User'S Guide Operating & Maintenance: Constant Current Regulator

USER’S GUIDE
OPERATING & MAINTENANCE
Constant Current Regulator

CCR
Table of Contents
Table of Contents.....................................................................................................................2
Record of Changes..................................................................................................................6
Safety precautions ...................................................................................................................7
1. Overview ..........................................................................................................................8
1.1 Introduction .................................................................................................................8
1.2 Technical-Features ......................................................................................................9
1.3 CCR Control Unit .......................................................................................................9
Fig 1.1 CCR Control Unit ............................................................................................9
1.3.1 Earth Fault Unit ........................................................................................................9
1.3.2 Lamp Fault Unit ......................................................................................................10
1.3.3 Communication Unit ...............................................................................................10
1.3.4 Keypad ...................................................................................................................10
1.3.5 Monitoring Unit .......................................................................................................10
1.3.5.1 Open Circuit (OPC I<1.5A) ..................................................................................10
1.3.5.2 Regulation Error (REG ER > +5%) ......................................................................10
1.3.5.3 Input Power Loss (IPL - 10%) ..............................................................................10
1.3.5.4 Current Regulation Error(Rating ±0.1A) ............................................................... 11
1.4 Protection .................................................................................................................. 11
1.5 Control & Display Unit: ..............................................................................................12
1.6 Power Unit ................................................................................................................12
1.7 Brightness Step Level................................................................................................13
Table 1.2 Nominal Step current(6.6A loop) ................................................................13
Table 1.3 Nominal Step current (20A loop) ................................................................13
2. CCR Operation ..................................................................................................................14
2.1 Operation Modes & Controls .....................................................................................14
Fig 2.1 Changing Mode.............................................................................................15
2.2 CCR Indications ........................................................................................................15
2.2.1 Remote Indications ..........................................................................................16
2.2.2 Serial Communication Indications ....................................................................16
.2.3 Keypad Process .......................................................................................................16
Fig 2.2 Keypad..........................................................................................................16
2.4 CCR-Database ..........................................................................................................18
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CCR
3. CCR Options .....................................................................................................................18

3.1 Earth Fault Detector (EFD) ........................................................................................18
Fig 3.1 Earth Fault Module ........................................................................................18
3.2 Lamp Failure Detector (LFD) .....................................................................................19
Fig 3.2 Lamp Fault Module .......................................................................................19
3.3 Elapsed Time ............................................................................................................19
Fig 3.3 Elapsed Timer ...............................................................................................19
Fig 3.4 Non-Illumination step ....................................................................................20
3.5 Circuit Selector ..........................................................................................................20
Fig 3.5 Circuit Selector..............................................................................................20
3.5.1 Remote Connection .........................................................................................20
Fig 3.6 Remote Connection ......................................................................................21
4. CCR Configuration Management .......................................................................................21
Fig 4.1 Password Screen ..........................................................................................21
4.1 General Setting .........................................................................................................21
4.2 Lamp Fault Setting(Option) .......................................................................................22
4.3 Earth Fault Setting(Option) ........................................................................................23
Fig 4.2 Earth Fault Settings ......................................................................................23
4.4 Circuit Selector(Optional spec) ..................................................................................23
Fig 4.3 Circuit Select Settings ...................................................................................23
5. Remote Control & Monitoring.............................................................................................24
5.1 Serial Communication(Option) ..................................................................................24
Fig 5-1 Communication Mode ...................................................................................24
5.1.1 System requirements .............................................................................................24
5.1.2 Installation of Software ...........................................................................................24
5.1.3 Setting Communication Ports .................................................................................24
5.1.4 Connection between PC and CCR .........................................................................24
5.1.5 Monitoring CCR ......................................................................................................24
FIG 5.2 Online Monitoring System window(Sample) .................................................25
5.1.6 SET CCR ADDRESS..............................................................................................26
Fig 5.3 CCR Address setting window(sample) ..........................................................26
5.1.4 Serial Communication Diagram ..............................................................................28
Fig 5.4 Serial Communication Connection Diagram ..................................................28
5.2 Parallel Communication ............................................................................................29
5.2.1 Parallel Communication Connection Table .............................................................29
Table 5.1 TB2 Connection Table ...............................................................................29
Table 5.2 TB3 Connection Table ...............................................................................30
CCR
5.2.2 Parallel Internal Connection Diagram .....................................................................30

Fig 5.11 Internal Parallel Connection Diagram ..........................................................30
5.2.3 Parallel External Connection Diagram ....................................................................31
Fig 5.12 External Parallel Connection Diagram .........................................................31
5.2.4 Other Parallel Control Voltage Optional ..................................................................31
6. CCR Installation .................................................................................................................32
6.1 Starting Up Procedure ...............................................................................................32
6.2 First Start UP .............................................................................................................32
Table 6-1 Load Combination Table ............................................................................33
Fig 6.2 Load Diagram ...............................................................................................33
Fig 6.3 Method of CCR output tap adjustment ..........................................................34
7. Name of part & Functions ..................................................................................................35
7.1 CCR Control Unit ..............................................................................................35
Fig 7.1 CCR Control Unit ..........................................................................................35
7.2 Front view(Low voltage parts)....................................................................................36
Fig 7-1 Low voltage panel .........................................................................................36
7.2 Side view...................................................................................................................37
Fig 7-2 Side view ......................................................................................................37
7.3 Rear view(High voltage panel)...................................................................................38
Fig 7-1 Rear view......................................................................................................38
8. Maintenance ......................................................................................................................39
8.1 Trouble Shooting .......................................................................................................40
8.2 Regulator does not turn ON.......................................................................................41
8.3 Regulator turns ON but De-Energize suddenly ..........................................................41
8.4 Regulator not produces the request output current ....................................................42
8.5 Serial Communication not sending data ....................................................................43
8.6 PC Communication Software Part List.......................................................................43
9. Basic operation of CCR .....................................................................................................44
9.1 CCR-Basic Operation ................................................................................................44
10.CCR Operation method ....................................................................................................47
10.1 CCR Local control mode .........................................................................................47
10.2 CCR Parallel Remote Control Mode ........................................................................49
10.3 CCR Serial Remote Control Mode ...........................................................................50
10.4 CCR Setting Method ...............................................................................................51
Fig 10.1 ....................................................................................................................51
Fig 10.2 ....................................................................................................................51
10.5 CCR ADDRESS Setting method..............................................................................52
CCR
10.6 Setting method for LFD module ...............................................................................53

Fig 10.3 ....................................................................................................................54
10.7 Setting Method for EFD Module ..............................................................................55
Fig 10.5 ....................................................................................................................55
11. CCR’s Boards Setting & Maintenance ..............................................................................56
11.1 Power Unit Setup or check list .................................................................................56
Fig. 11.1 Power Unit Layout ......................................................................................56
11.2 Control Unit Setup or check list................................................................................57
Fig. 11.2 Shows board layout for control unit ............................................................57
11.3 Driver Unit Setup and check list ...............................................................................58
Fig. 11.3 Driver Unit Layout.......................................................................................58
11.4 Monitoring Unit Setup and check list ........................................................................60
Fig. 10.4 Monitoring Unit Layout ...............................................................................60
11.5 Communication Unit Setup and check list ................................................................60
Fig. 11.5 Communication Unit Layout .......................................................................61
12. CCR’s Waveforms ...........................................................................................................63
12.1 CCR Output Current Waveform for each other current step(B0~B7) .......................63
12.2 CCR Output Current Waveform When CCR Turn On ..............................................65
12.3 CCR Output Current & Voltage Waveform When CCR Open Circuit .......................65
13. Drawings………………..………………………………………………………………………...66
CCR
Record of Changes
Version Description Checked Date(MM/YY)

