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Maintenance manual

Microprocessor controlled constant current regulator


Type MCR 2.5 kVA to 30kVA
AM.07.360e Edition: 1

N.V. ADB S.A., A Siemens Company


This manual or parts thereof may not be reproduced, stored in a retrieval system, or transmitted,
in any form or by any means, electronic, mechanical, photocopying, recording, nor otherwise,
without ADB's prior written consent.
This manual could contain technical inaccuracies or typographical errors.
ADB reserves the right to revise this manual from time to time in the contents thereof without
obligation of ADB to notify any person of such revision or change.
Details and values given in this manual are average values and have been compiled with care.
They are not binding, however, and ADB disclaims any liability for damages or detriments
suffered as a result of reliance on the information given herein or the use of products, processes
or equipment to which this manual refers. No warranty is made that the use of the information or
of the products, processes or equipment to which this manual refers will not infringe any third
partys patents or rights. The information given does not release the buyer from making their own
experiments and tests.

N.V. ADB S.A.


A Siemens Company

Address: Leuvensesteenweg 585, B-1930 Zaventem, Belgium


Tel.: +32 2 722 17 11, Fax: +32 2 722 17 64
Email: adb-air@siemens.com
Internet: www.adb-air.com

Guarantee
N.V. ADB S.A. guarantees that the performance of the equipment described in this manual, when
sold by ADB or its licensed representatives, meets the requirements of FAA specification AC 150/
5345-10E and IEC 61822.
Any defect in design, material or workmanship, which may occur during proper and normal use
over a period of one (1) year from date of shipment, will be repaired or replaced by ADB free of
charge, ex. works. Operational failure resulting from lamps burned out, improper maintenance or
installation, damage due to runway maintenance equipment, snow ploughs or aircraft arresting
gear hooks is not considered a result of proper use and is beyond the scope of the warranty.
Warranty does not cover natural wear and tear or damage arising after delivery owing to faulty or
negligent handling, excessive strain, unsuitable materials for operation, deficient civil engineering
work, unsuitable soil conditions, and such chemical, electrochemical or electrical influences as
were not assumed at the time of the conclusion of the contract.
All liability for consequences of any inexpert alterations or repairs carried out by Purchaser or a
third party shall be waived. N.V. ADB S.A. shall in no event be liable to Purchaser for any further
claims, particularly claims for damages not affecting the goods themselves.
The above constitutes the limits of ADBs liabilities in connection with the equipment covered by
this manual.

Table of Contents
1.

Safety
1.1.
1.2.
1.4.
1.5.
1.6.

2.

Specifications
2.1.
2.2.
2.6.
2.7.
2.8.

3.

MCR 2.5 to 12.5 kVa........................................................................................................................ 11


MCR 15 to 30 kVa............................................................................................................................14
Working principle .............................................................................................................................. 18
Components......................................................................................................................................21
Options.............................................................................................................................................. 28

Maintenance
3.2.
3.3.
3.4.

4.

Warning signs .....................................................................................................................................7


Intended use .......................................................................................................................................8
Safety devices.....................................................................................................................................8
Safety precautions ..............................................................................................................................8
Users...................................................................................................................................................9

General ............................................................................................................................................. 31
Replace parts .................................................................................................................................... 32
Parts list ............................................................................................................................................65

Operation
4.3. Select the correct brightness step.....................................................................................................74
4.12. Using the cut-out SCO ......................................................................................................................79

5.

Troubleshooting
5.4.
5.5.

6.

PCB drawings and settings


6.1.
6.2.
6.3.
6.4.
6.5.
6.6.
6.7.
6.8.
6.9.
6.10.
6.11.
6.12.

7.

Working with PCBs ........................................................................................................................... 89


TBM - PCB1517 -1593.14.212.......................................................................................................... 90
PSL PCB1521 1593.14.400........................................................................................................92
CCL - PCB1516 1590.03.541 ........................................................................................................95
LMC - PCB1513 1593.14.111 ........................................................................................................96
UI - PCB1507 1593.14.000.......................................................................................................... 101
Multiwire - PCB1486 1593.13.510 & 1593.13.520 (option)..........................................................104
J-Bus - PCB1502 1590.03.490 (option) ....................................................................................... 107
LFD - PCB1519 1590.03.551 (option) ......................................................................................... 108
EFD Logic - PCB1514 1590.03.520 (option) ............................................................................... 110
EFD-Resistor - PCB1515 1590.03.530 (option)........................................................................... 112
Circuit Selector PCB1523 1590.03.561 (option) ....................................................................... 113

Appendix
7.1.
7.2.
7.3.

- -

Error messages.................................................................................................................................82
Observed deviations .........................................................................................................................85

Checks and measurements ............................................................................................................ 115


Local user interface......................................................................................................................... 116
Configuration tool software ............................................................................................................. 123

- -

About this manual


The Microprosessor Controlled Constant Current Regulator (MCR3), hereafter referred to as the
regulator, is manufactured by ADB. The regulator can be ordered in several different types.
These types are divided into two main groups based on the size of the regulator cabinet. These
two cabinets are hereafter referred to as follows:
Cabinet size

Icon used

Description

Small cabinet

Regulators from 2.5 to 12.5 kVA.

Big cabinet

Regulators from 15 to 30 kVA.

This manual provides information about how to install and take the regulator into use.

Subject(s)

Chapter(s)

Safety, Description

1, 2

Maintenance

Operation

Troubleshooting

PCB drawings and settings

Familiarize yourself with the content;


Follow all instructions;
Never change the order of the operations to be carried out.

Safety

Safety
WARNING
Do not use the regulator unless you have read and understood all the
applicable safety regulations and standards.

1.1

Warning signs
Safety signs are attached to the equipment to give safety information. All safety signs are
repeated and usually further explained in this manual.

Classes of safety
signs

Safety signs are of the three internationally accepted types as given below.

Warning sign that identifies a hazard.


In this example: Electric shock.

Mandatory action sign that communicates an action to be taken to avoid a hazard.


In this example: Wear protective gloves.

Prohibition symbol that defines a prohibited action.


In this example: Do not touch.

Signs on the
equipment

ER

NG

SCO

DA

AGE
VOLT
HIGH EUR
ION
ULATOFF
E TENS LE REG OR
HAUT PERREGULAT

- 83

OUT
CUT

UALING
MANRAT
D
REA OPE UELN
ORE MANTIO
Z LE LISA
UTI

COU CH
SWIT

DANGER

BEF

LISE
NT
AVA

ER
DANG

ING
MANUAL
READ OPERAT
ION
MANUEL
BEFORELE
LISEZ UTILISAT
AVANT

DANGER

READ MANUAL
BEFORE OPERATING

HAUTE TENSION HIGH VOLTAGE


COUPER LE REGULATEUR
SWITCH REGULATOR OFF

LISEZ LE MANUEL
AVANT UTILISATION

CUTOUT SCO - 83
CONSTANT CURRENT REGULATOR
REGULATEUR A COURANT CONSTANT

READ MANUAL
BEFORE OPERATING

+T
PHASE
2P
R
SINGLE
CONSTANT BIPHASE
REGULATO
50/60Hz
CURRENT
A COURANT
UR
CONSTANT
REGULATE
:
TYPE
:
:
:
INPUT :
ENTREE
:
OUTPUT CONTROL
SORTIE :
REMOTE
TELECOM:
:
:
OPTIONS
NR SERIE
DE

A
B

AA

V
kVA

IN

8STEPS
MAX.
MAN.
8BRILL.

BELGIUM

MADE

ID-N

SERIES
NUMERO

LISEZ LE MANUEL
AVANT UTILISATION

V
kVA

A
A

50/60Hz
MAN. 8STEPS
8BRILL. MAX.

OPTIONS :

ID-N

SINGLE PHASE
BIPHASE 2P + T

TYPE :
INPUT :
ENTREE :
OUTPUT :
SORTIE :
REMOTE CONTROL :
TELECOM :

SERIES NR :
NUMERO DE SERIE :

MADE IN BELGIUM

Low-voltage compartment
High-voltage compartment

Maintenance Manual - MCR3 - AM.07.360e

Safety

1.2

Intended use
The regulator is a microprocessor-controlled constant current regulator. The regulator supplies
airport lighting series loops at different intensity levels. The regulator is in accordance with these
standards:

Table: 1

Applicable standards

Standard

Description

ICAO

Aerodrome Design Manual, Part 5 paragraphs


3.2.1.4/5/6

FAA

AC 150/5345-10F and L829

IEC

IEC 61822

Any other or additional use will be considered not to be in conformity with the purpose. Use this
regulator in a technical perfect condition in conformity with the purpose, described above.

Operation limits

Do not operate the regulator outside the limits of the specifications.


For limits about ambient conditions, see section 2.3 Ambient conditions.

EMC conformity

The regulator is designed to operate in an industrial electro-magnetic environment. The regulator


complies with IEC 61822, in accordance with IEC 61000-6-4 and IEC 6-6-2 (generic standard for
industrial environment). The regulator is, with adapted test levels, in accordance with IEC/
TS61000-6-5, G (substation environment, location G).

1.3

Modifications
WARNING
Do not try to make changes to the equipment without a prior express
agreement from ADB. Unauthorized modifications or changes to the
equipment could lead to serious personal injury, or death.

1.4

Safety devices

SCO microswitch
(option)

The cut-out SCO has a microswitch, which is connected to the removable cover. If the cover is
not in position, the microswitch stops the regulator and interrupts the output power supply to the
series circuit.

Signs on the
equipment

The signs on the equipment are part of the safety provisions. They must not be covered over or
removed. The signs must be present and legible during the entire life of the equipment.
Check regularly;
Replace or repair signs that have become illegible or damaged.

1.5

Safety precautions
Regulatory safety precautions are applicable in some countries, on some sites. If no such legal
prescriptions exist, refer to the FAA standard for Advisory Circular AC 150/5340-26
"Maintenance of Air Visual Aid Facilities".
WARNING
Personnel must obey the safety regulations at all times.

Maintenance Manual - MCR3 - AM.07.360e

Safety

Installation and
maintenance

Always follow the safe work procedures, which are defined by the standard IEC 618.9.

Disconnection
devices

All regulator installations must have devices that disconnect the input and output current from
and to the regulator.

Live circuits

Observe all safety regulations at all times. Do not make any adjustments on the regulator, lamps,
or the series circuit when the series circuit is energized.
See FAA Advisory Circular AC 150/5340-26 concerning safety precautions. See also IEC-61820.
WARNING
You must always wear protective gloves and shoes when you work with the
regulator or live circuits.

Electrostatic
Discharge (ESD)

When you work with components that are susceptible to electrostatic damage:
Do not touch electronic components unless this is unavoidable, for example during part
replacement;
Eliminate electronic charges from your own body immediately before you touch an
electronic component. To do this, touch, for example, a conductive earthed object;
Store and transport electronic components in conductive packages. Avoid highly insulating
surfaces, like plastic sheets or synthetic fibre clothing.

1.6

Users

Personnel
qualifications

All personnel must only carry out the work they have been trained to perform. This applies
to both maintenance work and equipment preparation.
The operators must be familiar with all situations that may occur so that they can act rapidly
and effectively in the event of an emergency.
All personnel must be trained in resuscitation and first aid techniques.

Maintenance Manual - MCR3 - AM.07.360e

Safety

10

Maintenance Manual - MCR3 - AM.07.360e

Specifications

Specifications

2.1

MCR 2.5 to 12.5 kVa

2.1.1

Overview of MCR 2.5 to 12.5 kVa


A

H
F
G

Main items

A
B
C
D
E
F
G
H

Thyristor heatsink
Fused input switch
User interface
Lifting lugs (option)
Cut-out SCO (option)
Circuit selector cabinet (option)
Wheels (option)
Ground stud M6

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11

Specifications

K
P

B
Q

C
D
F
G

Main items

A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R

12

Input terminals and fuses F2, F3 and F4


Earth fault detection module (option)
Output measurement transformers TI 2
and TI 3
Tap S6-S1
Lightning arrestors LA1 and LA2
Output terminals
Series choke L1
Multiwire control logic (option)
J-Bus logic (option)
Thyristor block module logic
Power supply logic
Current control logic
Local master controller logic
Lamp fault detection logic (option)
Main contactor K1
Input measurement transformer TI1
Output transformer
Thyristor

Maintenance Manual - MCR3 - AM.07.360e

Specifications

2.1.2

Specifications for MCR 2.5 to 12.5 kVa


Table: 1

Specifications for MCR 2.5 to 12.5 kVa

Item

Description

Rated powers [kVa]


Rated input voltage [V]

2.5 / 4 / 5 / 7.5 / 10 / 12.5


1

FAA: 220 / 230 / 240 / 380 / 400 ( 15 %)


IEC: 230/ 400 ( 15 %)

Rated frequencies [Hz]

50 / 60 ( 7.5 %)

Output current [A]

6.6

Current regulation limits

Current regulation is guaranteed under the following conditions


(1.5 %):
A minimum of 30 % of lamp transformers with an open
circuit in their secondary side. This is for a range from
half-load to full-load.
For nominal input voltage:
IEC: 10 %
FAA: + 10 % / -5 %
Operation from -5 % to -15 % (FAA) or from -10 % to -15 %
(IEC) of nominal input voltage with full load can cause output
current to be too low at the maximum brightness step.
Operation at +15 % of the nominal input voltage is restricted to
a maximum period of 1 hour. This helps to prevent that
components become overheated or overstressed.

Remote control and monitoring Multiwire, single or dual wire industrial field bus (J-Bus), or the
two combined
Dimensions
(width x depth x height) [mm]

400 x 600 x 930

Dimensions with options [mm]


Wheels
Lifting lugs
Circuit selector
Bolts M12

Height + 100
Height + 50
Height + 500
Height + 15

Weight [kg]
Maximum
4 kVA regulator
5 kVA regulator
15 kVA regulator
30 kVA regulator
crate
CS cabinet (option)

380
103
120
220
303
15
50

1)

Some readjustments are possible in the ranges 220 - 240 V and 380 - 415 (420 V). For
readjustments, contact ADB.

Maintenance Manual - MCR3 - AM.07.360e

13

Specifications

2.2

MCR 15 to 30 kVa

2.2.1

Overview of MCR 15 to 30 kVa


A

C
D

Main items

14

A
B
C
D
E
F
G
H

Thyristor heatsink
Fused input switch
User interface
Lifting lugs (option)
Cut-out SCO (option)
Circuit selector cabinet (option)
Wheels (option)
Ground stud M6

Maintenance Manual - MCR3 - AM.07.360e

Specifications

K
P

O
B

D
G

Main items

A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R

Input terminals and fuses F2, F3 and F4


Earth fault detection module (option)
Output measurement transformers TI 2
and TI 3
Lightning arrestors LA1 and LA2
Output terminals
Tap S6-S1
Series choke L1
Multiwire control logic (option)
J-Bus logic (option)
Thyristor block module logic
Power supply logic
Current control logic
Local master controller logic
Lamp fault detection logic (option)
Main contactor K1
Input measurement transformer TI1
Output transformer
Thyristor

Maintenance Manual - MCR3 - AM.07.360e

15

Specifications

2.2.2

Specifications for MCR 15 to 30 kVa


Table: 2

Specifications for MCR 15 to 30 kVa

Item

Description

Rated powers [kVA]


Rated input voltage [V]

15 / 20 / 25 / 30
12

FAA: 220/ 230 /240/ 380 / 400 / 415 V ( 15%)


IEC: 200/ 400 V (15 %)

Rated frequencies [Hz]

50 / 60 ( 7.5 %)

Output current [A]

6.6

Current regulation limits

Current regulation is guaranteed under the following conditions


(1.5 %):
A minimum of 30 % of lamp transformers with an open
circuit in their secondary side. This is for a range from
half-load to full-load.
For nominal input voltage:
IEC: 10 %
FAA: + 10 % / -5 %
Operation from -5 % to -15 % (FAA) or from -10 % to -15 %
(IEC) of nominal input voltage with full load can cause output
current to be too low at the maximum brightness step.
Operation at +15 % of the nominal input voltage is restricted to
a maximum period of 1 hour. This helps to prevent that
components become overheated or overstressed.

Remote control and monitoring Multiwire, single or dual wire industrial field bus (J-Bus), or the
two combined
Dimensions
(width x depth x height) [mm]
Dimensions with options [mm]
With wheels
With lifting lugs
With Circuit selector
With bolts M12

Height + 100
Height + 50
Height + 500
Height + 15

Weight [kg]
Maximum
4 kVA regulator
5 kVA regulator
15 kVA regulator
30 kVA regulator
crate
CS cabinet (option)

380
103
120
220
303
15
50

1)
2)

16

600 x 600 x 1260

25 and 30 kVA, only for 380/ 400/ 415 V.


Some readjustments are possible in the ranges 220 - 240 V and 380 - 415 (420 V). For
readjustments, contact ADB.

Maintenance Manual - MCR3 - AM.07.360e

Specifications

2.3

Ambient conditions
All regulators are air-cooled without fans. Thus, all regulators must have a good airflow,
especially if they operate near the maximum temperature.

Table: 3

2.4

Ambient conditions

Item

Description

Temperature

From -20 up to +55 C

Altitude

From 0 (sea level) up to 1000 meter

Relative humidity

From 10 % up to 95 % RH without condensation

Power factor and efficiency


The regulator power factor and efficiency are in accordance with the standards:

Table: 4

2.5

Standards for regulator power factor and efficiency

Standard

Specification

FAA

AC 150/5345-10F and L829

IEC

IEC 61822

Nameplate
Each regulator has a standard nameplate with this data:

CONSTANT CURRENT REGULATOR


REGULATEUR A COURANT CONSTANT
SINGLE PHASE
BIPHASE 2P + T

TYPE :
INPUT :
ENTREE :
OUTPUT :
SORTIE :
REMOTE CONTROL :
TELECOM :

V
kVA

A
A

50/60Hz
MAN. 8STEPS
8BRILL. MAX.

ID-N

OPTIONS :
SERIES NR :
NUMERO DE SERIE :

MADE IN BELGIUM

Maintenance Manual - MCR3 - AM.07.360e

17

Specifications

2.6

Working principle

Series circuit
system

A
B
C

Input power supply


Input disconnection device
Remote control system

D
E
F

Regulator
Output disconnection device
Series circuit

The regulator is a microprocessor-controlled constant current regulator. The regulator supplies


power to airport visual aid series circuits at different intensity levels.

