Page 1 CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Air-Cooled, 4-30 kW/6.6 A, A Air-Cooled, 4-30 kW/6.6 A, ACE3 User Manual User Manual 96A0505 96A0505, Re , Rev v . . G G , , 2024/12/10 2024/12/10...
Page 3: Disclaimer / Standard Warranty
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
2.16.2 Optional Scanning Monitor Interface..........................16 2.16.3 Optional Scanning Monitor Ready............................ 17 2.17 Optional Airfield Lighting Series Cutout (SCO) ......................... 17 2.18 L-828 CCRs (4-30 kW 6.6 A): Required Equipment ........................17 2.19 Input Wire Size....................................17 2.20 Input Power Breaker Sizing................................. 18 2.21 Specifications....................................
Page 6 9.1 L-828/L-829 CCR (4-30 kW) Parts Ordering Codes........................91 9.1.1 CCT XX XX / X X X X CCR Kits..............................93 9.1.2 L-828/L-829 CCR General Assembly (4-30 kW/208-480 Vac) Parts List................93 9.1.3 Assembly Parts: CCT 4-30kW Regulators ........................... 94 10.0 SUPPORT ................................
Page 7 10.2 Recycling......................................97 10.2.1 Local Authority Recycling ..............................98 10.2.2 ADB SAFEGATE Recycling ..............................98 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 8 CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Disclaimer / Standard Warranty List of Figures Figure 1: L-828 CCR Power Circuit Block Diagram ..........................13 Figure 2: Current Meter Display ................................14 Figure 3: L-829 CCR with ACE..................................15 Figure 4: URC4 CCR Controller .................................. 15 Figure 5: ACE3 Control Board ..................................
Page 9 Figure 62: 43A4822 CCT Schematic L1 Chokes............................88 Figure 63: 43A4822 CCT Schematic L1 Chokes............................89 Figure 64: L-828/L-829 CCT Part Ordering Code ............................. 92 Figure 65: AS00002 15-30kW Component Plate ............................. 94 Figure 66: AS00001 Component Plate 4, 7.5 and 10 kW CCT ....................... 95 Figure 67: ACE 3 Assembly 44A7733 ................................
Page 10 Table 33: General Troubleshooting ................................69 Table 34: URC4 Dip Switch Chart ................................76 Table 35: L-828/L-829 CCR (4-30 kW/6.6 A) Part Numbers ........................91 Table 36: 4 kW CCT 380V Component Plate Spare Parts ........................95 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 11: 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 12: Introduction To Safety
CCT (Thyristor Controlled) L-828/L-829 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. • Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment.
Page 13: Material Handling Precautions: Storage
• Never touch exposed electrical connections on equipment while the power is ON. Failure to follow these instructions can result in equipment damage 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 14: Maintenance Safety
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Safety 1.1.6 Maintenance Safety DANGER ELECTRIC SHOCK HAZARD THIS EQUIPMENT MAY CONTAIN ELECTROSTATIC DEVICES • DO NOT OPERATE A SYSTEM THAT CONTAINS MALFUNCTIONING COMPONENTS. IF A COMPONENT MALFUNCTIONS, TURN THE SYSTEM OFF IMMEDIATELY.
Page 15: 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 17: Introduction
2.2 CCT Introduction WARNING Read the instructions in their entirety before starting installation. This section describes the ADB Safegate Thyristor Controlled, L-828/L-829, constant current regulators (CCRs). These CCRs are manufactured according FAA specification AC 150/5345-10 (latest edition). 96A0505, Rev. G, 2024/12/10...
Page 18: Constant Current Regulator
VA (drop in load VA of 10%), Remote/Local status, and incorrect output current. ▪ To minimize the floor space required in a vault, ADB Safegate 4-30 kW regulators can be stacked using a stacking kit. See Kits section for details.
Page 19 ▪ 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 20 94A0343 Provides a dedicated contact closure if CCR output current is present. Time Meter Kit 94A0263/1GH Provides CCR run-time information on L-828 CCRs. This feature is included with Monitoring Option 6. CCR Output Analog Voltmeter Kit Part No. 7.5 kW...
Page 21 CCR. The frame sizes are L, M, and S. There are six allowable combinations: LL, LM, LS, MM, MS, and SS. When stacking ADB Safegate regulators, the upper regulator must be the same frame size or smaller than the bottom regulator. See data sheet 2096 for more details.