1.0 First Edition SJL,WYP 08/04
2.0 Updated Software/Hardware SJL,WYP 02/05
3.0 Updated OnLine Monitoring System SJL,WYP 08/05
4.0 Updated CCR Design SJL,WYP 03/06
4.1 Review & Update CCR Design SJL,JPL 02/12
4.2 Review & Update CCR Design SJL,JPL 09/16
CCR
 Safety precautions
Notice
Personal must observe the safety regulations at all times, while every practicable
safety precaution has been incorporated in this equipment.
In case user install the CCR, use a fixing ring as a tool for firmly fixing the power
cable of input/output to outbox of CCR.
The maximum short circuit current of this CCR is 10kA.
Caution
Authorized to work on high voltage equipment must observe all safety regulator
instructions.
Don’t change the Lamps or components or adjustments inside the equipment with the
light circuit energized.
Deliver the CCR treated vibration-proof and explosion-proof with wooden box
packaging so that protect from the outer shock.
Avoid the delivery way of giving damages on the packaging and CCR.
Warning
Human being must first of all eliminate electronic charges from his own body just
before touching an electronic module or component. The easiest ways of discharging
human being’s body is to touch a conductive-earthed object.
Electronic modules or components must not be brought in contact with highly
insulating materials such as plastic sheets, synthetic fiber clothing, they must be laid
down on conductive surface.
The tip of the soldering iron must be earthed. Electronic modules and components
must be stored and transported in conductive packing.
CCR
1. Overview
1.1 Introduction
Constant Current regulator designed for the power of Airport Lighting circuits with small,
medium and high requirements. Design and performance evaluations by engineers and
technicians with combinded experience in airport lighting.
 Proven Technology for airfield lighting
 Reliable for long life with low life cycle cost
 Exceed FAA performance requirements
 Durable for various electrical vault environments
 Versatile for medium or high intensity lighting
 Self protected from over loads and short loads
 Noise emission free
 Air-Cooled no hazardous cooling materials
 No harmful harmonics
 Easy Maintenance
User Selectable by configuration according to IEC, FAA specification 3-step, 5-step, and 7-
step additional Non-illumination step can be selected.
Current digitally adjustable for all intensity steps over full current range of 6.6A.
All the basic and optional functions are included in the electronic comparator and are
accessible from the front of the regulator
User Selectable features through keypad
 Switching CCR ON/OFF through keypad
 Commands for intensity step inputs can be processed
 Additional Non-Illumination step can be set
 Switching serial or parallel communication can be selected.
 Reset commands can be processed while on OPC, OVC, and FUSE error
occurred
 Complete configuration setting can be processed
 Monitors the Lamp Fault while CCR-ON can be viewed on separate screen by
pressing the key (5/LF)
 Monitors the Earth Fault while Power ON, can be viewed on separate screen by
pressing the key (6/EF)
 Circuit selector can be enable or disabled by configuring CCR settings
 Elapsed Time Monitors the CCR-ON & Intensity steps
CCR
1.2 Technical-Features
 Operating conditions: Room temperatures from 0C + 55C, with maximum of
relative humidity of 95%. Cooled by natural convection.
 Supply Voltage: Single phase with manufacturing levels: 208V, 220V, 230V,
240V, 380V, 415V, 440V, 460V, 480V,User require spec’ and 50 or 60Hz.
 Maximum Output Current: 6.6A (Other value on request)
 8 Maximum adjustable steps
 Remote Control: Standard: From 20V to 60V (Default Internal: 24VDC)
 Optional: Serial Communication (Dual ports)
 Output Power: 4, 5, 7.5, 10, 15, 20, 25, 30KVA
 Power factor and efficiency > 90% at nominal input voltage and resistive load
 Load Adjustment: The main output transformer has a power adjuster
1.3 CCR Control Unit
Power Unit Earth Fault Unit

Display Unit Lamp Fault Unit
Display Unit Communication Unit
Driver Unit Monitoring Unit
Fig 1.1 CCR Control Unit
1.3.1 Earth Fault Unit

Unit provides indications of 500V, Warning, Alarm, 70V over. Based on the process RED
LED set. If the value is more than 500V, activates an indication. Warning, Alarm will set while
the value is more than the limit of set value.
70V over will be set while if it’s on Remote state or in CCR-OFF state, while power on status
500V will be set, else problem in earth fault module does not work properly.
CCR
1.3.2 Lamp Fault Unit

In lamp fault unit, two thresholds can be set like warning & alarm. If the value reaches the
alarm level, buzzer starts for approximately 30 sec and return to the main options, starts
monitoring till the preset value change, activates an indication.
1.3.3 Communication Unit

In communication, indications set if data received (RX) and transmit of data TX will set. If
CCR is on dual communication, receives in two ports & transmits in two ports based on that
led will be activating.
1.3.4 Keypad
Keypad used on Local mode of operations and for configurations settings, configuration
setting can be enter by pressing SET key need to type the password (7382) for security
purpose, step can be controlled by UP or DOWN arrow as per need.
1.3.5 Monitoring Unit

Initially, error regulation unit will not set if error occurred like OVC, OPC, REG ER, and FUSE
occurred activates LED. After correcting the error, need to press RESET button to clear the
LED indication.
 Current Regulation Error( Rating ±0.1A)
 VA Low (Output Power -10%)
 Input Power Loss (IPL: -10%)
 Regulation Error (REG ER: OVER LOAD +5%)
1.3.5.1 Open Circuit (OPC I<1.5A)

While interrupt occurred in the series circuit of CCR goes to OFF position and the buzzer will
start for short duration and activates LED. After clearing the error, reset key should be
pressed to reschedule the process.
1.3.5.2 Regulation Error (REG ER > +5%)

Regulation error will set, while the load is over load than the maximum value, buzzer starts
for approximately 30 sec and appropriate LED will set REG ER.
1.3.5.3 Input Power Loss (IPL - 10%)

According to FAA specification, if input power loss is greater -10%. Indication should be set
in monitoring unit as per the rule.
If power loss is greater than the FAA specification. Indication will be set in monitoring unit IPL.
CCR
1.3.5.4 Current Regulation Error(Rating ±0.1A)

If the output current of the grade position is more or less than the limit of shown table 1.1,
leads to error, activates an indication in monitoring unit CURR ER.
According to the FAA specification, current regulation error will be set.
Nominal output Range
Style Step level
(A) (A)
3 6.6 6.50 ~ 6.70
1 2 5.5 5.40 ~ 5.60
1 4.8 4.70 ~ 4.90
5 6.6 6.50 ~ 6.70
4 5.2 5.10 ~ 5.30
2 3 4.1 3.90 ~ 4.20
2 3.4 3.30 ~ 3.50
1 2.8 2.70 ~ 2.90
7 6.6 6.50 ~ 6.70
6 6.4 6.30 ~ 6.50
5 5.2 5.10 ~ 5.30
3 4 4.1 4.10 ~ 4.30
3 3.4 3.30 ~ 3.50
2 2.8 2.70 ~ 2.90
1 2.2 2.10 ~ 2.30
Non-
Option 1.8 1.70 ~ 1.90
Illumination
Table 1.1 Current Regulation Error Ratings
1.4 Protection
Protection circuit protects from high surges based on the priority, CCR trips OFF.
1) Over Current (I2 > 6.75A)
2) Open Circuit (I2 < 1.5A)
3) Fuse(Optional spec)
CCR gets switched OFF in case of over current to the output circuit. The time delay to switch
OFF is proportional to the over current level. Threshold is adjustable factory settings is 6.87A,
the typical time delays are;
 4 seconds for 6.87A
 2 seconds for 6.93A
 1 Seconds for 7.1A
CCR
Short duration if it’s less than 0.2 seconds will not switch OFF. OVC will buzz for about 30
sec and activates appropriate LED. After clearing the error, reset should be pressed to clear
the error message.
1.5 Control & Display Unit:

Monitors the current, voltage of input and the output, shows the selected step and the
maximum step. While on power, CCR ON stage screen looks as show in Fig 1.2.
a C
b d
e
f g h
Fig 1.2 Control & Display
a.V1 : Input voltage c.I1: Input current
b.V2: Voltage Output d.I2: Input current
e. L: Local mode f.[5/6] : Step selected / Max step

g.5.2A: Selected step of standard current h. 0.88KVA : Actual load
On separate screen LFD, EFD, Elapsed Time simultaneously monitors. Based on the options
shows the display, detail description shown in next chapter.
As the status of mode shows in Local (L), if on remote status change to (R) and in serial
communication (C).
1.6 Power Unit

If power gets ON show’s an indication of +5, +12, -12, +24VDC, after switching power ON if
either of this LED not set please check the connection supply.
CCR
1.7 Brightness Step Level
Step 3-Step 5-Step 7-Step

1 4.8 2.8 2.2
2 5.5 3.4 2.8
3 6.6 4.1 3.4
4 5.2 4.1
5 6.6 5.2
6 6.4
7 6.6
Table 1.2 Nominal Step current(6.6A loop)
Step 3-Step 5-Step 7-Step

1 14.4 8.4 6.6
2 16.5 10.2 8.4
3 20.0 12.3 10.2
4 15.8 12.3
5 20.0 15.8
6 19.4
7 20.0
Table 1.3 Nominal Step current (20A loop)
CCR
2. CCR Operation
The operating mode of device controlled by pressing the appropriate key in keypad as show
in (fig 2.2).
Modes can be changed, only if CCR is on Stop position. All the operations are controlled by
microprocessor.
Classification of different task performed by the microprocessor
 Monitoring the current & the alarm are engaged if it’s in limit
 Updating indications of Remote, Local, and Serial
 Displaying the True RMS value of output current, voltage and input current,
voltage
 Displays Power Output in KVA
 Displays the Maximum step and the current step
 Displays the Time counters of CCR-ON and individual step operation time.
 Displays the Lamp fault Indication and the number of fail lamps
 Displays the Earth fault value and shows the warning level and alarm level if an
alarm set displays the error message
If microprocessor detects a stop signal, block optic signals to the Thyristor and waits for next
order to continue.
2.1 Operation Modes & Controls

 Local Mode
 Remote Mode (Parallel Communication)
 Remote Mode (Serial Communication)
1) Local Mode
CCR can set ON or OFF through keypad by pressing up arrow or down arrow on the keypad,
can control brightness levels.
Based on the option, screen can be changed to monitor LFD, EFD, and Elapsed Time
Modes can be changed while CCR-OFF.
By pressing Key (2/C) can change to communication mode as shown in fig 2.1. Return key
( ) should press else remain in same state.
CCR
Fig 2.1 Changing Mode
2) Remote Mode
Remote mode can be controlled by only through other external device not by keypad
All functional keys will be locked (step change, CCR-ON/OFF)
 Standard DC Voltage – 24V
 Optional DC Voltage – 12V, 48V, 60V
Only Mode can be changed to Local while on CCR-OFF state. LFD, EFD, Elapsed Time can
be checked while on any mode.
3) Serial Communication
Serial mode can be controlled by only through serial ports not by keypad
All functional keys will be locked (step change, CCR-ON/OFF).
 By default: single channel present
 Dual Channel Communication (optional)
At the same time data from PC will be sending on two ports (dual channel) failure of cable on
one port change automatically to the other port to monitor the CCR without any interrupt.
2.2 CCR Indications

The standard indications are displayed locally on front panel of the regulator.
Display of input voltage, current and output current, voltage is show in the front panel
of LCD.
 Display number of burnt lamps
 Display Earth leakage in kilo-ohm/Mega-ohm
 Display selected brightness level & constant step current
 Display of Elapsed Time of CCR-ON, step levels
 Alarm, indication of open circuit
 Alarm, indication of over current
 Alarm, Warning indication of burnt lamps
 Alarm, Warning indication of Earth Leakage
 Indication for input power loss
 Indication for current regulation error
 Indication for Output power (VA Low 10%)
CCR
2.2.1 Remote Indications

 Status of LCD changed to R->Remote
 Check the error indication as per local process
 Step level change based on other device input
 CCR-ON /OFF can be done through other device only not through keypad
2.2.2 Serial Communication Indications

 Status of LCD change to C->Communication mode
 Step level changed based on command given by PC(Optional)
 CCR-ON /OFF can be done through communication through PC not by
keypad(Optional)
.2.3 Keypad Process
Fig 2.2 Keypad
 Local Key (0/L):

While on CCR stop status, key will be enable to change the mode of remote or local,
If CCR status is ON position key will be locked for security reason.
 Remote Key (1/R):

While on remote process all functional keys are locked, only module keys can be hit
while on operation.
 Serial Communication Key (2/C):

As per the remote operation serial communication works it. While on transfer
position need to stop the CCR and change to local.
CCR
 Non-Illumination Step Key (3/I):

As per the factory setting Non-illumination step will be disabled (1.8A), Non-
illumination step can be enable by pressing the key (3) after pressing the key ,need
to give confirm return key (15).
 Elapsed Time Key (4/ET):

Elapsed time continuously monitors while CCR gets ON, status and monitor the
Individual step time, can go up to maximum of 9999Days,HH24:MM60.
.
 \Lamp Fault Module Key (5/LF):
Lamp fault module can be checked at any time while CCR on process, if need to go
previous status need to press return key.
 Earth Fault Module Key (6/EF):

Earth fault module can be checked at any time while CCR on process, if need to go
previous status need to press return key.
 Circuit Selector Key (7/CS):

Circuit selector can be change at any time by pressing the key (7), if CCR is ON
position will be there small delay to make out the CCR ON.
 Help Line (8/H):

Serial communication address can be checked in help line, while on any process can
be checked.
 Down arrow (●/↓):

Selecting step can scroll down the step level as per the requirement.
 Up arrow (↑):
Selecting step can scroll up the step level as per the requirement.
 Return Key (STOP/ ):

Return key should press as confirmation for all the function, which displays “Confirm”.
CCR
Notice
Return key should be given after pressing the functional buttons like Mode change,
CCR-ON, CCR-OFF else remains in the same state.
2.4 CCR-Database
The CCR has double database one in EEPROM and the other in Ram, after power down
while starting up again; all-important parameters are fetched from local EEPROM and copied
to RAM. During normal operation only copy of Ram is used. The entire setting configuration
will be stored in EEPROM, Next time while switching On, will be remain on same as the old.
3. CCR Options
User selectable options are serial communication (Dual, Single), earth fault detector, lamp
fault detector and circuit selector. By default remote parallel communication are available.
Serial communication can select by dual or single communication. Dual channel sends data
by parallel in two channels, if one channel fails without any interrupt can be monitor the CCR
& control.
3.1 Earth Fault Detector (EFD)

The Earth fault detector constantly monitors the electrical resistance between the floating
output circuit and earth. It is based on the principal of a DC injection (500V DC) into the
circuit and measures values 10k to 100M.
There are two available comparison threshold’s (Warning & Alarm) are 1M and 500K. By
pressing configuration setting (Set key) can modify pre-programmed values.
Fig 3.1 Earth Fault Module
Simultaneously monitors earth resistance to view screen need to press the key (6) and return
key to display the EFD module. Screen shows earth resistance value, setted warning level
CCR
(W), Alarm level (A) and shows the error message, if warning or alarm set else displays OK
(Err Msg).
Display the warning setted level in units Mega/Kilo as show in the above window. Warning
had setted for 1M and the Alarm had setted for 500 K. When the pre-programmed values
exceeds than the warning or alarm level. Activates the appropriate LED, if alarm set, buzzer
will start and buzzed for 30sec.
3.2 Lamp Failure Detector (LFD)

