ADB AGL3 - Module 4 The AGL Series Circuit

AGL 3
Module 4
Aeronautical Ground Lighting
AGL Series Circuit

Cables, Joints & Earthing
Content
1 The AGL Series Circuit Design
2 Isolating Transformers
3 Airfield Cable
4 Cable Joints
5 Counterpoise Earth System
6 Selection of Primary Circuit Equipment
7 Method used to join primary cables
8 Method used to join secondary cables
9 Earthing
AGL 3 - Module 4 1 Issue B

Author : Technical Support
Date : Sep 11
1.0 THE AGL SERIES CIRCUIT DESIGN
1.1 Electrical characteristics
Electrical power for aerodrome lighting aids is almost entirely alternating current (AC)
at nominally 50 or 60 Hz.
It is not necessary to supply airfield circuits on the series system but it must be
appreciated that to obtain anything like even lighting patterns with a parallel system
entails the use of heavy cables and a multiplicity of feeds. For this reason the series
system has been universally adopted.
Most airport lighting is energized by series circuits, but the incoming power is
distributed to the sub-stations using parallel circuits, and some single units or shorter
circuits of lights may be supplied conventionally. For example, sequence flashing
lights of approach lighting systems, some floodlights, and some obstacle lights are
airfield lighting systems commonly using parallel circuits.
1.2 The AGL Series circuit
The circuit elements are connected in a series loop with the same current flowing in
each element. The circuit is a continuous loop starting and ending at the power
source called the constant current regulator.
The constant current regulators will maintain a constant current independent of the
load on the circuit. The same level of current ( eg. 6.6 amps ) will flow in a large
circuit as in a small circuit and will remain at the same current level even if some of
the lamps fail.
The constant current means that a short circuit across the output of a constant
current regulator is a no load condition and an open -circuit is an overload.
In a simple direct-connected series circuit, a lamp failure would cause an open circuit:
hence it is necessary to provide a by-pass device, such as a fused film cutout or an
isolating transformer. The use of Isolating transformers is the preferred practice for
aerodrome lighting circuits.

Date : Sep 11
control cables
primary series circuit
constant current output

regulator (CCR) disconnecting
device
screened cable (optional)
input
disconnecting
device
L1
insulated screen
connection
N (earth optional)
PE
splice
connection
lightning connectors
arrestor
AGL
earth series
(optional) transformer
earth
(optional)
secondary
luminaire
series
circuits
AGL electrical system comprising constant current series circuits
1.3 Advantages of series lighting circuits
• All lamps are operating at the same current and thus at the same intensity.
This uniform intensity and appearance of the lamps are helpful;
• A single core cable of one conductor size and insulation voltage rating can be
used throughout the circuit;
• Intensity control of lights can be obtained over a wide range;
• Circuit may have a single earth fault at any point along the circuit without
affecting the operation of the light circuit.
• Earth faults are easy to locate.
1.4 Disadvantages of series lighting circuits
The major disadvantages of circuits when used for lighting are:
• installation costs are high and the constant current regulator and the isolating
transformers add appreciably to this cost;
• possible poor efficiency, primarily of the moving coil type of constant-current

regulator.
• all components such as cable, isolating transformers and lamp sockets must
be insulated for full voltage ( normally @ 5 kV )

Date : Sep 11
• an open-circuit fault anywhere in the circuit makes the entire circuit
inoperative and possibly may damage the cable insulation or the constant-
current regulator.
• location of faults, especially open circuit faults, may be difficult.
1.5 Choice of current.
Equipment development has limited the available options of current to be used in the
AGL series circuit.
ICAO have adopted airport lighting series circuit currents at either 6.6 or 20 amp at
rated full intensity, although other currents are sometimes used.
The line power loss for a fixed cable conductor and length for a 6.6 amp circuit is
about one/ninth that for 20 amp circuits. Either value of current can be carried in
5,000volt insulation cable of 4mm² diameter cross-section without excessive
temperature rise.
The load on the regulator of series circuits, should be at least one-half of its rated
capacity.
6.6 amp circuits are commonly used for long circuits with smaller electrical loads,
and 20 amp circuits are used for larger loads and shorter cable lengths.
All modern circuits are normally designed for 6.6 amps but occasionally at the higher
loads you may come across the 20 amp circuit.
You may also come across 12 amps circuits but these would normally be on an older
(military) installation.
2.0 ISOLATING TRANSFORMERS
2.1 Purpose.
• To maintain continuity in airfield lighting primary circuits while applying a low

voltage to lamps.
• To isolate secondary lamp circuit low voltage (typically 30.3V - 200 watt, 15V
- 100 watt 6.8V - 45 watt lamp) from high voltage primary circuit which can
be up to 5,000 volts.
2.2 Transformer design
An Isolating transformer consists of a primary and a secondary coil wound on a

magnetic core in an encapsulated covering with primary and secondary leads for
connecting the series circuit to the lamp.
The secondary circuit is subjected lesser electrical potential and one side of the
secondary should be brought out to an earthing connection. The core of an isolating
transformer is magnetically unsaturated in operation but becomes saturated if the
lamp fails or the secondary circuit is open-circuited, thus maintaining the integrity of
the primary circuit.
If the lamp circuit is short-circuited, the isolating transformer would be in no load

condition and have minimum effect on the series circuit. These transformers are
capable of continuous operation at rated load, open-circuit, or short-circuit without
damage.