Page 22: Total Harmonic Distortion1 (Thd)
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Introduction Electrical Supply Power Input 60 Hz, single-phase available in 208, 220, 240, 347, 380 and 480 VAC 50 Hz, single-phase available in 208, 220, 230, 240, 380 and 400 VAC Power Factor 0.90 minimum for 4 kW to 10 kW...
Page 23: Urc Pcb Inputs/Outputs
▪ Local control signals from the front panel rotary switch. ▪ Remote control signals from a remote control terminal block located in the L-828 chassis (120Vac/48Vdc) (TB1). ▪ A current proportional to the output current from a current transformer (T5).
Page 24: Remote Control Position Detection
OFF position (remotely or locally) or cycling the input power off for a minimum of 2 seconds and then back on. 2.13 L-828 CCR Figure 53. This subsection describes the L-828 CCR. The L-828 uses a CCR Control PCB to provide regulator and control functions. Note Figure 53 shows the display of a 15 kW 6.6 A L-828 Thyristor Controlled CCR.
Page 25: 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 Contr URC4 CCR Controller oller 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 26: Advanced Control Equipment
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Introduction 2.15.1 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 27: Optional Scanning Monitor Ready
6.6 amps AC. Note For more information refer to the SCO Manual 96A0294. See www.adbsafegate.com 2.18 L-828 CCRs (4-30 kW 6.6 A): Required Equipment Refer to Table 1 for required equipment that is supplied. Refer to Table 2 for required equipment that is not supplied.
Page 28: Input Power Breaker Sizing
164 A 114 A 104 A 98 A 82 A 2.21 Specifications This subsection provides specifications for L-828/L-829 CCR (4-70 kW 6.6 A/20 A). Table 5: Class, Style and Power Ratings Class L-828/L-829 CCR Max Output Current Style Brightness Steps...
Page 29: Efficiency
Operating Conditions. 2.21.5 Environmental Operating Conditions The L-828 CCRs are designed for indoor use only in an area with adequate ventilation for cooling the constant current regulator. The environmental operating conditions include temperature range, relative humidity, and altitude. Table 9: Environmental Operating Conditions...
Page 30: Protection Devices
2.21.8.1 Built-In True-rms-Reading Ammeter, L-828 only For the L-828 only, a flush-mounted true-rms-reading ammeter mounted on the front of the input module PCB indicates the output current. The meter accuracy is ±3.0 percent of the maximum output current.
Page 31: Cct Installation, L-828 / L-829
3.0 CCT Installation, L-828 / L-829 This section provides instructions for installing L-828/L-829 constant current regulators (CCRs) (4-30kW/6.6 A). Refer to the airport project plans and specifications for the specific installation instructions. 3.1 Intended Use CAUTION Use this equipment as intended by the manufacturer...
Page 32: Wiring Connections And Startup
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator CCT Installation, L-828 / L-829 WARNING Read installation instructions in their entirety before starting installation. If lift points (eye bolts) are used, lift straight up. Side loading on the eye bolts may cause them to bend.
Page 33: Table 11: Remote Control Connections (3-Step/6.6 A)
“Schematics” section for remote control connections. Note If the ADB Safegate Advanced Control Equipment (ACE) is used with the Ferroresonant L-828 CCR, refer to the Advanced Control Equipment manual (ACE) manual for wiring connections to remote control. Table 38 Table 3 provide the necessary connections for remote control.
Page 34: Stacking Ccr's (Optional)
3.5 Stacking CCR’s (Optional) CAUTION Read installation instructions in their entirety before starting installation. Before stacking CCRs larger than 10 kW or stacking more than 2 CCRs, contact the ADB Safegate Sales Department. ▪ To stack CCRs, perform the following procedure: 1.
Page 36: Figure 7: Anchor Bolt Template
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator CCT Installation, L-828 / L-829 Use the four ½ x 3.75 Lg HILTI anchor bolts with 4 nuts and lock washers to anchor the CCR to the concrete floor. Note Make sure the clearance behind the CCR is far enough from the wall for easy access to the regulator.