Detects the burnt lamps at the secondary series transformer, without secondary short circuit
relay. Pre-setting have to be made when the regulator are connected to the supply. The lamp
fault detector card installed on the motherboard just behind the regulation card, It has
microprocessor that does the calculation and detects the burnt lamps.
Fig 3.2 Lamp Fault Module
Lamp Fault module can be viewed by pressing the key (5) and need to press the return key to
make confirm for viewing LFD module. LFD monitoring Screen shows total number of lamps
(Total), fault no of lamps (Fault), setted warning level (Warn), Alarm Level (Alarm), and
percent of fail lamps.
Warning will set, if lamp numbers exceeds the value of warning level LED activates on Lamp
fault Unit.
Alarm will set, if lamp numbers exceeds the value of Alarm level (buzzer will be held
approximately 30 sec) and activates an LED on lamp fault unit.
3.3 Elapsed Time

Time counter automatically starts while CCR gets ON, and monitors the time of CCR-ON and
individual steps operation time. Display’s maximum of 9999Days HH24:MM60, Displays the
time on separate screen to view the time log, press key (4/ET) screens shows as in Fig 3.3.
Fig 3.3 Elapsed Timer
CCR
 Press key (1/R) to display the maximum time of CCR-ON and the max time of
step level, which had held.
 Press key (2/C) to display the maximum time of step 1 to 4
 Press key (3/I) to display the maximum time of step 5 to 8
3.4 Non-Illumination Step

Non-illumination is optional one, if NI enabled adds one more step 1.8A,Non-illumination
step can be enable or disable by pressing the key (3/I) ,for confirming the NI step need to
give confirm return key( ).
Fig 3.4 Non-Illumination step
3.5 Circuit Selector

In Configuration wizard need to give Enable circuit select, Factory setting will be on disable
position user can select as per the need.
After enabling circuit select, initially Circuit select, selects CS1 and shows the indication on
monitoring unit CS1, while on local mode circuit select can be changed by pressing the key
(7/CS) LCD screen looks as shown below.
If the key 2 pressed, CS2 will be selected as per the need circuit select can be setted.
Fig 3.5 Circuit Selector
3.5.1 Remote Connection

In Remote connection need to give an input by connecting the CSIN1, CSIN2 to TB4. TB2 is
the input from the remote device, can monitor the CCR from external device by connecting
TB3 CSS1, CSS2.
CCR
Fig 3.6 Remote Connection
4. CCR Configuration Management
By Default Factory setting will be set, as per need configuration can be adjusted by
pressing the Key (13/Set). After pressing the key screen shows as shown in below
Fig 4.1 Password Screen
After typing the password (7382) needs to confirm the password by pressing Return key ( ),
All the modified value stores in EEPROM, so no need to set the values again. After
confirming the password screen looks like below diagram
 By pressing key (1/R) general required data can be set detail description
 By pressing key (2/C) lamp fault data can be set like Lamp Load and threshold
levels, detail description in chapter 4.2
 By pressing key (3/I) Earth fault detection threshold values can be set detail,
description in 4.3
 By pressing key (4/ET) Modules can be set Like Lamp Fault Enable / Disable,
Earth Fault Enable/Disable, Circuit Selector Enable/Disable.
4.1 General Setting
By pressing the key (1/R) ,displays as show below

By pressing the numeric values on keypad appropriate values can be set, if the value is more
than the maximum, Value Error displays on screen in that case please set again.
 V1 : Setting voltage input by key (1/R)

 V2 : Setting voltage output by key (2/C)
 I1 : Setting current input by key (3/I)
CCR
 I2 : Setting current output by key (4/ET)

 Step: Step levels can be set like 1,3,5,7 by key (5/LF)
 Date/Time: Setting current date and Time by key (6/EF)
 Set VA: Setting CCR Load by key (7/CS)
 Elapsed Time: Can be cleared Elapsed Time by key (8/H)
 CCR ADDR : CCR Address Can be set (Please give different address which does
not match other CCR address)
4.2 Lamp Fault Setting(Option)
In lamp fault setting three type of setting can be made.

 Warning
 Alarm
 Lamp Load
Need to set all the value need, Warning, Alarm can be set number by percentage of lamp fault.
After entering all the values need to give return key.
 Warning
Warning can be set for number of fail lamps; based on percent or number of lamp fail can be
set. If reaches the warning value indication will be there on lamp fault unit warning.
 Alarm
Alarm Value can set in number or percent as like Warning value setting, if reaches the alarm
level, buzzer will start for approximately 30sec.
Notice
As per the requirement data will be setted if any problem comes on CCR need
to the check this configuration. Before changing this data please make it confirm
and change the data.
CCR
 Lamp Load:
Connected Load should be set accurately as per connected load else lamp fault may not
work properly because initially will be set on 100% load.
4.3 Earth Fault Setting(Option)

In Earth fault detection two threshold values can be set like warning, alarm
If reaches the alarm level buzzer will starts for approximately 30sec.
Fig 4.2 Earth Fault Settings
Warning will be set initially 1M, as per the need can change the value after entering the
value need to give return key.
After giving the return key will ask weather the value is for Mega or Kilo based on the need
can be enter by hitting the key 1 or 2.
 1:KiloΩ
 2:MegaΩ
4.4 Circuit Selector(Optional spec)

Circuit is an optional one if circuit had present can be configured according to the needs,
initially will be on disable position.
Fig 4.3 Circuit Select Settings
Can be set by entering to the configuration wizard, circuit select option can be enable or
disable.
Notice
Based on the numeric value on LCD key, can be pressed to set the appropriate
values. After setting the value need to give Return key ( ).
CCR
5. Remote Control & Monitoring
5.1 Serial Communication(Option)

Serial communication is used to monitor from PC & to control CCR, for monitoring need to
use dedicated software on PC side to control & monitor.
To Control the CCR need to change the CCR option to Communication mode
As shown below, If CCR changed to Communication mode CCR status in LCD change to C.
Fig 5-1 Communication Mode
5.1.1 System requirements

All computers, which are compatible to the IBM standard and equipped Pentium Processor
or higher, with at least one serial port of 2MB free space.
5.1.2 Installation of Software

Installation software will be given on floppy, copy the file to the hard disk, Double clicks the
installation file, starts install on you’re computer, after finishing the installation click the exe as
been installed.
5.1.3 Setting Communication Ports

By default communication will set for COM 1 and COM 2 with the baud rate of 9600. If ports
are COM1, COM 2 no need to change the setting levels, else need to set the values by
clicking settings channel 1.If channel 1 is set for COM 1 then automatically channel 2 sets for
COM 2 so no need to set separately for channel 2.
5.1.4 Connection between PC and CCR

Connecting serial ports of the PC to the CCR, through RS485 connector CCR has 4 different
ports one goes to PC of COM 1 and the other goes to COM2, remaining 2 ports of CCR goes
to another CCR.
Any number of CCR can be connected by this method and can communicate with different
CCR by changing address of CCR.
5.1.5 Monitoring CCR

CCR can be monitor through PC by dedicated software, which had been provided. After
opening the Application need to make setting, if PC is not having COM 1 or COM 2.
CCR
Please click the status bar as shown in fig 5.2.
FIG 5.2 Online Monitoring System window(Sample)
(Please Double Click the Status Bar for setting communication is not applicable to change
Channel without knowing in technical).
After finish setting need to establish connection click Log In, if the connection got through,
automatically changes the status bar as connected, if channel are good and no problem
occurred .Starts the communication and check for CCR connection if no CCR connected
shows error in RX/TX, if not, show’s OK in RX/TX column. Monitors all the values for every
100ms.
Notice
Online Computer Monitoring System Designed According to Customer Specification.
Monitors all the CCR and provides the CCR Name with CCR voltage input(V1), output(V2)
and Current input(I1), output(I2) and indicate the active step of CCR with status Local
( L ),Remote ( R ).For every 100ms all the data’s will be monitored.
Show’s the data on the appropriate column, relates to the CCR name.
CCR
5.1.6 SET CCR ADDRESS