18

Maintenance Manual - MCR3 - AM.07.360e

Specifications

Regulator

DS3
DS2
DS4
SW2
DS5
DS6
DS1

SW1
C01

C04

D
J3

J1

J6

D1
SW1

C07
C06

C04

C05

DS2
DS1

C02

C01

DS2

C03

DS3

DS4

SW3
C04

DS1

C03

DS4
DS3

DS3

C01

SW2

DS1

SW1
SW2

DS7

DS8
DS2

SW5

SW6

DS10

SW7

DS11 DS9

DS5
DS6

SW1
C01

J5

C09

J2

J1

C08

C010

SW2

S3

C014

S3

SW4

C012

C013

D5
D4
D3
D2

C011

C06

C03

C02

S3

C07

DS4

C05

SW2

D2
D3
D4
SW1
D5

J2

12
11
10
9
8
7
6
5
4
3
2
1

P2

P1

W5

W6

12
11
10
9
8
7
6
5
4
3
2
1

J1
12
11
10
9
8
7
6
5
4
3
2
1

P2

12
11
10
9
8
7
6
5
4
3
2
1

P3
P1

W5

X3

W6

X8

J1
12
11
10
9
8
7
6
5
4
3
2
1

X4

P2

12
11
10
9
8
7
6
5
4
3
2
1

X2

P3
P1

W5

W6

X1

X5

J1
P1

P2

P5

P6

P3

P4

X7

X6

P3

J
L

R
S

A
B
C
D
E
F
G
H
I
J
K
L
M

UI logic
Earth fault detection logic (option)
Main contactor K1
Thyristor block module logic
Current control logic
Lamp fault detection logic (option)
Local master controller logic
J-Bus interface (option)
Multiwire logic (option)
Power supply logic
Input measurement transformer TI 1
Fuses F2 and F3
Output power transformer T1

Maintenance Manual - MCR3 - AM.07.360e

N
O
P
Q
R
S
T

Output measurement transformer TI 2


and TI 3
Earth fault detection resistors (option)
Output terminals
Series choke L1
Fused input switch F1
Input terminals
Thyristors THP1

19

Specifications

The current regulator holds the output current constant by varying the output voltage to the series
circuit. The voltage can be adapted by changing the conduction angle of the thyristors in both the
positive and the negative difference of the input signal.
The TBM module fires the thyristors at the request of the CCL module.
The TBM module receives a signal from the remote control system.
The TMB module gives an output to a certain current level.
The CCL compares the requested step & actual output current level.
The CCL computes and sends the TBM a request to generate the required output voltage.
This process will be maintained until no output is anymore demanded or if any of the safety
features are triggered. The regulator stops immediately when triggered by a safety feature. The
safety can only be reset at the TBM module.

Remote control

The regulator can be controlled remotely with Multiwire, J-Bus, or a combination of these. The
system automatically detects which communication method is available.

Multiwire (option)

Each multiwire PCB consists of input and output terminals. These terminals handle the incoming
and outgoing signals between the regulator and the remote control system. The number of
multiwire PCBs on the regulator determines the maximum number of available signals.

J-Bus (option)

J-Bus can be either a single or a dual databus:


With a single databus, the regulator has only one communication channel.
With a dual databus, the regulator has two separate communications channels: Bus A and
Bus B. They should take different routes to avoid a communication failure if one cable is
interrupted.

Options

The regulator has these optional components:


Circuit selector (CS):
With a circuit selector you can connect several (up to eight) series circuits to a single
regulator and control them individually.

20

Cut-out SCO:
An output disconnecting device between the regulator and the series circuit. The cut-out
SCO isolates the series circuit from the regulator during maintenance or testing operations.
The cover can be locked with a key to prevent unauthorized access.

Earth Fault Detection (EFD):


Measures the insulation resistance between the series circuit and the ground or the cable
screen. You can set two alarm levels for the measured values.

Lamp Fault Detection (LFD):


The operation of the LFD is based on the change in the waveform when a series
transformer saturates as a consequence of the lamp having blown at the secondary side.
The accuracy is +- 1 lamp. The LFD module can be used together with a circuit selector,
provided the multiple calibration was installed. It is then possible to calibrate the LFD
module for two or more different circuit settings.

Hour counters:
Measure the number of hours the regulator is ON, or the number of hours the regulator is
ON and produces output current that is higher than a set value.

Maintenance Manual - MCR3 - AM.07.360e

Specifications

2.7

Components

2.7.1

Power input

Input terminals
(X1)

The input terminals connect the power input


cables to the regulator. The size of these
terminals depends on the input current rating of
the regulator:

Table: 5

Power input terminal sizes

Input current rating of


the regulator

Terminal size [mm2]

Up to 50 A

16

Up to 100 A

35

Above 100 A

70

Common mode
choke (wire A02)

This core blocks the high-frequency commonmode currents from the power circuitry.

Fused input switch


(F1)

The fused input switch disconnects the regulator


from the mains power supply. For specific fuse
types, see section 3.4 Parts list.

Maintenance Manual - MCR3 - AM.07.360e

21

Specifications

Fuses F2, F3 and


F4

The fuses F2, F3 and F4 protect the wiring of the


regulator from overcurrent:
F2 protects the low current mains wiring;
F3 protects the wiring to measure the
primary voltage of the power transformer;
F4 protects the mains wiring of the circuit
selector (option).

Overvoltage
The overvoltage protection modules (option)
protection (MOV1A protect the input circuit from overcurrent. The
and MOV1B)
system detects all defective or missing modules.

Main contactor
(K1)

The main contactor interrupts the maximum


input current. It also provides a positive
interruption of the input power circuitry on both
supply lines.

Input
measurement
transformer (TI1)

The input measurement transformer enables the


system to measure the input current accurately.

22

Maintenance Manual - MCR3 - AM.07.360e

Specifications

Thyristors (THP 1)

The thyristors use phase control as a closed


loop regulation system to obtain the required
output current.

Series choke (L1)

The series choke limits the current rise time of


the thyristors, the output transformer, and the
current loop. The series choke also limits the
harmonics on the current waveform.

2.7.2

Power output

Output power
transformer (T1)

The transformer has a set of primary and


secondary taps. The primary taps can adapt to
the typical input voltages of 220, 240, 380, 400
or 416 V - 50 or 60 Hz. The secondary taps allow
the regulator to adapt to the actual load with a
set of steps: 2/8, 3/8, 4/8, 6/8, 7/8, and 8/8.
The following exceptions apply:
The 25 and 30 kVA regulators have only
the primary taps 380, 400 or 416 V - 50 or
60 Hz.
The 25 and 30 kVA regulators have
available 6.6 and 20 A power transformers.
The 2.5 kVA regulators have available only
the secondary taps 8/8 and 4/8.

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23

Specifications

Output
measurement
transformer (TI2
and TI3)

The output measurement transformer enables


the system to measure the output current
accurately.

Output terminals
(X2)

The output terminals connect the regulator to the


series circuit. If the regulator has the optional
cut-out SCO, the output terminals are replaced
by this SCO.

Lightning arrestors
(LA1 - LA2)

The output terminals connect the regulator to the


series circuit. The output terminals are also used
as lighting arrestors..

24

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S3

The CCL compares the actual output current


and the received brightness step request. The
CCL calculates the optimal conduction angle
request. The CCL checks the tolerance of the
output current, the overcurrent, or open circuit
condition and produces the back-indication
signals. In addition, the CCL also monitors the
output circuit and the input parameters.
The CCL module also controls the backindication signals ON and REG.ERR. See
section 2.7.7 Back-indication signals ON and
REG.ERR.

J3

Current Control
Logic (CCL)

J1

The PSL supplies power to the other modules in


+12 / +5 / -12 V. If the power supply to the PSL is
interrupted, its signal (Power Good) goes low in
less than 20 ms. The PSL maintains the DC
voltages for about 2 seconds after a power
failure, which leaves sufficient time for the
Current Control Logic (CCL) to prepare a fast
restart without the loss of control data.
This board also provides 230 V AC for the
internal 230 V AC components of the regulator.
The input lines have supplementary filters to
reduce the conducted emission of the regulator.

D1

Power supply
Logic (PSL)

S3

The TBM is the interface between the Current


Control Logic (CCL) and the thyristor gates. The
TBM PCB produces the thyristor gate firing
signals in accordance with the requested
conduction angle. It also provides fast
overcurrent protection and asymmetric output
voltage monitoring.

S3

Thyristor Block
Module (TBM)

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C06

C04

C07

2
X

J2

D5
D4
D3
D
D2

PCB logic

J5

2.7.3

J6

Specifications

DS1

C02

DS2

DS4

DS3

C01

C05

C03

SW

SW

25

Specifications

C0

C0

11

C0

C0

12

SW

SW1
DS2

SW7
C0

SW6

DS8

14

C01

C0

DS1

DS7

13

SW2

C0

DS11 DS9
DS10

The LMC communicates with the other modules


as a master via a local bus. The LMC processes
and distributes the messages it receives from
the other modules. Each slave has a control line
to request transmission of data to the LMC.
The local bus connection uses the RS485
protocol to send isolated signals over two wires.

SW5

Local Master
Controller (LMC)

C0

SW3
C0

J1

SW2

D2
D3
D4

D5

SW1

The user interface allows you to operate the


regulator and to change parameters in a local
mode. For more information on the user
interface, see section 7.2 Local user interface.
J2

User interface (UI)

C04

C03

DS6

10

DS4
DS3

DS5

C0

26

Maintenance Manual - MCR3 - AM.07.360e

Specifications

2.7.4

Remote control
The regulator can connect to the remote control with Multiwire or J-Bus or a combination of
these. The system automatically detects which communication method the regulator has.

2.7.5

Multiwire (option)

Description

Each regulator has a maximum of three multiwire PCBs connected to the Local Master Controller
(LMC):
MW1;
MW2;
MW3 (for circuit selector only)
Each multiwire PCB has eight input and eight output terminals. They handle the incoming and
outgoing signals between the regulator and the remote control. The amount of multiwire PCBs
determines the maximum amount of available signals.
NOTE
It is impossible to attribute the same function to more than one terminal.

You can set each signal to either POSITIVE or NEGATIVE logic. For example, if you configure an
output signal for function A and if the condition of function A becomes TRUE, the signal contact
closes in positive logic and opens in negative logic.
To read these settings in the configuration tool, see the section 7.3.7 IO menu.

2.7.6

J-Bus (option)

Description

The regulator has an option for a single or a dual databus:


With a single databus, the regulator has only one communication channel.
With a dual databus, the regulator has two separate communications lines: Bus A and Bus
B. They should take different routes to avoid a communication failure if one cable is
interrupted, for example by an excavating machine.
In order to match the load to the characteristic line impedance, you must terminate the databus
lines with resistors. This creates a reflection-free communication with less disturbances. See
section 6.5 LMC - PCB1513 1593.14.111.

Master / slave

A regulator is always a slave on the J-Bus. There can be a maximum of 16 regulators on one bus
section with one common bus master.

2.7.7

Back-indication signals ON and REG.ERR

Description

The regulator can send basic back-indication signals to a monitoring system. These signals
indicate to the monitoring system if the regulator is ON or OFF.
These signals must have simple, potential free contacts. The maximum contact load is:
AC - 110 V - 2 A - 220 VA;
DC - 110 V - 2 A - 60 VA.

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27

Specifications

2.8

Options

2.8.1

Cut-out SCO

Description

The optional cut-out SCO acts as an output disconnection device between the regulator and the
series circuit. The cut-out SCO also isolates the series circuit from the regulator during
maintenance or testing operations. The cover can be locked with a key to prevent unauthorized
access.
WARNING
Always wear protective gloves and shoes when working with the regulator or
series circuit.

2.8.2

Earth Fault Detection (EFD)

Description

The EFD module measures the insulation resistance between the series circuit and the ground or
the cable screen. The EFD module works when the regulator is connected to the mains supply,
even if the regulator is turned OFF.

Working principle

The EFD module has the following functions:


A measurement range from 10 kOhm to 0.5 GOhm;
A high-voltage resistor applies a stable, current-limited voltage of 500 V DC between the
series circuit and the ground or cable screen.

Monitoring

To monitor the insulation resistance, the EFD module uses two alarm levels: Level 1 and Level 2.
Both alarm levels can be set to any value between 20 kOhm and 250 MOhm. However, Level 1
must always be higher than Level 2.
For how to change these levels, see section 7.2.6 EFD Earth Fault Detection (option).

2.8.3

Lamp Fault Detection (LFD)

Description

The operation of the LFD is based on the change in the waveform when a series transformer
saturates as a consequence of the lamp having blown on the secondary side. It does this by
comparing the waveform with a reference captured during calibration when the user has verified
that all the lamps are connected and working properly.
The LFD can be used together with a circuit selector, provided that the multiple calibration option
was installed. It is then possible to calibrate the LFD for two or more different circuit settings. The
tolerances are:
0 - 5 burnt lamps: +-1 lamp;
6 - 10 burnt lamps: +-2 lamps.

Restrictions

The LFD provides correct measurements if the following conditions apply:


All lamp transformers are of the same type and rating;
Reactive and constant loadings are low;
The cable capacitance towards ground is less than 1F and is equally distributed in the
series loop. To test capacitance, see section 7.1 Checks and measurements;
No non-linear lights, such as guidance signs, BRITE, serial-to-parallel adapts or poor
contacts at primary or secondary lamp transformers.

28

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Specifications

2.8.4

Circuit selector (CS)

Description

With a circuit selector you can connect several (up to eight) series circuits to a single regulator.
The circuit selector has two modes:
Simultaneous: the regulator can connect to a number of the available circuits at the same
time;
Alternate: the regulator can connect to only one circuit at a time.

Interface board

The board converts the logic control signals (12 V DC) that come from the CCL PCB into coil
control voltages. If the regulator has a multiwire interface, the multiwire PCB MW3 serves as the
remote control and back-indication interface for circuit selection.

Fuses (F4)

The fuses protect the power supply to the auxiliary transformer. These fuses are located close to
the main fuse F1 and are accessible after removing the user interface panel.

Auxiliary
transformer (T1)

The coil voltage of the HV contactors is standardized to 230 V 50/60 Hz. This auto-transformer
(250 VA) serves to adapt the regulator mains voltage level to this voltage.

High-voltage
contactors (K1-K8)

Depending on the cabinet size there are two types of high-voltage contactors. The number of
contactors depends on the number of circuits and can be from two to eight.
For the big cabinet (above 10 kVA) the HV-circuit connects directly to the HV contactor terminals.
For the small cabinet (up to 10 kVA) there are separate connection terminals for the circuit
connection.

2.8.5

Hour counters

Description

There are two types of hour counters:


Counters that measure the amount of hours the regulator is ON.
Counters that measure the amount of hours the regulator is ON and produces output
current that is higher than a set value.
If the regulator has a Circuit selector, each circuit has its own hour counter.

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29

Specifications

2.9

User interface
You can operate the regulator directly with the local user interface panel of the regulator.
The local user interface of the regulator always shows the selected control mode on the title row.
See table 6 below.

Table: 6

30

Control modes

Mode

Description

Local

Control the regulator through the local user interface. All the
parameters are accessible for reading and modifying. See section
7.2 Local user interface7.2 Local user interface.

Remote

Control the regulator through a remote control system. All the


parameters can be read but nothing can be modified.

Dongle

Control the regulator through a dongle and a software tool. The


display is locked and nothing can be visualized or modified. See
section 7.3 Configuration tool software7.3 Configuration tool
software.

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Maintenance

Maintenance
WARNING
Only personnel authorized to work on high-voltage equipment can do
maintenance work on the regulator.
Operate the regulator under local control when performing maintenance
tasks. This will prevent the regulator from being accidentally switched ON
and causing serious injury or death.

3.1

Preventive maintenance
The preventive maintenance checks should be done regularly to minimize service interruption
and avoid major breakdowns.

Table: 1

Preventive maintenance checks

Type of maintenance Check


Operational

Electrical

Visual

If the regulator voltage is not within


the tolerances, notify the power
company to correct the voltage

Output current (RMS value)

Record and adjust if out of tolerance.


Use a RMS-reading A-meter.

General

3.2.1

Before you start

Operation of the regulation Use a PC to log the data, if desired.


on all brightness steps;
All readings.

Input voltage

3.2

Action

Wiring of the regulator and


circuit;
Housing for rust spots and
damage;
Housing for dust
accumulation.

Repair damaged or loose wires;


Replace damaged components;
Clean and repaint rust spots;
Repair eventual damages;
Clean by blowing dry air over
the dirty components, PCBs,
and other components.

WARNING
Make sure you have read and understood all safety procedures and standards
related to this equipment. See chapter 1 SAFETY.
Before you do any work on the regulator, make sure that:
You are allowed to shut OFF the regulator;
You have opened the fused input switch;
You have opened the main switch on the main distribution board;
You have disconnected the regulator from the series circuit.

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31

Maintenance

Standard
procedures

During maintenance, make sure that:


You do not drop any screws or nuts inside the regulator. Collect all loose nuts and screws
immediately.
You label all cables you disconnect.
You have saved the regulator settings as a profile. For how to do this in the configuration
tool, see section 7.3.7 IO menu.
You put in the new parts in exactly the same way as the old part. For example, set the straps
and dip-switches of the new PCB in the same position.

3.3

Replace parts

3.3.1

Equipment required

Meters

True RMS Multimeter;


CAUTION
The output voltage of the 30 kVA / 6.6 A regulator can reach approximately
4600 V at full load. An isolating measurement transformer for use on the 5000
V AC line is recommended.

Multimeter;
Insulation tester "Megger" 500 V or 1000 V;
Clamp or A-meter true RMS scale 10 and 30 A.
CAUTION
The current regulation is + 1 %. To make an acceptable readjustment of the
output current, the precision of the meter must be higher than
0.5 % for the adjusted value.

Tools

32

A standard electrical and mechanical tool kit;


Screwdrivers with protection up to 1000 V;
A spanner set (ring or socket spanners);
Allen key 8 mm;
Torque screwdrivers:
Torque between 2.25 and 2.75 Nm (avg 2.5)
Torque between 2.5 and 4 Nm (avg 3.25);
Torque between 4.5 and 5.5 Nm (avg 5).
Short, slotted screwdriver;
Magnet rod for collecting loose items;
Angle socket wrench.

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

3.3.2

Remove panels
The panels of the regulator can be removed for installation or maintenance procedures.
CAUTION
Do not operate the regulator with any of the panels removed.
Do not mix panels from different regulators.
Always connect the ground wires before you put the panels back.

Front and back


panel

1.
2.

Open the lock (B). Use an Allen key 8 mm.


Take out the panel (A).

2
1

Top panel

3.

Disconnect the green/yellow grounding


wires (C). The wires have a fast-on
connector.

1.

Loosen the four bolts (A) or the optional


lifting lugs (B).

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33

Maintenance

2.

Take out the top panel (C).

Loosen the four screws (A).


Take out the panel (B).

3.

Disconnect the power cable from connector


J1 (C).
Disconnect the local bus cable from
connector J2 (D)
Disconnect the ground wire (E).

4.

SW2

D2
D3
D4

D5

J2

5.

J1

1.
2.

SW1

UI panel: small
cabinet

34

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Maintenance

UI panel: big
cabinet

1.

Take out the fused input switch and the


complete handle (A).

III
I

II

2.
3.

Loosen the six screws (B).


Take out the panel (C).

C
B

B
4.
5.

SW2

D2
D3
D4

D5

J2

J1

SW1

6.

Disconnect the power cable from connector


J1 (D).
Disconnect the local bus cable from
connector J2 (E)
Disconnect the ground wire (F).

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35

Maintenance

3.3.3

User interface PCB


,When you replace a PCB. Copy the settings of the dipswitches from the old PCB to
the new PCB.

6.
7.

SW1

SW2

J1

5.

