors Remove panel 1. Remove the side panels. See § 11.3. Remove 1.

  • Page 125: 19Line Filter Replacement

    Maintenance 11.2.19 Line filter replacement Parts: see § 13.8. Line filter Remove panel 1. Remove the side panels. See § 11.3. 2. Remove the lower rear panel. See § 11.3. Remove 1. Disconnect the wires (A). 2. Remove the fasteners (B). 3.

  • Page 126: 20Main Contactor Replacement, Small Cabinet

    Maintenance 11.2.20 Main contactor replacement, small cabinet WARNING Make sure that you switched OFF the power to the equipment. See § 9.3. Parts: see § 13.8. Main contactor Remove panel 1. Remove the lower front panel. See § 11.3. Disconnect 1.

  • Page 127: 21Main Contactor Replacement, Big Cabinet

    Maintenance 11.2.21 Main contactor replacement, big cabinet WARNING Make sure that you switched OFF the power to the equipment. See § 9.3. Parts: see § 13.8. Main contactor Remove panel 1. Remove the lower front panel. See § 11.3. Disconnect 1.

  • Page 128: 22Main Fuses Replacement

    Maintenance 11.2.22 Main fuses replacement Parts: see § 13.8. Fuses. See also § 13.5. Remove panel 1. Remove the lower front panel. See § 11.3. Replace 1. Open the fuse holder (A). 2. Replace the fuse (B). 3. Close the fuse holder. Install 1.

  • Page 129: 24Output Filter Replacement, Stackable Cabinet

    Maintenance Install 1. Install the new manual switch. 2. Connect all the wires. 3. Tighten the screws (A). Apply a torque of 4 Nm. 4. Install the lower front panel. See § 11.3. 11.2.24 Output filter replacement, stackable cabinet Parts: see § 13.8. Input filter Output filter Note...

  • Page 130: 25Output Filter Replacement, Small (Up To 10 Kva) Cabinet

    Maintenance Install 1. Install the new parts of the output filter (A). 2. Tighten the fasteners (B). Apply a torque of 3 Nm. 3. Connect the wires. 4. Tighten the fasteners (C). Apply a torque of 6 Nm. 5. Install the top panel. See § 11.3. 11.2.25 Output filter replacement, small (up to 10 kVA) cabinet Parts: see §...

  • Page 131: 26Output Filter Replacement, Small Cabinet 15 Kva And Big Cabinet

    Maintenance Install 1. Install the new output filter plate (A). 2. Tighten the fasteners (B). 3. Install the wires. 4. Tighten the fasteners (C). Apply a torque of 6 Nm. 5. Install the side panels. See § 11.3. 11.2.26 Output filter replacement, small cabinet 15 kVA and big cabinet Parts: see §...

  • Page 132: 27Output Measure Pcb (Eps442) Replacement

    Maintenance Install 1. Install the new complete output filter (A). 2. Tighten the fasteners (B). 3. Install the wires. 4. Tighten the fasteners (C). Apply a torque of 6 Nm. 5. Install the side panels. See § 11.3. 11.2.27 Output measure PCB (EPS442) replacement Parts: see §...

  • Page 133: 28Power Supply Pcb (Eps480) Replacement

    Maintenance 11.2.28 Power supply PCB (EPS480) replacement Parts: see § 13.8. Power supply PCB Remove panel 1. Remove the front panel. See § 11.3. Disconnect 1. Disconnect the connectors and the wires (A). 2. Remove the fasteners (B). 3. Remove the power supply PCB (C). Install 1.

  • Page 134: 30Series Cutout (Sco) Replacement (Option)

    Maintenance Install 1. Set the dip-switches of the new remote control PCB. See § 12.3. 2. Install the new remote control PCB. 3. Connect all the wires. CAUTION Depending on the configuration of the equipment, other wires need to be connected. These can be different from the illustration above.
  • Page 135 Maintenance Connect micro switch 1. Disconnect the cables to the micro switch (A). 2. Connect the cables to the micro switch (A) in the new SCO. Install 1. Install the new SCO. 2. Install the bolts (D). 3. Connect the earthing wire (C). Use the screw connection (C1).