By clicking the set CCR address, Address can be changed make sure CCR address is same
as in CCR. After clicking the set CCR Address show’s like Fig 5.3
Fig 5.3 CCR Address setting window(sample)
 CCR ADDRESS Setting

By double clicking the CCR address column. CCR Address are editable but make sure the
other end CCR had been changed to same. It is not advisable to set without knowing the
CCR name, based on CCR Name runway monitoring will show indication like LED on runway
picture.
 Receive data / Transmit Data :

By double clicking the RX/TX Communication appropriate CCR will set Enable/Disable CCR
can be stopped.
If CCR’s are not used its better to stop the communication by Enable/Disable.
 Record Data :
BY Double clicking the Record can be Enable/Disabled the recording ,if enable is set records
CCR
all CCR information in Excel sheet for every 10min by default timings. Timings can be
adjusted based on the requirement,in case if any event happen in CCR within 10min records
the data.
 Buzzer
Buzzer starts while an irregular event occurred on ccr this can be disabled premanently or
enbaled by Double clicking the Buzzer of the appropriate CCR.
 Set Default :
If Set Default Button is on clicked goes for factory setting, current setting will be changed CCR
Address, RX/TX, Record
 Record Time
Recording can be Enabled/Disabled by clicking the check box if its on enabled, time can be
adjusted .If its disabled, all CCR recording will disabled. In disabled case only event occur will
record.
 Status Bar(Channel 1,Channel 2,Baud Rate ,Data Bits,Stop Bits) :

Status Bar is used for the communication channel and the speed but its not advisable to
change factory setting in case of corruption of system can be setted in the maner of
Channel 1= COM 1
Channel 2= COM 2
Baud Rate = 9600 Bps
Data Bits = 8
Parity Bits = No
Stop Bits = 1
 Exit:
While Making Exit Make sure the mode in LogIn state, if its on LogOFF state it's on
communication mode so please press LogOFF it disconnects the communication and the
mode change to LogIn ,now its safe to make Exit.
CCR
5.1.4 Serial Communication Diagram
Fig 5.4 Serial Communication Connection Diagram
CCR
5.2 Parallel Communication

By default remote connection present in CCR, user needs to change the mode of CCR to
remote, by pressing the key (1/R) remote device.
If CCR changed to Remote CCR status in LCD change to “R”
Fig 5.5 Parallel Connection Diagram
5.2.1 Parallel Communication Connection Table

External Device need to connect, TB5 to monitor the CCR, TB4 is used to give an input to the
CCR. As show in the below Table
By performing as per the table connection need to connect in the CCR
Pin No Input To CCR from remote

1 CC1 (Control Power)
2 CC /B0 (CCR-ON/OFF)
3 B1 (Step 1)
4 B2 (Step 2)
5 B3 (Step 3)
6 B4 (Step 4)
7 B5 (Step 5)
8 B6 (Step 6)
9 B7 (Step 7)
10Option CSIN1 (Circuit Selector Input)
11Option CSIN2 (Circuit Selector Input)
12 GND (External Control Power Ground)
Table 5.1 TB2 Connection Table
CCR
Pin No Status Of CCR

1 NC
2 NC
3 ON (CCR-ON )
4 OPC (Open Circuit)
5 OVC (Over Current)
6 REG (Regulation Error & Over Load)
7 CRE (Current Regulation Error)
8 IPL (Input Power Loss)
9 FUSE (Fuse)
10 VALOW (Output VA 10% Low)
11 LF-W (Lamp Fault Warning)
12 LF-A (Lamp Fault Alarm)
13 EF-W (Earth Fault Warning)
14 EF-A (Earth Fault Alarm)
15Option CSS1 (Connection for External Circuit Selector)
16Option CSS2 (Connection for External Circuit Selector)
17 COM2 (Common)
Table 5.2 TB3 Connection Table
5.2.2 Parallel Internal Connection Diagram
Fig 5.11 Internal Parallel Connection Diagram
CCR
5.2.3 Parallel External Connection Diagram
Fig 5.12 External Parallel Connection Diagram
 Control Power Supplied by External Voltage

 Voltage source 18 to 30 V.DC - polarity: any
 Typical consumption per signal: max 20mA
5.2.4 Other Parallel Control Voltage Optional

DC Voltage source 12/48/60V DC
In this case the control power must be supplied externally. In this an optional relay board
PCB will be fitted in the CCR (factory installation).
CCR
6. CCR Installation
Warning
Only personnel qualified to work on high voltage systems should be permitted

to handle this regulator.
The high voltage involved with the unit and its environment makes them
potentially dangerous. If the regulator de-energizes suddenly, the output circuit
could be interrupted by an over current, open circuit or under voltage condition.
Before inspecting the output circuit or the inner parts of the regulator, place the
circuit breaker in OFF position (eventually, if possible switch off the power
supply of regulator) and ground the output circuit.
6.1 Starting Up Procedure

Check if all wires are correctly connected and well fixed and that no loose wires still remain.
Check if the CCR is wired for the correct input voltage. Check that the remote control voltage
level has the correct value.
6.2 First Start UP

Before connecting the load it is advised to make a first output current check on a short circuit.
Start the CCR in local control mode and watch the output current on the front panel check for
each step output current on the LCD.
Switch-off the CCR and put the circuit breaker in the off-position (Handle down-for safety
reasons) connect the series circuit to terminals.
Switch on the CCR again and check the output currents at each brightness step versus
values listed in Table1.1.
Notice
All adjustments are made in factory and normally the regulator will deliver
standard values of output current. If any problem comes on output current
please contact the company.
Switch the CCR to a convenient brightness make a visual check on the field, that all the
CCR
series circuit lamps are Set. If this is not the case locate the reasons and take the required
actions. One can now proceed with the adaptation of the output secondary taps to the
accrual load. The first step is to find out which tap combination must be used for the actual
load.
SEC. VOLTAGE (V)