Date : Sep 11
Isolating transformers are designed for a specific output ie lamp load, plus secondary
lead losses within the minimum current for maximum lamp brilliance setting for a 6.6A
unit.
The effects of overloading the secondary winding - ie by too long a secondary lead
will result in a reduction of secondary current.
Usual Types of Encapsulation
• Rubber Moulding
• Epoxy Resin
• Cast Iron Box
The Encapsulated transformer is suitable for installing direct into the ground or under
water, the encapsulation will protect the unit from damage, if the transformer is
dropped or is carried by a single lead.
3.0 AIRFIELD CABLE
3.1 Primary Cable
The AGL primary cable plays an essential role as one of the component involved in
the makeup of the series circuit.
It is installed in a pit and duct system or directly buried in dedicated cable trenches.
Under certain conditions voltages in excess of 5kV can produced at the output
terminals of a CCR ( open circuit condition ), so the cable used on civil airports is
generally insulated to operate continuously at 5 kV to ground.
The conductor cross section is normally 6 sq mm and above to limit power losses,
this is in fact has a much larger current carrying capacity then the circuits are
designed to carry.
The larger cross sections may have to be considered if the series current is higher
than 6.6A.

Date : Sep 11
All AGL series circuits use cable, isolating transformers and light fittings as part of the
normal design. They are not complex as an electrical design, so it is a relatively
simple exercise to estimate the number of high voltage joints that are present in a
particular circuit.
Each isolating transformer requires two high voltage joints in its primary side and at
least one low voltage joint on the secondary side.
Over the years it has been noted that faults on AGL series circuits are often attributed
to joints that have failed for one reason or another.
The AGL primary cable plays an essential role as one of the component involved in
the makeup of the series circuit.
It is installed in a pit and duct system or directly buried in dedicated cable trenches.
Under certain conditions voltages in excess of 5kV can produced at the output
terminals of a CCR ( open circuit condition ), so the cable used on civil airports is
generally insulated to operate continuously at 5 kV to ground.
The conductor cross section is normally 6 sqmm and above to limit power losses,
this is in fact has a much larger current carrying capacity then the circuits are
designed to carry.
The larger cross sections may have to be considered if the series current is higher
than 6.6A.
All AGL series circuits use cable, isolating transformers and light fittings as part of the
normal design. They are not complex as an electrical design, so it is a relatively
simple exercise to estimate the number of high voltage joints that are present in a
particular circuit.
Each isolating transformer requires two high voltage joints in its primary side and at
least one low voltage joint on the secondary side.
Over the years it has been noted that faults on AGL series circuits are often attributed
to joints that have failed for one reason or another.
3.2 Secondary Cable
The Secondary cables used in airfield lighting are low voltage rating, indeed the lamp
voltage never exceeds 50V in normal working conditions.
The current in these cables is generally 6.6A (20A in some applications). Due to the
normally short lengths involved the cross sections commonly used is small.
These cables are generally two-core, rubber insulated and polychloroprene sheathed.
In case the secondary cable is required for use in saw cuts filled with resin, special
abrasion resisting wires should be used. The secondary cables are usually supplied
with factory moulded connectors.
4.0 CABLE JOINTS
4.1 FAA Connector Kits
In recent years most series circuit connections have been made using connector kits.
Although the cost of connector kits is significant, the time saved in installation and the
ease with which circuits can be opened and re-closed when locating faults have
made their use desirable. Since the leads of most isolating transformers are now
manufactured with connectors, cable connectors are required and provide an easy
means of connecting or disconnecting the transformer into the series circuit and to
the light.
Installation of connectors

Date : Sep 11
The cable ends should be prepared carefully in accordance with the instructions,
keeping both the cable ends and the connector surfaces free of dirt and moisture.
Make certain that any cavities between the cable and interior of the connector are
filled with the gel provided to prevent voids. After joining the connectors ensure that
air is not trapped which may tend to force the connection apart. Taping over the joint
with vinyl electric tape to keep the area clean and from separating is suggested.
5.0 COUNTERPOISE EARTH SYSTEM
The counterpoise earthing system is a facility to protect the installed primary cables
in the event of excessive electrical storms and lightning.
Scope :
This item shall consist of furnishing and installation of counterpoise wire and earth
electrodes for protection of the underground cables and light bases, in areas where
damage from lightning strikes may be expected. The system shall only be installed in
the ducts and in cable trenches.
Materia l :
Counterpoise wire shall b e tinned copper wire, solid or stranded with a minimum size
of minimum 8 AWG, protected by a thermoplastic sheath. In ducts insulated copper
wire of similar size shall be used;
Installation :
The bare counterpoise wire shall be installed in the same trench for the entire length
of the insulated cable it is designed to protect, and shall be placed in trenches at a
distance of approx. 150mm above the insulated cables.
In PVC ducts the wire shall be placed in the same conduits.
The counterpoise system shall be securely attached to earth electrodes, installed nor
more than 300m apart around the entire circuit, and to all metal light bases, steel
base plates, steel elbow conduits, metal transformers or housings and other fixtures
along its route.