Page 37: Figure 8: Location Of Bolts For Stacking Ccrs
3. Remove the 4 eye bolts from the anchored CCR. 4. Stack the second CCR by positioning its 4 holes carefully on top of the holes of the CCR anchored to the concrete floor. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 38: Figure 9: Stacking Bolt
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator CCT Installation, L-828 / L-829 5. Install the 4 hex head bolts and split lock washers (See Figure 55, Item 1). Figure 9: Stacking Bolt Stacking Bolt ◦ 1. Stacking Bolt ◦ 2. Bottom CCR Anchored to Concrete ◦...
Page 39: Operation
4.0 Operation This section provides the operational procedures listed below for the L-828/L-829 constant current regulator (CCR) (4-30 kW). ▪ CCR control procedures ▪ CCR shutdown procedures ▪ CCR adjustment procedures ▪ SCO cutout working positions 4.1 Operation Safety CAUTION...
Page 40: Remote Control
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Operation Figure 10: L-828/L-829 Switches L-828/L-829 Switches B100 LOCAL CONTROL LOCAL CONTROL 3-Step 5-step Switch Switch Table 15: Output Current from Rotary Switch (3-Step/6.6 A) If you set the rotary The result is...
Page 41: Ccr Shutdown Procedure
See Figure 24. 2. If the optional current clamp test point is present the clamp-on instrument on the CCR component plate should be utilized. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 42: Figure 11: Output Current Clamp
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Operation Figure 11: Output Curr Output Current Clamp ent Clamp TRUE RMS MULTIMETER FLUKE 87 Auto-Range Button OUTPUT MIN MAX RANGE HOLD H Select mA ))))) PEAK MIN MAX Ω Ω mA uA...
Page 43: 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. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 44: Adjusting Overcurrent Control Board (44A6546)
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Operation 9. Repeat Step 2 for the remaining lower brightness step(s). When the output current adjustment has been completed, turn off the CCR. 4.3.2 Adjusting Overcurrent Control Board (44A6546) ADJUSTING THE CCR OVER CURRENT DETECTION LEVEL Before adjusting the Over Current Detection level, set up the regulator and adjust the output current per the ADJUSTING THE CCR OUTPUT CURRENTsection of this section.
Page 45: Reducing Ccr Power Consumption
1 and 4 1 and 5 1 and 6 Figure 13: CCR T CCR Tr r ansformer T ansformer Taps 4.4 SCO Operation This subsection provides the SCO cutout working positions. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 46 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 47: Table 18: Cutout Working Positions
CCR to be ON be ON (operation in short circuit) switch is The cover can be locked by the key can be locked by the key can be locked by the key 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 49: 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. HMI Screen Map 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 50: Figure 14: Output Current Gauge
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Graphic User Interface (GUI) Main Display The main screen is the first usable screen (not the splash screen) the user sees after starting the ACE3 (except when in L828 Display mode). The page is laid out with a header at the top and the body below it. The body contains a large display which shows the primary item being monitored.
Page 51: Figure 15: Output View And Diagram View
The board components, LED, and channel indicator on the card will turn red for outputs and green for inputs when activated. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 52: Menu Screen
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Graphic User Interface (GUI) Figure 18: Regulat Regulator Inter or Interface Car face Card View (4x4 Car d View (4x4 Card) d) This view is shown when only the 4x4 Regulator Interface Card is installed in a URC4 integrated CCR. The user will have to be in control before they can change the output.
Page 53: Alarms View
The Alarm View shows the user the current alarms and warnings. Alarms/warnings that are cleared will not be shown on this screen. The list of alarms/warnings will be sorted by date/time. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 54: Events View
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Graphic User Interface (GUI) 5.1.2 Events View Figure 20: Alarms and W Alarms and Warnings Scr arnings Screen (E een (Ev v ents View) ents View) On the Alarms and Warning screen the event view shows a history of alarms (red), warnings (yellow), and events (grey).
Page 55: Status Menu - Waveform
The Temperature view displays ambient temperature in both Celsius and Fahrenheit values. It also shows the min and max ambient temperature since the device was started. This information is not persisted through power cycles. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 56: Ccr Menu - Configuration
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Graphic User Interface (GUI) Figure 24: Status Menu – Miscellaneous Status Menu – Miscellaneous The IRMS History view allows the user to query IRMS data from the past and display it in a graph form so the user can notice trends.
