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Manuals and User Guides for ADB Safegate L-828. We have
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ADB Safegate L-828 manuals available for free PDF download: User Manual
ADB Safegate L-828 User Manual (110 pages)
CCT (Thyristor Controlled) Constant Current Regulator Air-Cooled, 4-30 kW/6.6 A, A Air-Cooled, 4-30 kW/6.6 A, ACE3
Brand:
ADB Safegate
| Category:
Controller
| Size: 4 MB
Table of Contents
Disclaimer / Standard Warranty
3
Table of Contents
5
Safety
11
Safety Messages
11
Introduction to Safety
12
Intended Use
12
Material Handling Precautions: Storage
13
Material Handling: Heavy Equipment
13
Operation Safety
13
Maintenance Safety
14
Material Handling Precautions, ESD
14
Arc Flash and Electric Shock Hazard
15
Introduction
17
About this Manual
17
How to Work with the Manual
17
CCT Introduction
17
Constant Current Regulator
18
Total Harmonic Distortion1 (THD)
22
Power Circuit
22
Output Measurement
22
CCR Control PCB
22
URC PCB Inputs/Outputs
23
Output Current Monitor Circuitry
23
Local Control Position Detection
23
Contactor Drive
23
Figure 1: L-828 CCR Power Circuit Block Diagram
23
Remote Control Position Detection
24
Fault Protection
24
Ccr
24
Figure 2: Current Meter Display
24
URC4 CCR Controller
25
Figure 3: L-829 CCR with ACE
25
Figure 4: URC4 CCR Controller
25
Advanced Control Equipment
26
L-828/L-829 CCR Monitoring Options
26
Optional Insulation Resistance Monitoring System
26
Optional Scanning Monitor Interface
26
Figure 5: ACE3 Control Board
26
Optional Scanning Monitor Ready
27
Optional Airfield Lighting Series Cutout (SCO)
27
Ccrs (4-30 Kw 6.6 A): Required Equipment
27
Input Wire Size
27
Table 1: Required Equipment Supplied
27
Table 2: Required Equipment Not Supplied
27
Input Power Breaker Sizing
28
Specifications
28
Table 3: Recommended Input Wiring Rating
28
Table 4: CCR Input Voltage and Current for the CCR Power Ratings
28
Table 5: Class, Style and Power Ratings
28
Table 6: Power Factor
28
Efficiency
29
Reactive Loading
29
Resistive Loading
29
Regulation
29
Environmental Operating Conditions
29
Table 7: Efficiency
29
Table 8: Output Current and Limits
29
Table 9: Environmental Operating Conditions
29
Protection Devices
30
Open-Circuit Protection
30
Overcurrent Protection
30
Input Voltage
30
Built-In True-Rms-Reading Ammeter, L-828 Only
30
Rating and Input Voltage
30
Temperature Rise
30
Table 10: Rating and Input Voltage
30
CCT Installation, L-828 / L-829
31
Intended Use
31
Unpacking
31
Material Handling: Heavy Equipment
31
Installation Overview
31
Wiring Connections and Startup
32
Figure 6: Wiring on Right Side of the CCR
32
Table 11: Remote Control Connections (3-Step/6.6 A)
33
Table 12: Remote Control Connections (5-Step/6.6 A)
33
Stacking Ccr's (Optional)
34
Table 13: Input/Output Connections
34
Figure 7: Anchor Bolt Template
36
Table 14: Bolt Patterns for the 2 CCR Sizes
36
Figure 8: Location of Bolts for Stacking Ccrs
37
Figure 9: Stacking Bolt
38
Operation
39
Operation Safety
39
CCR Control Procedures
39
Local Control
39
Remote Control
40
Figure 10: L-828/L-829 Switches
40
Table 15: Output Current from Rotary Switch (3-Step/6.6 A)
40
Table 16: Output Current from Rotary Switch (5-Step/6.6 A)