  • Page 136: 31Series Connection Box (Scb) Replacement (Option)

    Maintenance 11.2.31 Series Connection Box (SCB) replacement (option) Parts: see § 13.8. Series Connection Box (SCB) Prepare 1. Switch OFF the power supply. See § 9.3. 2. Make sure that the circuit is earthed. Remove panel 1. Loosen the fasteners (A). 2.

  • Page 137: Remove Panels

    Maintenance 11.3 Remove panels The panels of the equipment can be removed for installation or maintenance procedures. WARNING 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. The panels can be heavy, especially the side panels.

  • Page 138: Remove The Display / Keyboard Panel Of The Small Cabinet

    Maintenance 11.3.2 Remove the display / keyboard panel of the small cabinet Disconnect HMI 1. Remove the front panel. See § 11.3.1. 2. Disconnect the wires (A) to the HMI from the CPU PCB (B). 3. Disconnect the earthing wire (C). Remove panel 1.

  • Page 139: Remove The Display / Keyboard Panel Of A Cabinet With A Cs (Option Cs)

    Maintenance Remove panel 1. Remove the screws (A). 2. Carefully remove the panel (B). CAUTION Do not damage cables and/or connectors. 11.3.4 Remove the display / keyboard panel of a cabinet with a CS (option CS) Open panel 1. Remove the screws (A). 2.

  • Page 140: Top Panel (Small Cabinet)

    Maintenance Remove panel 1. Remove the screws (A). 2. Remove the panel (B). 11.3.5 Top panel (small cabinet) Disconnect HMI 1. Remove the front panel. See § 11.3.1. 2. Disconnect the wires (A) to the HMI from the CPU PCB (B). 3.
  • Page 141 Maintenance Disconnect wires 1. Disconnect the green/yellow earthing wires. The wires have a fast-on connector. A.07.370e - Edition 2.1...

  • Page 142: Firmware Update

    Maintenance 11.4 Firmware update 11.4.1 Firmware update procedure Tools: PC with serial port connection Firmware update dongle: ‘Pin to Pin DB9P & DB9S cable’ Correct firmware upload file 1. Install the software to upload the firmware. See § 11.4.2. 2. Change the SD flash file paths, if necessary. See § 11.4.3. 3.

  • Page 143: Change The Sd Flash File Paths

    Maintenance 11.4.3 Change the SD Flash file paths Note Do this procedure if you extracted the zip file ‘sdflash.zip’ to a different location than D:\sdflash. 1. Go to Project>Settings. 2. In the indicated tabs, change the indicated fields to the correct file path. Field Target Driver...

  • Page 144: Start The Equipment After A Firmware Update

    Maintenance Upload the firmware 1. Go to Project>Settings>Programming tab>Flash Data File field. 2. Select the correct firmware version file from the files with a *.out extension. 3. Go to Device>Flash. If asked to save changes, click yes. 4. Make sure that the Erase, Program and Verify checkboxes are checked. 5.

  • Page 145: Pcb Drawings And Settings

    PCB drawings and settings 12 PCB drawings and settings 12.1 CPU PCB (EPS479) 12.1.1 Printed Circuit Board (PCB) LDX3 LDX2 LDX1 LDX4 12.1.2 LEDs Table: 12.1 CPU PCB LED functions Color Function LDX1 Red The LED is red when the voltage for the power supply is +5V DC (generated on the PCB). LDX2 Red The LED is red when the voltage is +5V DC.

  • Page 146: Power Supply Pcb (Eps480)

    PCB drawings and settings 12.2 Power supply PCB (EPS480) 12.2.1 Printed Circuit Board (PCB) LD11 LD10 LD12 12.2.2 LEDs Table: 12.2 Power supply PCB LED functions Color Function Green The LED is green when the voltage for the fans, if applicable is +24 V DC (generated on the PCB) The LED is red when the voltage of the power supply on the PCB is 12 V DC.