B
D2
D3
D4

3.
4.

J2

2.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Remove the user interface panel. See
section 3.3.2 Remove panels.
Disconnect the cables from the PCB.
Disconnect the ground wire from ground
terminal (B).
Take out the four or six nuts (A). Use a
number 5.5 socket wrench.
Take out the ground terminal (B).
Take out the old PCB from the user
interface panel.

D5

1.

J1

SW2

D2
D3
D4

D5

SW1

Put in the new PCB on the user interface


panel.
9. Put back the ground terminal (B).
10. Put back the four or six nuts (A). Use a
number 5.5 socket wrench.
J2

8.

SW2

D2
D3
D4

J2

J1

SW1

D5

11. Connect the power cable to connector J1


(C).
12. Connect the local bus cable to connector
J2 (D).
13. Connect the ground wire to the ground
terminal (E).
14. Put back the user interface panel. Use an
Allen key 8 mm.

36

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Maintenance

3.3.4

Local Master Controller (LMC) PCB


NOTE
You need the configuration tool to perform this procedure. See section
7.3 Configuration tool software.

B
C0

C0

11

C0

C0

12

SW

DS2

DS11 DS9
DS10

C0

SW1

DS8

14

C01

C0

DS1

DS7

13

SW2

C0

C0

10

C0

C04

C03

SW3

DS5

C0

DS6

Take out the top panel. See section


3.3.2 Remove panels.
7. Disconnect the serial connection from the
connector C05. Loosen the two screws of
the connector.
8. Disconnect the cables from the PCB (B).
9. Take out the eight nuts (A). Use an angle
socket wrench.
10. Take out the old PCB (B).

DS4
DS3

6.

SW7

5.

SW6

2.
3.
4.

Switch ON the regulator. Use the fused


input switch and the disconnection device.
Open the configuration tool.
Go to menu SAVE.
Save the used IO profile. Select Save and
save the profile on your PC.
Switch OFF all power to the regulator.
Use the fused input switch and the
disconnection device.

SW5

1.

B
C0

C0

11

C0

C0

12

SW

SW1
DS2

SW6

SW7
C0

SW5

DS8

14

C01

C0

DS1

DS7

13

SW2

C0

DS11 DS9
DS10

11. Put in the new PCB (B).


12. Put back the eight nuts (A). Use an angle
socket wrench.

C0

SW3
C0

C04

C03

DS6

10

DS4
DS3

DS5

C0

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37

Maintenance

SW1
SW2

DS2

SW3
C04

C03

DS4
DS3

DS6

DS5

C08

C09

15. Put back the top panel. See section


3.3.2 Remove panels.

DS10

SW5

DS11 DS9

SW6

C013
C014

C01

DS7

C012

DS8

SW4

DS1

C06

C07
C011

SW7

13. Connect the serial connection to the


connector C05. Tighten the two screws of
the connector.
14. Connect the cables to the connectors:
Local bus to C03;
EFD to C04;
J-Bus to C01;
Power supply to C07;
MW1 to C09, MW2 to C010, and MW3
to C08.

C010

C05

16. Switch ON the regulator. Use the fused


input switch and the disconnection device.
17. Open the configuration tool.
18. Go to menu SAVE.
19. Restore the IO profile. Select Restore and
browse to the saved profile on your PC.
20. Switch OFF all power to the regulator. Use
the fused input switch and the
disconnection device.

3.3.5

Current Control Logic (CCL) PCB


NOTE
You need the configuration tool to perform this procedure. See section
7.3 Configuration tool software.

6.
7.
8.

SW

DS1

C02

DS2

DS4

DS3

C01

C05

C03

9.

Take out the top panel. See section


3.3.2 Remove panels.
Disconnect the cables from the PCB (B).
Take out six nuts (A). Use a number 5.5
socket wrench.
Take out the old PCB (B).

C07

5.

C04

2.
3.
4.

Switch ON the regulator. Use the fused


input switch and the disconnection device.
Open the configuration tool.
Go to menu SAVE.
Save the used IO profile. Select Save and
save the profile on your PC.
Switch OFF all power to the regulator.
Use the fused input switch and the
disconnection device.

C06

1.

SW

38

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Maintenance

10. Put in the new PCB (B).


11. Put back the six nuts (A). Use a number 5.5
socket wrench.

C06

C04

C07

DS1

C02

DS2

DS4

DS3

C01

C05

C03

SW

SW

C06
C05

C04

SW2

C02

C01

DS2

13. Put back the top panel. See section


3.3.2 Remove panels.

C03

DS3

DS4

12. Connect the cables to the connectors:


Power supply cable to C06;
Power supply to C05;
Local bus to C02;
TBM module to C01;
LFD module to C03;
CS module to C04;
Current transformer TI2 to C07.

C07

DS1

SW1

14. Switch ON the regulator. Use the fused


input switch and the disconnection device.
15. Open the configuration tool.
16. Go to menu SAVE.
17. Restore the IO profile. Select Restore and
browse to the saved profile on your PC.
18. Switch OFF all power to the regulator.
Use the fused input switch and the
disconnection device.

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39

Maintenance

3.3.6

Thyristor Block Module (TBM) PCB


It is not required to safe or reload the configuration of the PCB.

J6

S3

J1

J3

S3

D1

S3
D5
D4
D3
D
D2

Put in the new PCB (B).


Put back the four nuts (A). Use a number
5.5 socket wrench.

D1

D5
D4
D3
D
D2

S3

J5

J1

J3

S3

6.
7.

J6

5.

S3

3.
4.

J5

2.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the top panel. See section
3.3.2 Remove panels.
Disconnect the cables from the PCB (B).
Take out the four nuts (A). Use a number
5.5 socket wrench.
Take out the old PCB (B).

J2

1.

J2

8.

Connect the cables to the connectors:


Thyristor bank connection to J5;
Power supply to J6;
CCL module to J1;
Local bus to J1.

Put back the top panel. See section


3.3.2 Remove panels.
10. Switch OFF all power to the regulator.
Use the fused input switch and the
disconnection device.

J2

J5

9.

D5
D4
D3
D2

S3

S3

S3
D1
J1

40

J3

J6

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Maintenance

3.3.7

Power Supply Logic (PSL) PCB


It is not required to safe or reload the configuration of the PCB.

5
X

X
X

5.

3.
4.

2.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the top panel. See section
3.3.2 Remove panels.
Disconnect the cables from the PCB (B).
Take out the six nuts (A). Use a number 5.5
socket wrench.
Take out the old PCB (B).

2
X

1.

Put in the new PCB (B).


Put back the six nuts (A). Use a number 5.5
socket wrench.

A
B

X8
X7

X6

X5

X4

X2

Connect the cables to the connectors:


Power input supply to X1;
Cut-out SCO to X2 (option). If the
regulator does not have a cut-out
SCO, make the connector jumpered.
Power output to the MW boards to X3;
DC power distribution to X8;
CCL to X4;
Current transformer to X5;
Overvoltage protection (MOV1) to X6;
Back-indication signals ON and
REG.ERR (optional) to X7.

X1

8.

X3

2
X

5
X

6.
7.

9.

Put back the top panel. See section


3.3.2 Remove panels.
10. Switch OFF all power to the regulator. Use the fused input switch and the disconnection
device.

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41

Maintenance

3.3.8

Multiwire MW1, MW2, MW3 PCBs (option)


It is not required to safe or reload the configuration of the PCB.

This procedure applies to both 24 V DC and 48 V DC multiwire PCBs.

J1

J1

P1

W6

P2

12
11
10
9
8
7
6
5
4
3
2
1

J1

12
11
10
9
8
7
6
5
4
3
2
1

W5

P1

W6

P2

P2

W5

P1

W6

12
11
10
9
8
7
6
5
4
3
2
1

P3

5.

12
11
10
9
8
7
6
5
4
3
2
1

P3

3.
4.

W5

2.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the back panel. See section
3.3.2 Remove panels.
Disconnect the cables from the PCB (B).
Take out the six nuts (A). Use a number 5.5
socket wrench.
Take out the old PCB (B).

P3

1.

Put in the new PCB (B). Make sure that you


use the same type of PCB.
Put back the six nuts (A). Use a number 5.5
socket wrench.

J1

J1

W6

P1

12
11
10
9
8
7
6
5
4
3
2
1

P2

P2

12
11
10
9
8
7
6
5
4
3
2
1

W5

P1

W6
W5

12
11
10
9
8
7
6
5
4
3
2
1

P3

P2

12
11
10
9
8
7
6
5
4
3
2
1

P3

P1

W6
P3

W5

7.

12
11
10
9
8
7
6
5
4
3
2
1

W5

P1

J1

Connect the cables to the connectors:


Power supply to J1;
LMC to P3;
Input and output signal connectors to
P1 and P2.

P2

P3

42

12
11
10
9
8
7
6
5
4
3
2
1

W6

A
8.

12
11
10
9
8
7
6
5
4
3
2
1

J1

6.

12
11
10
9
8
7
6
5
4
3
2
1

12
11
10
9
8
7
6
5
4
3
2
1

12
11
10
9
8
7
6
5
4
3
2
1

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

9.

Switch ON the regulator. Use the fused


input switch and the disconnection device.
10. Put back the back panel. See section
3.3.2 Remove panels.
11. Switch OFF all power to the regulator.
Use the fused input switch and the
disconnection device.
12. Verify the functionality of the replaced PCB

3.3.9

J-Bus PCB (option)


CAUTION
Do not disconnect the J-Bus without a permission. When one regulator on the
databus chain is disconnected, the other regulators on that databus are also
disconnected at the same time.

It is not required to safe or reload the configuration of the PCB.

1.

2.
3.
4.
5.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the back panel. See section
3.3.2 Remove panels.
Disconnect the cables and the ground wire
from the PCB (B).
Take out four screws (A). Use a number 5.5
socket wrench.
Take out the old PCB (B).

B
P6

P4
P3
P22
P1

P5

6.
7.

Put in the new PCB (B).


Put back the four screws (A).
Use a number 5.5 socket wrench.

B
P6

P4
P3
P22
P1

P5

Maintenance Manual - MCR3 - AM.07.360e

43

Maintenance

8.

Connect the cables to the connectors:


LMC to P6;
J-Bus control for Bus A to P1 and P2;
J-Bus control for Bus B to P3 and P4;
Earth wire to the ground terminal.

Put back the back panel. See section


3.3.2 Remove panels.
10. Switch OFF all power to the regulator.
Use the fused input switch and the
disconnection device.

P6

9.

P1

P2

P4

P3

P5

3.3.10

Earth Fault Detection (EFD) PCB and resistor (option)

Replace PCB

This procedure applies to both big and small cabinet. In this section, the small cabinet is used as
an example.
It is not required to safe or reload the configuration of the PCB.

1.

2.

C04
C01

6.
7.

SW1

5.

2
SW

DS1

4.

DS5
DS6

3.

Switch OFF all power to the regulator. Use


the fused input switch and the
disconnection device.
Take out the front panel. See section
3.3.2 Remove panels.
Disconnect the cables and the ground wire
from the PCB.
Take out the six nuts (A).
Use a number 5.5 socket wrench.
Take out the old PCB.

Put in the new PCB.


Put back the six nuts (A).
Use a number 5.5 socket wrench.

C04
DS1

DS5
DS6

2
SW

C01

SW1

44

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

Connect the cables to the connectors:


Power supply to C01;
Local bus to C04;
High-voltage connection from the
resistor to C02;
Earth wire to the ground terminal C03.

C04
SW1

DS5
DS6

9.

Put back the front panel. See section


3.3.2 Remove panels.
10. Switch ON the regulator. Use the fused
input switch and the disconnection device.
11. Recalibrate the EFD see section 5.5 of the
inslallation manual.
12. Verify the functionality of the PCB.

EFD resistor

C01
DS1

SW2

8.

DS2
DS4

DS3

This procedure applies to both small and big cabinets. In small cabinets this module is in a
horizontal position. In big cabinets this module is in a vertical position.
It is not required to safe or reload the configuration of the PCB.

1.

3.
4.
5.

B
C01

2.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the front panel. See section
3.3.2 Remove panels.
Disconnect the wires from the PCB (B).
Take out the two slotted screws (A).
Use a short, slotted screwdriver.
Take out the old PCB (B).

C02

6.
7.

Put in the new PCB (B).


Put back the two slotted screws (A).
Use a short, slotted screwdriver.

B
C01

C02

Maintenance Manual - MCR3 - AM.07.360e

45

8.

Connect the cables to the connectors:


EFD connection to C01;
Output terminal connection to C02.

C02

Maintenance

Put back the front panel. See section


3.3.2 Remove panels.
10. Switch ON the regulator. Use the fused
input switch and the disconnection device.
11. Recalibrate the EFD see section 5.5 of the
inslallation manual.
12. Verify the functionality of the PCB.
C01

9.

EFD calibration
(option)

The EFD shows the insulation resistance of the series circuit on the user interface. This value is
only an indication. To find out a more accurate value (up to 10 000 V), use a specific
measurement tool (Megger). If the regulator has an EFD option, you must calibrate the unit in
order to have this function.
NOTE
We recommend to use the configuration tool to perform this procedure. See section
7.3 Configuration tool software.
In the following procedure, the configuration tool is used as an example. For more information on
how to do this with the local user interface, see section 7.2 Local user interface. If you use the
local user interface, switch the regulator OFF and back ON after each setting.
1.
2.
3.
4.

5.

6.

7.

46

Open the configuration tool.


Switch the regulator ON. Use the fused
input switch.
Select the menu EFD.
Go to section Control commands > ON/
OFF control. Set the parameter to
enabled. See the graphic.

Go to section Setup > Startup time.


Change the correct time for the series
circuit. To do this, calculate at least 4 s/1km
of cable if the capacitance is less than
0.2F/km.
Select the parameters Isolation level 1
and 2. Fill in the alarm levels you want to
use:
Level 1: 2x isolation value. See
section 7.1.5 Insulation resistance.
Level 2: 0.5x isolation value. See
section 7.1.5 Insulation resistance.

Select Calibrate the EFD. Wait while the


regulator goes through the calibration
procedure.

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

EFD calibration
(option)

The EFD calibration can also be performed on the Local user interface screen.
1.
2.
3.
4.

5.

3.3.11

Select menu from the main menu of the


Local user interface screen,
Press menu 3 times.
Select EFD with down or up button and
press Select
In the EFD Earth Fault Detection Screen
select EFD Calibration with down or up
button and press Select
The MCR preforms the EFD Calibration
automatically. The main menu appears
when the procedure is done.i

MCR: NAME

Iout:
Step:

LOCAL

0.0A
OFF

REMOTE

No Errors
No
Errors

CSM: OFF
EFD: 256M
LOCAL

MENU

RESET

Lamp Fault Detection (LFD) PCB (option)

Replace PCB
NOTE
You need the configuration tool to perform this procedure. See section
7.3 Configuration tool software.

7.
8.
9.

Take out the top panel. See section


3.3.2 Remove panels.
Disconnect the cables from the PCB.
Take out the four nuts (A).
Use a number 5.5 socket wrench.
Take out the old PCB.

C01

6.

C03

5.

2
SW

2.
3.
4.

Switch ON the regulator. Use the fused


input switch and the disconnection device.
Open the configuration tool.
Go to menu SAVE.
Save the used IO profile. Select Save and
save the profile on your PC.
Switch OFF all power to the regulator.
Use the fused input switch and the
disconnection device.

DS4

1.

DS1
DS2

1
SW

C02

DS3

Maintenance Manual - MCR3 - AM.07.360e

47

Maintenance

10. Put in the new PCB.


11. Put back the four nuts (A).
Use a number 5.5 socket wrench.

C03

C01

2
SW

DS4
DS1
DS2

1
SW

C02

DS3

Connect the cables to the connectors:.


CCL connection to C01;
Local bus to C02;
Power supply to C03.

C03

C02

DS4

DS1

13. Put back the top panel. See section


3.3.2 Remove panels.

DS3

DS2

SW2

SW1

12.

C01

14. Switch ON the regulator. Use the fused


input switch and the disconnection device.
15. Open the configuration tool.
16. Go to menu SAVE.
17. Restore the IO profile. Select Restore and
browse to the saved profile on your PC.
18. Switch OFF all power to the regulator.
Use the fused input switch and the
disconnection device.

48

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

Calibration,
step 1

In the following procedure, the configuration tool is used as an example. For more information on
how to do this with the local user interface, see section 7.2 Local user interface. If you use the
local user interface, switch the regulator OFF and back ON after each setting.
1.
2.

3.
4.

5.

6.

7.

Open the configuration tool.


Make sure the regulator is connected to the
series circuit and that you have set the
correct tap.
Switch the regulator ON. Use the fused
input switch.
Set the regulator to the highest brightness
step 6.6 A. Use the Active Step field (see
the graphic).
Check that all lamps have the same
brightness level. Go to the runway area to
make a visual inspection.
Set the regulator to brightness step OFF.

Select the menu LFD > Control


commands > ON/OFF control. Set the
parameter to enabled (see the graphic).

8.
9.

Select the menu LFD > LFD calibration.


Select a set. See the graphic. You can
configure different sets for different circuit
selector combinations.
10. If the regulator has a circuit selector, select
the series circuits that are active during
calibration. See the graphic.

11. Select Loop warm-up time. See the


graphic. Change the correct time for the
series circuit (10-1275 s).
Short series circuit (under 1000m):
30 s;
Medium series circuit (up to 3000m):
120 s;
Long series circuit (more than 3000m);
240 s.

Maintenance Manual - MCR3 - AM.07.360e

49

Maintenance

Calibration,
step 2

1.

2.
3.

4.

5.
6.

7.
8.
9.

10.
11.
12.
13.
14.
15.

50

Select Do the reference measurement.


See the graphic. Wait while the regulator
goes through the calibration procedure.
Switch the regulator OFF. Use the fused
input switch.
Do remove the transformer from the
circuitmake sure that the secondary side of
the isolating transformer is in open circuit
condition
Switch the regulator ON. Use the fused
input switch.
Fill in the number of lamps you removed
(see the graphic).
Select Do the Lamps Removed
measurement. See the graphic. Wait while
the regulator goes through the procedure.
Switch the regulator OFF. Leave the
regulator OFF for 10 seconds.
Switch the regulator ON. Use the fused
input switch.
In the LFD menu, select the parameters
Lamp failure levels 1 and 2. Fill in the
alarm levels you want to use.
Switch the regulator OFF.
Connect the first lamp you disconnected.
Switch the regulator ON.
Make sure that the number of lamps removed corresponds to the LFD reading on the main
menu.
Switch the regulator OFF. Leave the regulator OFF for 10 seconds.
Connect the rest of the lamps one by one. Switch the regulator OFF for 10 seconds each
time before you connect a lamp.

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

3.3.12

Circuit selector PCB


1.

10
9
8
7
6
5
4
3
2

X01

DS8

DS7

X0

DS5

TP
3

DS6

12
11

DS3

TP
2

DS4

10
9

DS1

DS2

8
7
6
5
4
3
2

C04

5.

11

3.
4.

