AUGIER Energy DIAM4000 Guía de mantenimiento y servicio

I-1

DIAM4000

L828/L829 and IEC Single-phase SCR-type

Constant Current Regulator

Compliance with standards:

ICAO Aerodrom design manual, part 5

IEC 61822 et 61822

CENELEC (ENV 50231)

FAA (AC 150/5345 - 10E Spec.L828/L829)

STNA (CCTP n°91068)

AENA (PPT2, rev.5, ed3(1995) and ed4(2004)

60 21032 Diam4000 (IM) rev.9

Installation & maintenance

I-2

RECORD OF CHANGES

Rev. Pages Description From S/N By App. Date

1.0 First issue ED RG 07/01/04

1.1 V48-49 Diagrams update SC RG 15/01/04

1.2 Cover composition NA RG 19/02/04

1.3 Text corrections –IEC spare list – part number OE RG 08/03/04

1.4 Jbus table, cabinet, ECB option ED RG 18/05/04

1.5 II37-38 FAA Multiwire remote control ED RG 15/09/04

1.6 II37-38 FAA Multiwire remote control, jbus table ED RG 11/10/04

1.7 cover Standard and qualification precision’s RG RG 02/11/04

1.8 IV53 to V55 Spare lists and diagrams update 24 532 OE RG 24/11/04

1.9 II37,38,41 Connections, interlock SC RG RG 30/11/04

I-3

WARRANTIES

Guarantee

AUGIER’s goods are guaranteed for one year from delivery date on the signed delivery note, and are

guaranteed to be free from defects in materials used, design and manufacture.

The guarantee covers repair, modification or replacement of parts or products recognised to be defective, in

the shortest possible time, at AUGIER’s cost, provided always that the goods have been properly handled and

stored prior installation, properly installed and properly operated after installation.

Unless otherwise specifically laid down in contract, the guarantee does not cover:

•Costs of consignment to factory and re-consignment of defective goods to Buyer

•If these are repaired in AUGIER’s factory;

•Travelling & sojourn expenses of AUGIER’s personnel if goods have to be repaired on site; assembly

and dismantling of any goods other than those recognised to be defective; expenses incurred for

waiting times by AUGIER’s personnel on site for reasons independent of their will;

•Unjustified travel expenses.

Guarantee shall not apply in the following cases:

•Defects in materials supplied by Buyer or from any designs imposed by them;

•Repairs or replacements due to normal wear and tear, or damages or accidents.

•Repairs or replacements due to damages or accidents resulting from negligence or lack of due care,

inadequate supervision or maintenance, or erroneous use of the equipment or software;

•Any other causes for which AUGIER shall not be held responsible, e.g. resulting from an case of Force

Majeure.

•When Buyer has replaced AUGIER’s parts with other parts.

Buyer must inform AUGIER in writing and without delay of any defects in goods, giving all necessary

information and detailed description of how equipment has been utilised, together with purchase date. Buyer

undertakes not to have repairs carried out by third parties; any repairs carried out without AUGIER’s express

prior agreement shall invalidate the guarantee.

It is expressly agreed between the two parties that Buyer cannot avail himself of the beneficial dispositions

contained in the guarantee without having first satisfied payment conditions laid down in contract

Disclaimers

This manual could contain technical or typographical errors. AUGIER reserves the right to make changes and

revise this manual from time to time without obligation to notify any person or organisation of such changes or

revision.

Values and measurements given in this manual are average values and are not binding. AUGIER disclaims any

liability for damages suffered as a result of reliance on the information given in this manual, or the use of

equipment or processes which this manual refers.

No guarantee is made that the use of the products, equipment, processes or information to which this manual

refers will not infringe any third party’s patent or rights. Information given does not release the buyer from

making their own tests.

I-4

SAFETY

Safety precautions

This equipment is normally used or connected to circuits that may employ dangerous and lethal voltages.

Extreme caution should be exercised by operating or maintenance people when working on or with this

equipment.

See IEC 61820 & 61821 standard (CCR type IEC), or FAA AC150/5340-26 advisory circular (CCR type FAA),

concerning safety rules and precautions. While practical safety precautions have been incorporated in this

equipment, the following rules must be strictly observed :

•KEEP AWAY FROM LIVE CIRCUITS :

Operating and maintenance people must at all time observe all safety regulations. Do not change

components nor perform maintenance inside equipment with power ON or the lighting loop energised.

•RESUSCITATION :

Operating and maintenance personnel should familiarise and keep themselves trained with resuscitation

techniques found in widely published manuals about first aid instructions.

