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Constant Current Regulator Microprocessor Controlled

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					Constant Current Regulator
Microprocessor Controlled


                                                                A.06.350e


 Compliance with Standards
 FAA:        AC 150/5345-10E
 ICAO:       Aerodrome Design Manual Part 5,
             para 3.2.1.4. to 3.2.1.6.
 IEC:        61822.
 CENELEC: ENV 50231.
 Various national standards.


 Use
The ADB MCR regulator is specially designed for
the supply of airport lighting series circuits at various
intensity levels.

 Features
• Proven reliability: the MCR represents an evolution of the
  TCR 5000,over 3000 copies of which are in use world-
  wide.
• Modular concept: two power modules and one control
  module cover the 2.5 to 30 kVA range.
  Both modules are withdrawable units.
• Versatility: available as a stand alone unit.
  Alternatively, several MCR's may be grouped in a
  common rack system.
• Minimum floor space requirements.
• Natural air convection cooling. No cooling fans.
• Built-in microprocessor allows for:
  - Comprehensive status monitoring                             MCR         FIG. 1
  - Diagnosis
  - Adaptation by the user of operational parameters
  - Remote control and monitoring via a field bus.
• Redundant remote control and monitoring field bus
  (optional).
• Circuit selector compatible.
• Matching taps on output transformer for improved
  primary power factor and efficiency. This also reduces
  waveform distortion and harmonic content.
• Built-in main fused switch.
• 8 brightness steps, user-adjustable.
• Up to 30% of open circuited isolating transformers will
  not affect output current regulation.
• Dielectric strength test from output circuit to ground at
  5 times the full load RMS voltage.
• Reliable and fast data transfer to and from the remote
  control units (PC or PLC).
• Integrated Lamp Fault and Earth Fault detection (optional).               FIG. 2
• PC-assisted Lamp Fault detector calibration and setting of
  operational parameters.
• Operates from both 50 Hz and 60 Hz mains.
 Concept (FIG. 4)
The MCR's operating principle is based on back to back
coupled thyristors controlling the supply voltage to the
output transformer. A comparator determines the thyristor
firing angle to adjust the output current to a reference value.
The reference value varies with the selected brightness
step.
The regulator consists of three main components:
1) a power module
2) a control module
3) an output transformer

 Conditioning
The MCR is delivered with defined parameter values.
Via a standard IBM-compatible PC, loaded with a dedicated
software, the user has access to the parameters and can
modify them. With this PC, the user can also monitor the
MCR performance even for those functions for which no                                   MCR 2.5 kVA                                                FIG. 3
visual back-indication is provided on the front panel.

The user can also optimize the MCR operation by adapting
the output power to the circuit load by using the taps on the
secondary of the output transformer.

Status informations are available on the front panel display
or via the PC when connected (FIG. 16).




                           Power Module KSR 43 A /110 A
                                                    Thyristor                                                       H.V. Compartment
        Fused input                                             Input Current
                                        Main          Pack
          Switch                                                 Transformer
                                      Contactor K                                                                      Choke
                                                                     Tin                                                             Output
                                                                                                                                  Transformer
     Mains
     Input            Auxiliary
                       Fuses                                                                  Control Module
                                                                                                                                    Load
                                                                                                                                  Adaptation
                                                                                                                                    Taps
                                                                                                                                     Output
                                                                                                                                    Current
                                                                                                                                  Transformer
                                                                                                                                      Lamp
                            Auxiliary Supply                                                                                         Monitor
                                                                                                    Lamp Fault
                            Transformer T1                                          1            Detection Module                 Transformer
                                                                                    2
                                                                                    3
                                                                                    4
                                                                                    5
                                                                                                                                     Output
                                                                                    6
                                                                                    7                                               Voltage
                                                                                    8
                                                                                                                                  Transformer
                                                         PC or Laptop
                                                         X1 connector           1            LFD Piggyback PCB

                                                                                         3
                                                       Remote Control                                                              Lightning
                                                       and Monitoring                         Remote Control
                                                                                2
                                                                                              Piggyback PCB         Earth Fault    Arresters
                                                        X3 connector
                                                                                                                    Detection
  MCR Block Diagram                                                                                                  Module

  with multiwire remote control,
  including optional LFD and EFD
                                                                                                                           Output
  modules.                                                                                                                                      FIG. 4
 Power Modules KSR43A and KSR110A
The MCR power modules are built around the thyristor
packs.
Irrespective of the supply voltage, the complete power
range, from 2.5 to 30 kVA, is covered with two modules,
one rated 43 A (FIG. 5 and 6), the other rated 110 A
(FIG. 5 and 7).
Together with the control module, the power module forms
an easily serviceable withdrawable low voltage unit for rack
mounting or for integration in a stand alone configuration.