12

2.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the front panel of the circuit
selector cabinet. See section 3.3.2 Remove
panels.
Disconnect the cables from the PCB (B).
Take out four nuts (A).
Use a number 5.5 socket wrench.
Take out the old PCB.

TP
1

11

Put in the new PCB (B).


Put back the four nuts (A).
Use a number 5.5 socket wrench.

12

6.
7.

10
9
8
7
6
5
4
3
2

X01

DS8

DS7
DS6

X0

DS5

TP
3

12
DS4

11

DS3

TP
2

10
DS2

DS1

9
8
7
6
5
4
3

C04

2
1

TP
1

DS1

5
6

DS2

C04
DS3
DS4

7
8

DS5

9
DS6

10
11

TP1

TP2

Put back the front panel of the circuit


selector cabinet. See section 3.3.2 Remove
panels.

9.

4
3

8
7
6
5

10
9

X01

11

Connect the cables to the connectors:


LMC connection to X04;
Control and power connection to X01;
Feedback connection from the
contactors to X02;

12

8.

X02

DS7
DS8

Maintenance Manual - MCR3 - AM.07.360e

TP3

12

51

Maintenance

3.3.13

Power components, input

Fused input switch,


small cabinet

1.
2.

3.
4.

5.
6.

Switch OFF all power to the regulator.


Use the disconnection device.
Open the fused input switch.

Take out the fuse holder (A). Turn the


holder anticlockwise until it comes out.
Replace the fuse (B). Use a fuse of the
same type. Use the spring lever to release
the fuse from the holder.
Put back the fuse holder (A). Turn the
holder clockwise until it is securely in place.
Close the fused input switch only when it is
safe to do so. The switch cannot close if the
fuse holder is not securely in place.

B
A
Fused input switch,
big cabinets

1.
2.

Switch OFF all power to the regulator.


Use the disconnection device.
Take out the fused input switch and the
complete handle (A). Open the fuse (I), lift
the handle up (II), and pull the handle out
(III).

III
II

I
A

52

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

3.
4.
5.

Replace the fuse (B). Use the spring lever


to release the fuse from the holder.
Put back the handle (A).
Close the fused input switch only when it is
safe to do so.

B
A
Fuses F2, F3 and
F4

1.

2.
3.
4.

5.
6.
7.

MOV1/A, MOV1/B
(option)

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the front panel. See section
3.3.2 Remove panels.
Open the switch (B).
Take out the fuse (A). Use a fuse of the
same type. Use the spring lever to release
the fuse from the holder.
Put back the fuse (A). Make sure that you
put the fuse back to the upper holder.
Close the switch (B).
Put back the front panel. See section
3.3.2 Remove panels.

The overvoltage protection modules have indicators. These indicators become red when the
overcurrent protection is activated.
1.

2.
3.
4.
5.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the front panel. See section
3.3.2 Remove panels.
Take out the old over-voltage protection
module (A).
Push in the new over-voltage protection
module (A).
Put back the front panel. See section
3.3.2 Remove panels.

Maintenance Manual - MCR3 - AM.07.360e

53

Maintenance

Main contactor
(K1)

1.

2.
3.

4.
5.

6.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the top panel. See section
3.3.2 Remove panels.
Disconnect the four cables 1 L1, 3 L2, 5 L3
and 7 L4 on top of the main contactor (A).
Each cable is connected with a screw.
Label the cables before you disconnect
them.
Loosen the two screws of the terminal
stopper (B).
Take out the rail stopper (B).

A
B

Take out the main contactor (A).


Use a screwdriver as a lever to release the
main contactor from the rail (B).

7.
8.

Disconnect the connectors A1 and A2 (B)


on top of the main contactor (A).
Disconnect the four cables 2 T1, 4 T2, 6 T3
and 8 T4 (C) at the bottom of the main
contactor. Each cable is connected with a
screw. When you disconnect the terminals
T2 and T3, also the mains filtering
connectors A1 and A2 (D) at the bottom
become loose.

A
D
C

54

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

9. Take the new contactor (A).


10. Connect the four cables 2 T1, 4 T2, 6 T3
and 8 T4 (C) at the bottom of the main
contactor (A). Each cable is connected with
a screw. When you connect the terminals
T2 and T3, connect also the mains filtering
connectors A1 and A2 (D) at the bottom.
11. Connect the connectors A1 and A2 (B) on
top of the main contactor (A).

A
D
C

12. Put in the new main contactor (A). Push the


main contactor to the rail (B).

13. Put back the rail stopper (B). Tighten the


two screws.
14. Connect the four cables 1 L1, 3 L2, 5 L3
and 7 L4 on top of the main contactor (A).
Each cable is connected with a screw.
15. Put back the top panel. See section
3.3.2 Remove panels.

Maintenance Manual - MCR3 - AM.07.360e

A
B

55

Maintenance

Main contactor K1,


RC coil protection

1.

2.
3.
4.
5.
6.

Main contactor K1,


mains filtering

1.

2.
3.
4.
5.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the top panel. See section
3.3.2 Remove panels.
Take out the main contactor (A). See
section Main contactor (K1) above.
Replace the RC coil protection module (B).
The module has a clip on connection.
Put back the main contactor (A). See
section Main contactor (K1) above.
Put back the top panel. See section
3.3.2 Remove panels.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the top panel. See section
3.3.2 Remove panels.
Take out the main contactor (A). See
section Main contactor (K1) above.
Take out the mains filtering module (B). The
module has a clip-on connection.
Disconnect the mains filtering cables A1
and A2 from the mains contactor. When
you disconnect the terminals 4 T2 and 6
T3, also the mains filtering connectors A1
and A2 become loose.

Take out the crimp (A) that connects the


mains filtering cables and the cables 4 T2
and 6 T3.
7. Put in the new mains filtering module.
8. Put back the crimp (A) that connects the
mains filtering cables and the cables 4 T2
and 6 T3.
9. Put back the main contactor (B). See
section Main contactor (K1) above.
10. Connect the mains filtering cables A1 and
A2 to the mains contactor. Make sure that
you connect cables 4 T2 and 6 T3 together
with cables A1 and A2.
11. Put back the top panel. See section
3.3.2 Remove panels.

6.

56

B
A

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

Input
measurement
transformer (TI1)

1.

2.
3.
4.

5.
6.
7.
8.

9.
10.

11.

12.
13.

Thyristor pack
(THP-1,THP-2)

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the top panel. See section
3.3.2 Remove panels.
Disconnect the cable (A) coming from the
series choke.
Disconnect the two cables 2 T1 and 4 T2 at
the bottom of the main contactor. See
section Main contactor (K1) above.
Take a photograph or note down how the
cables (C) go through the transformer (B).
Pull the two cables 2 T1 and 4 T2 (C)
through the transformer (B).
Take out the two screws (D).
Replace the input measurement
transformer (B). Put the new transformer in
the same position as the old transformer.
Put in the two screws (D).
Put the two cables 2 T1 and 4 T2 (C)
through the transformer. Place the cables in
the same way as they were in the old
transformer. If the regulator has an input
current less or equal to 62 A, put these
cables in a loop around the transformer.
Connect the two cables 2 T1 and 4 T2 at
the bottom of the main contactor. See
section Main contactor (K1) above.
Connect the cable (A) going to the series
choke.
Put back the top panel. See section 3.3.2 Remove panels.

WARNING
Handle the heat sink with care. The heat sink becomes hot during operation.

1.

2.
3.

4.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the top panel. See section
3.3.2 Remove panels.
Disconnect the two control cable pairs (A).
These cables have a clip-on connection.
Make sure that you label these cables
before you take them out.
Take out the three screws (B) and the
copper plate to disconnect the two cables
(C) attached. Use a torque screwdriver.

Maintenance Manual - MCR3 - AM.07.360e

57

Maintenance

5.
6.

Take out the four screws (A).


Take out the heat sink (B).

Take out the two screws (A).


Take out the thyristor pack (B).
Wipe the heat sink clean under the thyristor
pack (C).
10. Apply an even layer of conductive paste on
the back of the new thyristor pack.
11. Put in the new thyristor pack (B).
12. Put in the two screws (A). Use a torque
screwdriver. Use a torque value as follows:
Type CTT90GK (M5): Torque between
2.5 and 4 Nm (avg 3.25);
Type CTT165GK (M6): Torque
between 4.5 and 5.5 Nm (avg 5).

7.
8.
9.

13. Put in the heat sink (A).


14. Put in the four screws (B).
Use a torque screwdriver.

58

B
C

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

15. Connect the two cables (C) and the copper


plate with the three screws (B).
Use a torque screwdriver. Use a torque
value as follows:
Type CTT90GK (M5): Torque between
2.5 and 4 Nm (avg 3.25);
Type CTT165GK (M6): Torque
between 2.25 and 2.75 Nm (avg 2.5).

16. Connect the two control cable pairs (A). Put


these back in the same order as before.
17. Put back the top panel. See section
3.3.2 Remove panels.

3.3.14

Power components, output

Lightning arrestors
(LA1 - LA2), small
cabinet

In this procedure, three lightning arrestor modules are removed as an example. You can remove
all six in the same way.

1.

2.
3.
4.
5.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the front panel. See section
3.3.2 Remove panels.
Disconnect the wires (A) that come from
the output terminals.
Disconnect the earth wire (B).
Take out all copper plates (C). Each plate is
connected with two screws.

A
6.

7.

Take out the required modules (A).


Each module is connected to the base
plate with two screws.
Put in the new modules (A). Connect each
module to the base plate with two screws.

Maintenance Manual - MCR3 - AM.07.360e

59

Maintenance

8.

Put in all copper plates (C). Each plate is


connected with two screws.
9. Connect the earth wire (B).
10. Connect the wires (A) that come from the
output terminals.
11. Put back the front panel. See section
3.3.2 Remove panels.

Output current
transformer (TI2,
TI3)

1.

2.
3.

4.

5.
6.
7.
8.
9.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the front panel. See section
3.3.2 Remove panels.
Disconnect the two connectors (A). Use a
pair of pliers if necessary. Label the
connectors.
Disconnect the cable (B) that goes through
the transformer. To do this, disconnect the
cable at the output terminal 2.
Push the cable (B) trough the transformer.
Take out the two screws (C).
Take out the old transformer (D).
Put in the new transformer (D).
Put in the two screws (C).

D
C

10. Put the cable (A) through the transformer


(B) in a loop.
11. Connect the cable (A) at the output terminal
2.
12. Connect the two connectors (C).
13. Put back the front panel. See section
3.3.2 Remove panels.

A
B

60

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

3.3.15

Cut-out SCO (option)


1.

2.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the cover of the cut-out SCO (A).

3.
4.
5.
6.
7.

Disconnect the series circuit cables (A).


Disconnect the input current cables (B).
Disconnect the ground wire (C).
Take out the two bolts (D).
Take out the old cut-out SCO.

B
D
B1
A1
A2
C1

D
A

8.
9.

Disconnect the cables to the microswitch


(A).
Connect the cables to the microswitch (A)
in the new cut-out SCO.

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61

Maintenance

10.
11.
12.
13.
14.

Put in the new Cut-out SCO.


Put back the two bolts (D).
Connect the ground wire (C).
Connect the input current cables (B).
Connect the series circuit cables (A).

B
D
B1
A1
A2
C1

D
A

15. Put back the cover of the Cut-out SCO (A).

3.3.16

Circuit selector (option)

High-voltage
contactor (CS - K1
- K8)

The shown connector is applicable for voltages up to 1515 V. The contactor


for 4545V looks different, but the procedure remains the same.

1.

2.

3.
4.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the back panel of the circuit
selector cabinet. See section 3.3.2 Remove
panels.
Disconnect the eight cables (A). The cables
have a screw connection.
Take out the rail stopper (B).

B
A

62

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

5.

Take out the contactor (A) from the rail.


Push down the contactor (I) from the top of
the contactor to release the lock. Then pull
out the contactor (II).

II

6.
7.
8.
9.

Put in the new contactor. Push the


contactor on the rail (C).
Put in the rail stopper (B).
Connect the eight cables (A). The cables
have a screw connection.
Put back the back panel of the circuit
selector cabinet. See section 3.3.2 Remove
panels.

B
A

Auxiliary contact
(CS - K1 - K8)

1.

2.
3.
4.
5.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the back panel of the circuit selector
cabinet. See section 3.3.2 Remove panels.
Take out the cables (A).
Replace the RC coil protection module (B).
The module has a clip on connection.
Put back the back panel of the circuit
selector cabinet. See section 3.3.2 Remove
panels.

A
B

Maintenance Manual - MCR3 - AM.07.360e

63

Maintenance

CSM voltage
transformer (CS K1 - K8)

1.

2.
3.

4.
5.
6.
7.

Switch OFF all power to the regulator.


Use the fused input switch and the
disconnection device.
Take out the back panel of the circuit selector
cabinet. See section 3.3.2 Remove panels.
Pull out the cables from the input supply
terminals (A).

Take out the one bolt (A).


Take out the old auxiliary contact (B).
Put in the new auxiliary contact (B).
Put in the one bolt (A).

8.

Put in all terminals (A). Slide the terminals


out.
9. Connect the cables (A) to the input supply
terminals.
10. Put back the back panel of the circuit
selector cabinet. See section 3.3.2 Remove
panels.

64

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

3.4

Parts list
WARNING
Use only original ADB spare parts.
Using other than ADB spare parts may damage the part itself or the regulator.
This can also put the personnel in danger.

3.4.1

General

Part orders

Each part of the equipment has a part number. When you order parts:
Always mention the part number of the ordered part;
Always mention serial number, type, power rating, input voltage, frequency, number of
brightness steps, and output current of the regulator. These are indicated on the nameplate
of the regulator. See section 2.5 Nameplate.
For all spare part orders, contact ADB or our local representative.

Recommendations

To reduce downtime during maintenance, have one or more extra regulators in stand-by at the
substation. This is especially important at major airports, which have a large amount or
regulators.
Keep spare parts always in stock. For example:
Fuses;
Lightning arrestors;
PCBs;
Terminals;
Connectors;
Fused input switches;
Circuit breaker;
Power packs.

3.4.2

Basic circuit boards


Table: 2

Basic circuit boards

Item

Part number

Description

Quantity
per order

UI

1593.14.000

PCB1507 - User Interface

LMC

1593.14.113

PCB1513 - Local Master Circuit

CCL

1590.03.541

PCB1516 - Current Control Logic

TBM

1593.14.213

PCB1517 - Thyristor Block Module

PSL

1593.14.400

PCB1521 - Power Supply Logic

Maintenance Manual - MCR3 - AM.07.360e

65

Maintenance

3.4.3

Optional circuit boards


Table: 3

66

Optional circuit boards

Item

Part number

Description

Quantity
per order

MW1, MW2, MW3

1593.13.510

PCB1486.1 - LMC Multiwire 24V


remote control interface

MW1, MW2, MW3

1593.13.520

PCB1486.2 - LMC Multiwire 48V


remote control interface

JB

1590.03.490

PCB1502 - J-Bus Interface

EFD

1590.03.521

PCB1514 - Earth Fault Detector, logic


board

EFD Res.

1590.03.530

PCB1515 - Earth Fault Detector,


resistor board

LFD

1590.03.551

PCB1519 - Lamp Fault Detector, logic


board

CS

1590.03.561

PCB1523 - Circuit Selector board

Dongle

1444.00.030

Dongle with MCR3 Calibration


Software

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

3.4.4

Power components, input

Parts

To select the applicable fuses from table 4, see the tables 5 and 6 below. To select the applicable
main contactor and thyristor pack from table 4, see the tables 7 and 8 below.

Table: 4

Power input components

Item

Part number

Description

Fused switch F1

6132.00.212

5SG7 fused switch - fuse interrupter for 10


Neozed fuses (small cabinet)

Fused switch F1

6130.54.460

Input fuse 20A - Neozed for 5SG7


fused switch

Fused switch F1

6130.57.360

Input fuse 25A - Neozed for 5SG7


fused switch

Fused switch F1

6130.61.363

Input fuse 35A - Neozed for 5SG7


fused switch

Fused switch F1

6130.63.363

Input fuse 50A - Neozed for 5SG7


fused switch

Fused switch F1

6130.66.270

Input fuse 63A - Neozed for 5SG7


fused switch

Fused switch F1

6132.00.220

NH00 fused switch - fuse interrupter


(big cabinet)

Fused switch F1

6130.66.280

Input fuse 63A NH00, for NH00 fused


switch

Fused switch F1

6130.68.330

Input fuse 80A NH00, for NH00 fused


switch

Fused switch F1

6130.71.280

Input fuse 100A NH00, for NH00 fused 2


switch

Fused switch F1

6130.75.330

Input fuse 125A NH00, for NH00 fused 2


switch

Fused switch
F2, F3, F4

6112.45.203

Fuse holder for symmetric rail 35 mm,


fuses DIA 6.3 L 32

Fused switch
F2, F3

6130.27.005

Fuse M1.6A HBC DIA 6.3 L 32


(medium)

10

Fused switch
F4 (option)

6130.37.180

Fuse T4A HBC DIA 6.3 L 32 (slowblow)

10

PSL / F1
PSL / F2

6130.26.134

Fuse T1A HBC DIA 5 L20 (slow-blow)

10

CS - F1(option)

6130.37.132

Fuse T4A HBC DIA 5 L20 (slow-blow)

10

MOV1/A, MOV1/B
(option)

6134.03.010

Lightning arrestor for mains input

CS - T1(option)

6300.03.160

Autotransformer 250 VA for Circuit


Selector

K1

6148.45.580

Main contactor up to 50A

Maintenance Manual - MCR3 - AM.07.360e

Quantity
per order

67

Maintenance

Item

Part number

Description

Quantity
per order

K1

6148.45.630

Main contactor for 63A and 80A

K1

6148.45.590

Main contactor for 100 A and 125 A

For K1

6148.45.590

Main contactor, RC coil protection - up


to 80 A

For K1

6148.45.610

Main contactor, RC coil protection 100 A and 125 A

For K1

6322.99.055

Mains filtering at contactor contacts, all 1


power ratings

T.I.1

6302.03.200

Input current measurement transformer 1


200/0.2 A

THP-1, THP-2

6351.85.320

Thyristor pack CRPTT90GK (up to 50


A)

THP-1, THP-2

6351.85.330

Thyristor pack CRPTT165GK (above


50 A)

Wire A2

6304.10.600

Common mode choke, ferrite core OC/ 1


2

Fuse types
Table: 5

Internal and external fuses for 220 / 230 / 240 V (230 V IEC) regulators

Input supply voltage 220 / 230 / 240 V (230 V IEC)

68

Output Fuse in fused switch


power
[kVA]
Rating [A]
Type

External fuse [A]

2.5

20

Neozed

25

25

Neozed

35

35

Neozed

50

7.5

50

Neozed

63

10

63

Neozed

80

12.5

80

NH00

100

15

100

NH00

100

20

125

NH00

125

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

Table: 6

Internal and external fuses for 380 / 400 / 415 V (400 V IEC) regulators

Input supply voltage 380 / 400 / 415 V (400 V IEC)

Thyristors and
main contactor
types

Output Fuse in fused switch


power
[kVA]
Rating [A]
Type

External fuse [A]