•ELECTROSTATIC DISCHARGE (ESD) :

Electronic sub-assemblies and boards should be touched only for unavoidable operation (replacement,

for example). Before to operate, maintenance people must first of all eliminate unwanted electronic

charges, discharging his own body while touching a conductive earthed object or part. Electronic boards

and components as power semiconductors must be stored and carried an conductive packing.

•DESTRUCTION :

In case of dismantling, scrapping or placing out of service, the user must follow all the required

precautions for component, materials or equipment elimination, according the local rules.

EEC DIRECTIVES

This equipment complies with the requirements of EC directives :

•89/336/EEC, 92/31/EEC and 93/68/EEC with regard of Electromagnetic

Compatibility

•73/23/EEC with regard of Low Voltage Equipment

I-5

TABLE OF CONTENTS

RECORD OF CHANGE ……………………………………………………………………………………………… I-2

WARRANTIES …………………………………………………………………………………………………………… I-3

SAFETY ……………………………………………………………………………………………………………….….. I-4

TABLE OF CONTENTS ……………………………………………………………………………………………… I-5

IDESCRIPTION _______________________________________________________ I-9

I.1 OVERVIEW _______________________________________________________________________ I-9

I.2 MECHANICAL DESCRIPTION _______________________________________________________ I-10

I.2.1 DESCRIPTION ________________________________________________________________ I-10

I.2.2 GENERAL MECHANICAL FEATURES _____________________________________________ I-10

I.2.3 STORAGE CONDITIONS________________________________________________________ I-11

I.2.4 DIMENSIONS_________________________________________________________________ I-11

I.3 ELECTRICAL DESCRIPTION________________________________________________________ I-12

I.3.1 BLOCK DIAGRAMS ____________________________________________________________ I-12

I.3.1.1 Overview: __________________________________________________________________ I-12

I.3.1.2 Electronic: __________________________________________________________________ I-12

I.3.2 GENERAL CIRCUIT DIAGRAMS__________________________________________________ I-12

I.3.3 GENERAL ELECTRICAL FEATURES______________________________________________ I-13

I.4 INSTRUCTIONS FOR USE __________________________________________________________ I-14

I.4.1 USER INTERFACE_____________________________________________________________ I-14

I.4.2 CONTROL ___________________________________________________________________ I-16

I.4.3 LOCAL INFORMATION FEEDBACK _______________________________________________ I-16

I.4.4 REMOTE INFORMATION FEEDBACK _____________________________________________ I-18

I.5 OPERATION _____________________________________________________________________ I-19

I.5.1 CONFIGURATION _____________________________________________________________ I-20

I.5.2 SETTING ____________________________________________________________________ I-20

I.5.2.1 Current range: _______________________________________________________________ I-20

I.5.3 PROTECTIONS _______________________________________________________________ I-20

I.5.3.1 LV power monitoring: _________________________________________________________ I-20

I.5.3.2 “Open circuit”: _______________________________________________________________ I-20

I.5.3.3 “Overcurrent”: _______________________________________________________________ I-21

I.5.3.4 Cancelling “Open circuit” and “Overcurrent” faults:___________________________________ I-21

I.5.4 AUTOMATIC OPERATION: ______________________________________________________ I-21

I.6 SUB-ASSEMBLIES________________________________________________________________ I-22

I.6.1 LOAD PLATE _________________________________________________________________ I-22

I.6.1.1 Adaptation to load: ___________________________________________________________ I-22

I.6.1.2 Computation of the output voltage and output power: ________________________________ I-23

I.6.2 CUT OUT AND EARTHING PLATE (OPTION) _______________________________________ I-24

I.6.2.1 Normal position : _____________________________________________________________ I-24

I.6.2.2 Safety position: ______________________________________________________________ I-24

I.6.2.3 Load measurements:__________________________________________________________ I-24

I-6

I.7 ACCESSORIES___________________________________________________________________ I-25

I.7.1 “ALIZE4000” SOFTWARE _______________________________________________________ I-25

I.7.2 “RDTS4000” SOFTWARE _______________________________________________________ I-25

I.8 OPTIONS________________________________________________________________________ I-26

I.8.1 EARTH FAULT DETECTOR (EFD) ________________________________________________ I-26

I.8.2 OPTIONAL ISOLATING DEVICES_________________________________________________ I-26

I.8.2.1 Cut-out and earthing plate : See 1.6.2 ____________________________________________ I-26

I.8.2.2 FAA cut-out plug:_____________________________________________________________ I-26