Date : Sep 11
The counterpoise system shall terminate at the AFL equipment building(s), where it
shall be securely attached to the earthing grid system.
All connections shall be made by means of crimp connectors.
The resistance to earth of each ground rod shall be maximum 10 ohms.
Ground rods may be used either singly or in a cluster. Ground rods in a cluster will
only be accepted by the Supervisor if installation of deep driven ground rods is not
possible due to rock just below the surface. Drive the ground rods to ground water
level for an effective and permanent installation, if conditions allow.
Provide for corrosion prevention by a proper choice of metals or by cathodic

protection. Where ground water cannot be reached, chemicals such as magnesium
sulphate (MgS04) or copper sulphate (CuS04) may be used to improve soil
conductivity where necessary.
Manufacturers of ground rods can provide data on such treatment. Provide for easy
maintenance and periodic testing. Although driving ground rods deeper (sectional
type) may be more effective than multiple rods, in many cases, soil variations and
possible bedrock may make provision of additional rids less expensive.
Cable separation complete with counterpoise
6.0 SELECTION OF PRIMARY CIRCUIT EQUIPMENT
Perhaps the single most consideration for contractors is the type of cabling and cable
jointing to use on the airfield. Generally, the choice of AGL Fittings , Isolating
Transformers and CCR's etc has been determined ( mostly by preference and cost ).
The practical consideration in the primary circuit involves the choice, method of
connection, installation methods etc.
It is constructive to divide cables into groups or basic types rather than pursue more
specialised cables that one may never come across.

Date : Sep 11
The standard cabling is designed to withstand 5000 volts, however, it is possible to
come across lesser rated cables on existing installations.
This following paragraph is from the AERODROME DESIGN MANUAL Part 5,

Electrical Systems :
( The intention being it gives an indication of what little information there is about
connections associated with AGL circuits. Most people assume that installers and
maintainers always make good cable joints ….. this is an incorrect assumption ! )
Extract ADM Part 5 - 3.2.1.8

Connections for series circuits : The connections in series circuits should be
carefully made to assure circuit continuity and to prevent development of
ground faults.
An open-circuit fault in the primary will cause an outage of all lights in that circuit.
Unless the constant-current regulator is equipped with open-circuit protection, the
regulator may be damaged. Most ground-type faults on series circuits occur at
connections. A single ground fault does not cause an outage of the lights, but two or
more ground faults will short-circuit all lights between the faults.
6.1 PRIMARY CABLE
6.1.1 Primary Cable Type No 1 :
This is a non-screened type made up of three components, they are :
a) the current carrying conductor - eg. 6mm square section

b) the insulation - 2000, 3000 or 5000 volt rated.
c) the outer sheath - for mechanical protection.
(a) (b) (c)
Makeup of Non-screened AGL Cable as used on Series Circuits.
6.1.2 Primary Cable Type No 2 :
The main difference between the cable makeup as seen in the diagram above, is the
inclusion of a metal tape or mesh commonly referred to as screened, sheathed or
armoured cable.
This metal screen or shield is wound around the conductor’s insulation and earthed to
provide an means to equalise the voltage gradient over the whole cable length and
thus increase its projected working life span.

Date : Sep 11
This type of screening is recommended when a cable runs cross various earth layers
or conduits thus presenting differences in electric conductivity. They are produced
with a brass tape shield that also acts as an effective mechanical protection against
attacks from insects and small rodents.
It is recommended that all airfield lighting cables should have a classification inline
with standards such as European and British Standards or the American FAA
guidelines.
Care should be taken if considering the use of none approved types as problems may
be experienced after installation.
The PVC outer jackets can be produced in different colours to facilitate series circuit
identification.
This screened type is made up of four components, they are :

a) the current carrying conductor - 6mm squared.
b) the insulation - 5000 volt rated.
c) the metal screen - brass or copper.

d) the outer sheath - for mechanical protection.
a b c d
Typical Screened Cable as used on AGL Series Circuits.
There are a number of variations of this type of cable, but as a general rule the
method or type of joint needed to terminate the cable will fall into either inline solid
joints or plug and socket connections.
Advantages of screened cable
Electrical :
The addition of a metallic or non-magnetic shield, generally a helically wound copper

or brass tape properly earthed, equalises the voltage gradient over the length of the
cable run, the voltage pressure within the insulation eliminates the surface tracking
over the insulation. This is a phenomenon commonly found on non-shielded cables
operating at circuit voltages in the excess of 2kV.
2.5mm², 4mm² or 6mm² is normally used, the smaller one is used for short run
lengths and the larger size is for long run lengths.
You should note that the effects of surface tracking are :

• premature cable ageing
• destruction of the insulation under the combined effects of ozone
• temperature generated by ionisation.