2.5

20

Neozed

25

20

Neozed

25

20

Neozed

25

7.5

25

Neozed

35

10

35

Neozed

50

12.5

50

NH00

63

15

50

NH00

63

20

80

NH00

80

25

80

NH00

100

30

100

NH00

125

Table: 7

Thyristors and main contactors for 220 / 230 / 240 V (230 V IEC) regulators

Input supply voltage 220 / 230 / 240 V (230 V IEC)


Output Current rating
power
(kVA)

Thyristor

Main contactor

2.5

/01

CTT90GK12

3RT1326+3RT1926-1CD00

/01

CTT90GK12

3RT1326+3RT1926-1CD00

/01

CTT90GK12

3RT1326+3RT1926-1CD00

7.5

/01

CTT90GK12

3RT1326+3RT1926-1CD00

10

/02

CTT165GK12

3RT1336+3RT1936-1CD00

12.5

/03

CTT165GK12

3RT1336+3RT1936-1CD00

15

/03

CTT165GK12

3RT1344+3RT1936-1CD00

20

/03

CTT165GK12

3RT1344+3RT1936-1CD00

Table: 8

Thyristors and main contactors for 380 / 400 / 415 V (400 V IEC) regulators

Input supply voltage 380 / 400 / 415 V (400 V IEC)


Output Current rating
power
(kVA)

Thyristor

Main contactor

2.5

/01

CTT90GK12

3RT1326+3RT1926-1CD00

/01

CTT90GK12

3RT1326+3RT1926-1CD00

/01

CTT90GK12

3RT1326+3RT1926-1CD00

7.5

/01

CTT90GK12

3RT1326+3RT1926-1CD00

10

/02

CTT90GK12

3RT1326+3RT1926-1CD00

Maintenance Manual - MCR3 - AM.07.360e

69

Maintenance

Input supply voltage 380 / 400 / 415 V (400 V IEC)

3.4.5

Output Current rating


power
(kVA)

Thyristor

Main contactor

12.5

/03

CTT90GK12

3RT1326+3RT1926-1CD00

15

/03

CTT90GK12

3RT1326+3RT1926-1CD00

20

/03

CTT165GK12

3RT1336+3RT1936-1CD00

25

/03

CTT165GK12

3RT1336+3RT1936-1CD00

30

/03

CTT165GK12

3RT1344+3RT1936-1CD00

Power components, output


Table: 9

3.4.6

Power output components

Item

Part number

Description

Quantity
per order

LA1-LA2

6314.32.750

2
Lightning arrestor type Siemens
B32K750 for 2.5 kVA to 10 kVA - 6.6 A
units

LA1-LA2

6134.03.322

Lightning arrestor type G.E. 3kV-XEP


for 15 kVA - 6.6 A. units Qty 2x1 -

LA1-LA2

6134.03.622

Lightning arrestor type G.E. 6kV-XEP


for 20 to 30 kVA-6.6 A. units Qty 2x1

T.I.2, T.I.3

6302.03.180

Output current measurement


transformer for 6.6 A. 50 / 0.05 A

Power components, transformers


Set the wires according to the input voltage of the regulator.

Table: 10

70

Power transformer components

Item

Part number

Description

Quantity
per order

T1

1476.03.195

Power transformer, 2.5 kVA, 6.6 A

T1

1476.03.742

Power transformer, 4 kVA, 6.6 A

T1

1476.03.752

Power transformer, 5 kVA, 6.6 A

T1

1476.03.762

Power transformer, 7.5 kVA, 6.6 A

T1

1476.03.772

Power transformer, 10 kVA, 6.6 A

T1

1476.03.783

Power transformer, 15 kVA, 6.6 A

T1

1476.03.793

Power transformer, 20 kVA, 6.6 A

T1

1476.03.813

Power transformer, 25 kVA, 6.6 A

T1

1476.03.803

Power transformer, 30 kVA, 6.6 A

T1

1476.03.843

Power transformer, 25 kVA, 20 A

T1

1476.03.833

Power transformer, 30 kVA, 20 A

Maintenance Manual - MCR3 - AM.07.360e

Maintenance

3.4.7

Power components, choke


Set the wires according to the input voltage of the regulator.

Table: 11

3.4.8

Power choke components

Item

Part number

Description

Quantity
per order

L1

1476.02.500

Series choke, 2.5 kVA

L1

1476.02.504

Series choke, 4 kVA

L1

1476.02.505

Series choke, 5 kVA

L1

1476.02.507

Series choke, 7.5 kVA

L1

1476.02.510

Series choke, 10 kVA

L1

1476.02.515

Series choke, 15 kVA

L1

1476.02.520

Series choke, 20 kVA

L1

1476.02.525

Series choke, 25 kVA

L1

1476.02.530

Series choke, 30 kVA

Circuit selector
Table: 12

Circuit selector components

Item

Part number

Description

SCO

1475.92.030

Plug-in high voltage Cut-Out type SCO 1

CS - K1K8

6148.47.510

High-voltage contactor, up to 1515 V /


6.6A RMS

CS - K1K8

6148.45.229

High-voltage contactor, up to 4545 V /


6.6A or 1515 V / 20A RMS

CS - K1K8,
RC coil protection

6148.98.250

RC coil protection, for contactors up to 1


1515 V RMS

CS - K1K8,
RC coil protection

6148.45.238

RC coil protection, for contactors up to 1


4545 V / 6.6A or 1515 V / 20A RMS

CS - K1K8,
Auxiliary contact

6148.45.484

Auxiliary contact, for contactors up to


1515 V RMS

CS - K1K8,
Auxiliary contact

6148.45.236

Auxiliary contact, for contactors up to


4545 V / 6.6 A or 1515 V / 20 A RMS

Maintenance Manual - MCR3 - AM.07.360e

Quantity
per order

71

Maintenance

3.4.9

Hardware
Table: 13

3.4.10

Item

Part number

Description

Quantity
per order

Wheels (optional)

7015.35.241

Fixed Wheel

Wheels (optional)

7015.35.251

Wheel with lock

Lifting lugs (optional) 7015.20.120

Lifting lugs M12

PCB

7510.08.300

Standoffs for PCBs M3 L10

10

PCB

7154.04.010

Nut Hex M3 for PCB mounting

100

Wiring

6126.83.810

Cable clamp, for cable diameter up to 8 10


mm

Wiring

6126.83.820

Cable clamp, for cable diameter from 7 10


up to 16 mm

Connectors
Table: 14

72

Hardware components

Connectors

Item

Part number

Description

Quantity
per order

PSL/X7

6112.32.517

Spring clamp terminal box 4-pole

MW1-2 or 3 / P1 or
P2

6112.33.112

Spring clamp terminal box 12-pole

JB / P1, P2, P3 or P4 6112.32.518

Spring clamp terminal box 6-pole

Cage-clamp

Connector accessory, operating lever,


231-131

10

6112.32.500

Maintenance Manual - MCR3 - AM.07.360e

Operation

Operation
NOTE
Throughout this chapter the local user interface is used when parameter changes
are needed. You can also use the configuration tool to do these changes. For more
information about the configuration tool, see section 7.3 Configuration tool software.

4.1

Switch ON the regulator in local mode


When you switch ON the regulator, it starts to produce the same output current that was valid
before the regulator was switched OFF. To set a different output current, you must select another
brightness step. For more information about brightness steps, see 4.3.1 Available brightness
steps. For more information on the produced output currents, see 4.4 Output circuit values.
1.
2.

Switch ON the disconnection device.


Switch ON the regulator. Use the fused
input switch.

3.

Put the regulator in local mode. Push the


Local button on the user interface. You can
now see the status local on the screen.
Go to the Setup menu. Push the Menu
button once.
Select a step. Push the STP up or Step
down button until the Step field changes to
the correct step.

4.
5.

Maintenance Manual - MCR3 - AM.07.360e

MCR: NAME

Iout:
Step:

LOCAL

0.0A
OFF

REMOTE

CSM: OFF
EFD: 256M
LOCAL

MENU

No Errors
No
Errors
RESET

73

Operation

4.2

Switch OFF the regulator in local mode


1.

2.
3.

4.
5.

Put the regulator in local mode. Push the


Local button on the user interface. You can
now see the status local on the screen.
Go to the Setup menu. Push the Menu
button once.
Set the regulator to the step OFF. Push the
STP Down button until the Step field
changes to OFF.

MCR: NAME
Vin:
400V
Iout:
6.6A
Vout:
0V
Step:
5
Iin:
0A
STP DOWN

LOCAL

LFD:
Lmp
CSM: 0OFF

EFD: 256M

STP UP

MENU

No Errors
No
Errors
RESET

Switch OFF the regulator. Use the fused


input switch.
Switch OFF the disconnection device.

4.3

Select the correct brightness step

4.3.1

Available brightness steps


All regulators are set to five steps by default. You can change the number of available steps, for
example, for taxi runways.
Table 1 shows the current values that the regulator produces at each step, depending on how
many steps are available. You can set the regulator to use any of the available steps by using
any of the control modes (local, remote or configuration tool).
Example:
The regulator is set to have five steps available. If you set the regulator to use step 3, the current
value is 4.1 A.

74

Maintenance Manual - MCR3 - AM.07.360e

Operation

Table: 1
Brightness
step

Current values produced at each brightness step


Default current value [A]
No. of steps used
3

5 (default)

4.8

3.3

2.8

2.7

2.2

2.8

5.5

4.4

3.4

3.4

2.8

3.1

6.6

5.5

4.1

3.9

3.4

3.4

6.6

5.2

4.5

4.1

3.9

6.6

5.4

5.2

4.6

6.6

6.4

5.5

6.6

6.4

4
5
6
7
8

6.6

These values apply when the minimum current is 1.8 A and the maximum current is 6.6 A.

4.3.2

Change the number of available of brightness steps


You can change the number of available steps, for example, for taxi runways. For details about
how to change the number of brightness steps, see also section 7.2.4 MCR Setup.
1. In the local user interface, go to menu MCR Setup > Stepdata.
2. Set the number of available steps and the values for the individual steps.
3. Test all brightness steps one by one. Make sure that all the lamps have the same brightness
level.

4.4

Output circuit values


Rated
Output
powers [kVA] current [A]

Max. RMS
output
voltage [V]

Dielectric
test on
output
circuit [V]1

Max. open
circuit RMS
output [V]2

Max. open
circuit peak
voltage [V]3

2.5

6.6

378

1895

530

750

6.6

606

3030

850

1200

6.6

757

3790

1060

1500

7.5

6.6

1136

5680

1590

2250

10

6.6

1515

7575

2120

3000

15

6.6

2272

11360

3180

4490

20

6.6

3030

15150

4240

5990

25

6.6

3788

18940

5300

7490

30

6.6

4545

22730

6360

8990

25

20

1250

6250

1750

2470

30

20

1500

7500

2100

2970

1)
2)
3)

50 Hz RMS voltage during 1 minute.


Under worst condition, considered 1.4 times max. RMS output voltage.
Under worst condition, considered 1.4 times max. RMS output voltage.

Maintenance Manual - MCR3 - AM.07.360e

75

Operation

4.5

Switching between local and remote mode


To control the regulator through the local user interface during maintenance work, you must
switch to the local mode. To switch the control of the regulator to the remote control system, you
must switch to the remote mode.
1.

Push the LOCAL or REMOTE button on


the user interface. You can now see the
new status on the screen.
MCR: NAME

Iout:
Step:

REMOTE

4.6

REMOTE

0.0A
OFF

CSM: OFF
EFD: 256M
LOCAL

MENU

No Errors
No
Errors
RESET

Resetting the regulator


You must reset the regulator in case the regulator:
Does not respond;
Does not produce the requested output;
Was switched OFF.
1.
2.

Press Reset. The regulator now tries to


restart.
If the regulator does not restart, see
chapter 5 Troubleshooting.

MCR: NAME

Iout:
Step:

REMOTE

76

REMOTE

0.0A
OFF

CSM: OFF
EFD: 256M
LOCAL

MENU

No Errors
No
Errors
RESET

Maintenance Manual - MCR3 - AM.07.360e

Operation

4.7

View and clear errors


The system does not store error messages and shows only the latest 15 error messages. You
can view and clear these error messages trough the local user interface. If you clear the error list,
the errors disappear but are not solved.
1.
2.
3.

4.
5.

On the start page, press Menu twice.


Press Start. You can now see the available
menus.
Select View errors. Press Down until the
asterisk is next to MCR: View errors. Then
press Select to view the error list.
Press Down or Up to scroll trough the error
list (see the graphic).
After you resolve the errors, press Clear.

*EFD warning level reached

REMOTE
No Errors

Overtemperature alarm
--DOWN

UP

CLEAR

BACK

NOTE
For how to clear Earth Fault
Detection (EFD) errors, see section
7.2.6 EFD Earth Fault Detection
(option).

4.8

Activate circuits with a circuit selector (option)


If your system has a circuit selector, you must activate separately all circuits that are in use. You
can also deactivate circuits to stop the regulator from producing output current to them.
1.

2.

3.
4.

5.
6.
7.

In the user interface start page, push the


Menu button twice. Scroll through the
available menus with the Down and Up
buttons.
Select the MCR Control menu. Push the
Down button until the asterisk (*) is next to
MCR Control.
Push the Select button.
Select Circuit 1. Push the Down button
until the asterisk (*) is next to Circuit 1. See
the graphic.
Push the Select button. See the graphic.
Activate or deactivate Circuit 1. Push the
Toggle button to set the circuit ON or OFF.
Repeat steps 4 - 6 for all available circuits.

Maintenance Manual - MCR3 - AM.07.360e

MCR MASTER

Step:
Circuit 1:
DOWN

2
ON
UP

SELECT

LOCAL
No Errors
BACK

77

Operation

4.9

Check Earth Fault Detection (EFD) levels


To check the insulation resistance between the series circuit and the ground or the cable screen,
check the EFD value.
1.
2.

Check the EFD value in the local user


interface (see the graphic).
Make sure that the value is in accordance
with local and IEC standards.

MCR: NAME

Iout:
Step:

REMOTE

4.10

LOCAL

0.0A
OFF

CSM: OFF
EFD: 256M
LOCAL

MENU

No Errors
No
Errors
RESET

Check Lamp Fault Detection (LFD) levels


To check the number of burnt lamps in the series circuit, check the LFD value.
1.
2.

3.

On the start page, press Menu twice.


Check the LFD value. Press Down to scroll
down the menu until the LFD field is visible
(see the graphic).
Make sure that the value is in accordance
with local and IEC standards.

MCR: NAME

Step:
Vin:

OFF
400V

DOWN

4.11

EFD: 256M
LFD: 0 Lmp
UP

START

LOCAL
No Errors
BACK

Check hour counter levels


To check the amount of hours the regulator is ON or produces output current that is higher than a
set value, check the hour counter levels.
1.
2.
3.

4.

78

On the start page, press Menu twice.


Press Start. You can now see the available
menus.
Select Hour Counters. Press Down until
the asterisk is next to Hour Counters.
Then press Select to view the menu.
Press Select to view the counters (see the
graphic).

warning
level
EFD
warning
levelreached
reached
*EFD
Hours
Counters
Hours Limits
Overtemperature
alarm
Hours Counters Reset
--DOWN

UP

REMOTE
No Errors
SELECT

BACK

Maintenance Manual - MCR3 - AM.07.360e

Operation

4.12

Using the cut-out SCO


WARNING
Always wear protective gloves and shoes when working with the regulator or
series circuit.
The cut-out SCO has three operation modes. For more information on the modes, see section
4.12.1 Choose the operation mode. For more information on how to change between modes, see
section 4.12.2 Change the operation mode.

4.12.1

Choose the operation mode


The Cut-out SCO has three operation modes:
Description

Mode A

Mode B

Mode C

Purpose

Normal operation.
Regulator delivers
current to series circuit.

Maintenance operation.
Regulator or series
circuit can be serviced
safely.

Measurement possible.
The series circuit
insulation relative to
ground can be
measured.

Diagram

Microswitch

CCR

Microswitch

Series
Circuit

Microswitch
Series
Circuit

CCR

Ground

Series
Circuit

CCR

Ground

Measurement
socket

Cover1

Handle position

Horizontal.

Turned 90 degrees ccw. Turned 90 degrees cw


from position A.
from position A.

Series circuit

Connected to the
regulator.

Shorted and grounded

Disconnected from
regulator, shorted and
connected to
measurement terminal.

Regulator

Delivers current to the


series circuit.

Shorted and grounded.

Shorted and grounded.

Microswitch2

Activated. Regulator is
ON.

Not activated. Regulator Activated. Regulator is


is OFF.
ON.

1)
2)

Only the three positions specified here can be used. In other positions, the cover does not fit
the body correctly.
When the cover is closed, the microswitch is activated. When the cover is open, the
microswitch is not activated and the system shuts down the regulator.

Maintenance Manual - MCR3 - AM.07.360e

79

Operation

4.12.2

Change the operation mode


For more information on which operation mode to use, see section 4.12.1 Choose the operation
mode.
1.
2.

Open the lock (A).


Take out the cover (B). Use the handle.

B
A

3.

4.

Put in the cover (B). Place the cover so that


you can see the required operation mode
symbol. In this example, the selected mode
is mode A and the symbol ON is visible.
Close the lock (A).

B
A

80

Maintenance Manual - MCR3 - AM.07.360e

Troubleshooting

Troubleshooting
WARNING
Do not attempt to do any maintenance work on the regulator unless you have
read and understood all the information in the chapter Safety and you are
qualified to work on high-voltage systems.

5.1

General
The control panel only displays information about errors that are detected by the machine
control. When a critical error occurs, the machine stops automatically. The control can not detect
every error that results in an unacceptable output. The operator has to observe whether the
machine functions correctly.
WARNING
Set the regulator to local control before you do any maintenance work on
the regulator.
Switch the regulator OFF from the main switch before you replace any
parts on the regulator.
Set the regulator to brightness step OFF before inspection of the series
circuit;
Refer to chapter 1: Safety.

5.2

Preliminary checks
Before you do any adjustments on the regulator, check the following items:
The communication between regulator and remote control works;
Power supply to the regulator works normally;
Fused input switch works normally;
Input fuses and auxiliary fuses work normally (see MCR3 Maintenance manual);
All connectors are firmly in place;
Components are not charred or burned;
Wires are not broken or damaged.

5.3

Showing / hiding alarms


You can specify which alarms the regulator shows and sends to the remote control. To do this, go
to Configuration tool > IO settings > Warning messages.

Maintenance Manual - MCR3 - AM.07.360e

81

Troubleshooting

5.4

Error messages
The error messages shown on the local user interface are listed in the tables below.

Errors and
warnings

Table: 1

Regulator faults

Alarm text (message)

82

Alarm
status:
error (E) /
warning (W)

Description

MCR switched OFF for OVERCURRENT E

The regulator creates an alarm and


switches OFF when the output
current is higher than one of the two
preset levels and after the
corresponding delay of each level.
Restart the regulator only after you
have found the cause of the alarm.

Crest factor too high

The crest factor is too high.

Zero crossing error

An error in zero crossing detection.