Page 57: Screen 2
The Timings view allows the user to change various delays and timeouts. These timings are for operations such as changing the step or alarm conditions such as how long to stay in a 5% over current condition before generating the Over Current Alarm. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 58: Screen 3
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Graphic User Interface (GUI) Figure 27: CCR Configur CCR Configuration Scr ation Screen 2 een 2 The following table describes the configurable parameters on view 2: Step Delay milliseconds Amount of time to pause between steps when changing CCR step...
Page 59: Screen 4
▪ Input Polarity - (only in advanced mode) Active high or low (default high) None of the changes will take effect until the "Set" button has been pressed. Figure 31: CSS Loops CSS Loops 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 60: Ccr Menu - Measurement Calibration
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Graphic User Interface (GUI) 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" is set to true then the slot, channel, polarity can be edited.
Page 61: Ccr Menu - Va 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. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 62 CCT (Thyristor Controlled) L-828/L-829 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 63: 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. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 64: Ccr Menu - Lamps Out Calibration
CCT (Thyristor Controlled) L-828/L-829 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 65 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*. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 66 CCT (Thyristor Controlled) L-828/L-829 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 67: 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. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 68: Figure 35: Ace Info Config Screen (Network Config)
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Graphic User Interface (GUI) The network configuration views allow the user to configure both the LAN interfaces as well as the wireless interface. 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"...
Page 69: Ace Menu - Failsafe
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. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 70: Ace Menu - About
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Graphic User Interface (GUI) 5.1.14 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 71: Figure 38: About Screen Menu
There is no limit on the length of the text since this view's contents are scrollable. Figure 39: About Scr About Screen Disclaimer een Disclaimer 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 73: Maintenance And Repair
6.0 Maintenance and Repair This section provides preventive maintenance for Thyristor Controlled L-828/L-829 constant current regulators (CCRs) (4-30 kW). 6.1 Maintenance Safety DANGER ELECTRIC SHOCK HAZARD THIS EQUIPMENT MAY CONTAIN ELECTROSTATIC DEVICES • DO NOT OPERATE A SYSTEM THAT CONTAINS MALFUNCTIONING COMPONENTS. IF A COMPONENT MALFUNCTIONS, TURN THE SYSTEM OFF IMMEDIATELY.
Page 74: Short-Circuit Test
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Maintenance and Repair 6.2.1 Short-Circuit Test WARNING 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 short-circuit test.
Page 75: Troubleshooting
7.3.1 L-828/L-829 Input Power Fuses F1 and F2. Amp rating as a function of input voltage and CCR kW rating for input power fuses F1 and F2 on the L-828 and L-829 CCRs. Input Power Fuses, F1 and F2, per CCR Input Voltage and CCR kW Rating 96A0505, Rev.
Page 76: Table 20: Cct/Xxxx Input Fuses (F1, F2)
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Troubleshooting Table 20: CCT/XXXX INPUT FUSES (F1, F2) SIZE 208 Volts 220 Volts 240 Volts 347 Volts 380/400 Volts 480 Volts 47A0092 47A0069 47A0069 47A0191 47A0191 47A0090 7.5kW 47A0093 47A0093 47A0070 47A0193 47A0085...
Page 77: Table 22: Cct/Xxxx Ace Fuses F5, F6
7.5kW 53A0412/50 53A0412/40 53A0412/40 53A0412/40 53A0412/40 10kW 53A0412/60 53A0412/50 53A0412/40 53A0412/40 53A0412/60 15kW 53A0412/90 53A0412/75 53A0412/50 53A0412/40 53A0412/75 20kW 53A0412/120 53A0412/90 53A0412/75 53A0412/50 53A0412/150 30kW 53A0331 53A0412/150 53A0412/150 53A0412/75 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 78: Table 25: Cct/Xxxx Dual Scr Block (Scr)
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Troubleshooting 53A0331 Contactor 3P 200A 170A 120VAC Coil 53A0412/25 Contactor 2P 25 FLA 53A0412/40 Contactor 2P 40 FLA 53A0412/50 Contactor 2P 50 FLA 53A0412/60 Contactor 2P 60 FLA 53A0412/75 Contactor 2P 75 FLA...