 Construction (FIG. 6-7)                                                                                 KSR43A
1.   Auxiliary fuses                                                                                     module
2.   Dual in/out terminals
3.   Thyristor pack THP1
4.   Thyristor trigger and contactor on/off control PCB
5.   2-pole contactor K
6.   Auxiliary supply transformer T1
7.   Plugs P2 and P7 for the Control Module
8.   Input current transformer Tin.

 Dimensions
Height: Double-height Eurocard format 6U (267 mm)
Width: 122 mm for the KSR43A power module and
        244 mm for the KSR110A                                                 KSR110A
Designed for insertion in 19-inch racks.                                        module
                                                                          (shown with Control Module inserted)                 FIG. 5




        1       2       3            4                                     1       2       3         4
                                              F1    F2
                                                                                                                  F1      F2




                                                   MCR-43A                                                                     MCR-110A




                                                                                       5         6                    7
                    5            6                           7




                                           KSR43A                                                           KSR110A
                                           module                                                           module
            8                                                                  8
                                                                 FIG. 6                                                        FIG. 7
 Control Module (FIG. 8-9)
The on-board micro-controller controls and monitors the
operation of the regulator.
The main monitoring functions are :                                                1
– Supply voltage monitoring
– Output current monitoring for overcurrent
– Output current monitoring for open circuit
                                                                                   2
  (too low output current)
– Capacitive output current monitoring. With an open                               3
  circuit on long, screened series cables, the output
  current, due to cable capacitance, may remain above the                 1                      1
                                                                          2                      2
  open circuit threshold level thus inhibiting the operation              3
                                                                                   4             3
                                                                          4                      4
  of the open circuit shut down.                                          5
                                                                          6
                                                                                                 5
                                                                                                 6
                                                                          7                      7
  The MCR monitoring circuit will sense this capacitive                   8                      8

  current and shut down the regulator.                                             5
                                                                                             1
– Monitoring of the output current for asymmetry.                     1

                                                                                   6                  A

The control module motherboard accepts a piggy-back PCB
                                                                              3
interface for either a multiwire remote control or a multiplex
remote control. The module accepts also a second piggy-                                               B
                                                                      2                      2
back PCB for Lamp Fault Detection.
                                                                                   7

 Description (FIG. 8)
1. 4 digit, multiple info alphanumerical display :
   output current, brightness step, % of maximum output           Multiwire            Multiplex
                                                                  remote control       remote control
   load, output voltage, number of failed lamps, series circuit
   insulation value, series circuit identification, display and                                  FIG. 8
   LED test.
   The selection is made by the “select” push button.
2. LED’s for CCR ON, I-fault, Earth-fault, Lamp fault and
   Local operation.
3. Reset button
4. Remote, OFF, Brightness step 1 to 8 selector
5. DB9-male connector for connection to a PC (X1)
6. DB37-male multiwire remote control connector
   (X3) or 2 DB9-female multiplex remote control connectors
   (XA,XB)
7. DB25-male connector (X2) for feedback signals
   (current, LFD and EFD) duplicated to P7 on the rear.                                              FIG. 9


 Dimensions
Height: Double-height Eurocard format 6U (267 mm)
Width: 45.7 mm
Designed for insertion in the power module or in a 19-inch
rack.
 Technical Data
                                                                    Primary power factor and efficiency
Performance figures are always equal to, or better than,
those specified.                                                                                 TAP
Output power ratings :                                                            2/8 3/8 4/8            6/8     7/8 8/8
  2.5 - 4 - 5 - 7.5 - 10 - 12.5 - 15 - 20 - 25 - 30 kVA             100%
                                                                                                                                      Efficiency
                                                                     90
Output current ratings :
                                                                     80
 Standard 6.6 A; also 20 A for 25 & 30 kVA regulators                                                                                 Primary
                                                                     70                                                               power
Input voltage ratings :                                                                                                               factor
  220, 230, 240, 380, 400, 415 V, 50/60 Hz,                          60
  single phase, 2-wires.                                             50

Remote control voltage:                                              40
  Multiwire : 24 or 48 to 60 V DC                                             12     25 37 50           75 87              100%
  Multiplex : according to RS485 with J-Bus protocol                               LOAD in % of rated power
                                                                    Typical curves for a regulator rated 30 kVA                      FIG. 10
Brightness control (FIG. 12) :
In 1 to 8 steps or also 255 steps (multiplex version only).