Date : Sep 11
Therefore the practice using screened cable is recommended for circuits with
operating voltages in the excess of 2kV, or when one or more of the following
installation conditions exist :
• In dry soil, such as in the desert.

• When the cable transits from conductive to non-conductive soil or conduits.
• When the cable transits from dry to wet soil or from dry to moist conduits.
• In moist conduits.
• When lubricants have to be used to pull cables into conduits.
Radio Interference :
The advantage of the screened cable is a reduction of the RFI signals emitted by the
cables and the Thyristor-controlled CCR that generate RFI, particularly when they
operate at reduced load and /or low brilliancy level.
Mechanical :
The mechanical resistance of the cable gives :
• Protection against attacks from termites, perforating insects and small

rodents. Even if the cable outer jacket is damaged the cable remains perfect
from the electrical standpoint, as the voltage pressure occurs within the well
protected insulation.
• The earthed screen avoids any shock hazard from damaged cable as the
screen will divert any leakage current to earth.
Shielded cables should be specified for all major Airfield Lighting Installations with
good earthing at regular intervals is essential. A good quality joint kit is
recommended for all primary cable joints.
6.2 SECONDARY CABLE
The Secondary cables used in airfield lighting are low voltage rating, indeed the lamp
voltage never exceeds 50V in normal working conditions.
The current in these cables is generally 6.6A (20A in some applications). Due to the
normally short lengths involved the cross sections commonly used is small.
These cables are generally two-core, rubber insulated and polychloroprene sheathed.
In case the secondary cable is required for use in saw cuts filled with resin, special
abrasion resisting wires should be used. The secondary cables are often supplied
with factory moulded connectors.
6.3 CABLE BURIED DIRECTLY IN THE GROUND
The majority of cables which are laid direct in the ground have sheaths of conducting
material, usually lead, but for some purposes, e.g. airfield lighting, cables having
sheaths of non-conducting materials, such as P.C.P. (neoprene) or P.V.C, are
utilised.
This latter practice gives rise to certain electrical phenomena which may prove
harmful. Details of these phenomena are give below :
o When the working voltage is applied to a cable an electrical stress will exist
between the conductor and the nearest earthed object. In the case of cables

Date : Sep 11
having sheaths of conducting material the sheath is earthed and the electrical
stress will be confined to the cable insulation.
o Where, however, the sheath is non-conducting an electrical stress will exist in

the ground surrounding the cable, the intensity and distribution of which will
depend on the electrical properties of the ground, and in particular the
conductivity and permitivity. If pockets of air are left between the cable and
the surround ground, the electrical properties of the air will affect the
distribution of stress.
Stress may be radial, longitudinal or circumferential and in some cases it is

great enough to cause electrical discharge. Cases have occurred where the
longitudinal stress at the surface of the cable has caused currents to flow
along the cable surface (i.e. tracking) causing carbonisation of the sheath
material, this in turn results in increased tracking and eventually to cable
failure.
In some cases there will be a potential gradient on the surface of the ground
near the cable. The differences of potential will probably be small but it must
be remembered that quite small potential differences have proved fatal to
livestock on farms.
o Failure may also occur if the stress in air pockets between the cable and the
ground is great enough to cause electrical discharge. Failure may result
directly from the discharge; alternatively the oxygen (0 2 ) in the air may be
converted into ozone (0 3 ) and failure will then result from the destructive
effects of the ozone on the cable materials.
Failure of this type can be prevented by the inclusion of an earthed metal

screen over the cable insulation.
As the majority of service experience with non-conducting sheathed cables laid in the
ground has been obtained in America the recommendations of I.P.C.E.A. (Insulated
Power Cable Engineers Association) form a useful guide to cable screening practice.
The I.P.C.E.A. recommends that screening should be considered for cables operating
at voltages over 2,000 volts where any of the following conditions exist :
• Connections to aerial lines

• Transition from conducting to non-conducting environment
• Transition from moist to dry earth
• Dry soil, such as in the desert
• Dump conduits
• Where conducting pulling compounds are used.
• Where the surface of the cable collects conducting materials, such as soot,
salt or cement density.
• Where electrostatic discharges are of low enough intensity not to damage the
cable but are of sufficient magnitude to interfere with radio or television
reception.
• Where safety to personnel is involved
The screen may take a number of forms, the most common being as follows:-
• A helical layer of copper tape

• A helical layer of brass tape (used also as a protection against termites)
• A braid of copper wires
• A layer of steel armour wires helically applied.