40
Table 17: Remote Control
40
CCR Shutdown Procedure
41
CCR Adjustment Procedures
41
Figure 11: Output Current Clamp
42
Adjusting Output Current (no ACE3)
43
Figure 12: Regulator URC4 Control PCB
43
Adjusting Overcurrent Control Board (44A6546)
44
Reducing CCR Power Consumption
45
SCO Operation
45
Figure 13: CCR Transformer Taps
45
Table 18: Cutout Working Positions
47
Graphic User Interface (GUI)
49
Figure 14: Output Current Gauge
50
Figure 15: Output View and Diagram View
51
Figure 16: IO Card Cage View
51
Figure 17: Regulator Interface Card View
51
Menu Screen
52
Figure 18: Regulator Interface Card View (4X4 Card)
52
Alarms View
53
Figure 19: Alarms and Warnings Screen (Alarms View)
53
Events View
54
Status Menu - Hours/Cycle Count
54
Figure 20: Alarms and Warnings Screen (Events View)
54
Figure 21: Hour/Cycle Count Screen
54
Status Menu - Waveform
55
Status Menu - Miscellaneous
55
Figure 22: Wave Form Screen
55
Figure 23: Status Menu - Miscellaneous
55
CCR Menu - Configuration
56
Screen 1
56
Figure 24: Status Menu - Miscellaneous
56
Figure 25: CCR Configuration Screen 1
56
Screen 2
57
Figure 26: CCR Configuration Screen 1 for 20A Ccrs
57
Screen 3
58
Figure 27: CCR Configuration Screen 2
58
Figure 28: Current Set Point
58
Figure 29: Current Set Point for 20A Ccrs
58
Screen 4
59
Screen 5
59
Figure 30: I/O CCR Alarm
59
Figure 31: CSS Loops
59
CCR Menu - Measurement Calibration
60
CCR Menu - VA Calibration
61
Figure 32: Calibration Screen
61
Figure 33: Calibration Screen Override
61
Figure 34: Calibration Screen with the Red X Shown
61
CCR Menu - IRMS Configuration
63
CCR Menu - Lamps out Calibration
64
ACE Menu - Configuration
67
Figure 35: ACE Info Config Screen (Network Config)
68
ACE Menu - Failsafe
69
ACE Menu - Feature Enable
69
Figure 36: Failsafe Config Screen
69
ACE Menu - about
70
Figure 37: about Screen
70
Figure 38: about Screen Menu
71
Figure 39: about Screen Disclaimer
71
Maintenance and Repair
73
Maintenance Safety
73
Maintenance Schedule
73
Table 19: L-828/L-829 CCR (4-30 Kw) Maintenance
73
Short-Circuit Test
74
Open-Circuit Test
74
Troubleshooting
75
Introduction
75
Preliminary Troubleshooting
75
Troubleshooting Failed Components
75
L-828/L-829 Input Power Fuses F1 and F2
75
Table 20: CCT/XXXX INPUT FUSES (F1, F2)
76
Table 21: CCT/XXXX T3 Fuses (F3, F4)
76
Table 22: CCT/XXXX ACE Fuses F5, F6
77
Table 23: CCT/XXXX Input Fuse Blocks
77
Table 24: CCT/XXXX CONTACTORS (K2)
77
Table 25: CCT/XXXX Dual SCR Block (SCR)
78
Table 26: CCT/XXXX Current Transformer T2
78
Table 27: CCT/XXXX Input Lightning Arrestor
78
Table 28: CCT/XXXX Output Lightning Arrestor
78
General Troubleshooting
79
Table 29: CCT/XXXX Current Sensing Transformer (T5)
79
Table 30: CCT/XXXX Power Transformer (T4)
79
Table 31: CCT/XXXX Other Parts
79
Table 32: CCT/XXXX Ammeter
79
Table 33: General Troubleshooting
79
Additional L-829 General Troubleshooting Procedures
81
Component Replacement Procedures
81
Replacing an ACE3 Unit
81
Figure 40: Backside of ACE3 Control Board
82
Figure 41: ACE3 about
82
Figure 42: ACE3 about
83
Figure 43: ACE3 Configuration
85
Figure 44: URC4
85
Figure 45: URC4 Dip Switches
85
Table 34: URC4 Dip Switch Chart
86