Output current regulation :
Within ± 1% of 6.6 A (or 20 A), under the following conditions:
– For nominal input voltage from -5 to +15%
  Operation from -5 to -15% of the nominal input voltage
  is still possible but may entail an output current drop at
  full brightness.
– For mains frequency comprised between 48 and 63 Hz.
– From full load to short-circuit
– For ambient operating temperature from -20°C to +55°C
– For an altitude range from 0 (sea level) to 1000 m
– For a relative humidity range of 10 to 90% without
  condensation
– Up to 30% series transformers with open secondary.                                                                                    FIG. 11
  NB: At lower brightness settings, tolerances on output
  current exceed ± 1 %.
                                                                   Standard Output Current Presets (A)
Open circuit output voltage :
Less than 1.2 times the nominal output voltage (RMS).             Selector                               CCR Type
                                                                   switch
Efficiency :                                                      position 3-step     4-step      5-step       6-step      7-step       8-step
90 to 92% depending on the size, under nominal resistive load,
nominal output current and nominal input voltage                     1     4.8 (15)   3.3 (10)    2.8 (8.5)    2.7 (8.2) 2.2 (6.7) 2.8 (8.5)

                                                                     2     5.5 (17)   4.4 (13)    3.4 (10)     3.4 (10)   2.8 (8.5) 3.1 (9.3)
Primary power factor :
> 0,9 for ratings up to 10 kVA                                       3     6.6 (20)   5.5 (17)    4.1 (12)     3.9 (12)   3.4 (10)    3.4 (10)
> 0,95 for ratings 12.5 kVA and up.
under same conditions as for "Efficiency"                            4        "       6.6 (20)    5.2 (16)     4.5 (14)   4.1 (12)    3.9 (12)

Taps on secondary of output transformer (FIG. 11) to match           5        "          "        6.6 (20)     5.4 (16)   5.2 (16)    4.6 (14)
the MCR to the actual load of the series circuit and to
                                                                     6        "          "           "         6.6 (20)   6.4 (19)    5.5 (17)
achieve best efficiency and primary power factor (FIG. 10).
Also to reduce waveform distortion.                                  7        "          "           "            "       6.6 (20)    6.4 (19)
Temperature :                                                        8        "          "           "            "          "        6.6 (20)
– Operating temperature : -20°C to +55°C.
– Non operating temperature : -40°C to +70°C.                      Notes
Temperature rise under the most adverse conditions meets           ( ) Values for 20 A CCR
ANSI C57.12.91.                                                    Minimum output currents :
                                                                      1.8 A (6.6 A) or 5.5 A (20 A)                                  FIG. 12
Degree of protection : IP 22
 Construction
                                                             Outline Dimensions (mm)
Stand alone (FIG. 13, 14, 15) :
                                                                              440                          645
This FAA-style execution houses a complete regulator in
one enclosure divided into two compartments :                   SELECT




1) Low Voltage compartment, containing the
                                                                ON
                                                                FAULT
                                                                FAULT




                                                                                                                        267
                                                                FAULT
                                                                LOCAL

                                                                RESET


                                                                    REM
                                                                    OFF
                                                                    S1
                                                                    S2
                                                                    S3
                                                                    S4
                                                                    S5
                                                                    S6




   power module, the control module and a fused
                                                                    S7
                                                                    S8


                                                                X
                                                                1




                                                                          X
                                                                          3



                                                                X
                                                                2




   input switch.
2) High Voltage compartment, containing the output           MCR - 2.5 kVA                                       FIG. 13
   transformer, current and voltage measurement
   transformers and lightning arresters.
                                                                                    411                   606
Note :
Since the output voltage of a 2.5 kVA CCR is limited                          SELECT

                                                                              ON
                                                                              FAULT
                                                                              FAULT
                                                                              FAULT
                                                                              LOCAL

                                                                              RESET




to 380 V, all components are housed in one common
                                                                                  REM
                                                                                  OFF
                                                                                  S1
                                                                                  S2
                                                                                  S3
                                                                                  S4
                                                                                  S5
                                                                                  S6
                                                                                  S7



                                                                              X
                                                                              1




compartment.
                                                                                        X
                                                                                        3



                                                                              X
                                                                              2




Rack or panel mounted :
The modules and the output transformer are mounted




                                                                                                                       1260
together in one cabinet enclosure. Alternatively, the
low-voltage components and the high-voltage ones are
installed in separate enclosures. The power modules
and the control module may be installed in a standard
19-inch rack.