Date : Sep 11
However, in order to be effective the screen must be properly earthed, the earth
connection being usually made at the termination positions; on long cable runs an
earth connection should also be made at each joint.
When terminated the screen should be trimmed back far enough to prevent flash-over
from the conductor to screen and a stress cone should be provided at the end of the
screen to avoid a high stress at this point.
TYPICAL TRENCH CROSS SECTION DETAIL
AGL cables and Isolating transformers to be buried a minimum of 300mm below

finished grade. A 14 sq mm Counterpoise Earth wire to be laid in trench 150mm above
AGL cables
backfill
300 mm
cable 150 mm
counterpoise
75 mm
30 mm cable duct
bedding
100 mm
material 30 mm
min 150 mm

Date : Sep 11
6.4 UNDERGOUND CABLE CONNECTIONS
In-line connections of underground AFL and R.C. cable shall be made by cable
splices consisting of a plastic mould around the joint, which is to be filled with an
epoxy resin preferably using the pressure method and if so finally taped for water
tightness.
6.5 Installation in a Duct or Conduit
The maximum number of voltage ratings of cables installed in each single pipe of
duct of conduit, shall be as follows:
• Power cables of the same voltage may be installed in the same duct;
• installed in the same duct
• Power cables of less than 600 volts should not be installed in the same duct,
with control, telephone, or coaxial type cables
• Power cables of more than 600 volts should not be installed in the same duct,
with control, telephone, or coaxial or power cables of less than 600 volts;
• Control, telephone, and coaxial cables may be installed in the same duct;
• No more than two AFL cables are allowed in the 2" duct between lights.
Connections or joints made in any cable shall not be installed in any conduits or
ducts.
The installer shall make sure that :

• the complete duct is open, continuous and clear of debris before installing
cables.
• the pulling wire installed in the pipes is to be used for pulling the rope for the
cable installation.
• the cable should be installed in a manner to prevent harmful stretching of the
conductor, injury to the insulation, or damage to the outer protective
covering.

Date : Sep 11
• the ends of all cables shall be capped or sealed with tropical moisture-seal
tape or crimp socket before installation and they shall be left sealed until
connections are made.
• where more than one cable is to be installed in a duct or conduit under the
same contract, all of the cables shall be installed at the same time. The
pulling of cable through ducts or conduits shall be accomplished with the use
of cable grips or pulling eyes. Maximum pulling tensions shall be obtained
from the manufacturer of the cable for straight ends and bends.
A lubricant recommended for the type of cable being installed shall be used where
pulling lubricant is required. Duct or conduit markers temporarily removed for
excavations shall be replaced as required. Kinks or cuts in the insulation or the
sheath of the cable shall not be permitted and will cause rejection of that part of the
cable length. Damaged cable should be replaced without an additional cost to the
project.
After installation of cables in ducts or conduits, the Contractor shall ensure that the
pulling wire in each pipe of the duct/conduit is re-installed and that the ends of
ducts/conduits are provided with plugs.
In manholes or hand holes, the cables shall be carefully formed around the interior,
avoiding sharp bends. All cables and splices should be properly supported by plastic
cable racks where necessary.
paved area
150 mm
counterpoise
300 mm
backfill
30 mm
cable concrete
duct 75 mm
75 mm
bedding
100 mm material
min 150mm

Date : Sep 11
Cable protection during installation
6.6 Cable Tags and Markers
All cables shall be identified by means of PVC strips or lead strips and stamped
according to circuit identification as per drawing with letters and numbers 6mm high.
Cable tags shall be fixed to the cable with binding wire. Due to possible aggressive
soil conditions Any PVC cable tags could be replaced by lead markers, if indicated by
the Supervisor.
Cable tags shall be spaced at approximately 10 metres separation, additional cable

markers shall be placed at test link points and manholes, handholes or at cable ends
to identify the cables. In case the conduit system between the light base also
contains cables of different circuits, these cables are to be marked with an extra tag
at each light base.
All HV, LV, RC and AFL cables shall be identified by a plastic net or strip such as
"Plyage", placed 15cm above the cables and over the top of the counterpoise
whichever applicable throughout the full width of the trench. The colour of the plastic
has to be yellow for AFL cables and of a different colour or other types of cables
which are to be approved by the Supervisor.