I.8.3 OUTPUT LIGHTNING ARRESTORS_______________________________________________ I-26

I.8.4 INPUT LIGHTNING ARRESTORS_________________________________________________ I-26

I.8.5 CASTERS____________________________________________________________________ I-26

I.8.6 BURNT LAMPS DETECTION: ____________________________________________________ I-27

I.8.7 OUTPUT POWER DROP DETECTION: ____________________________________________ I-27

I.8.8 TIME METERS: _______________________________________________________________ I-27

I.8.9 4-20MA LOOP CURRENT : ______________________________________________________ I-28

I.8.9.1 4-20mA current loop for output current and power measurements : _____________________ I-28

I.8.9.2 4-20mA loop current (ground insulation):__________________________________________ I-28

I.8.10 BUZZER _____________________________________________________________________ I-29

I.8.11 WIG WAG ____________________________________________________________________ I-29

I.8.12 OTHER OPTIONS _____________________________________________________________ I-29

II INSTALLATION _____________________________________________________ II-30

II.1 PREPARATION___________________________________________________________________II-30

II.1.1 EQUIPMENT RECEPTION ______________________________________________________II-30

II.1.1.1 Equipment delivered:________________________________________________________II-30

II.1.1.2 Checking the equipment:_____________________________________________________II-30

II.1.2 DEVICE LOCATION____________________________________________________________II-30

II.1.3 CHECKING THE INSTALLATION _________________________________________________II-31

II.1.3.1 Single phase power supply:___________________________________________________II-31

II.1.3.2 LV Protection: _____________________________________________________________II-31

II.1.3.3 Lighting loop: ______________________________________________________________II-31

II.1.3.4 Management by remote control: _______________________________________________II-31

II.2 CONNECTIONS___________________________________________________________________II-32

II.2.1 ELECTRICAL _________________________________________________________________II-32

II.2.1.1 LV supply: ________________________________________________________________II-32

II.2.1.2 Earthing __________________________________________________________________II-32

The Main Earth circuit must be connected to the earthing stud situated in the lower part of the frame at left

(external or internal connection, at rear) __________________________________________________II-32

II.2.1.3 Lighting loop: ______________________________________________________________II-33

II.2.1.4 Remote control connections __________________________________________________II-34

II.2.1.4.1 CONFIGURATION OF REMOTE CONTROL TYPE________________________________II-34

II.2.1.4.2 FAA Multiwire remote control (FAA type CCRs only, with 20 to 60Vdc inputs))___________II-35

II.2.1.4.3 IEC Multiwire remote control (IEC type CCRs only): _______________________________II-37

II.2.1.4.4 Operating modes for multiwire (FAA & IEC) remote control :_________________________II-39

I-7

II.2.1.5 Serial Link:________________________________________________________________II-40

II.2.1.6 Circuit selector: ____________________________________________________________II-41

II.3 ADJUSTING THE CCR _____________________________________________________________II-43

II.3.1 ADAPTATION TO LOAD ________________________________________________________II-43

II.3.1.1 Maximum power levels by power settings: _______________________________________II-43

II.3.2 PARAMETER MODIFICATION ___________________________________________________II-43

II.3.2.1 Preferred configuration values: ________________________________________________II-43

II.3.2.2 Brightness values: __________________________________________________________II-44

II.3.2.3 Value of “Open Circuit” protection level: _________________________________________II-44

II.3.2.4 Value of “Overcurrent” protection levels:_________________________________________II-44

III COMMISSIONING_________________________________________________ III-45

III.1 PROCEDURE ___________________________________________________________________ III-45

III.2 TESTS _________________________________________________________________________ III-46

III.2.1 SHORT-CIRCUIT TESTS_______________________________________________________ III-46

III.2.2 OVERLOAD TESTS ___________________________________________________________ III-46

III.2.3 OPEN-CIRCUIT TEST _________________________________________________________ III-46

IV MAINTENANCE___________________________________________________ IV-47

IV.1 FORMALISATION ________________________________________________________________ IV-47

IV.2 PREVENTIVE ___________________________________________________________________ IV-47

IV.2.1 FIRST MONTHS______________________________________________________________ IV-47

IV.2.2 ANNUAL PROCEDURE ________________________________________________________ IV-47

IV.2.3 EVERY THREE YEARS ________________________________________________________ IV-47

IV.3 CORRECTIVE ___________________________________________________________________ IV-48

IV.3.1 FAULT DIAGNOSIS ___________________________________________________________ IV-48

IV.3.1.1 LV power fault:____________________________________________________________ IV-48

IV.3.1.2 “Open Circuit” fault: ________________________________________________________ IV-49

IV.3.1.3 “Overcurrent” fault:_________________________________________________________ IV-50