Finish
Baked epoxy powder coating.
Colour : light grey RAL 7032.




                                                                                                                       100
 Packing Data
                                 Seaworthy packing (*)       MCR - 4 kVA to 10 kVA                               FIG. 14
  Rating            Net                                      (Shown with rolling castors)
   kVA      FIG.   Weight       Case          Gross weight
                    (kg)
                            Dimensions (cm)       (kg)
                                                                                            611            606
    2.5      13       37      50 x 28 x 66         152
   4                  83                           133
   5                  88                           138                                      SELECT

                                                                                            ON
                                                                                            FAULT
                                                                                            FAULT
                                                                                            FAULT
                                                                                            LOCAL




   7.5       14      123     49 x 69 x 144         173
                                                                                            RESET


                                                                                                REM
                                                                                                OFF
                                                                                                S1
                                                                                                S2
                                                                                                S3
                                                                                                S4
                                                                                                S5
                                                                                                S6
                                                                                                S7




  10                 155                           205
                                                                                                S8


                                                                                            X
                                                                                            1




                                                                                                      X
                                                                                                      3



                                                                                            X
                                                                                            2




  12.5               161                           211
  15                 187                           237
  20                 220     69 x 69 x 144         270
  25         15      235                           285
  30                 250                           300
                                                                                                                        1260




* For information only.