Date : Sep 11
Cable Marking during installation
6.7 Cable Grounding
Shields are to be grounded, to reduce the hazard of shock. Grounding is required,

otherwise dangerous induced shield voltages may occur.
All shielded HV, LV and AFL cables shall have the shield or armour grounded at each
end and at intervals of about 300m.
All shielded control cables shall have the shield or armour grounded at each end and
at intervals of about 1500m. Earth Electrodes and protection pits are specified and
provided under a separate section hereafter: Earthing Systems. However, the
resistance to earth of each ground rod shall be a max 10 ohm.
Telephone cables shall have the shields or armour grounded at each end.
Coaxial cable shields shall be insulated from the ground throughout the whole length
and the shields shall be grounded at each end of the cable.
7.0 METHODS USED TO JOIN PRIMARY CABLES
7.1 In-line slice joints :
In-line spliced joints can be used to connect either two pieces of AGL cable or one
piece of cable and an isolating transformer together.
It consists of a few basic components whether it be a heat shrink or resin joint kit.
To make a joint using this type of kit you need :

a)a inline 6mm copper crimp (ferrule)
b)a strip of self amalgamating insulating tape.
c) ideally an inner shrink sleeve
d)an outer shrink sleeve
or
e) a resin joint case complete with resin.
The joint is made in stages.

It should be possible to construct a joint in such a way to suit a shrink or resin type of
joint.
When making a connection using non-screened cables the following steps can be
adopted :
See overleaf :

Date : Sep 11
Step 1
Two pieces of AGL cable to be jointed.
Step 2
Remove sections of outer sheath.
Cables with Outer Sheath Removed.
Step 3
Remove sections of insulation.
Cables with Inner Insulation Removed.
Step 4
Cables with Chamfered Insulation (ends).
Chamfer the insulating material as shown to increase the area a fault has to travel
and provide a gradual slope on which to re-construct the insulation barrier when
making good before sealing the joint.
Note : Step 1 to 4 are all associated with cable preparation. This is the area that
determines the quality of the finished joint, needless to say it is often the part that
gets rushed which results in poor joints.
Step 5
Location of In-line Crimp Connecting both Cables Together.
Insert copper inline crimp (furrel) and secure using the correct pliers for crimp type.

Date : Sep 11
Step 6
Shows Re-Construction of Insulation Layer.
Re-construct the insulation around the crimp and extend it along the cable for a
reasonable distance to again make a sound electrical barrier so prevent any electron
leakage.
Step 7
Finished Joint with Shrink Sleeve Reduced After Applying Heat.
Fit a shrink sleeve and apply heat to reduce its size to fit tightly around the cable.
OR
Outer Case of Resin Joint showing Filler Funnels.
Fit a plastic case around the joint and fill it with resin as instructed by the
manufacturer, after reading relevant directives.

Date : Sep 11
AND IF YOU GET IT WRONG …..
THIS CAN BE THE RESULT IN THE FIELD !!!

Date : Sep 11
7.2 Connecter Kit method of connecting AGL Cables :
When connecting cables via plugs and sockets, it is essential that the correct kit
matches the cable installed and is identified verified as the right one before placing a
purchase order, otherwise you will have major problems with circuits failing through
earth and open circuit faults.
A connector kit would normally include both plug (male) and socket (female) parts.
They would consist of a limited number of components as follows :
1. Outer protective rubber type housings x 2.

2. Waterproof glands x 2.
3. Central metal electrodes x 2.
4. Nylon guides x 2.
5. Packet of silicone grease x 1.
Always follow the manufacturers instruction when fitting the connector kit to achieve a
sound electrical and structural joint.
If assembled correctly they are waterproof and should not cause any problems
providing simple precautions such as making sure air is not trapped inside the plug
and socket chamber when mating the electrodes.
Should this happen the air pressure inside the housing may force the joint apart
causing an open circuit or a high resistance joint that will fail after some period of
time.
AGL Cable. Crimp Area. Metal Electrode
Waterproof Gland Housing
Components making up a Typical Plug as Fitted to Non-Screened Cable.
Metal Electrode (Socket). Crimp Area AGL Cable.
Housing. Waterproof Gland.
Typical Components making up an AGL Socket Connector Kit.

Date : Sep 11
8.0 METHODS USED TO JOIN SECONDARY CABLES
Depending on the airport the policy that is adopted with regard to joining secondary
cables will depend on a number of factors.
Secondary leads can be ordered from the manufacturer as long as the length is
specified. They do provide a quick and easy way of extending transformer secondary
cables by means of factory fitted plugs and socket connectors and moulded cable
ends.
Another way is to make inline joints.

When using this method, we must adopt a few basic engineering practices and this
type of joint will not cause serious problems for the maintenance team.
The dimension of the cable used on AGL secondary circuits appears much larger
than is actually required. This is necessary so that insulation values can be
maintained, volts drop kept to a minimum and contamination of outer sheaths is
reduced even if not totally prevented.
As with other joints, it is the preparation that governs what the end result will be.
The major cause of these joints failing is an internal short circuit. This can be avoided
by staggering the connection, as it prevents a short developing should the joint be put
under some sort of mechanical pressure such weight of other cables or the insulating
material wrapped around the joint breaks down.
8.1 Making a joint in a Secondary.
Cable No 1. Cable No 2.
Staggered Joints
Indication of how Inline Crimp Connectors should be staggered.