MCR switched OFF for open circuit

The regulator creates an alarm and


switches OFF when the output
current drops below the minimum
output current.
Restart the regulator only after you
have found the cause of the alarm.

Meas. PCB disconnected

The system cannot detect the output


current measurement connector.

Output current DEVIATES

The output current is different from


the set value.

MCR in OVERLOAD

In case of overload, the output


current may be lower than required.
You can configure the regulator to
consider this as an open circuit
condition and to switch OFF.
By default, the regulator does not
switch OFF.

Output current is UNSTABLE

The output current of the regulator is


not stable.

OPEN DOOR error

One of the panels of the regulator is


open.

AGLAS is disconnected

The system cannot detect the AGL


system.

Thermal sensor missing

The system does not detect an


internal thermal sensor.

OVERTEMPERATURE

The regulator is too hot.

Maintenance Manual - MCR3 - AM.07.360e

Troubleshooting

Alarm text (message)

Alarm
status:
error (E) /
warning (W)

Description

Mains supply is LOW

If the mains supply voltage drops


below a preset level, the regulator
switches OFF.
When the mains supply voltage has
reached a higher (user-adjustable)
level again, the regulator restarts
automatically.

Mains supply HIGH

The regulator generates an alarm


when the mains supply voltage
reaches a preset level.

Mains supply unstable

The regulator generates an alarm


when the mains supply voltage is
not stable.

POWER LOSS!!

The regulator is about to have a


power loss.

Mains frequency out of range

The mains frequency is out of range.

CSM is disconnected

The system cannot detect the circuit


selector unit.

Table: 2

Earth Fault Detection (EFD) faults

Alarm text (message)

Alarm
status:
error (E) /
warning (W)

Description

EFD warning level reached

The EFD unit is above the value set


for level 1.

EFD alarm level reached

The EFD unit is above the value set


for level 2.

EFD calibration running

The system performs the EFD


calibration.

EFD calibration done

Maintenance Manual - MCR3 - AM.07.360e

The system has finished the EFD


calibration.

83

Troubleshooting

Table: 3

Alarm text (message)

Alarm
status:
error (E) /
warning (W)

Description

LFD warning level reached

The LDFD unit has reached the set


number of burnt lamps for level 1.

LFD alarm level reached

The LDFD unit has reached the set


number of burnt lamps for level 2.

LFD VA warning level reached

The LFD unit has detected a VAdrop (load loss), which is above the
set value for level 1.

LFD VA alarm level reached

The LFD unit has detected a VAdrop (load loss), which is above the
set value for level 2.

LFD is calibrating

REFERENCE calibration not done

LAMPS REMOVED calibration not done

Table: 4

Hour counter faults

Alarm text (message)

Alarm
status:
error (E) /
warning (W)

Description

Hours counter exceeds limit

The total hours counter is above the


set limit for any selected hours
counter.

Hours counter exceeds limit

The hours counter for the threshold


output current is above the set limit.

Hours counter exceeds limit

The hours counter for the circuit


selector circuit 1-8 is above the set
limit

Alarm text (message)

Alarm
status:
error (E) /
warning (W)

Description

Bus A down

BUS A does not function correctly.

Bus B down

BUS B does not function correctly.

Table: 5

84

Lamp Fault Detection (LFD) faults

J-Bus faults

Maintenance Manual - MCR3 - AM.07.360e

Troubleshooting

Table: 6

Thyristor Block Module (TBM) faults

Alarm text (message)

Alarm
status:
error (E) /
warning (W)

Description

TBM Disconnected

The system cannot detect the TBM


unit.

TBM current too high

The TBM unit has overcurrent.

TBM crowbar active

The crowbar is active.

TBM communication down

The communication between the


TBM and CCL units is down.

5.5

Observed deviations

5.5.1

Regulator does not turn ON


Table: 7

Regulator does not turn ON

Problem

Possible cause

Solution (See)

No local indications on
boards.

Damaged fuse on fused switch.

Change if applicable. See


MCR3 Maintenance manual.

Damaged auxiliary power fuses


(F3/F4) in the top cabinet.

Change if applicable. See


MCR3 Maintenance manual.

Defective PSL board.

Change if applicable. See


MCR3 Maintenance manual.

Damaged internal fuses on PCBs. Change if applicable. See


MCR3 Maintenance manual.
Alarm Error and the main
contactor (K) in the power
module is not energized.

Power supply level is lower than


the pre-set value.

Check the power supply.


Correct the voltage level, if
applicable. Check the
calibration of the input
voltage measurement.

Damaged fuse on the PSL board


(PSL/F1).

Check the wires and the main


contactor coil. Replace the
fuse, if applicable.

Failure in the CCL or PSL module Check the wires. Replace the
wires.
defective module. See MCR3
Maintenance manual.
Failure in the CCL or TBM
Main contactor (K) in the
power module is energized module.
but the regulator does not
generate any output current.

Maintenance Manual - MCR3 - AM.07.360e

Check the wires. Replace the


defective module. See MCR3
Maintenance manual.

85

Troubleshooting

5.5.2

Regulator turns ON but suddenly de-energizes


Table: 8

Regulator turns ON but suddenly de-energizes

Problem

Possible cause

Solution (See)

Protection of the power


supply to the regulator
became operational.

Power supply is too fast or the


level is lower than the pre-set
value.

See the settings for the


Configuration tool in section
8.2.4 MCR Setup.

Failure in power supply wires or


regulator components.

Check the wires going to and


inside the regulator. Check
the Fused switch and the
terminals.

One of the thyristors is not


operating or is short-circuited.

Check the wires going to the


thyristor gates and inspect
the TBM module.

Noise coming from the


regulator unit and the fuses
of the Fused switch have
blown.

Alarm Overcurrent error.

Failure in thyristor control pulses. Replace the TBM module.


See MCR3 Maintenance
manual.
One of the thyristors is
interrupted.

Replace the TBM module.


See MCR3 Maintenance
manual.

Overcurrent.

Check the maximum output


current and adjust if
necessary.
Check the overcurrent alarm
level and adjust if necessary.
See the settings for the
Configuration tool in section
8.3.4 MCR Setup menu.

Alarm Open circuit error.

Alarm Overload condition.

An open circuit in the circuit loop. Check the series loop for
interruptions.
Regulator malfunction.

Check the thyristors, the


wires of the transformer and
the choke, the main
contactor, the output
measurement transformer,
and the TBM module.

Regulator malfunction.

Check the load of the series


loop.
Check the power
components, the wiring and
the parameter setting of TBM
and CCL.

86

Maintenance Manual - MCR3 - AM.07.360e

Troubleshooting

5.5.3

Regulator does not produce the requested output current


Table: 9

Regulator does not produce the requested output current

Problem

Possible cause

Solution (See)

Regulator produces the


maximum output current at
all times.

The maximum brightness step is


always set.

Disconnect the remote


control line for the max.
brightness step and then
check the remote control
signals.

Failure of the logic.

Check the parameter settings


and the CCL.

You can select all brightness One brightness step is always


set.
steps up to a certain step,
but no steps above that
Failure of the logic.
step.
You can select only the
minimum brightness step.

Check the remote control


signals.
Check MW and CCL.

Failure of the remote control line.

Check the remote control


line, if the module works
correctly in local control.

Failure of the logic.

Check MW and CCL.

Regulator is overloaded.
The regulator does not
reach the output current and
sends the signal I fault.

Check the output transformer


tap, the power supply
voltage, and the load.

No output current.

Input voltage is too low.

Check input voltage and the


regulator parameter settings.

Failure of the logic.

Check local control, Local


Bus, MW, LMC, CCL, and
TBM modules.

Power supply failure.


No display on the user
interface. The LED lights on
the boards are not lit.

Maintenance Manual - MCR3 - AM.07.360e

Check mains power supply,


fuses, wires, and PSL board.

87

Troubleshooting

88

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

PCB drawings and settings


WARNING
Do not attempt to use the machine unless you have read and understood
all the information in the safety chapter and you are sure of your ability to
use the machine safely;
Do not attempt to use the machine unless you know how to stop it in an
emergency as described under emergency stop in the chapter Safety.

6.1
6.1.1

Working with PCBs


Line termination resistors
To prevent line reflections, place line termination resistors (150 to 850 Ohm) only on the modules
that are at either end of the line. The J-Bus and Local bus lines must be terminated this way.
Terminate the Local Bus line on the TBM and LMC modules. For how to terminate the J-Bus line,
see section 6.5 LMC - PCB1513 1593.14.111.

6.1.2

LED RUN
Each PCB has LED lights that signal specific functions related to that PCB. For the specific
functions and locations, see the sections below that describe the PCBs.

Table: 1

LED RUN light functions

LED RUN

Description

Blinks once per second

The microcontroller is operational.

Blinks at a much higher


rate

The microcontroller is in boot-loader mode and a software upload is


required.

Maintenance Manual - MCR3 - AM.07.360e

89

PCB drawings and settings

6.2

TBM - PCB1517 -1593.14.212


This is the interface between the Current Control Logic (CCL) and the thyristor gates. The TBM
module produces the thyristor gate firing signals in accordance with the requested conduction
angle. It also provides fast over-current protection and asymmetric output voltage monitoring.

6.2.1

PCB board
NOTE
Install strap J5, if the regulator has an input voltage range from 208 to 240 V.
Remove strap J5, if the regulator has an input voltage range from 380 to 415 V.
If the strap J5 is not placed correctly, output voltage monitoring may be inaccurate.
Strap J4 is only for factory use (removed for normal operation).

J2

J5

D5
D4
D3
D2

S3

S3

S3
D1
J1

90

J3

J6

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

6.2.2

Connectors
Table: 2

6.2.3

TBM connectors

Connector

Type

Connection to

J1

10-pin, flat connector, grey

Local bus

J2

6-pin WAGO, orange

Not in use

J3

6-pin Phoenix contact, green

CCL PCB

J5

20-pin, flat connector, grey

Thyristor bank

J6

8-pin WAGO, orange

Power supply

Dip-switches
Factory setting of the switches:
S1 - all ON
S2 - 1:OFF 2:OFF 3:OFF 4:ON 5:OFF 6:ON 7:ON 8:ON

S1 Local Bus Line termination

S2 Various
functions

Table: 3

S1 local bus line termination

Switch

Function

ON: Transmit / E pull up 680 Ohm

ON: Transmit / E line termination 150 Ohm

ON: Transmit / E pull down 680 Ohm

Table: 4

S2 various functions

Switch

Function

Recall default parameters

CCL-TBM communication, parity:


For 115200 Bd: 0 = even / 1 = odd
For 38400 Bd: 0 = even / 1 = no parity

ON: Lock in boot-loading mode

CCL-TBM communication, baudrate: 0 = 115200 Bd / 1 = 38400 Bd

Local Bus baudrate:

Local Bus parity:

6
7
8

Maintenance Manual - MCR3 - AM.07.360e

9600 1
Bd
0

19200
Bd

NO
1
parity
0

NO
parity

0
1
0
1

38400
Bd
ODD
parity

1
1
1
1

9600
Bd
EVEN
parity

91

PCB drawings and settings

S3 Various
functions

Not in use.

6.2.4

LEDs
Table: 5

6.3

TBM LED RUN light functions

LED

Function

D1

Local Bus isolated 5 V present

D2

Microcontroller RUN

D3

Local Bus TXD

D4

Local Bus TXD

D5

Local Bus enabled

PSL PCB1521 1593.14.400


The PSL module supplies power to the other modules in +12 / +5 / -12 V. If the power supply to
this board is interrupted, its signal (Power Good) goes low in less than 20 ms. This leaves
sufficient time for the CCL to prepare a fast restart without the loss of control data.
This board also provides 230 V AC for the internal 230 V AC components of the regulator. The
input lines have supplementary filters to reduce the conducted emission of the regulator.

92

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

6.3.1

PCB board
CAUTION
To prevent any damage or electrical shock on the Capacitor, discharge the
Capacitor with the power resistor. The capacitor remains charged at about
70 V DC a long time after the regulator is disconnected from the power supply.
The remaining energy in the capacitor is approximately 2 Joule. Use a resistor
of about 1000 Ohm / 3 W across the capacitor terminals to discharge the
capacitor to below 24 V.

X2

X1

X7

X6

X5

X4

X3

X8

TP7 TP6 TP5


TP4 TP3 TP2 TP1

Maintenance Manual - MCR3 - AM.07.360e

93

PCB drawings and settings

6.3.2

Connectors
Table: 6

6.3.3

Connector

Connection to

X1

Power input supply

X2

Cut-out SCO to X2 (option). If the regulator does not have a Cut-out SCO,
make the connector jumpered.

X3

Power output to the MW boards

X4

CCL

X5

Current transformer

X6

Overvoltage protection (MOV1)

X7

Back-indication signals ON and REG.ERR (optional)

X8

DC power distribution

Test points
Table: 7

94

PSL connectors

PSL test points

Test point

Function

TP1

+12 V DC - Relay control common

TP2

Ground, relative to +12 V DC signal

TP3

Relay control signal - K1 (main contactor)

TP4

Relay control signal - K2 (regulation error)

TP5

Relay control signal - K3 (SCO locking)

TP6

5 V AC1 - input voltage reference, AC signal

TP7

5 V AC2 - input voltage reference, AC signal

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

6.4

CCL - PCB1516 1590.03.541


The CCL module compares the actual output current and the received brightness step request.
The CCL module then calculates the optimal conduction angle request. The CCL checks the
tolerance of the output current, the overcurrent, or open circuit condition and produces the backindication signals. In addition, the CCL also monitors the output circuit and the input parameters.
The CCL module also controls the back-indication signals ON and REG.ERR.

6.4.1

PCB board

C02

DS4

C05

C06

SW1
DS2

DS3

DS1
SW2

C01

6.4.2

C03

C04

C07

Connectors
Table: 8

CCL connectors

Connector

Type

Connection to

C01

20-pin, flat connector, grey

TBM PCB

C02

10-pin, flat connector, blue

Local bus

C03

3-pin WAGO, grey

LFD PCB

C04

26-pin, flat connector, grey

CS PCB

C05

4-pin WAGO, grey

Power supply

C06

16-pin, flat connector, grey

Power supply

C07

6-pin WAGO, grey

Current transformer

Maintenance Manual - MCR3 - AM.07.360e

95

PCB drawings and settings

6.4.3

Dip-switches
Factory setting of the switches:
SW1 - all OFF
SW2 - 1:OFF 2:OFF 3:OFF 4:ON 5:OFF 6:ON 7:ON 8:ON

SW1 Local Bus Line termination

SW2 Various
functions

Table: 9
Switch

Function

ON: Transmit / E pull up 680 Ohm

ON: Transmit / E line termination 150 Ohm

ON: Transmit / E pull down 680 Ohm

Table: 10

Function

Recall default parameters

CCL-TBM communication, parity:


For 115200 Bd: 0 = even / 1 = odd
For 38400 Bd: 0 = even / 1 = no parity

ON: Lock in boot-loading mode

CCL-TBM communication, baudrate: 0 = 115200 Bd / 1 = 38400 Bd

Local Bus baudrate:

Local Bus parity:

7
8

9600 1
Bd
0

19200
Bd

NO
1
parity
0

NO
parity

0
1
0
1

38400
Bd
ODD
parity

1
1
1
1

9600
Bd
EVEN
parity

LEDs
Table: 11

6.5

SW2 various functions

Switch

6.4.4

SW1 local bus line termination

CCL LED RUN light functions

LED

Function

D1

Microcontroller RUN

D2

Local Bus isolated 5 V present

D3

Local Bus TXD

D4

Local Bus TXD

LMC - PCB1513 1593.14.111


The LMC module communicates with the other modules as a master via a local bus. The LMC
processes and distributes the messages it receives from the modules. Each slave has a control
line to request transmission of data to the LMC.
The local bus connection uses the RS485 protocol to send isolated signals over two wires.

96

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

6.5.1

PCB board
NOTE
Install strap J5, if the regulator has an input voltage range from 208 to 240 V.
Remove strap J5, if the regulator has an input voltage range from 380 to 415 V. If the
strap J5 is not placed correctly, output voltage monitoring may be inaccurate. Strap
J4 is only for factory use (removed for normal operation).

SW3
C04

C010

6.5.2

C03

DS4
DS3

DS6

DS5

C08

C09

C01

DS2
DS10

DS11 DS9

SW5

SW6

SW7

C013
C014

SW1
SW2

C012

DS1

SW4

DS8

C011

DS7

C06

C07

C05

Connectors
Table: 12

LMC connectors

Connector

Type

Connection to

C01

20-pin, flat connector, grey

J-bus

C03

10-pin, flat connector, blue

Local bus

C04

20-pin, flat connector, blue

EFD PCB

C05

9-pole, Sub-D female

Dongle

C07

6-pin Phoenix, grey

Power supply

Maintenance Manual - MCR3 - AM.07.360e

97

PCB drawings and settings

6.5.3

Connector

Type

Connection to

C08

26-pin, flat connector, grey

MW3

C09

26-pin, flat connector, grey

MW1

C10

26-pin, flat connector, grey

MW2

C11

3-pin stocko

Not in use

C12

3-pin stocko

Not in use

Dip-switches
Factory setting of the switches:
SW1 - all OFF
SW2 - all OFF
SW3 - 1:ON 2:ON 3:ON 4:OFF 5:OFF 6:OFF 7:OFF 8:OFF
SW4 - J-Bus slave number
SW5 - Depending on the presence of the modules
SW6 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON

SW1 J-Bus A Line termination

This switch handles line termination for J-Bus A. The switch also determines the use of two- or
four-wire transmission.
Terminating the line at both ends of the databus with straps helps to match the load closely to the
characteristic line impedance. This creates a reflection-free communication bus that has less
disturbances. Set the straps as follows:
For a two-line system, set only the straps for the line Transmit / E.
For a four-line system, set the straps for both lines Transmit / E and Receive / R.
NOTE
Make sure that you only place the line termination resistors at the end of the line. If
you set the straps also elsewhere on the line, the signals are weakened. This can
cause the regulator to not function correctly!

Table: 13

SW2 J-Bus B Line termination

98

SW1 J-Bus A line termination

Switch

Function

ON: Transmit / E pull up 680 Ohm

ON: Transmit / E line termination 150 Ohm

ON: Transmit / E pull down 680 Ohm

OFF = 2 wire / ON = 4 wire

ON: Receive / R pull up 680 Ohm

ON: Receive / R Line termination 150 Ohm

ON: Receive / R pull down 680 Ohm

Not used

This switch handles line termination for J-Bus B. The switch also determines the use of two- or
four-wire transmission.
Terminating the line at both ends of the databus with straps helps to match the load closely to the
characteristic line impedance. This creates a reflection-free communication bus that has less
disturbances. Set the straps as follows:

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

For a two-line system, set only the straps for the line Transmit / E.
For a four-line system, set the straps for both lines Transmit / E and Receive / R.
NOTE
Make sure that you only place the line termination resistors at the end of the line. If
you also place other straps, the signals on the line are weakened. This can cause an
incorrect functioning of the MCR!