Capacity PRI VOLTAGE CURRENT
(kW) (V) (A) Sensor
60% 80% 100%
tap
4 -10%,standard,+10% 6.6 100 400 533 667
7.5 -10%,standard,+10% 6.6 100 750 1000 1250
10 -10%,standard,+10% 6.6 100 1000 1347 1667
15 -10%,standard,+10% 6.6 100 1500 2000 2500
20 -10%,standard,+10% 6.6 100 2000 2667 3334
25 -10%,standard,+10% 6.6 100 2500 3334 4167
15 -10%,standard,+10% 20 100 495 660 825
20 -10%,standard,+10% 20 100 660 880 1100
25 -10%,standard,+10% 20 100 825 1100 1375
30 -10%,standard,+10% 20 100 990 1320 1650
Table 6-1 Load Combination Table
The second step is to wire the current tap combination. By mean of output taps on the
secondary (high voltage) side, the power transformer can be optimized the actual load at full
brightness, the following taps are provided.
242V,220V,198V,0V
0V
100V
60%
80%
100%
Earth
Fig 6.2 Load Diagram
CCR
For exemple tap adjustment in 70% of load
0V 0V
100V
OUTPUT LOAD
INPUT VOLTAGE 70%
220V -10% 60%
STANDARD 80%
+10% 100%
E
POWER TRANSFORMER
Fig 6.3 Method of CCR output tap adjustment
Benefits of taps
 The Power factor can be optimized
 The main input current will be decreased
 The maximum of output voltage in case of open circuit will be less
 The power losses will decrease
7. Name of part & Functions
7.1 CCR Control Unit
1 2 5 6 7 8 9
Fig 7.1 CCR Control Unit
No. Symbol Name of part Function
1 PCB-5001 Power unit Supply of control powers
2 PCB-5002 CPU unit Micro process control for CCR
3 - Key pad Key pad for commend & setting
4 - LCD Panel Display window by the LCD
5 PCB-5004 Driver unit Drive for current control
6 PCB-5005 Monitoring unit Monitoring & indication
7 PCB-5006 Communication unit Measurement & serial communication
8 PCB-5007 Lamp Fault Unit Detection & indication of the lamp fail status
9 PCB-5008 Earth Fault Unit Detection & indication of isolation resistant value
CCR
7.2 Front view(Low voltage parts)
3 4
1
5 6 7 8
9 10
12 11
13 14
Fig 7-1 Low voltage panel
1 DS1 Door switch Interlock switch of front side
2 MCCB Molded Case Circuit Blacker Main Circuit blacker
3 MC Magnetic Contactor Power on-off contactor
4 TH1,2 SCR Module Phase control switch
5 TB1 Terminal Block Connection of input power cable
6 CT1 Current Transformer Detection of input current
7 T1 Control Transformer Supply of control power
8 PCB-3406 Trigger board Pulse signal control board for SCR
9 F4~6 Fuses Protection for circuit of control lines
10 TB4 Terminal block Connection of remote control cable
11 TB5 Terminal block Connection of remote monitoring cable
12 THS Thermostat Temperature setting of control switch
13 LA1 Lighting arrestor Protection of input power
14 CH1,2 Serial port Serial communication for remote control
CCR
7.2 Side view
2
1
Fig 7-2 Side view
1 A2,3 Arrester Protection of output lines
2 EF EMI Filter Filtering of EMI for the input lines
3 CH1 Choke Filtering for noise input power
4 PT1 Power transformer Supply of power for load
CCR
7.3 Rear view(High voltage panel)
1 2
3 4
Fig 7-1 Rear view
1 DS2 Door switch Interlock switch for rear side
2 PCB-5009 Rear board Sensing of voltage & current
3 CT2 Current Transformer Detection of output current
4 T2 Potential transformer Detection of output voltage
5 H1,2 High voltage bus Connection of output cable
6 PT1 Power transformer Supply of power for load
7 E Earth terminal Connection of earth cable
8. Maintenance
Warning
Only personal authorized to work on high voltage equipment should perform

maintenance on the regulator. Operate regulator under local control when performing
maintenances tasks on the regulator. This will prevent the regulator from accidentally
being turned ON and cause serious injury or death.
Caution
Measurements of the output load of a CCR require taking voltage measurements at

the load output terminals of the CCR.
A CCR can develop as much as 4,545 volts in the case of fully loaded 30kW CCR.
Never attempt to measure the voltage across the output of a regulator without a load
connected.
In open circuited conditions, the voltage can reach extremely high values before
open-circuit shut down of the regulator occurs.
Only qualified electricians exercising extreme caution and using the correct
instruments and safety precautions should attempt these measurements.
Interval Maintenance Task Action
Check All the Control Equipment for Check Remote Control for all
Daily
proper operation Brightness.
If regulator is not within the
Check Input Voltage & record output
Monthly ±10% of design voltage notify
Current all brightness.
company to correct voltage
Replace contacts excessively
Check contactor circuit breaker
burned or pitted. Operate the
Annually wiring and insulation inspect housing
Control switch to check for
for rust and damages
proper.
CCR
MTHL SMAN ANNL UNSC

Maintenance Requirement DAILY WKLY
Y LY Y H
1. Check control circuits on all brightness steps X
2. Check condition and operation of regulator X
3. Check input voltage and current X
4. Check output current on each brightness step X
5. Check output load on regulator if needed X
6. Check relays, wiring and insulation X
7. Check dielectric strength of cooling oil (if used) X
8. Perform a short-circuit test X

9. Perform an open-circuit test
X
(only on regulators with open circuit protection).
10. Clean rust spots and repaint as necessary. X
Table 8-1 Preventive Maintenance Inspection Schedule

for Constant Current Regulators
8.1 Trouble Shooting
 Before any operation or adjustment check for

 Local panel indications (or back-indication signals)
 Power supply voltage off
 Cut off input fuses
 Cut off auxiliary fuses
 Loose connections
 Opens in wiring
CCR
8.2 Regulator does not turn ON
Observations Possible Cause Solutions
Check the power supply

circuit breaker and fuse.
No Local Indications Power supply to the board Strap RV-DV(or the remote
contact that makes
connection)
Check the power supply.
Power supply level too low Correct Eventually (if
Indication "RE" and main
(less than 80% of the possible) The Voltage level.
contactor are not
nominal value) Current Replace or debug the
energized.
control module module (volt age level
monitoring).
Shut Down by Inter Check if the signal is given
Indication "RE" and main
connecting Terminal "COM" and correct Replace or
Contactor Are
with "SHUT-DOWN" debug the module (thyristor
Energized.
Current control module turn-off control circuit)
8.3 Regulator turns ON but De-Energize suddenly
Observation Possible Cause Solutions
Eventually resize this

Protection of the power Too fast acting or too low Protection Check the wiring
supply to the CCR Became level Power supply wiring to the CCR Check the CCR
operational or CCR components (internal wiring, terminals,
circuit breaker)
Check the CCR for short-
Internal wiring or
circuits or damaged
Components of the CCR
insulations. Check the
Circuit Breaker trips Output circuit (intermittent?)
insulation of the output
short-circuit. Too sensitive
circuit. Check the circuit
circuit breaker
breaker.
CCR
Caution
If the circuit breaker trips without any obvious reason the current control module
should be replaced. This module must be capable to handle any occurring over current
so that damage to the load is excluded
8.4 Regulator not produces the request output current
Observations Possible Cause Solutions

Disconnect the remote
Maximum brightness step
control line for the Maxim-
is always selected. Failure
Always Maximum Output um brightness Step
of the optional relay board.
current Accentually check the
Failure of the current
Remote control signals.
regulator.
Check the relay contacts.)
Check the remote control
Only the maximum output Signals (one selection is
Brightness step id always
current and one other are always present) Check the
selected.
correct. optional relay board.Check
the current control module
If the module operates
Failure of the remote Correctly in local than
Only the minimum
control line Failure of the check the remote control
Brightness step is selected
current control module. line Check the current
control module
Check the output
The output current is not
transformer tap. Check the
reached and signal "RE" is The CCR is overloaded
power supply voltage.
given.
Check the load.
CCR
8.5 Serial Communication not sending data
Observation Possible Cause Solutions
Receiving Data not Only RX indication Check the CCR address,

transmitting send address correctly
from PC
Check the CCR port,
Which connected. If dual
Data Not receiving, no
Data Transmitting From PC Communication not present
Indication on CCR
Only Need to connect on
Com1 of CCR.
8.6 PC Communication Software Part List
Ref Part NO Description Order Quantity
Software Version 1.01

5001 1
(Single channel with Control & Monitoring)
5002 1
(Dual channel with Control & Monitoring)
5003 1
(Single channel without Control)
5004 1
(Dual channel without Control)
[INSTRUCTION MANUAL FOR CONSTANT CURRENT REGULATOR VER 4.01] L-829
9. Basic operation of CCR in Fig 9.3 If not key pad will be

9.1 CCR-Basic Operation
locked.
a. Power on sequences by MCCB
Fig 8.1
Local mode
Fig 9.3 Display unit
d. If CCR is not in local mode. Must
change to local mode, by pressing
the local key (0/L) for confirmation

Fig 9.1 MCCB ON
press the return key return
b. After power gets on make sure
key(STOP/ ).
all power LED’s or ON as
shown in Fig 9.2
Fig 9.1 POWER UNIT
c. Check status the CCR is in local