Date : Sep 11
9.0 EARTHING
9.1 All electrical equipment in control and distribution centres must be bonded to earth
mass in accordance with IEC Standards.
If AGL series circuits could maintain the highest insulation integrity possible they
could be classified as ideal installation, so would not require any form of earthing.
That is because this type of circuit is designed to continue working under curtain fault
conditions. To do that the design characteristics of the power unit known as a CCR is
such that it can not discriminate between an actual load and a short circuit. So the
output side of a CCR is not provided with the type of protection built into normal
lighting and power circuits.
In an ideal AGL installation it would not be “theoretically” necessary to earth the

series loop as a means of tripping out the circuit under fault conditions. So why bother
with any form of earthing? On the other hand, as it appears that earthing of the series
circuits is provided, beware, there must be no doubt in your mind that this is no
guarantee of the safety of personnel who happen to come into direct or indirect
contact with a live circuit. Certain equipment failure modes (eg double earth faults
and isolating transformer primary-secondary shorts) could present a potentially
hazardous situation for maintenance personnel as the system to all intent and
purpose appears to be earthed. Therefore, whether or not it is currently the practice
of the airport you work at to earth the series circuit, care must be taken to ensure that
adequate protection from electric shock is provided.
Where provided, earth connections should be measured to be no greater than 6

ohms in order to provide protection from electric shock.
Where shielded cable is used in a constant current series circuit (for EMC purposes),
the shield should be continuous throughout the loop and earthed at the ends of the
primary series circuit within the CCR. Cable shields also provide some protection
against insulation deterioration due to high voltage stress and it is recommended that
the shield be earthed at every practicable point.
9.2 AGL Earth Network.
Most airports install a 6mm squared bare copper wire along with the AGL series
circuits in the field. This provides a facility that all light fittings and isolating
transformers can be connected to. As it covers the whole of the AGL installation it
effectively bonds everything together and connects to earthing rods at various places
around the airfield allowing any voltage potential to dissipate to earth mass.
Where several AGL circuits run in trenches or ducts there is a requirement for one
earth wire. As an example in figure 1 it shows how one earth wire provides a general
earth for two interleaved runway edge circuits. The number of AGL series circuits that
can be found in trenches or duct systems going from an equipment room to the
runway can be substantial. But as the drawing shows, only one earth wire is provided
to complete the earth network.

Date : Sep 11
S/S No1. S/S No2.
CCR 1. CCR 2.
Earth Rod.
Additional Earth Rod.
Typical Earth Wire Configuration Bonding All Isolating Transformers, Light Fittings
Together With Associated Earthing Rods.
9.3 Lightning Protection
To determine the requirements for lightning protection, consider the risk of a strike
against the Category of Airfield, amount of cable installed along with weather
conditions and cost of possible replacement parts should the field circuit suffer from a
direct or indirect strike. Some countries are prone to massive and regular electrical
storms, so the design must reflect that by including systems that can handle and
shunt surges away from specific equipment. Some installation in another locality may
only require a minimum of protection as the risk of a lightning strike is remote.
Typical Lightning Discharge.

Date : Sep 11
Should an installation be hit by a lightning strike of several Megawatt capacity as
indicated in figure 1, providing precautions have been taken the effect can be
minimised. The question is how or what can be done to limit the amount of damage
that can result from a lightning strike.
9.4 Lightning Arrestor.
One way of addressing high voltage spikes induced into AGL series circuits is an
option by the CCR manufacturer, that is to include devices known as a lightning
arrestor. They are supplied in twos, which are connected between the CCR output
winding and earth often inside the CCR itself.
The principle of operation is, a predetermined voltage limit is identified at which point
it as sufficient potential to jump an air gap inside a porcelain tube. At the piont the
voltage is high enough to bridge the gap, it should still be below a value that would
cause the insulation of either CCR windings or series circuit cables to fail. Once the
air gap is bridged a current flow takes place effectively shunting it to earth mass.
CCR Secondary Winding. Output to AGL Circuit.
Airgap Type Lightning

Arrestor.
Connection to
Earth Mass
Typical Connection of Lightning Arrestor inside a CCR.
There are other devices that can be employed on remote control cables. They are
relatively small in size and cost affective, but operate in a similar manner to the much
large CCR device. The more recent types use either a dielectric film or gas that
reforms its barrier to electron flow under normal circuit operating conditions..
9.5 Counterpoise Earth.
We have described the generalities of the Counterpoise Earth earlier in this chapter.
On some installations a more substantial earth wire will be require as a means of

transmitting large voltages and associated currents to earth mass. This system is
referred to as a counterpoise earth. The policy being a 16mm squared copper
conductor is snaked across the top of AGL cable runs to intercept a lightning strike
before it effects the cables below. In a ducted system this will not be possible, but it is
common for a special duct to be installed above other ducts housing AGL cables. It is