Table: 14

SW3 Local Bus


and Sync line Line termination

SW4 J-Bus slave


number

SW2 J-Bus B line termination

Switch

Function

ON: Transmit / E pull up 680 Ohm

ON: Transmit / E line termination 150 Ohm

ON: Transmit / E pull down 680 Ohm

OFF = 2 wire / ON = 4 wire

ON: Receive / R pull up 680 Ohm

ON: Receive / R line termination 150 Ohm

ON: Receive / R pull down 680 Ohm

Not used

Table: 15

SW3 local bus and sync line termination

Switch

Function

ON: Transmit / E pull up 680 Ohm

ON: Transmit / E line termination 150 Ohm

ON: Transmit / E pull down 680 Ohm

Not used

ON: Receive / R pull up 680 Ohm

ON: Receive / R line termination 150 Ohm

ON: Receive / R pull down 680 Ohm

Not used

J-Bus slave number, composed by the switches in the position OFF:

Table: 16

SW4 J-Bus slave number

Switch

Hexadecimal value

Decimal value

01 hex

03 hex

04 hex

Maintenance Manual - MCR3 - AM.07.360e

99

PCB drawings and settings

SW5 Local Bus modules

Switch

Hexadecimal value

Decimal value

08 hex

10 hex

16

20 hex

32

40 hex

64

80 hex

128

This switch allows you to enable or disable Local Bus modules. The switch setting on LMC
permits disabling the detection of the optional units. This means that the Local Bus to these units
is deactivated.

Table: 17

SW6 Various
functions

Switch

Function

ON: UI enabled

ON: EFD enabled

ON: LFD enabled

Not used

Not used

Not used

Not used

ON: dongle enabled

Table: 18

SW6 various functions

Switch

Function

ON: Local Kill

ON: E2P init

ON: Lock in boot-loader

Not used

Local Bus baudrate:

Local Bus parity:

6
7
8

100

SW5 local bus modules

9600 1
Bd
0

19200
Bd

NO
1
parity
0

NO
parity

0
1
0
1

38400
Bd
ODD
parity

1
1
1
1

9600
Bd
EVEN
parity

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

SW7

Not used.

6.5.4

LEDs
Table: 19

6.6

LMC LED RUN light functions

LED

Function

DS1

J-Bus A isolated 5 V present

DS2

J-Bus B isolated 5 V present

DS3

Local Bus isolated 5 V present

DS4

Local Bus TXD

DS5

Sync line signal

DS6

Local Bus RXD

DS7

J-Bus A RXD

DS8

J-Bus A TXD

DS9

J-Bus B RXD

DS10

J-Bus B TXD

DS11

Microcontroller - RUN

UI - PCB1507 1593.14.000
The user interface allows you to operate the regulator and to change parameters in a local mode.
For more information on the user interface, see section 7.2 Local user interface.

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101

PCB drawings and settings

6.6.1

PCB board

D5

J2
SW1

D2
D3
D4

SW2

J1

6.6.2

Connectors
Table: 20

6.6.3

UI connectors

Connector

Connection to

J1

Power supply

J2

Local bus

Dip-switches
Factory setting of the switches:
SW1 - all OFF
SW2 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON

102

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

SW1 Local Bus Line termination

SW2 Various
functions

Table: 21
Switch

Function

ON: Transmit / E pull up 680 Ohm

ON: Transmit / E line termination 150 Ohm

ON: Transmit / E pull down 680 Ohm

Not used

Table: 22

SW2 various functions

Switch

Function

Not used

Not used

ON: Lock in boot-loading mode

Not used

Local Bus baudrate:

Local Bus parity:

6
7
8

6.6.4

SW1 local bus line termination

9600 1
Bd
0

19200
Bd

NO
1
parity
0

NO
parity

0
1
0
1

38400
Bd
ODD
parity

1
1
1
1

9600
Bd
EVEN
parity

LEDs
Table: 23

UI LED RUN light functions

LED

Function

D2

Local Bus RXD

D3

Local Bus TXD

D4

Microcontroller RUN

D5

Local Bus isolated 5 V present

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103

PCB drawings and settings

6.7

Multiwire - PCB1486 1593.13.510 & 1593.13.520 (option)


Each regulator has maximum three multiwire PCBs connected to the LMC unit:
MW1;
MW2;
MW3 (for optional circuit selector only).
Each multiwire PCB has eight input and eight output terminals. They handle incoming and
outgoing signals between the regulator and the remote control. The number of multiwire PCBs
on the regulator determines the maximum number of available signals. You can configure these
signals by using the configuration tool software.
NOTE
It is impossible to attribute the same function to more than one terminal.

For each signal, you can set either a POSITIVE or a NEGATIVE logic. For example, if you
configure an output signal for function A and if the condition of function A becomes TRUE, the
signal contact closes in positive logic and opens in negative logic.
To read the present settings in the configuration tool, see the section 7.3.7 IO menu.

6.7.1

PCB board
The multiwire board delivers a remote control voltage usable to control the relays of this board. It
is protected with polyswitch fuses. This internal remote control voltage is brought to the terminal
block P2:

Terminal P2/10: positive pole;

Terminal P2/11: negative pole.


The following straps are available:

Table: 24

104

Multiwire PCB straps

Strap

Description

W5

With strap W5 installed, the internal remote control voltage (negative


pole also internally wired to P2/11) is connected to the common of
the remote control line (P2/9).

W6

With strap W6 installed, the positive pole of the internal remote


control voltage is connected to the common pole for the backindication signals.

Maintenance Manual - MCR3 - AM.07.360e

P2

P3

W5

P1

J1

W6

PCB drawings and settings

6.7.2

12
11
10
9
8
7
6
5
4
3
2
1

12
11
10
9
8
7
6
5
4
3
2
1

PE
Vext
GNDext
Common
Output 8
Output 7
Output 6
Output 5
Output 4
Output 3
Output 2
Output 1

12
11
10
9
8
7
6
5
4
3
2
1

PE
GNDext
Vext
Common
Input 8
Input 7
Input 6
Input 5
Input 4
Input 3
Input 2
Input 1

Connectors
Table: 25

6.7.3

12
11
10
9
8
7
6
5
4
3
2
1

MW connectors

Connector

Connection to

P1

Back-indication/output signals

P2

Control/input signals

P3

LMC

J1

Power supply

Factory settings
The following table shows the factory settings for the back-indication signals. Connect the wires
according to these settings.

Table: 26

Factory settings for the MW back-indication signals

MW1 input

MW2 input

MW3 input

Step 1

Reset EFD error

Circuit 1

Step 2

Use LFD degraded 2


mode

Circuit 2

Step 3

Allow write via Bus 3

Free

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105

PCB drawings and settings

MW1 input

MW2 input

MW3 input

Step 4

Free

Free

Step 5

Free

Free

Free

Free

Free

Free

Free

Free

Free

Free

Free

The following table shows the factory settings for the control signals. Connect the wires
according to these settings.

Table: 27

106

Factory settings for the MW control signals

MW1 output

MW2 output

MW3output

Step 1 obtained

Over current alarm 1

Circuit 1 active

Step 2 obtained

Open circuit alarm

Circuit 2 active

Step 3 obtained

EFD warning level

Free

Step 4 obtained

EFD alarm level

Free

Step 5 obtained

LFD warning level

Free

MCR is ON

LFD alarm level

Free

Regulation error

LFD VA drop
warning level

Free

Over temperature
alarm

LFD VA drop alarm 8


level

Free

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

6.8

J-Bus - PCB1502 1590.03.490 (option)


In order to match the load to the characteristic line impedance, you must terminate the databus
lines with resistors provided on the LMC. This creates a reflection-free communication with less
disturbances. See section 6.5 LMC - PCB1513 1593.14.111.
A regulator is always a slave on the J-Bus. There can be a maximum of 31 regulators on one bus
section with one common bus master.

6.8.1

PCB board
This small PCB provides the interconnection of the user J-Bus(ses) with the LMC. The PCB is
equipped with gas arrestors for overvoltage protection. For how to terminate the J-Bus line, see
section 6.5 LMC - PCB1513 1593.14.111.

P6

P1

P2

P3

P4

P5

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107

PCB drawings and settings

6.8.2

Connectors
Table: 28

J-Bus connectors

Connector

Connection to

P1

J-Bus control for Bus A

P2

J-Bus control for Bus A

P3

J-Bus control for Bus B

P4

J-Bus control for Bus B

P5

PE

P6

LMC

6.9

LFD - PCB1519 1590.03.551 (option)

6.9.1

PCB board
DS1
DS2
DS3
C01

C02

SW1
DS4

SW2

C03

6.9.2

Connectors
Table: 29

6.9.3

LFD connectors

Connector

Connection to

C01

Output measurement transformer

C02

Local bus

C03

Power supply

Dip-switches
Factory setting of the switches:
S1 - all OFF
S2 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON

108

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PCB drawings and settings

S1 Local Bus Line termination

S2 Various
functions

Table: 30
Switch

Function

ON: Transmit / E pull up 680 Ohm

ON: Transmit / E line termination 150 Ohm

ON: Transmit / E pull down 680 Ohm

Not used

Table: 31

S2 various functions

Switch

Function

Not used

Not used

ON: Lock in boot-loading mode

Not used

Local Bus baudrate:

Local Bus parity:

6
7
8

6.9.4

S1 local bus line termination

9600 1
Bd
0

19200
Bd

NO
1
parity
0

NO
parity

0
1
0
1

38400
Bd
ODD
parity

1
1
1
1

9600
Bd
EVEN
parity

LEDs
Table: 32

LFD LED RUN light functions

LED

Function

DS1

Microcontroller RUN

DS2

Local Bus isolated 5 V present

DS3

Local Bus TXD

DS4

Local Bus RXD

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109

PCB drawings and settings

6.10

EFD Logic - PCB1514 1590.03.520 (option)

6.10.1

PCB board
WARNING
Be careful when you handle the EFD module.
The EFD produces a voltage of 500 V DC. This voltage is connected to the
output circuit of the regulator, thus all high-voltage components have this
voltage level relative to ground. The energy is limited but still sufficient to
startle a person coming into contact with it.

C04

C01
DS1

SW1

SW2

DS5
DS6

DS2
DS4

DS3

110

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

6.10.2

Connectors
Table: 33

6.10.3

EFD connectors

Connector

Connection to

C01

Power supply

C02

High-voltage connection from the resistor to C02

C03

PE

C04

Local bus

Dip-switches
Factory setting of the switches:
SW1 - all OFF
SW2 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON

SW1 Local Bus Line termination

SW2 Various
functions

Table: 34

SW1 local bus line termination

Switch

Function

ON: Transmit / E pull up 680 Ohm

ON: Transmit / E line termination 150 Ohm

ON: Transmit / E pull down 680 Ohm

Not used

Table: 35

SW2 various functions

Switch

Function

Not used

Not used

ON: Lock in boot-loading mode

Not used

Local Bus baudrate:

Local Bus parity:

6
7
8

Maintenance Manual - MCR3 - AM.07.360e

9600 1
Bd
0

19200
Bd

NO
1
parity
0

NO
parity

0
1
0
1

38400
Bd
ODD
parity

1
1
1
1

9600
Bd
EVEN
parity

111

PCB drawings and settings

6.10.4

LEDs
Table: 36

EFD LED RUN light functions

LED

Function

DS1

Local Bus isolated 5 V present

DS2

Ohm-test activated

DS3

Output disconnected

DS4

Microcontroller RUN

DS5

Local Bus TXD

DS6

Local Bus RXD

6.11

EFD-Resistor - PCB1515 1590.03.530 (option)

6.11.1

PCB board

C01

6.11.2

Connectors
Table: 37

112

C02

EFD-Res connectors

Connector

Connection to

C01

EFD

C02

Output terminal

Maintenance Manual - MCR3 - AM.07.360e

PCB drawings and settings

X01

4
3

8
7
6
5

10
9

PCB board

11

6.12.1

12

Circuit Selector PCB1523 1590.03.561 (option)

X02

6.12

1
2

TP1

DS1

DS2

C04

DS3

DS4

7
8

TP2

DS5

9
DS6

10
11

DS7
DS8

6.12.2

Connectors
Table: 38

6.12.3

TP3

12

Circuit selector connectors

Connector

Connection to

X01

Control and power

X02

Feedback connection from the contactors

C04

CCL

Test points
Table: 39

Circuit selector test points

Test point

Function

TP1

Ground, relative to +12 V DC signal

TP2

+12 V DC signal for relay control K1 to K4

TP3

+12 V DC signal for relay control K5 to K8

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113

PCB drawings and settings

6.12.4

LEDs
Table: 40

114

Circuit selector LED RUN light functions

LED

Function

DS1

Relay K1 energized / Circuit 1 short-circuited

DS2

Relay K2 energized / Circuit 2 short-circuited

DS3

Relay K3 energized / Circuit 3 short-circuited

DS4

Relay K4 energized / Circuit 4 short-circuited

DS5

Relay K5 energized / Circuit 5 short-circuited

DS6

Relay K6 energized / Circuit 6 short-circuited

DS7

Relay K7 energized / Circuit 7 short-circuited

DS8

Relay K8 energized / Circuit 8 short-circuited

Maintenance Manual - MCR3 - AM.07.360e

Appendix

Appendix

7.1

Checks and measurements

7.1.1

Input current
1.
2.
3.
4.
5.

7.1.2

Output current
1.
2.

7.1.3

7.1.4

The main switch is OFF.


Make sure that the main power supply is dedicated to that regulator only.
Make sure that all connectors are securely in place.
Measure the input voltage (V) to the regulator. Use a True RMS Multimeter, current clamp
and protection gloves.
Make sure that the input current is compatible with the regulator. Check the regulator
nameplate.

The main switch is OFF.


Measure the output voltage (V) of the regulator. Use a True RMS Multimeter, current clamp
and protection gloves.

Switchboard current
1.
2.

The main switch is OFF.


Make sure that the fuse breaker voltage of the switchboard is compatible with the regulator.
Check the regulator nameplate. Allowed variance by standards:
IEC: +10 %
FAA: +-10 %

3.
4.

Switch the main switch ON.


Measure the voltage (V) of the switchboard. Use a True RMS Multimeter, current clamp and
protection glowes.

Continuity of series circuit


Calculate the continuity of the series circuit. Use the following formula:
Rprim = x 1/s
= 18 x 10-3 Ohm mm2:m
Example
circuit length is 8000m
cable section is 6mm2
Rprim = x 8000:6 = 24 Ohm

7.1.5

Insulation resistance
Calculate the insulation resistance of the series circuit as follows:
Measure the insulation resistance of the series circuit. Use the insulation tester Megger
500V or 1000V.
Calculate the theoretical insulation resistance of the series circuit. Use the following
specification:

Table: 1

Theoretical insulation resistance for the series circuit

Item

Maximum insulation resistance current (standard:


ICAO, part 5, 3.9.4.7) [A]

Series transformer

100 m of cable with standard number 1


of connectors

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115

Appendix

Example: a runway centre-line circuit with 133 light fixtures


Total length of the circuit is 8 Km;
Allowed leakage for transformers is 133 x 2A = 266 A
Allowed leakage for the cable is 80 x 1A = 80 A
Total allowed leakage for this circuit is 266 A + 80 A = 346 A
When you test with 5000 V:
R >> 5000 V
R >> 14450867 Ohm
R >> 14 MOhm

7.1.6

Cable capacitance
Measure the cable capacitance towards the ground as follows:
1. The main switch is OFF.
2. The LFD module (option) is connected to the regulator.
3. Connect a multimeter to the regulator output cable. Use a Multimeter that has an internal
resistance of 10 MOhm. A reading of 400 V DC means that the cable is properly insulated.
4. Disconnect the 500 V DC power cable to the LFD module. The Multimeter now measures
the discharge time of the cable capacitance from 400 V DC to 147 V DC.
If the cable capacitance is 1 F, the measured voltage decreases from 400 V DC to 147 V DC
(=0.37x400) in approximately 10 seconds.
If the voltage you measure with the LFD module connected is already 330 V DC, the cable
leakage resistance is approximately 10 MOhm. In this case, the discharge time is approximately
5 seconds for a cable capacitance of 1 F.

7.2

Local user interface

7.2.1

Local user interface screen

Screen

D
C
B

A
A
B

Navigate the local


use interface

116

Push-buttons
Push-button functions

C
D

Menu rows
Title row

Use the push-buttons to navigate through the menus. The selected function of each push-button
shows on the screen above the button. The table shows the available functions for the pushbuttons:

Maintenance Manual - MCR3 - AM.07.360e

Appendix

Table: 2

7.2.2

Push-button functions

Function

Action

ABORT

Stop the selected action and to return to the previous menu.

BACK

Go back to the previous menu.

CLEAR

Clear the error list.

CONTINUE

Confirm an action and go to the next step.

DOWN

Scroll down on a menu that has more lines that the screen can show
at one time.

MENU

On the start page, push Menu to browse the available menus.

RESET

When a fatal errors occur, you can clear the error after you have
found the cause.

SELECT

Confirm a selection.

START

Push Start to open the menu that is selected on the screen.

TOGGLE

Push Toggle to choose an option from a list.

UP

Scroll up on a menu that has more lines that the screen can show at
one time.

MCR Control
The menu allows you to change between local and remote control. You can also change the
selected brightness step and select the circuits for a circuit selector (option).

Table: 3

7.2.3

MCR Control menu

Item

Range

MCR master

Change between local and remote mode.

Step

Change the selected brightness step.

Circuit 1-8

Set the enabled circuits ON or OFF if the regulator has a circuit


selector.

MCR View errors


The menu shows a list of latest error messages.
CAUTION
Be careful when you clear the screen because error messages are not stored.
The clear button does not solve the errors.

Table: 4

MCR View menu

Item

Range

Error

Shows only the latest error messages. The system does not
store error messages.

Maintenance Manual - MCR3 - AM.07.360e

117

Appendix

7.2.4

MCR Setup

Output current

The menu allows you to change the settings for the output current.

Table: 5

Step data

Item

Range

Nominal output current [A]

6.6 or 8.3 or 12 or 20

Overcurrent level 1 [%]

2.0 - 7.5

Overcurrent delay 1 [s]

1.0 - 12.0

Overcurrent level 2 [%]

4.5 - 25

Overcurrent delay 2 [s]

0.0 - 10.0

Step settling speed [s]

0.0 - 2.5

Regulation error value [%]

1.5 25

Regulation error delay [s]

1.0 - 12

Switch ON delay [s]

0.0 - 1.0 s

Switch OFF if overload

NO / YES

Shut-down current value [A]

0.00 - 2.40

Remote reset allowed

YES / NO

MCR in STOPBAR mode

NORMAL / STOPBAR

LOW speed regulation

ON / OFF

The menu allows you to set the number of brightness steps available.

Table: 6

118

MCR Setup menu

Step data menu

Item

Description

Number of steps

Set to a minimum of 3 and maximum of 8 steps.

Step 1 [0.01 A]

1.8 up to the value of the next step.

Step 2 - 7

Set a value from the previous step to the next step. For a 6.6 A
regulator, set a difference of at least 0.1 A between two steps.
For a 20 A regulator, set a difference of at least 0.3 A between
two steps.

Step 8

Set the value from the previous step to the maximum value.