Fig 9.4 “0/L “ Local key is pressed
mode by the indication “L” as shown
Fig 9.6 Monitoring Unit
f. Brightness level are adjustable by

key pad, while on Local mode by
pressing key brightness level can be
adjusted. Down arrow (●/↓) selecting
Fig 9.5 After pressing return key step can scroll down the step level
as per the requirement. Up arrow (↑)
selecting step can scroll UP the step
level as per the requirement.
g. If CCR need to stop press the return
key(STOP/ ), for confirmation press
Make sure the output load is connected
the return key (STOP/ ).
properly before making CCR-ON else
h. CCR optional functions are remote
leads to OPC(open Circuit).
serial, parallel as briefly explained in
chapter 5.If the CCR display unit
e. Now CCR is ready to start, press show’s the status “R” as shown in
start button in key (Start), for Fig 8.7 keypad will be locked. Only
confirmation press the return by remote desktop CCR ON/OFF
key(STOP/ ). If CCR get ON, and brightness levels are operating.
indication will be shown in
monitoring unit as shown in Fig.8.6
Fig 9.7 Monitoring Unit

“remote mode”
i. CCR optional functions like lamp

fault detection, earth fault detection
are explained briefly in Chapter 3.
j. If the setting need to change
like warning, alarm level of
EFD/LFD or need to enable
circuit select. Press the key
set(SET) for configuration.
10.CCR Operation method
10.1 CCR Local control mode
Sequence Setting method Result
Press 0/L button in Key Pad LCD Display Command Local
Press Enter button in Key Pad Local Mode Is Set LCD Display “L”
Press Start button in Key pad LCD Displays Command Start
Press Enter button in Key Pad Monitoring Unit Green LED Set
Press Up Arrow Key in keypad,

LCD Display: Show’s Incremented Step
Brightness Level Increase one step
and show Maximum step.
for a single press.
Press Down Arrow Key in keypad,

LCD Display: Show’s Decremented
Brightness Level Decrease one step
Step and show Maximum step.
for a single press.
Press 5/LF in Keypad LCD Display’s Command Lamp Fault
LCD Displays: Lamp Fault Module

Press Enter button in Key Pad
percentage of fail lamps
Press Enter button in Key Pad LCD Display Return’s to main screen
Press 5/EF in Keypad LCD Display’s Command Earth Fault
Press Enter button in Key Pad LCD Display Return’s to main screen
Press Enter button in Key Pad LCD Display Command Stop
Monitoring Unit Green LED Goes OFF
Now CCR is Safe to power OFF. EFD
Unit Set RED LED 70V over, mean to

say is EFD unit is switch OFF. according
to IEC document. Now CCR ready to
change remote mode.
10.2 CCR Parallel Remote Control Mode
Sequence Setting Method Result
Press 1/R button in Key Pad LCD Display Command Remote
LCD Displays Now Key Pad Will be in
Press Enter button in Key Pad Locked Position. Controlling CCR can
be done only through Remote Desktop.
Press 0/L button in Key Pad LCD Display Command Local
Press Enter button in Key Pad Returns to Local Mode
10.3 CCR Serial Remote Control Mode
Press 1/C button in Key Pad LCD Display Command Communication
LCD Displays Now Key Pad Will be in
Locked Position. Controlling CCR can

be done only through Serial Remote
Control(PC).
Press Key in button Pad 0/L LCD Display Command Local
Press Enter button in Key Pad Returns to Local Mode
10.4 CCR Setting Method

 Example of 5-Step Setting method
Press SET button in Key Pad LCD Display Enter Password:
LCD Displays As shown in Fig 9.1 press

7,3.8.2 Press button’s in Key Pad 7382
Enter Button in Keypad
Press button 1 in Key Pad. LCD Display As shown in Fig 9.2
LCD Display Step Selection Like 3,5,7
Press button 5/LF in Key Pad. Step. If Key 5 is pressed One more time
5-Step Will be Set.
Press Enter button in Key Pad LCD Display Return to Fig 9.1
Press Enter button in Key Pad LCD Display Return to main screen.
Fig 10.1
Fig 10.2
10.5 CCR ADDRESS Setting method
LCD Displays As shown in Fig 9.1 press

7,3,8,2 Press button’s in Key Pad 7382
Enter Button in Keypad
LCD Display CCR-Address, Select addr

Press button 9 in Key Pad.
like 1…2
Press Enter button in Key Pad LCD Display Return to main screen.
Note:
All other settings followed by the same setting method , based on the Numeric
values in LCD Display press Key’s in Keypad.
 V1= Input Voltage
 I1 = Input Current
 V2 = Voltage Output
 I2 = Output Current
 Step = Maximum Step Should Be Entered Like 3,5,7
 Date = Enter The Current Date
 Time = Enter The Current Time
 CT = Clear Timer(For CCR ON/OFF Recording)
All Setting had been done by Factory, in case need to change any setting,
follow the example setting method for 5-Step.
10.6 Setting method for LFD module

Press Enter Button in Keypad LCD

7,3,8,2 Press button’s in Key Pad 7382
Displays As shown in Fig 9.1
LCD Display Enter Total Number of
Press button 1/R in Key Pad. Lamps. Enter the number of Lamps
Connected to CCR
Enter The Lamp Watts connected to the

Press button 2/C in Key Pad
CCR
Warning can be set for number for fail
lamps; based on percent or number of
lamp fail can be set, as shown in Fig
Press button 3/I in Key Pad 9.4.If reaches the warning value
indication will be there on lamp fault unit
warning Based on the requirement
press key 1 or 2.
Enter The Total Lamp Load connected
Press button 5/I in Key Pad to the CCR. For Ex: If 300W Lamp 5
Lamps are connected. Enter: 1.5
Press Enter button in Key Pad Returns To Main Screen
Fig 10.3
10.7 Setting Method for EFD Module

Example of 5-Step Setting method
7,3,8,2 Press button’s in Key Pad 7382 Press Enter Button in Keypad
Press button 2 in Key Pad. LCD Display 1.Warning 2.Alarm
Entered value goes for Kilo Ohm ,if 2
Press button 1/R in Key Pad. pressed in keypad Value set for Mega
Ohm. As Shown in Fig 9.5
LCD Display Return to 1.Warning

2.Alarm
Press Enter button in Key Pad LCD Display Return to Main Screen
Fig 10.5
11. CCR’s Boards Setting & Maintenance

This chapter describes basic settings for CCR compositions like Power unit,
Control unit, Driver unit, Monitoring unit, Communication Unit, Lamp Fault Unit,
Earth Fault Unit.
These units initial settings were already adjusted before come out from factory.
So the user required to use CCR without modify setting. But, in case of CCR
has to be set or CCR unit part is out of order, the user will do new adjustment
for setting.
11.1 Power Unit Setup or check list

Power unit can be used after insert wreck without special hardware setting.
Standard power supply value for power unit is the table as below and these
standard measurements can be measured like Fig. 10.1. At this case,
measurement device for voltage is DMM(Digital Multi-Meter) and its deviation
should be
within 0.5%.
No. Normal Voltage Error Range
1 +5 V ±0.25 V
2 +12 V ±0.50 V
3 +24 V ±1.00 V
When perform measurement, the user shall use ground point which available at
the outer place of the case.
+24V -12V +12V +5V
Fig. 11.1 Power Unit Layout
11.2 Control Unit Setup or check list

When the user has operation with new control unit, the user should loading
U9(16V8), U3(29C256) program which contained with IC chip. If the user has
used control unit, the above IC chip should be separated from the old board.
After that, attach them to the new board. Pin the Control Unit Board, insert
“EXT-ROM” to J3 head jumper.Make use of J5 connector with supplied cable
in order to connect LCD module. J2 should be connected to Keypad module.
After control power source is approved, the user check the text description is
appeared on LCD window or not. If it is not appeared, adjust VR1 in the unit
board. After that, adjust LCD back light. Even if the user follow our suggestion
as above, the text description is not appeared, the user may check connected
cable or connector once again. After do the above thing, using LCD and
Keypad to re-input CCR’s standard setting.
Fig. 11.2 Shows board layout for control unit
11.3 Driver Unit Setup and check list