Removing and Replacing URC4 Regulator Control PCB
87
Figure 46: PCB URC4 Regulator Control (44A7693)
87
Removing and Replacing Dual SCR Module Assembly
88
Figure 47: Dual SCR Module Assembly
88
CCR Contactor Replacement
89
Figure 48: Mounting Adapter 63A1153
90
Figure 49: Mounting Adapter 63A1153 Location
90
Removing and Replacing Input Lightning Arrestors (Front of Component Mounting Plate)
91
Removing and Replacing Output Lightning Arrestors
91
Figure 50: 94A0576 Type Output Lightning Arrestors
92
Figure 51: Output Lightning Arrestors
92
Schematics
93
Figure 52: 43A4822 CCT Schematic
93
Figure 53: 43A4822 CCT Schematic T4 Connections
94
Figure 54: 43A4822 CCT Schematic T1 Voltages
95
Figure 55: 43A4822 CCT Schematic SCR Connections
95
Figure 56: 43A4822 CCT Schematic L1 Chokes
96
Figure 57: 43A4822 CCT Schematic Input Monitor Option
96
Figure 58: 43A4822 CCT Schematic L1 Chokes Analog Meter Option (6.6 A)
96
Figure 59: 43A4822 CCT Schematic Power Transformer (Stand Alone)
97
Figure 60: 43A4822 CCT Schematic Power Transformer Windings (30Kw Only)
97
Figure 61: 43A4822 CCT Schematic SCO Option
98
Figure 62: 43A4822 CCT Schematic L1 Chokes
98
Figure 63: 43A4822 CCT Schematic L1 Chokes
99
CCT Parts
101
L-828/L-829 CCR (4-30 Kw) Parts Ordering Codes
101
Table 35: L-828/L-829 CCR (4-30 Kw/6.6 A) Part Numbers
101
Figure 64: L-828/L-829 CCT Part Ordering Code
102
CCT XX XX / X X X X CCR Kits
103
L-828/L-829 CCR General Assembly (4-30 Kw/208-480 Vac) Parts List
103
Assembly Parts: CCT 4-30Kw Regulators
104
Figure 65: AS00002 15-30Kw Component Plate
104
Figure 66: AS00001 Component Plate 4, 7.5 and 10 Kw CCT
105
Table 36: 4 Kw CCT 380V Component Plate Spare Parts
105
Figure 67: ACE 3 Assembly 44A7733
106
Support
107
ADB SAFEGATE Website
107
Local Authority Recycling
108
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ADB Safegate L-828 User Manual (112 pages)
CCT (Thyristor Controlled) Constant Current Regulator Air-Cooled, 4-30 kW/6.6 A
Brand:
ADB Safegate
| Category:
Controller
| Size: 2 MB
Table of Contents
Disclaimer / Standard Warranty
3
Table of Contents
5
Safety
11
Safety Messages
11
Introduction to Safety
12
Intended Use
12
Material Handling: Heavy Equipment
13
Operation Safety
13
Maintenance Safety
13
Material Handling Precautions, ESD
14
Arc Flash and Electric Shock Hazard
14
Introduction
15
About this Manual
15
How to Work with the Manual
15
CCT Introduction
15
Constant Current Regulator
15
Remote Control
19
Total Harmonic Distortion* (THD)
19
Theory of Operation Introduction
19
ACE Unit
20
Environmental Operating Conditions
20
Monitoring Option
20
Application Notes
20
Figure 1: CCT Ordering Codes
20
Theory of Operation
21
Power Circuit
21
Output Measurement
21
CCT Control PCB
21
Figure 2: L-828 CCR Power Circuit Block Diagram
21
URC PCB Inputs/Outputs
22
Output Current Monitor Circuitry
22
Local Control Position Detection
22
Contactor Drive
22
Remote Control Position Detection
22
Fault Protection
22
Ccr
22
Ccr
23
Figure 3: L-828 CCR (4 -30Kw/6.6 A)
23
CCT Control Board
24
Figure 4: L-829 CCR with ACE
24
Advanced Control Equipment (ACE)
25
Figure 5: CCT Control PCB (44D1475)
25
Figure 6: CCT Control PCB (44A6546)
25
L-828/L-829 CCR Monitoring Options
26