Maintenance Manual - MCR3 - AM.07.360e

Appendix

Default mode

The menu allows you to set default values that the regulator uses when the remote control (JBus) connection is down for longer than the time set in the menu.

Table: 7

Default mode menu

Item

Description

Default mode

Set the parameter either to Use default or Use actual. You can
only set default values if you select Use default.

Default time [s]

The time after which the regulator start using the default
settings.

Default step

Choose a default step. You can set the parameter either to OFF
or from 1 to 8.

Default CSM

Set each circuit to ON / OFF.

Supply voltage
CAUTION
Do not change these parameters without a recommendation from ADB.
Wrongly set parameters can damage the regulator.

Table: 8

Supply voltage menu

Item

Range

Nominal supply voltage [V]

220, 230, 240, 380, 400 or 415

Mains frequency [Hz]

50 or 60 (measured)

Fuse range

63 or 125

Mains switch OFF level [%]

70 - 80

Mains switch ON level [%]

80 - 90

Mains warning level [%]

110 - 130

TAP setting

2/8 to 8/8

IO
Table: 9

IO menu

Item

Range

Multiwire 1

The system detects the available multiwire modules. Multiwire 3


is reserved for the circuit selector. You cannot change the input /
output functions wit the local interface. To change these
functions, use the configuration tool, see section 7.3.7 IO menu.

Multiwire 2
Multiwire 3
Bus A
Bus B

Maintenance Manual - MCR3 - AM.07.360e

The J-Bus(ses) must be enabled before you can use them. This
section allows you to monitor the slave number for Bus A. You
can also change J-Bus baudrate and parity settings separately
for Bus A and B.

119

Appendix

Item

Range

Arbiter

Set the signal source for remote control. You can also set a
priority for different systems. If you set this parameter to
disabled, remote control is not possible.

Local kill

Disable local control.

Temperature limit

Set an upper temperature limit between 20 oC and 70 oC. This


gives only an alert, it does not shut down the regulator.

Mains protection

Option.

Door open

Option.

Versions

This menu shows the present software version of each module. If the local bus does not detect a
module, the marking -.-- shows instead of the software version. You can update these software
versions only with the configuration tool. See section 7.3 Configuration tool software.

Serial numbers

This menu shows the serial number of each module. If the local bus does not detect a module,
the marking -.-- shows instead of the module serial number. You cannot change these numbers.

7.2.5

CSM Circuit Selector and AGLAS (options)


CSM and AGLAS are mutually exclusive.

Table: 10

120

CSM Circuit Selector menu

Item

Range

AGLAS installed

The parameter shows whether the AGLAS system is detected.

CSM installed

The parameter shows whether the CSM is detected.

CSM mode

The available modes:


Simultaneous: the regulator can connect to a number of the
available circuits at the same time;
Alternate: the regulator can connect to only one circuit at a
time.

Circuit 1 - 8

Set each circuit to enabled / disabled.

Maintenance Manual - MCR3 - AM.07.360e

Appendix

7.2.6

EFD Earth Fault Detection (option)


Table: 11

7.2.7

Earth Fault Detection menu

Item

Range

EFD Control

Disabled / enabled

EFD Reset error

YES / NO

EFD ON if MCR is OFF

YES / NO
If this is set to YES, the EFD works even if the regulator is
switched OFF.

EFD Startup [s]

4 - 120

EFD Level 1 [MOhm]

1 - 255
You can set a warning level even if you do not specify a value.

EFD Level 2 [MOhm]

0.06 - 9.99
You can set an error level even if you do not specify a value.

EFD Calibration

Start the calibration.

LFD Lamp Fault Detection (option)

CAUTION
Level 1 and level 2 both have a range of up to 31, but level 2 must always
be larger than level 1.
LFD VA-drop levels: both can be set to any value between 1 and 50, but
level 2 must always be higher than level 1.

Table: 12

Lamp Fault Detection menu

Item

Range

LFD Control

Disabled / enabled

LFD Degraded mode

YES / NO

LFD Level 1 [lamps

1-4

LFD Level 2 [lamps]

3 - 31

LFD VA-drop level 1 [%]

1 - 19

LFD VA-drop level 2 [%]

11 - 50

Maintenance Manual - MCR3 - AM.07.360e

121

Appendix

7.2.8

LFD Calibration (option)


Table: 13

7.2.9

LFD Calibration menu

Item

Description

LFD View sets

Display the different circuit combinations (sets) for the LFD


calibration. There are 1, 2, 4, or 8 sets available, depending on
the installed options.

LFD Active set

Select the circuit combination (set) to be calibrated.


If no sets are selected, the display shows Invalid.

LFD Select CSM circuits

Select the circuit combination for which the LFD calibration is


performed.

LFD Warm-up time [s]

Set the time to 10 - 1200 seconds. The time depends on the


length of the circuit and the number of transformers.

LFD Do REFERENCE
Calibration

Start the calibration.

LFD No. of lamps removed

Set the number of lamps to be removed to a value from 1 to 31.

LFD LAMPS REMOVED


Calibration

Start the calibration.

LFD Erase calibration

Erase LFD calibrations for the active set.

Hour Counters (option)


Hour counters are set to disabled by default. If a CSM is installed, you can enable hour counters
for different circuits.

Table: 14

Hour Counters menu

Item

Description

Hour counters (h)

There are two types of hour counters:


Counters that measure the number of hours the regulator is
ON.
Counters that measure the number of hours the regulator is
ON and produces output current that is higher than a set
value.
If the regulator has a circuit selector, each circuit has its own
hour counter.

122

Hour Limits

Set the values that the hour counters use to monitor the output
current.

Hour Counters Reset

Reset hour counters.

Maintenance Manual - MCR3 - AM.07.360e

Appendix

7.2.10

Display
Table: 15

7.3

Display menu

Item

Description

Display Contrast [%]

The contrast of the display is locked to 100 %.

Display time-out [s]

Set the parameter from 5.0 to 124.5 seconds. The last value
locks the display, that is, the backlight always remains ON and
the display shows LOCK.

Embedded language

Shows the main language of the user interface.

Extra language

Choose an alternative language if another language is available.

Configuration tool software


You can operate the regulator directly from your PC with the configuration tool. To install the
configuration tool on your PC, see section 7.3.1 Install configuration tool.

7.3.1

Install configuration tool


The configuration tool is a software that gives you full control of the entire regulator from your PC.
You can use the tool to configure the regulator after installation or maintenance work.
WARNING
Do not use the configuration tool unless you have permission to do so. If you
activate the configuration tool, you transfer all control of the regulator to the
tool. In this situation, remote or local control of the regulator is not possible.

Requirements

System requirements:
PC with Microsoft Windows 2000 or XP operation system;
At least 50 Mbytes free disk space;
1 free serial communication (COM) port, or a virtual serial communication port over a USB
bridge or a PCMCIA card;
PC user account with either administrator or power user rights.
Configuration tool package:
1 dongle with embedded software;
1 installation CD-Rom with a flasher program;
2 cables:
Extension cable (DB9M/DB9M-1,5 m;
Cable null modem (DB9F/DB9F-1,8 m.

Install software

1.
2.
3.
4.

Open Windows Explorer.


In Windows Explorer, open the main folder of the installation CD-ROM.
Run the setup application file. Follow the instructions of the installation program. The
software is now installed.
Copy the system upgrade files (.upl) from the installation CD to the directory where you
installed the software.
NOTE
If you want to use a dongle for the FCU system with the regulator, you must install
the applicable dongle software in the configuration tool, from the menu Configuration
> Software update.

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123

Appendix

Connect cables

1.
2.
3.

Make sure the regulator is switched OFF.


Take off the front panel.
Connect the extension cable to the dongle
(B) and to the PC connector of the regulator
(A). You can connect directly to any
regulator or to an LMC unit.
Put back the front panel. Use a clamp to
hold the panel to its place so that the cable
can come out freely.
Connect the cable null modem to the
dongle (B) and to the serial communication
port of your PC (C).

4.

5.

Start software

1.
2.

Switch the regulator ON. The regulator also supplies power to the dongle.
Start the configuration tool. Go to Start > All programs > MCR_WIN > MCR_WIN.
Alternatively click the MCR_WIN.exe file in the directory where you installed the software.
The configuration tool opens.
Select the menu Configuration.
Select the applicable serial communication port (COM) to which you connected the dongle.

3.
4.

NOTE
The baud rate and parity settings for the communication between the PC, dongle
and the regulator must be the same. For the dongle, the default baud rate is 38400
and the default parity setting is EVEN.
5.

7.3.2

The dongle makes the connection to the regulator automatically.

Configuration tool screen


A

E
C
A
B
C

124

Menu bar
Status view
Communication connection status view

D
E

Active menu view


Error message

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Appendix

Table: 16

7.3.3

Screen structure

Screen item

Description

Menu bar

The menu bar shows the available menu items and the Exit button.

Status view

This view is always visible. The view shows the present status of the
input and output current. It allows you to change the selected
brightness step and select the active circuits. The view also shows
error messages and status of burnt lamps.

Communication
connection status view

This view shows possible communication errors between the dongle


and the regulator.

Active menu view

The active menu changes when you select a menu item from the
menu bar. You can scroll this view up or down.

Control menu
The menu allows you to change the selected brightness step and select circuits (optional).

Table: 17

Control menu

Item

Range

Step

You can change the selected brightness step.

Circuit 1 - 8

If the regulator has a circuit selector, you can set the enabled
circuits ON or OFF.

Remote reset

You can reset the regulator.

7.3.4

MCR Setup menu

Identification and
software versions

The menu shows you the software versions and serial numbers of all the PCBs installed in the
regulator. If a mode is not detected, the marking -.-- shows instead of the software version. Note
that you cannot change the software version without a corresponding software upload.

Output current

The menu allows you to change the default settings for output current.

Table: 18

Output current menu

Item

Description

Output current

Shows the maximum and minimum output current of the


regulator. You can change this value in the Installation menu.

Steps

Set the number of brightness steps available. For each step, you
can set a step value. For a 6.6 A regulator, set a difference of at
least 0.1 A between two steps. For a 20 A regulator, set a
difference of at least 0.3 A between two steps.

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125

Appendix

Mains supply

Item

Description

Shut-down

If the regulator has a circuit selector, you can set a Shut-down


current value. When you switch OFF a circuit, the regulator
lowers temporarily the output current of the circuit to this value.

Overcurrent alarm levels

Set alarm levels for overcurrent situations.

Mode of operation

Set parameters that define the operation mode for the output
current.

Remote reset

Reset the regulator. The Remote reset allowed parameter shows


you if a reset is possible.

Default operation

Set parameters for default mode operation. These parameters


are used during a communication failure between the regulator
and remote control or LMC/CCL modules.

This menu shows the present mains supply values.

Table: 19

Circuit selector

Item

Range

Mains supply & frequency

This section shows information about the mains supply. You can
only change these values in the Installation menu.

Alarm levels

Define alarm levels for mains supply.

If the regulator has a Circuit selector, this menu allows you to enable or disable circuits.

Table: 20

Error simulation

Circuit selector menu (option)

Item

Range

Mode of operation

This section shows if a Circuit selector is installed. You can also


set the mode of operation to alternate or simultaneous.

Circuits

This section allows you to enable or disable circuits.

This menu allows you to simulate errors. You can use the simulated errors to test the connection
between the regulator and the remote control system.

Table: 21

126

Mains supply menu

Error simulation menu

Item

Range

Output current

Simulate output current errors. Available options are:


overcurrent, open circuit, overload, output current deviates, or
output current unstable.

Mains voltage

Simulate mains voltage errors. Available options are: mains


voltage too low, mains voltage too high, or mains voltage
unstable.

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Appendix

Input/output
measurements

This menu shows the status data for different input and output values. The menu also lets you to
calibrate some measurements for the CCL module.
WARNING
Any calibration is potentially harmful because high voltages and currents are
involved.

Hour counters

Item

Range

Measurements

This section shows the different input and output values.

Calibration

Calibrate input and output measurements for the CCL module.


You must do this every time after you replaced the CCL unit.
When other PCBs are exchanged, a calibration is not required.
When the regulator is in short-circuit, you can calibrate the
regulator only roughly. For fine-tuning, the regulator must be in
full load.
For most values, when you start a calibration, there is first an
offset adjustment. This means that the regulator switches OFF.
Then it switches to the maximum output current and requests
you to enter the correct reading.

Hour counters are set to disabled by default. If a CSM is installed, you can enable hour counters
for different circuits.

Table: 22

Hour counter menu (option)

Item

Description

Hour counters [hour]

There are two types of hour counters:


Counters that measure the number of hours the regulator is
ON.
Counters that measure the number of hours the regulator is
ON and produces an output current that is higher than a
user-defined value.
If the regulator has a circuit selector, each circuit has its own
hour counter.

Hour Limits

Maintenance Manual - MCR3 - AM.07.360e

Set the upper limit of hour counters. When this limit is exceeded,
an alert is generated.

127

Appendix

7.3.5

EFD menu (option)


This menu allows you to control the Earth Fault Detection (EFD) module.

Table: 23

7.3.6

EFD menu

Item

Range

Control commands

This section allows you to enable or disable the EFD module.

EFD Calibration

Start the calibration.


After a successful calibration, the module can measure correctly
the leakage current of the field circuit. The EFD module then
translates this to a corresponding leakage resistance.

Setup

Set a startup time for the series loop. Count four seconds for
each 1km of cable, if the cable capacitance is less than 0.2 F/
km.

Alarms

Set alarm levels to warn about leakages and simulate EFD


errors.

LFD menu (option)


This menu allows you to control the Lamp Fault Detection (LFD) module.

Table: 24

7.3.7

Item

Range

Control commands

This section allows you to enable or disable the LFD module.

Alarms

Set alarm levels to warn about leakages and simulate an LFD


errors.

LFD Calibration

Start the calibration.

IO menu
Table: 25

128

LFD menu

IO menu

Item

Description

Hardware present

Shows the detected hardware modules.

IO Arbiter

Set the signal source for remote control. You can also set a
priority for different systems. If Arbiter is set to disabled, remote
control is not possible.

Local Kill

Allows you to disable local control.

Warning messages

Shows the UI and J-Bus warnings detected by the system.

Temperature

Set an upper temperature limit between 20 oC and 70 oC to


protect the regulator from overheating.

Bus

If ADB has enabled J-Bus, you can change the J-Bus baudrate
and parity settings separately for Bus A and B. You can also
monitor the slave number value.

Multiwire

Change the back-indication/control functions of each signal for


MW 1, MW 2, and MW 3. MW 3 is reserved for the circuit
selector.

Maintenance Manual - MCR3 - AM.07.360e

Appendix

7.3.8

Save
This menu allows you to save and restore IO profiles.

Table: 26

7.3.9

Save menu

Item

Description

Save

Save the IO settings parameters as a profile on your PC. You


can later restore the profile if necessary or upload the profile to
another regulator.

Restore

Upload an IO settings profile to the regulator. Before you can do


this, you must have a profile saved on your PC.

Installation
This menu allows you to view and change factory settings of the regulator.
CAUTION
Do not change these parameters without a permission from ADB. If you give
wrong values to these parameters, you can damage the regulator and the load.

Table: 27

7.3.10

Installation menu

Item

Description

Nominal supply voltage [V]

220, 230, 240, 380, 400 or 415

Maximum output current [A]

6.6 or 8.3 or 12 or 20.

Mains supply fuse [A]

63 or 125

Power transformer
specifications

This section shows the different power transformers of the


regulator.

Circuit selector or AGLAS

This section shows the presence and operational mode of the


circuit selector or AGLAS.

Fast startup

Do not use this option!

Configuration
This menu allows you to configure the communication between the regulator and your PC. It also
configures this software and allows you to upload new software versions to the regulator.

Maintenance Manual - MCR3 - AM.07.360e

129

Appendix

Table: 28

7.4

Item

Range

Communication port

Select the serial communication port your PC uses to connect to


the dongle.

COM port configuration

Change the baudrate and parity parameters for the serial


communication port.

Buzzer control

Enable or disable a sound notification for the PC.

Upload software

Upload a new software version for a module.


Each module has its own software version that can be changed
when a new release becomes available. To upload a software
file:
Save the file to the installation menu of the configuration
tool;
Available software versions show on the screen;
Click a file to start the upload.

Language selection

This section shows the available languages for the configuration


tool. The default language is English.

Abbreviations
Table: 29

130

Configuration menu

Abbreviations

Abbreviation

Description

AGLAS

Airfield Ground Lighting Automation System

CCL

Current Control Logic

CS

Circuit Selector

CSM

Circuit Selector Module

EFD

Earth Fault Detection

LA

Lightning arrestor

LFD

Lamp Fault Detection

LMC

Local Master Circuit

MW

Multiwire

PCB

PC Board

PE

Protective Earth

PSL

Power Supply Logic

TBM

Thyristor Block Module

UI

User Interface

Maintenance Manual - MCR3 - AM.07.360e

Appendix

Maintenance Manual - MCR3 - AM.07.360e

131

Further information:

Addresses:

N.V ADB S.A.

Siemens SAS,
Department ADB

Leuvensesteenweg 585,
B-1930 Zaventem,
Belgium
www.adb-air.com
Phone: +32 (2) 7221711
Fax: +32 (2) 7221764

9, Rue du Docteur Finot,


F-93527 Saint-Denis Cedex 2,
France

P.O. Box 30829,


977 Gahanna Parkway,
Columbus, OH 43230,
USA

www.adb-air.com
Phone: +33 (1) 49229250
Fax: +33 (1) 49229255

www.sas.siemens.com
Phone: +1 (614) 8611304
Fax: +1 (614) 8642069

ADB N.V/S.A.
A Siemens Company

ADB regional Sales HQ


Middle East

Unit 3310
Hunter Bouleward,
Magna Park,
Lutterworth, LE17 4XN
United Kingdom

P.O. Box 2154,


Dubai,
UAE

www.adb-air.com
Phone: +44 1 455 883130
Fax: +44 1 455 883179
Siemens AG
Industrial Solutions and Services

www.adb-air.com
Phone: +971 (4) 3660573
Fax: +971 (4) 3660755
ADB Regional Sales HQ
Asia Pasific

RD NBY I&S ITS FVD A


P.O. Box 4844
D-90327 Nuremberg
Germany

Level 1 reception, CP Tower 11,


Section 16/11,
Pusat Dagang Seksyen 16,
46350 Petaling Jaya Selangor,
Darul Ehsan,
Malaysia

www.siemens.de/airports
Phone: +49 (911) 6543439
Fax: +49 (911) 6543404

www.adb-air.com
Phone: +60 (3) 79525397
Fax: +60 (3) 79557916

Registered Office
ADB NV/SA
Marie Curiesquare 30
1070 Brussels
Belgium

The information provided in this document


contains merely general descriptions or
characteristics of performance which in actual
case of use do not always apply as described
or which may change as a result of further
development of the products. An obligation to
provide the respective characteristics shall only
exist if expressly agreed in the terms of
contract.

Siemens Airfield Solutions, Inc.

Order No.: AM.07.360e


Printed in Belgium
Subject to change without prior notice
N.V. ADB S.A.