                                                             MCR - 12.5 kVA to 30 kVA                            FIG. 15
 Standard Options
Lamp Fault Detection (LFD)
The LFD module provides accurate and real time detec-
tion of the number of burnt out lamps and power loss in a
series circuit.
The module consists of a piggy-back PCB mounted onto
the Control Module, a current transformer, including
voltage limitation for level adaptation, and a voltage
transformer.
The number of failed lamps is reported to the
alphanumerical display on the Control Module,
to the remote control and to the PC if connected.
The LFD functionality is adjustable with a dedicated
software running on a PC connected to the Control
Module.
Earth Fault Detection (EFD)
The EFD module measures the insulation resistance of
the series circuit versus ground with the regulator both
on and off. A stabilized DC voltage is applied between
the series circuit and the ground, irrespective of the
operating voltage.
The resistance is calculated from the resulting leakage
current and is reported to the alphanumeric display on the                                                       FIG. 16
Control Module, to the remote control and to the PC if
connected. The measuring range is from 6.3 kΩ to 0.5 GΩ.
Remote control and monitoring
The MCR offers the following choices:
• A multiwire remote control with two voltage
  ranges: 24 or 48 V DC
  The multiwire version provides remote control and
  back indications of all basic functions such as remote
  control of brightness steps or back indication of alarms
  due to overcurrent, open circuit and the mode of
  operation (local or remote).
• A multiplex remote control
  The multiplex version is possible thanks to the integra-
  tion of a microprocessor into the Control Module.
  It uses a field bus with hardware according to RS485
  and J-Bus protocol. It allows the remote monitoring of
  a larger quantity of parameters ( e.g. the number of
  brightness steps is brought up to 255, selection of the
  local displayed value, etc...).                                                                                FIG. 17
  A single and a dual J-Bus version are available. The dual
  J-Bus makes the control system fully redundant up to
  the CCR.                                                    Time Counter
Rolling castors                                                Time counters can be mounted on the right front panel
  The MCR can be equipped with rolling castors.                of the low-voltage compartment (FIG. 17).
                                                               Two versions ”ON“ and ”maximum brightness step“
Plug-in, HV cutout                                             are available. Time counter ”ON“ starts counting as soon
  A safety device that isolates the series circuit from the    as the MCR is switched ON, independent of the bright-
  CCR output. It also provides earthing and insulation         ness step. Time counter ”maximum brightness step“
  resistance measurement functions.                            runs only, when the MCR operates in maximum bright-
  (see cat. leaflet A.06.455e)                                 ness step (6.6 A or 20 A).
 Ordering code                                                               Suggested Specification
                          MCR - 15-6.6 - 38 - M4R - ON - L - E - R - C - S   The Constant Current Regulator shall be microprocessor
                                                                             assisted and of the solid state type using thyristors in
 Output-Power/Current :                                                      series with the output transformer for automatic current
   12.5 kVA-6.6A = 2.5-6.6                                                   regulation against load and mains voltage variations. It shall
   14 kVA-6.6A = 4-6.6
   15 kVA-6.6A = 5-6.6                                                       comply strictly with FAA specifications L-828 in Advisory
   17.5 kVA-6.6A = 7.5-6.6                                                   Circular AC 150/5345-10E.
   10 kVA-6.6A = 10-6.6                                                      – Use: indoor in ambient temperature up to 55°C.
   12.5kVA-6.6A = 12.5-6.6                                                   – Design and construction: self contained, metal sheet,
   15 kVA-6.6A = 15-6.6                                                        floor standing or adaptable in a rack.
   20 kVA-6.6A = 20-6.6                                                      – Cooling: natural air cooled. Forced air cooling shall not
   25 kVA-6.6A = 25-6.6 (1)                                                    be accepted.
   30 kVA-6.6A = 30-6.6 (1)
   25 kVA-20A = 25-20 (1)                                                    – Brightness control: in 3, 4, 5, 6, 7, 8 or 255 steps.
   30 kVA-20A = 30-20 (1)                                                    – Operational parameters will be adaptable and modifiable
                                                                               with a PC and dedicated software.
 Input Voltage (50/60 Hz) :
   220 V = 22                                                                – Possibility to display the status values
   230 V = 23                                                                – Multiplexed remote control with a well established field
   240 V = 24                                                                  bus or multiwire remote control with either 24 V or
   380 V = 38                                                                  48 to 60 V DC power.
   400 V = 40                                                                – Remote monitoring : via potential free N/O contacts.
   415 V = 41                                                                – Automatic input voltage compensation : from +15%
 Remote control (2) :                                                          to -15%.
   Multiwire 48 V = M4R                                                      – Permanent monitoring of input voltage with automatic
   Multiwire 24 V = M2R                                                        shutdown on low voltage (lower than 0,8 of nominal
   Single J-Bus                                                                voltage) and automatic restart when the supply voltage
   rear connection = SJR                                                       exceeds 0,85 of nominal voltage.
   Dual J-Bus
   rear connection = DJR                                                     – Tripping in case of output overcurrent and open circuit.
   Single J-Bus                                                              – In case of shutdown, the CCR will be re-energized by a
   front connection = SJF                                                      remote or local OFF/ON operation.
   Dual J-Bus                                                                – Fused switch in power input and fuses in auxiliary
   front connection = DJF                                                      circuits.
 Time counter (3) :                                                          – Primary power factor, efficiency, temp. rise:
   Without TC                            = NO                                  as per FAA L-828.
   TC operating at all brightness steps = ON                                 – Local control: to be provided for all functions.
   TC operating at max brightness                                            – True RMS output current digital ammeter.
   step only                             = MB (4)                            – Positive back indication of operation such as:
   TC operating at all brightness steps
   and TC operating at max brightness                                          • Shutdown by output overcurrent


                                                                                                                                              2/10.99 - Subject to modifications Order No. E10001-A95-A52-V2-7600
   step                                  = OB (4)                              • Shutdown by output open circuit
 LFD :
                                                                               • Asymmetrical output current
   Without LFD = O                                                             • Capacitive current
   With LFD = L                                                                • Discrepancy between actual and selected output
                                                                                 current.                                                     11D6046 95D995265 PA 10983. Dispo 21649 SEK 21856
 EFD :
   Without EFD = O                                                           – The regulator shall be fully compatible with L-827
   With EFD = E                                                                monitoring system.
 Rolling castors :                                                           – Taps on the output winding shall allow for matching
   Without roling castors = O                                                  the regulator output capacity to the actual series
   With rolling castors = R                                                    circuit load.
 Cutout SCO :
   Without cutout = O
   With cutout       =C
 Special requirements to be specified in full text = S
 (1) Only for 380, 400 or 415 V input
 (2) If the MCR works together with a CSM, both must have the same
     remote control system.
 (3) If the MCR works together with a CSM, the time counter is only
     available on the CSM.
 (4) Not available for single and dual J-Bus.
 CSM = Circuit selector for MCR : Refer to cat leaf A06.412e

                                 Complete, delete are modify as necessary.




N.V. ADB S.A.
Leuvensesteenweg, 585 - B 1930 Zaventem - Belgium
Tel : 32/2/722.17.11 - Fax : 32/2/722.17.64 - Telex : 22154
Companies in France, U.K., and U.S.A. - Agents all over the world.

				
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