Constant Current Regulator Microprocessor Controlled A.06.350e Compliance with Standards FAA: AC 150/5345-10E ICAO: Aerodrome Design Manual Part 5, para 18.104.22.168. to 22.214.171.124. 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.