  • Page 147: Remote Control Pcb (Eps495)

    PCB drawings and settings 12.2.3 Fuses Table: 12.3 Power supply PCB Fuses 1.6 A 2.5 A 12.3 Remote control PCB (EPS495) 12.3.1 Printed Circuit Board (PCB) 12.3.2 LEDs Table: 12.4 Remote control PCB LED functions LED Color Function Green The LED is green when the voltage of the power supply on the PCB is 12 V DC. Green The LED is green when the voltage from the DCDC1, generated on the PCB, is + 5 V DC insulated.

  • Page 148: 3Jumper Settings

    PCB drawings and settings 12.3.3 Jumper settings Table: 12.5 Remote control PCB jumper settings Jumper Position Function insert enable TX serial channel 1 termination resistance insert enable RX serial channel 1 termination resistance insert enable TX serial channel 2 termination resistance insert enable RX serial channel 2 termination resistance position 1-3 and position 2-4...

  • Page 149: 4Multiwire / J-Bus Connection Scheme

    PCB drawings and settings Jumper Position Function position 2-3 serial channel 1: RS485 configuration position 1-2 serial channel 1: RS422 configuration (not used) position 2-3 serial channel 2: RS485 configuration position 1-2 serial channel 2: RS422 configuration (not used) position 2-3 serial channel 2: RS485 configuration position 1-2 serial channel 2: RS422 configuration (not used)
  • Page 150 PCB drawings and settings Table: 12.6 Factory set terminal assignments for remote control connections with multiwire and single J-Bus Function Terminal number on 32-pole Relay number on Remote Control connector PCB (unless indicated otherwise) Control signals (fixed) Step 1 J1.1 Step 2 J1.2 Step 3...
  • Page 151 PCB drawings and settings Function Terminal number on 32-pole Relay number on Remote Control connector PCB (unless indicated otherwise) J-Bus interface (fixed) RS485 BusA GND DB9.3 RS485 Data - DB9.2 RS485 Data + DB9.1 Configurable with HMI Table: 12.7 Factory set terminal assignments for remote control connections with multiwire dual J- Function Terminal number on 32-pole Relay number on Remote Control...
  • Page 152 PCB drawings and settings Function Terminal number on 32-pole Relay number on Remote Control connector PCB (unless indicated otherwise External signals (fixed) J-Bus interface (fixed) RS485 BusA GND DB9.3 RS485 Data - DB9.2 RS485 Data + DB9.1 RS485 BusB GND DB92.3 RS485 Data + DB92.1...
  • Page 153 PCB drawings and settings Multiwire and J-Bus connection A Equipment B Remote control equipment C Remote control PCB - input signals D Remote control connector on the equipment E Opto coupler F 48 V DC power supply G Isoground H +48 V DC Rel com J Remote control PCB - feedback signals K Relais...

  • Page 154: Igbt Pcb (Eps477 / Eps 496)

    PCB drawings and settings 12.4 IGBT PCB (EPS477 / EPS 496) 12.4.1 Printed Circuit Board (PCB) EPS477 for2s Semix LDX2 LDX4 LDX1 LDX3 LDX3 LDX1 LDX4 LDX2 12.4.2 LEDs EPS477 for 2s Semix Table: 12.8 IGBT PCB LED functions Color Function LDX1 Red The LED is red when the voltage for the high side IGBT, generated on the PCB, is +18 V...
  • Page 155 PCB drawings and settings 12.4.3 Printed Circuit Board (PCB) EPS496 for 3s Semix LDX5 LDX4 LDX3 LDX2 LDX1 A LDX1 - red B LDX2 - red C LDX3 - red D LDX4 - red E LDX4 - red 12.4.4 LEDs EPS477 for 1s and 2s Semix Table: 12.9 IGBT PCB LED functions Function LDX1...