Page 79: General Troubleshooting
Note Refer to ACE Manuals for Optional L-829 Monitoring and Control. 7.3.2 L-828 General Troubleshooting This subsection provides general troubleshooting procedures for the L-828 CCR. WARNING Read the instructions in their entirety before starting installation. Only personnel authorized to work on high-voltage equipment should perform maintenance on the regulator.
Page 80 CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Troubleshooting Table 33: General Troubleshooting Problem Possible Cause Corrective Action Check SCRs and wiring. Replace SCR. Refer to “Output Current Adjustment” CCR controller not calibrated 3. Output Current Check remaining steps to verify the values from Table always 6.6 A...
Page 81: Additional L-829 General Troubleshooting Procedures
1. Power off the two ACE3 units. 2. On the back side of the ACE3 main board to be replaced, remove the microSD card and transfer it to the new ACE3 unit. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 82: Figure 40: Backside Of Ace3 Control Board
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Troubleshooting Figure 40: Backside of A Backside of ACE3 Contr CE3 Control Boar ol Board d Transferring settings via USB 1. On the ACE3 unit to be replaced, insert a USB thumb drive into either USB port.
Page 83: Figure 42: Ace3 About
5. On that ACE3’s user interface, navigate to the “About” page. Navigate to the second screen. Figure 42: A A CE3 About P CE3 About Page 2 age 2 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 85: Figure 43: Ace3 Configuration
Set “Control Type” to “Integrated.” Take note of the DIP switch positions on the URC4 board. Figure 44: URC4 URC4 Figure 45: URC4 Dip Switches URC4 Dip Switches 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 86: Table 34: Urc4 Dip Switch Chart
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Troubleshooting Ensure that the following settings coincide between the physical regulator, the URC4 board DIP switches, and the ACE3 configuration: Table 34: URC4 Dip Switch Chart Physical CCR Configuration: Set this ACE3 setting:...
Page 87: Removing And Replacing Urc4 Regulator Control Pcb
8. Ensure that the DIP switches of the new board match exactly to those of the board being replaced. 9. Mount the new PCB by replacing the 4 screws and the standoffs at the corners of the PCB. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 88: Removing And Replacing Dual Scr Module Assembly
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Troubleshooting 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 89: Ccr Contactor Replacement
8. Remove wires 400 and 401 from the top connectors of the contactor. 9. Remove the wires 531 and 501 from the contactor coil connections at the bottom of the contactor. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 90: Figure 48: Mounting Adapter 63A1153
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Troubleshooting 10. Remove the mounting screws until the contactor is free. k. Remove the mounting adapter (ADBSG# 63A1153) if used. Only used for contactor, part number 53A0412/ Figure 48: Mounting Adapter 63A1153 Mounting Adapter 63A1153 Replace the contactor.
Page 91: Removing And Replacing Input Lightning Arrestors (Front Of Component Mounting Plate)
1. Turn CCR local switch to the OFF position. 2. Remove and lock out/tag out primary power to the CCR at the breaker panel. 3. Lock out/tag out the SCO in the maintenance position. 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 92: Figure 50: 94A0576 Type Output Lightning Arrestors
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Troubleshooting 4. Remove the side panel of the CCR, by removing the 8 mounting screws. Be careful as you will also need to disconnect the ground wire attached from the frame to the panel.
Page 94: Figure 53: 43A4822 Cct Schematic T4 Connections
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Schematics Figure 53: 43A4822 CC 43A4822 CCT Schematic T4 Connections T Schematic T4 Connections T4 INPUT CONNECTIONS DETAIL "G" "T4" CONTROL TX: "T4" CONTROL TX: "T4" CONTROL TX: 208/220/240V, 50/60HZ INPUT 347/380V, 60HZ INPUT...
Page 95: Figure 54: 43A4822 Cct Schematic T1 Voltages
208-480V (NO GND WIRE) 208-480V (NO GND WIRE) K1 G1 20 & 30KW, SCR 28A0041, (ALSO 28A0028), 15KW, SCR 28A0034, 208-480V (NO GND WIRE) 208-480V (NO GND WIRE) G2 K2 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 96: Figure 56: 43A4822 Cct Schematic L1 Chokes
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Schematics Figure 56: 43A4822 CC 43A4822 CCT Schematic L1 Chok T Schematic L1 Chokes es "L1" CHOKES 400V-50HZ; 400V-50HZ; 15KW 4, 10 & 20KW 480V, 60HZ CHOKE CHOKE CHOKE Figure 57: 43A4822 CC...