IV.3.2 OTHER FAULTS______________________________________________________________ IV-51

IV.4 VERIFICATION PROCEDURES _____________________________________________________ IV-52

IV.4.1 THYRISTORS________________________________________________________________ IV-52

IV.5 SPARE PARTS LIST FOR FAA TYPE CCR ___________________________________________ IV-52

IV.6 SPARE PARTS LIST FOR IEC TYPE CCR ____________________________________________ IV-55

VAPPENDIX A: DIAGRAMS ____________________________________________V-56

VI APPENDIX B: JBUS TABLE_________________________________________ VI-58

VII APPENDIX C: PART NUMBER IDENTIFICATION________________________VII-66

I-8

ABBREVIATIONS

Abbreviation Definition

AAmpere

AC Alternating Current

B Brightness

CCR Constant Current Regulator

DC Direct Current

EFD Earth Fault Detector

HV High Voltage

IT Injection Transformer

LFD Lamp Fault Detector

LV Low Voltage

OO Out of order

VVolt

VA Volt-Ampere

I-9

IDESCRIPTION

I.1 OVERVIEW

DIAM4000 series CCRs are low costs fully static devices controlled by two thyristors (anti-parallel mounting

type dimmer). They are designed to maintain a constant, pre-displayed and adjustable output current

independently of the load and power supply fluctuations.

These devices are specifically designed for airfield lighting on runways, taxiways, aprons. They meet both

national and international standards.

In order to do this, they use an adapted triggering and regulation mechanism that is not affected by external

interference and does not emit measurable interference in the Aviation Band between 100 and 400 MHz.

This type of regulator uses natural air-cooling. The output current remains constant with an accuracy of 1%

for mains voltage fluctuations of –5/+10% (+/-10% for IEC type). At the rated load and the rated or higher

voltage, accuracy of regulation is maintained for all load between 0 and 100%, and for up to 30% of

transformers with open secondary. The output power of the regulator can be adjusted to the load by means of

transformers taps, by steps of 12.5%.

Here are some of its advantages:

•Flexibility of use:

The alphanumeric display and menu type keyboard allow the CCR to be configured without connection

with a computer.

Regulation is fully digital which enables parameters to be simply modified for a particular load.

Emergency and warning messages are clearly displayed.

•Simplicity:

CCR type regulators have a very simplified architecture both for the electronic control unit and the LV

and HV power parts.

•Adaptability and safety:

An optional Cut-out and Earthing plate, using two pluggable jumpers can be used to disconnect the

CCR from the loop, to earth or short-circuit the loop without disconnecting the load at any time.

•Construction:

It has been optimised to keep the number and variety of spare parts to a minimum. The device is made

up of modular sub-assemblies.

•Standards:

ICAO: Airport design manual, part 5

STNA: CCTP 91068 rev.93

CENELEC: prENV 50231

FAA: AC150/5345-10E, L828 or L829

AENA: PPT NTA2-rev.5 (1995) & ed.4 (2004)

IEC: 61822 (CCRs), 61821 (Maintenance)

I-10

I.2 MECHANICAL

DESCRIPTION

I.2.1 DESCRIPTION

Each CCR is housed in a cabinet fitted with lifting rings. The frame has three distinct parts: an “electronic”

control part, a “low voltage” compartment and a “high voltage” compartment.

•The Electronic unit of the CCR consists of a main electronic circuit board fitted to the upper panel of the

cabinet.

All the basic functions of the regulator are included in the electronic compartment and are accessible from

the front and the top of the CCR.

•The Low voltage unit contains all the components connected to the power supply with, for example, the

thyristors and associated driver boards, the master switch, the LV fuses and connection terminals. It is

located in the upper part of the CCR.

•The High voltage unit, situated at the back of the CCR, contains all the components connected to the

output loop such as the power transformer, the lightning arrestors, the CI-MALT (optional) and the HV part

of the insulation fault detection unit. The load regulating plate and the load loop connections are accessible

from the front of the device.

All these components are easily accessible from the front, the top or the back of the cabinet.

I.2.2 GENERAL MECHANICAL FEATURES

Regulators are contained in the same cabinet for all powers and input voltage. A taller one (+ 20cm) is available

when inside additional equipment is requested by customer, as ECB (*) option. Both cabinets are provided with

hoisting eye rings, with or without casters, and can be located cuddled up to each other.

Standard cabinet : 500mm Wide x 700mm Deep x 1380mm High

Big cabinet : 500mm Wide x 700mm Deep x 1580mm High

•Protection Index for the Casing: IP 21. (Contact us for other Protection Indices)

•Distances inter-axes (if casters option) : 355 x 610 mm

•Usage: Ambient temperature between -40°C and +55°C (FAA type) or –20°C to +55°C (IEC type),

with maximum relative humidity of 95%. Natural air cooling.

(*) ECB : Loop Communication Equipment, type STB or SCB (Please ask for more informations)

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