  • Page 156: Output Measure Pcb (Eps442)

    PCB drawings and settings 12.5 Output measure PCB (EPS442) 12.5.1 Printed Circuit Board (PCB) 12.5.2 LEDs Table: 12.103 Phase bridge PCB LED RUN light functions Color Function The LED flashes red is the CPU on the PCB is active. A.07.370e - Edition 2.1...

  • Page 157: Diode Bridge And Sensing Pcb (Eps476 / Eps 507)

    PCB drawings and settings 12.6 Diode bridge and sensing PCB (EPS476 / EPS 507) 12.6.1 Printed Circuit Board (PCB) LDX2 LDX3 LDX1 LDX4 12.6.2 LEDs Table: 12.11Diode bridge and sensing PCB LED functions Color Function LDX1 Red The LED is red when the nominal voltage for the IGBT test is 24 V DC. LDX2 Red The LED is red when the voltage from the power supply PCB is +5 V DC.

  • Page 158: Interface Pcb (Pcb1702) (Option Cs)

    PCB drawings and settings 12.7 Interface PCB (PCB1702) (option CS) 12.7.1 Printed Circuit Board (PCB) RJ45 12.7.2 Jumper J2 Installed: more than one series circuit Not installed: only one series circuit 12.7.3 Connectors Table: 12.12CS connectors Connector Connection to Connection Description point Flat cable connection to EPS495 (remote control PCB)
  • Page 159 PCB drawings and settings Connector Connection to Connection Description point Remote control multiwire CS1RC Remote control input circuit 1 connection CS2RC Remote control input circuit 2 CS3RC Remote control input circuit 3 CS5RC Remote control input circuit 4 CS5RC Remote control input circuit 5 CS6RC Remote control input circuit 6 CS7RC...
  • Page 160 PCB drawings and settings Connector Connection to Connection Description point Remote control multiwire CS1FB Feedback circuit 1 connection CS2FB Feedback circuit 2 CS3FB Feedback circuit 3 CS4FB Feedback circuit 4 CS5FB Feedback circuit 5 CS6FB Feedback circuit 6 CS7FB Feedback circuit 7 CS8FB Feedback circuit 8 CSE-FLT...
  • Page 161 PCB drawings and settings Connector Connection to Connection Description point Remote control multiwire B1FB Feedback equipment, configurable spare connection J5.1 B2FB Feedback equipment, configurable spare J5.2 B3FB Feedback equipment, configurable spare J5.3 B4FB Feedback equipment, configurable spare J5.4 B5FB Feedback equipment, configurable spare J5.5 ON_FB Feedback equipment ON...
  • Page 162 PCB drawings and settings Table: 12.14LEDs that indicate the interface functionality Function LED ‘CRE_ON_IN’.The LED is ON if the equipment is operational and supplies power to the output circuit. LED J5.7 IN. The LED is ON if the equipment is in remote mode. LED J7.1 IN.

  • Page 163: Cs Pcb (Pcb1619) (Option Cs)

    PCB drawings and settings 12.8 CS PCB (PCB1619) (option CS) 12.8.1 Printed Circuit Board (PCB) 12.8.2 Connectors Table: 12.15CS connectors Connector Connection to Flat cable to piggy with 24VDC power supply, earthing and CAN-bus Connection for the current sensor. Not used. Not used.
  • Page 164 PCB drawings and settings 12.8.4 Dip switch Table: 12.16Dip switch SW1 Dip switch Function setting Circuit 1 (Address 0) Circuit 2 (Address 1) Circuit 3 (Address 2) Circuit 4 (Address 3) Circuit 5 (Address 4) Circuit 6 (Address 5) Circuit 7 (Address 6) Circuit 8 (Address 7) A.07.370e - Edition 2.1...

