Tools Required

• True RMS Digital Multimeter (DMM) with voltage probes and current clamp.
• Basic tools including SAE wrenches (including a 9/16” wrench for output connection), screwdrivers (including a 3mm or SAE equivalent slotted for terminal block connections), hammer, adjustable pliers, etc. for removing knockouts and installing appropriate fittings.
• For ground lug connection: 1/4” slotted screwdriver for CCRs of kW sizes from 1kW to 15kW, or 3/16” hex bit, Allen wrench, or t-handle for CCRs of kW sizes from 20kW to 30kW.
• For incoming power connections: slotted (flathead) screwdriver; a 4mm Allen key is included with CCRs of kW sizes from 15kW to 25kW (a 4mm hex bit or t-handle may be preferred in field); for 30kW CCRs, a 5/16” hex bit or Allen wrench / t-handle is required.
  
  

Installation Precheck

• Unpack the CCR and inspect for shipping damage.
• Check the CCR nameplate.
• Verify that the input voltage listed on the nameplate matches source voltage.
• Verify that the kW output is correct.
• Verify that the current output is correct (6.6A or 20A).
• If the nameplate information does not match the site requirements, STOP INSTALLATION and contact Airport Lighting Company.
• Verify that the input wiring and all appropriate disconnects are properly sized to the load.
• If site-specific sizing calculations have not been made, refer to FAA Advisory Circular 150/5340-30 Design and Installation Details for Airport Visual Aids, current revision, Chapter 13 Power Distribution and Control Systems.
• Using the dimensions in Small Cabinet Dimensions and Large Cabinet Dimensions, verify the installation footprint is adequate.
• Position the included ground lug in the preferred orientation.
• Your CCR has two (2) threaded holes that provide flexibility during installation.
• The ground lug and brass ground screw are installed inside the CCR in factory to prevent damage during shipping.
  
  

Terminating CCR Connections

• Follow all necessary lock out / tag out procedures.
• Open the CCR supply circuit and lock out during installation.
• Once you have completed the Installation Precheck and installed all required fittings, position the CCR into its final location.
• Connect a ground to the CCR using the included lug.
• Connect L1 & L2 from the supply breaker directly to the contactor in the top left corner of the CCR panel.
• The panel has Input stickers designating this location.
• If the CCR has Input Power Monitoring installed, run one of the supply legs through the current transformer on the left side of the enclosure.
• Do not loop the supply leg through the CT multiple times.
• The output connections must be made on the output surge arrestors, positioned on the bottom floor of the CCR.
• The surge arrestors are marked with Output stickers.
• If the CCR has an Internal S-1 Cutout Installed, the output connections will be made directly in the S-1.
• Remove the S-1 handle and connect to the available lugs.
• The bottom edge of the installed S-1 has an Output sticker to designate this location.

 
Once output connections are made, connect remote wiring if applicable. Once all connections have been made, it is recommended to complete the initial start-up with the output shorted. This will ensure high-voltage protection of the field circuit while device operation is validated. Connect a wire, 12AWG or larger, between the output connections in the CCR. If your airfield circuit has an Airport Lighting Company S-1 installed, removing the handle will short the CCR output circuit.

Turning the CCR on for the First Time

• 
  Use all required personal protection equipment while completing work on or around live circuits. Exercise caution at all times.
• Open the three (3) DIN rail-mounted fuse holders labeled FA3, FA4, and FA5.
• Turn on the power to the CCR at the supply disconnect.
• Using a digital multimeter (DMM), verify the input voltage. Due to natural occurrences, measured voltage may not exactly match anticipated voltage. The measured voltage should match the nameplate-rated voltage for the CCR within 5%.
• Using a DMM, check the output voltage of the CCR Control Transformer.
• The voltage across terminals 9 and 10 is expected to be between 115V and 130V.
• The voltage across terminals 11 and 12 is expected to be between 14.5V and 16.5V.
• If the measured voltage of either control transformer winding does not match the anticipated voltage, disconnect power to the CCR and contact Airport Lighting Company. Once your control transformer output voltages are verified, disconnect power to the CCR.
• Once power is disconnected, close the DIN rail-mounted fuse blocks – FA3, FA4, and FA5.
  
  

System Check in Local Mode

• Complete the section even if you have connected a remote control.
• Turn on CCR supply power.
• Place a current clamp on an output wire and connect the clamp to a DMM.
• Using the LOCAL UP and LOCAL DOWN buttons, increment through each brightness step and verify the current output.
• Once the current measurements are verified, push the OFF button once to turn the CCR output off.
• Disconnect power to the CCR and remove the output shorting wire that was installed, or reinsert the S-1 handle if equipped.
• The CCR is now ready for operation in Local mode.
  
  

If the CCR is to be configured for use with a remote control refer to the following articles:
Remote Control Overview

24v Internally Powered

24v Externally Powered

120v Internally Powered

120v Externally Powered

 

Airport Lighting Company | Type L-828, Type L-829 Ferroresonant Constant Current Regulator