Date : Sep 11
considered to be reasonably effective and works as a way of limiting the risk of
serious damage.
Where a counterpoise is provided (for protection against lightning) it may be used as

an earth source for AGL installations if no suitable alternative exists.
Care should be taken to ensure that in the event of a lightning strike the connection of
equipment to a counterpoise will not cause unacceptable damage to the AGL.
9.6 Grounding ( see also 9.2 - AGL Earth Network )
Ground or earthing rods may be used either singly or in clusters. Drive the rods down
to the ground water level for an effective and permanent installation. Provide for
corrosion prevention by a proper choice of metals or by cathodic protection. Where
ground water cannot be reached, chemicals such as magnesium sulphate (MgSO4)
or copper sulphate (CuSO4) may be used to improve soil conductivity where
necessary. Manufacturers of ground rods can provide data on such treatment.
Provide for easy maintenance and periodic testing. Although driving ground rods
deeper (sectional type) may be more effective than multiple rods, in many cases, soil
variations and possible bedrock may make provision of additional rods less
expensive.
Always ensure that your installation has the necessary earthing systems installed to
minimise risk to the person and offers a means of limiting damage from lightning
strikes. Make sure that systems are included in maintenance programmes and tested
periodically to prove serviceability.
Note: Some modern AGL remote control systems, particularly field equipment is
susceptible to induced emf under normal working conditions. So the method of earth
needs to be discussed at length to make sure compatibility between services. This
can have a dramatic effect on the reliability of some AGL installations.
There are differing views on how screened cables should be earthed. They range
from earthing only at the ends of individual circuits at the CCR or CTP or as implied
earlier in the text at selective points around the airfield.
The requirement for earthing electrical equipment is understood by most maintenance

personnel, but when considering AGL things do not automatically fit into or match a
particular regulation. When addressing the need for earthing of AGL always identify
the role each system plays. Never forget that HIGH VOLTAGE Series Circuits will not
trip off if someone comes in contact with a live cable or component.

Date : Sep 11

ADB AGL3 - Module 4 The AGL Series Circuit

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ADB AGL3 - Module 4 The AGL Series Circuit

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AGL 3

Aeronautical Ground Lighting

AGL Series Circuit

1 The AGL Series Circuit Design

5 Counterpoise Earth System

6 Selection of Primary Circuit Equipment

7 Method used to join primary cables

8 Method used to join secondary cables

AGL 3 - Module 4 1 Issue B

1.1 Electrical characteristics

1.2 The AGL Series circuit

AGL 3 - Module 4 2 Issue B

constant current output

AGL electrical system comprising constant current series circuits

1.3 Advantages of series lighting circuits

• Intensity control of lights can be obtained over a wide range;

• Earth faults are easy to locate.

1.4 Disadvantages of series lighting circuits

The major disadvantages of circuits when used for lighting are:

• possible poor efficiency, primarily of the moving coil type of constant-current

AGL 3 - Module 4 3 Issue B

• location of faults, especially open circuit faults, may be difficult.

1.5 Choice of current.

2.0 ISOLATING TRANSFORMERS

• To maintain continuity in airfield lighting primary circuits while applying a low

2.2 Transformer design

An Isolating transformer consists of a primary and a secondary coil wound on a

If the lamp circuit is short-circuited, the isolating transformer would be in no load

AGL 3 - Module 4 4 Issue B

Usual Types of Encapsulation

• Cast Iron Box

3.0 AIRFIELD CABLE

3.1 Primary Cable

AGL 3 - Module 4 5 Issue B

3.2 Secondary Cable

4.0 CABLE JOINTS

4.1 FAA Connector Kits

AGL 3 - Module 4 6 Issue B

5.0 COUNTERPOISE EARTH SYSTEM

In PVC ducts the wire shall be placed in the same conduits.

AGL 3 - Module 4 7 Issue B

All connections shall be made by means of crimp connectors.

The resistance to earth of each ground rod shall be maximum 10 ohms.

Provide for corrosion prevention by a proper choice of metals or by cathodic

Cable separation complete with counterpoise

6.0 SELECTION OF PRIMARY CIRCUIT EQUIPMENT

AGL 3 - Module 4 8 Issue B

This following paragraph is from the AERODROME DESIGN MANUAL Part 5,

Extract ADM Part 5 - 3.2.1.8

6.1 PRIMARY CABLE

6.1.1 Primary Cable Type No 1 :

This is a non-screened type made up of three components, they are :

a) the current carrying conductor - eg. 6mm square section

(a) (b) (c)

Makeup of Non-screened AGL Cable as used on Series Circuits.

6.1.2 Primary Cable Type No 2 :

AGL 3 - Module 4 9 Issue B

This screened type is made up of four components, they are :

c) the metal screen - brass or copper.

Typical Screened Cable as used on AGL Series Circuits.

Advantages of screened cable

The addition of a metallic or non-magnetic shield, generally a helically wound copper

You should note that the effects of surface tracking are :

AGL 3 - Module 4 10 Issue B