  • Page 165: Hmi Sin Pcb (Pcb1703) (Option Cs)

    PCB drawings and settings 12.9 HMI SIN PCB (PCB1703) (option CS) 12.9.1 Printed Circuit Board (PCB) SCN7 D2 D1 12.9.2 Connectors Connector Connection to CSN 7 KEY_LED1 flat cable connection to the interface PCB (1702). 12.9.3 LEDs LED Colour LED status Description Green The CS is in remote mode.
  • Page 166 PCB drawings and settings LED Colour LED status Description Green Circuit 1 is selected and the equipment supplies output current. Flashing: 0.5 s ON, 2.5 s The equipment is OFF or in stand-by. Flashing (interval 1 s) The CS PCB is faulty. Green Circuit 1 is selected and the equipment supplies output current.

  • Page 167: Test Parameters

    PCB drawings and settings 12.10Test parameters 12.10.1Analog channels Table: 12.17Analog channels Channel Description Value range Temperature 17000 - 32000 Temperature 27000 - 32000 I bridge 100 - 2000 V bridge 0 - 30000 V in ± 31000 Aux 1 x = 0 Aux 2 x = 0 Ref1...
  • Page 168 PCB drawings and settings 12.10.3Outputs Table: 12.19Test output parameters Connector Function 0 = Main control switch enabled 0 = Precharge control switch enabled 0 = Gate H activation 1 = Fan enabled Display font 1 = Display back lighting ON 1 = Red fault LED ON 1 = Green power LED ON 12.10.4External inputs...

  • Page 169: Technical Data

    Technical data 13 Technical data 13.1 Specifications Table: 13.1 Technical specifications Item Description Rated input voltage [V] 400 V AC (± 10%) single phase 230 V AC (± 10%) single phase Rated frequencies [Hz] 50 or 60 Current regulation limits Current regulation is guaranteed under the following conditions (±...

  • Page 170: Applicable Standards

    Technical data Type Rated output RMS output voltage Insulated test on Output overvoltage power [kW] at 6.6 A RMS output output [kV] protection 25kApk current [kV] CRE 10 10.0 1.50 2.2 kV , 4.2 kJ CRE 15 15 2.30 3.0 kV , 5.6 kJ CRE 20 20 3.03...

  • Page 171: Dimensions And Mass

    Technical data 13.4 Dimensions and mass The stackable cabinet (A), the small cabinet (B) and the big cabinet (C): Table: 13.4 Dimensions Item A - 2.5 kVA B - 2.5 kVA B - 4 to 15 kVA C - 20 to 30 kVA (stackable) X [mm] Y [mm]...

  • Page 172: Protection Devices

    Technical data Table: 13.5 Mass Type Net mass Crate mass Crate dimensions width x depth x height [mm] 2.5 (rack) 600 x 1000 x 650 1200 x 800 x 1500 1200 x 800 x 1500 1200 x 800 x 1500 1200 x 800 x 1500 1200 x 800 x 1500 1200 x 800 x 1500...

  • Page 173: Used Brightness Steps

    Technical data 13.6 Used brightness steps All equipments are programmed with five steps by default. You can change the number of required steps. Table shows the current values that the equipment produces at each step, depending on how many 13.7 steps are programmed.

  • Page 174: Ambient Conditions

    If you use other spare parts, the specific module or the equipment may be damaged. This can also put the personnel in danger. Note The parts list may be subject to change without prior notice. Contact ADB Safegate to obtain the latest version. Part orders Each part of the equipment has a part number.