Adjust input power frequency for J3 Jumper. Regarding initial setting for
OVC, changeable resistance VR3 should be turned more than 20 times by
opposite clock direction. Regarding initial setting for OPC, changeable
resistance VR2 should be turned more than 20 times by clock direction. In
this case, if changeable resistance is perform 20 times turn, changeable
resistance shall be modified with maximum or minimum value. After
approved power source, turn on CCR by keypad. Leave ‘CCR-ON status’
(Maximum step) more than 10 minutes. After adjust CCR with maximum
step, adjust VR1 until output current can be 6.6A. If out current is not able to
be increased up to 6.6A, adjust VR5 to increase current. After adjust CCR
with minimum step, CCR output current should be 1.8A by adjust VR4.
After adjust CCR with maximum step, the user may adjust changeable
resistance as following step. Also related CCR out current for changeable
resistance (VR) is the table as below;
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Fig. 11.3 Driver Unit Layout
No. Description VR Number
1 6.6A VR1
2 6.4A VR5
3 5.5A VR6
4 5.2A VR7
5 4.8A VR8
6 4.1A VR9
7 3.4A VR10
8 2.8A VR11
9 2.2A VR12
10 1.8A VR4
11 GND Test point
12 OVC-GND Test point
13 OVC VR3
14 OPC VR2
15 OPC-GND Test point
For OVC adjustment, the user refer to Fig.10.3. At first, install DMM to OVC TP
and both sides of GND. In order to 6.6A to be 6.67A, adjust VR1 to opposite
clock direction then adjust VR3 to clock direction with care. At this case, turning
it until OVC voltage is started to increase then OVC voltage shall be increased
and CCR trip shall be occurred. After OVC voltage is increased, adjust VR3 in
order to the allotted time for CCR trip shall be within 3 up to 5 seconds. After
finish OVC adjustment for CCR, adjust VR1 in order to output current could be
6.6A. Then check if CCR can be operated normally or not. In spite of CCR
output current is 6.6A, OVC fault trip occur, try again OVC adjustment like the
above and adjust exact OVC adjustment.
For OPC adjustment, install DMM between GND both sides and OPC TP. Then
select step as minimum value (1.8A) and adjust VR4 with clock direction. At this
point, make sure that
CCR output current should be 1.4A. Adjust VR2 with opposite clock direction
then DMM OPC voltage shall be increased slowly. Make sure that CCR trip
should be occur within 1 second. After finish CCR OPC adjustment, adjust VR4
in order to CCR output current can be 1.8A. Turning direction should be
opposite clock direction. After finish OPC adjustment, when the user would like
to restart CCR, CCR may result in OPC fault due to low current and CCR trip
occur. Accordingly, after finish OPC adjustment, in order to CCR can be
minimum step (B01.8A), CCR current step should be modified to B1-2.2A then
turn on CCR. Then if the user adjust VR4 with opposite clock direction and
adjust CCR step with B0, CCR trip shall not be happened. At this case, adjust
again VR4 in order to CCR current shall be 1.8A within B0 step.
11.4 Monitoring Unit Setup and check list

Monitoring Unit can be used with control wreck without any special hardware
setting.
Fig. 10.4 Monitoring Unit Layout
11.5 Communication Unit Setup and check list

Communication Unit is able to recognize CCR input/ output voltage, current and
it is available to control CCR by remote with RS-485 serial communication
method.
The user adjusts VR4 like Fig.10.4. The indicated input voltage from the tester
and indicated voltage from CCR LCD should be same. At this point, CCR
standard setting (refer to CCR setting) should be adjusted after adjust input
voltage.
The user should turn on CCR after make CCR output load same with CCR’s
maximum capacity. Adjust VR2 then refer to output current from the tester. This
value(output current from the tester) should be same with output voltage which
indicate from CCR LCD.
Adjust CCR output current as 6.6A and make use of VR6 in order to input
current value which under the full load status (indicated by tester) can be same
with indicated value from CCR LCD. After this, make adjustment for VR7 by
turning and the value between TP1 and TP2 should be DC 100[mV]. Then
perform re-adjustment for current value by means of VR 6.
At the same time, out current for CCR should be 6.6A and under the full load
status, output current value which adjusted with VR9 should be same with
measured value. After this, make adjustment by turning VR10 in order to the
value can be DC 150[mV] between TP3 and TP4. Then make use of VR10
again for re-adjustment for current value.
1 2 3 4 5 6 7 8 9 10
Fig. 11.5 Communication Unit Layout
No. Description VR Number
1 Test point(150mA) TP4
5 V2 VR10
6 V1 VR9
7 I1 VR7
8 I1-Ref VR6
9 I2 VR4
10 I2-Ref VR2
12. CCR’s Waveforms

This chapter describes main CCR wave form.
12.1 CCR Output Current Waveform for each other current step(B0~B7)
1.8A Step 2.2A Step
2.8A Step 3.4A Step
4.1A Step 5.2A Step
6.4A Step 6.6A Step
12.2 CCR Output Current Waveform When CCR Turn On
12.3 CCR Output Current & Voltage Waveform When CCR Open Circuit
13. Drawings

User'S Guide Operating & Maintenance: Constant Current Regulator

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USER’S GUIDE

OPERATING & MAINTENANCE

Constant Current Regulator

3. CCR Options .....................................................................................................................18

5.2.2 Parallel Internal Connection Diagram .....................................................................30

10.6 Setting method for LFD module ...............................................................................53

Version Description Checked Date(MM/YY)

1.3 CCR Control Unit

Power Unit Earth Fault Unit

Fig 1.1 CCR Control Unit

1.3.1 Earth Fault Unit

1.3.2 Lamp Fault Unit

1.3.3 Communication Unit

1.3.5 Monitoring Unit

1.3.5.1 Open Circuit (OPC I<1.5A)

1.3.5.2 Regulation Error (REG ER > +5%)

1.3.5.3 Input Power Loss (IPL - 10%)

1.3.5.4 Current Regulation Error(Rating ±0.1A)

Table 1.1 Current Regulation Error Ratings

1) Over Current (I2 > 6.75A)

2) Open Circuit (I2 < 1.5A)

1.5 Control & Display Unit:

Fig 1.2 Control & Display

a.V1 : Input voltage c.I1: Input current

b.V2: Voltage Output d.I2: Input current

e. L: Local mode f.[5/6] : Step selected / Max step

1.6 Power Unit

1.7 Brightness Step Level

Step 3-Step 5-Step 7-Step

Table 1.2 Nominal Step current(6.6A loop)

Step 3-Step 5-Step 7-Step

Table 1.3 Nominal Step current (20A loop)

2.1 Operation Modes & Controls

Fig 2.1 Changing Mode

2.2 CCR Indications

2.2.1 Remote Indications

2.2.2 Serial Communication Indications

.2.3 Keypad Process

Fig 2.2 Keypad

 Local Key (0/L):

 Remote Key (1/R):

 Serial Communication Key (2/C):

 Non-Illumination Step Key (3/I):

 Elapsed Time Key (4/ET):

 Earth Fault Module Key (6/EF):

 Circuit Selector Key (7/CS):

 Help Line (8/H):

 Down arrow (●/↓):

 Return Key (STOP/ ):

3.1 Earth Fault Detector (EFD)

Fig 3.1 Earth Fault Module

3.2 Lamp Failure Detector (LFD)

Fig 3.2 Lamp Fault Module

3.3 Elapsed Time

Fig 3.3 Elapsed Timer

3.4 Non-Illumination Step

Fig 3.4 Non-Illumination step

3.5 Circuit Selector

Fig 3.5 Circuit Selector

3.5.1 Remote Connection

Fig 3.6 Remote Connection

4. CCR Configuration Management

Fig 4.1 Password Screen