Page 97: Figure 59: 43A4822 Cct Schematic Power Transformer (Stand Alone)
Tr r ansformer Windings (30kW only) ansformer Windings (30kW only) DETAIL "D" PWR TX WINDINGS (30KW ONLY) 240V, 60HZ 1-0% 2-30% 3-60% 4-80% 5-90% POWER TX 6-100% 44A7693 PCB 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 98: Figure 61: 43A4822 Cct Schematic Sco Option
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator Schematics Figure 61: 43A4822 CC 43A4822 CCT Schematic SCO option T Schematic SCO option SERIES CUT OUT (SCO) OPTION DETAIL "E" OUTPUT LEADS (INDICATED BY HEAVY BLACK LINE), TO BE COVERED BY 1/2" SPLIT,...
Page 99: Figure 63: 43A4822 Cct Schematic L1 Chokes
(44A7694) J38- J40- BLUE GRAY BLUE GRAY COM A COM B 44A6397 IRMS (COLORS IF BELDEN 9842 IS USED) REF. ONLY 44A7693 PCB POWER FROM 44A6139 WIRE HARNESS REGULATOR 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 101: Cct Parts
9.0 CCT Parts To order parts, call ADB Safegate Customer Service or your local representative. Use this parts list, and the accompanying illustration, to describe and locate parts correctly. 9.1 L-828/L-829 CCR (4-30 kW) Parts Ordering Codes Table 1 for the CCT L-828 and L-829 CCR (4-30 kW) part numbers.
Page 102: Figure 64: L-828/L-829 Cct Part Ordering Code
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator CCT Parts Figure 64: L-828/L-829 CC L-828/L-829 CCT P T Par art Or t Ordering Code dering Code Ordering Code and Kit Notes A ferroresonant CCR is preferred for airports that require low output harmonic content (EMI) or that have varying loads, such as Runway Guard Lights using incandescent (tungsten-halogen) lamps, L-849 REILs using xenon flash lamps, or Runway Status Lights (RWSL).
Page 103: Cct Xx Xx / X X X X Ccr Kits
Current Sensing Relay Kit 94A0343 Provides a dedicated contact closure if CCR output current is present. Time Meter Kit Provides CCR run-time information on L-828 CCRs. This feature is included with Monitoring Option 6 (L828). Auxiliary ACE Monitoring 94A0512 Provides CCR Run Time, which displays total hours in each CCR step setting, and CCR Cycle Count, which displays the total number of times the CCR has been turned on/off.
Page 104: Assembly Parts: Cct 4-30Kw Regulators
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator CCT Parts 9.1.3 Assembly Parts: CCT 4-30kW Regulators Figure 65: AS00002 15-30kW Component Plate AS00002 15-30kW Component Plate F1-F2 FUSE TABLE 15kw 20kw 30kw 47A0099 47A0072 47A0102 47A0096 47A0072 47A0101 DUAL SCR ASSEM.
Page 105: Figure 66: As00001 Component Plate 4, 7.5 And 10 Kw Cct
28A0045 SCR ASSY 1.2KV SCR/1.6KV 35A0539 Transformer T4, CONTROL POWER FOR 4KW-10KW CCRS 35A0548 CURRENT SENS Transformer 6.6A-66MA W/LEADS 44A7693 PCB Assembly, URC4 Control PCB 47A0191 FUSE 20A 600V 96A0505, Rev. G, 2024/12/10 Copyright ®2018—2024 ADB Safegate, All Rights Reserved...
Page 106: Figure 67: Ace 3 Assembly 44A7733
CCT (Thyristor Controlled) L-828/L-829 Constant Current Regulator CCT Parts Table 36: 4 kW CCT 380V Component Plate Spare Parts Part Number Part Description 47A0108 FUSE 1A 500V 49A0081 FUSE BLOCK 1/10-30A 600V 53A0412/25 CONT 2P 25 FLA 120VAC COIL 94A0576/07 OUTPUT VAR.
Page 107: Support
Live Technical Support – Americas If at any time you have a question or concern about your product, contact ADB SAFEGATE’s US-based technical support specialists, available 24 hours a day, seven days a week, to assist you via phone.
Page 108: Local Authority Recycling
10.2.1 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.

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