  • Page 175: 2Preventive Spare Parts

    Technical data 13.8.2 Preventive spare parts Item Table Main fuse 13.9 Preventive spare parts - Main fuse Main contactor 13.10 Preventive spare parts - Main contactor Lightning arrestors 13.11 Preventive spare parts - Lightning arrestors Overvoltage protection 13.12 Preventive spare parts - Overvoltage protection Capacitors 13.13 Preventive spare parts - Capacitors Safety switches...
  • Page 176 Technical data Table: 13.10 Preventive spare parts - Main contactor Description Part number Quantity per order 400 V 230 V Contactor LC1D12B7 6148.46.030 Contactor LC1D32B7 6148.46.000 Contactor LC1D40B7 6148.46.010 Contactor LC1D80B7 6148.46.020 Table: 13.11 Preventive spare parts - Lightning arrestors Description Part number Quantity per order...
  • Page 177 Technical data Table: 13.14 Preventive spare parts - Safety switches Description Part number Quantity per order 400 V 230 V Doorswitch EPS: 684 6150.49.060 Table: 13.15 Preventive spare parts - Fans Description Part number Quantity per order 400 V 230 V CCR FAN 120x120x38 7074.10.100 24vdc ball bearing...
  • Page 178 Technical data Table: 13.17Preventive spare parts - IGBT bridge Description Part number Quantity per order 400 V 230 V Semix 202 GB 12E4s 6351.88.040 (IGBT) Semix 453 GB 12E4s 6351.88.060 (IGBT) ISOLAT.M6 0.6kV 6126.12.485 Semix 341D16s (Bridge 6351.88.030 Rectifier) Table: 13.18 Preventive spare parts - Output measure PCB Description Part number Quantity per order...
  • Page 179 Technical data Table: 13.19 Preventive spare parts - Power supply PCB Description Part number Quantity per order 400 V 230 V EPS480/30 CRE 1597.00.210 pow.sup.board PCB CS00180 rev.1.2(6 fans, with SHVS) Table: 13.20 Preventive spare parts - Remote control PCB Description Part number Quantity per order...
  • Page 180 Technical data Table: 13.21 Preventive spare parts - Diode bridge PCB and diode bridge PCB with OVP Description Part number Quantity per order 400 V 230 V EPS476/5 CRE2.5/ 1597.00.401 7.5KVA PCB CS00176 rev.2.0 (diode bridge & sensing) EPS476e/5 CRE2.5/ 1597.00.402 7.5KVA PCB CS00176 rev.2.0 (diode bridge &...
  • Page 181 Technical data Table: 13.22 Preventive spare parts- IGBT PCB Description Part number Quantity per order 400 V 230 V EPS477 CRE/VIS 2.5/ 1597.00.510 15KVA PCB CS00177 rev.1.1 (IGBT driver) EPS496 CRE/VIS 20/ 1597.00.530 30KVA PCB CS00191 rev. 1.0 (IGBT driver) EPS478 CRE/VIS 2.5/ 1597.00.520 15KVA PCB CS00178...

  • Page 182: 3Corrective Spare Parts

    Technical data 13.8.3 Corrective spare parts Item Table Manual swiitch 13.25 Corrective spare parts - Manual switch Main fuse housing 13.26 Corrective spare parts - Main fuse housing Line filter 13.27 Corrective spare parts - Line filter Input filter 13.28 Corrective spare parts - Input filter Output filter 13.29 Corrective spare parts - Output filter Main transformer...
  • Page 183 Technical data Table: 13.27 Corrective spare parts - Line filter Description Part number Quantity per order 400 V 230 V Line filter 284.003(1Ph 6115.18.090 10A/400V) MK1015 (1Ph 230V) 6115.18.120 Line filter 284.001(1Ph 6115.18.050 20A/400V) Line filter 284.002(2Ph 6115.18.060 40A/400V) EMK1065 (1Ph 230V) 6115.18.130 Line filter 284.004(2Ph 6115.18.070...
  • Page 184 Technical data Table: 13.29 Corrective spare parts - Output filter Description Part number Quantity per order 400 V 230 V Toroidal inductor 750uH/ 6166.50.350 Inductance 285uH/40A 6166.50.310 CAP. PMC1704500KVR 6322.60.220 5uF/700V step 20-25+ Induct 150uH 100A - 20- 6166.50.360 25-30 kVA Induct 300uH 50A - 6166.50.370 15 kVA...
  • Page 185 Technical data Table: 13.31 Corrective spare parts - Hall sensor Description Part number Quantity per order 400 V 230 V Hall sensor old version 1597.00.500 Hall sensor new version 1593.21.000 PCB1628 CRE current sensor 200A Shape: square. Location: connected to the sensing PCB. Shape and location: see §...
  • Page 186 adbsafegate.com...

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