Optional Insulation Resistance Monitoring System
26
Optional Scanning Monitor Interface
26
Optional Scanning Monitor Ready
26
Figure 7: ACE Control and Monitor Boards
26
Optional Series Cutout Type SCO
27
Ccrs (4-70 Kw 6.6 A/ 20 A): Required Equipment
27
Input Wire Size
27
Table 1: Required Equipment Supplied
27
Table 2: Required Equipment Not Supplied
27
Table 3: Recommended Input Wiring Rating
27
Input Power Breaker Sizing
28
Specifications
28
Table 4: CCR Input Voltage and Current for the CCR Power Ratings
28
Table 5: Class, Style and Power Ratings
28
Efficiency
29
Reactive Loading
29
Resistive Loading
29
Regulation
29
Table 6: Power Factor
29
Table 7: Efficiency
29
Table 8: Output Current and Limits
29
Environmental Operating Conditions
30
Protection Devices
30
Open-Circuit Protection
30
Overcurrent Protection
30
Input Voltage
30
Built-In True-Rms-Reading Ammeter, L-828 Only
30
Table 9: Environmental Operating Conditions
30
Rating and Input Voltage
31
Temperature Rise
31
Table 10: Rating and Input Voltage
31
CCT Installation
33
Unpacking
33
Installation
33
Wiring Connections and Startup
34
Figure 8: Wiring on Right Side of CCR
34
Table 11: Remote Control Connections (3-Step/6.6 A)
35
Table 12: Remote Control Connections (5-Step/6.6 A)
35
Stacking Ccr's (Optional)
36
Table 13: Input/Output Connections
36
Figure 9: Anchor Bolt Template
38
Table 14: Bolt Patterns for the 2 CCR Sizes
38
Figure 10: Location of Bolts for Stacking Ccrs
39
Figure 11: Stacking Bolt
40
Frames
41
Figure 12: Medium Frame Assembly
41
Operation
43
Introduction
43
CCR Control Procedures
43
Local Control
43
Figure 13: L-828/L-829 Switches
43
Remote Control
44
CCR Shutdown Procedure
44
CCR Adjustment Procedures
44
Table 15: Output Current from Rotary Switch (3-Step/6.6 A)
44
Table 16: Output Current from Rotary Switch (5-Step/6.6 A)
44
Table 17: Remote Control
44
Output Current Adjustment
45
Figure 14: Output Current Clamp
45
Regulator Control Board (44D1475)
46
Figure 15: Regulator Control PCB
46
Adjusting Overcurrent Control Board (44D1475)
47
Table 18: Potentiometers for 3-Step Output Current Levels
47
Table 19: Potentiometers for 5-Step Output Current Levels
47
Adjusting Output Current (44A6546)
48
Figure 16: Regulator Control PCB (44A6546)
48
Adjusting Overcurrent Control Board (44A6546)
49
Reducing CCR Power Consumption
49
Adjusting over Current
50
Figure 17: CCT Transformer Taps
50
SCO Cutout Working Positions
51
Figure 18: SCO Cutout Handle Orientations
51
Figure 19: SCO Cutout Operation Position
51
Application Notes
52
Figure 20: SCO Cutout Maintenance Position
52
Figure 21: SCO Cutout Test and Measure Position
52
Digital Power Meter Calibration
53
Figure 22: Digital Power Meter
53
Function Buttons
54
Displays
54
Figure 23: Function Buttons
54
Figure 24: Displays
54
Calibration
55
Figure 25: DPM Calibration Menu
55
Figure 26: Irms - High Step Calibration
56
Figure 27: Irms - Low Step Calibration
56
Figure 28: Vrms Calibration
57
Figure 29: Vrms Hi-Step Loaded
57
Figure 30: Save Vrms Calibration
57
CCT Maintenance
59
Introduction to Maintenance
59
Maintenance Schedule
59
Table 20: L-828/L-829 CCR (4-30 Kw) Maintenance
59
Short-Circuit Test
60
Open-Circuit Test
60
Troubleshooting
61
Introduction
61
Preliminary Troubleshooting
61
L-828/L-829 Input Power Fuses F1 and F2
61
Table 21: CCT/XXXX INPUT FUSES (F1, F2)
62
Table 22: CCT/XXXX T3 Fuses (F3, F4)
62
Table 23: CCT/XXXX ACE Fuses F5, F6
63
Table 24: CCT/XXXX Input Fuse Blocks
63
Table 25: CCT/XXXX CONTACTORS (K2)
63
Table 26: CCT/XXXX Dual SCR Block (SCR)
64
Table 27: CCT/XXXX Current Transformer T2 (and T3 for 20A)
64
Table 28: CCT/XXXX Power Transformer T1 (Core)
65
Table 29: Power Core List
65
Table 30: CCT/XXXX Choke (4-15Kw Only)
66
Table 31: CCT/XXXX Input Lightning Arrestor
66
Table 32: CCT/XXXX Output Lightning Arrestor
66
Table 33: CCT/XXXX Current Sensing Transformer (T5)
66
Table 34: CCT/XXXX Power Transformer (T4)
66
General Troubleshooting
67
Table 35: CCT/XXXX Other Parts
67
Table 36: CCT/XXXX Circuit Voltage Monitor Assembly (CVM) (Option)
67
Table 37: CCT/XXXX Ammeter
67
Table 38: General Troubleshooting
67
Additional L-829 General Troubleshooting Procedures
69
Component Replacement Procedures
69
Removing and Replacing CCT Regulator Control PCB
70
Figure 31: CCT Regulator Control PCB (44D1475)
70
Figure 32: Regulator Control PCB (44A6546)
71
Removing and Replacing Dual SCR Module Assembly
72
Figure 33: Dual SCR Module Assembly
72
Removing and Replacing Contactor
73
Figure 34: CCR Power Contactor
73
Removing and Replacing Input Lightning Arrestors (Front of Component Mounting Plate)
74
Removing and Replacing Output Lightning Arrestors (Front of Component Mounting Plate)
74
Figure 35: Output Lightning Arrestors
75
Figure 36: Output Lightning Arrestors
76
Schematics
77
Figure 37: 43A2845 CCT Schematic Page 1/ Side a
77
Figure 38: 43A2845 CCT Schematic Page 1/ Side B
78
Figure 39: 43A2845 CCT Schematic Page 2/ Side a
79
Figure 40: 43A2845 CCT Schematic Page 2/ Side B
80
CCT Parts
81
L-828/L-829 CCR (4-30 Kw) Parts Ordering Codes
81
Table 39: L-828/L-829 CCR (4-30 Kw/6.6 A) Part Numbers
81
L-828/L-829 CCR General Assembly (4-30 Kw/208-480 Vac) Parts List
82
Figure 41: L-828/L-829 CCT Part Ordering Code
82
Assembly Parts
83
KW CCT Regulator Parts
84
Figure 42: CCT L-828/L-829 CCR Component Parts
85
Table 40: 15-30KW CCT Bill of Material
87
Table 41: Configuration Bill of Material, 30Kw CCT
91
Table 42: Configuration Bill of Material, 15KW CCT
91
Table 43: 15-30KW CCT Configured Component Plates
92
Table 44: 15-30KW CCT Configured Component Plates
92
Table 45: 15-30KW CCT Configured Component Plates
93
Table 46: 15-30KW CCT Configured Component Plates
93
Figure 43: 15-30 KW Component Plate Parts (Front)
94
Figure 44: 15-30 KW Component Plate Parts (Back)
95
KW CCT Regulator Parts
96
Figure 45: 4, 7.5 and 10 Kw CCT Diagrams
97
Table 47: 4, 7.5, 10 Kw CCT General Assembly Bill of Material
99
Table 48: 4, 7.5, 10 Kw CCT, Configured Cores, Chokes and Power Wire Kits
104
Table 49: 4, 7.5, 10 Kw CCT, Configured Cores, Chokes and Power Wire Kits
104
Table 50: 4, 7.5, 10 Kw CCT Configured Component Plates
105
Figure 46: 4-10 KW Component Plate Parts (Front)
107
Figure 47: 4-10 KW Component Plate Parts (Back)
108
Appendix A: Support
109
ADB SAFEGATE Website
109
Recycling
109
Local Authority Recycling
110
ADB SAFEGATE Recycling
110
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