Journal of Physics: Conference Series

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Design of Constant Constant Current Regulator Control System of NBF

1200 Using Programmable Logic Controller at The Airport
To cite this article: Hartono et al 2021 J. Phys.: Conf. Ser. 1845 012077

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ICIASGA 2020 IOP Publishing
Journal of Physics: Conference Series 1845 (2021) 012077 doi:10.1088/1742-6596/1845/1/012077

Design of Constant Constant Current Regulator Control

System of NBF 1200 Using Programmable Logic Controller
at The Airport.

Hartono1, R I Sudjoko2, S Hariyadi, D A Kumalawati3

Politeknik Penerbangan Surabaya

Email: hartono.poltekbang@gmail.com

Abstract. International Civil Aviation Organization (ICAO) regulated Visual Aids for
Navigation stated on Annex 14 Chapter 5 consist of mandatory item which provides important
guidance’s for piloting the airplane. Presently, the system of visual aids for navigation has been
working with the Constant Current Regulator (CCR) which in its development there are
various type at CCR used at airport. One type CCR is still widely used at airport today is the
CCR NBF 1200 power supply using its control system. Reliability and time respons become
problem related those system. Therefore this paper presents an design on CCR NBF 1200
control system simulation to control the brightness level of the lamps which indicating as
visual aid for navigation. The result shows brightness level success controlled by PLC
remotely based on the power level.

Keywords : CCR, NB8F 1200, PLC

1. Introduction
Airfield lighting system or visual aids used by pilot to land and take off visually at night or in bad
weather. Visual aids are the beacon that consisting of lights with certain types, numbers, and layout
intended for facilitating the pilot [1]. Visual aids are required for both commercial and military pilots
which support the comfortable, safe and expedite flights. In addition, visual aids need reliable power
supply. The power supply equipment of visual aids is recognized as CCR (Constant Current
Regulator) that in the development has several types of CCR used in airport. CCR NBF 1200 made by
ADB is one of the types that mostly used in airport.
The power supply voltage is current constant with series resonance or better known as
compensation static as the working principle of CCR NBF 1200, its control system uses
electromagnetic [2]. In the development of electric control system is currently most used
Programmable Logic Controller (PLC) as control system that has more advantages such as practical,
easy to program and reliable [3].Therefore in this study, the researchers use PLC control system to
replace CCR NBF 1200 electromagnetic control, this design is expected to enhance the reliability of
this control so that the continuity and reliability of this equipment is maintained to supply the visual
aids equipment.

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ICIASGA 2020 IOP Publishing
Journal of Physics: Conference Series 1845 (2021) 012077 doi:10.1088/1742-6596/1845/1/012077

2. Control System of CCR NBF 1200

The control system of CCR type NBF 1200 currently uses electromagnetic control. The use of
electromagnetic control system has experienced many drawbackes such as reliability and the speed of
program execution.

a) Local Operation
In operation of local main relay G-K2 and brightness relay B1-K4 to B4-K7 remote operation relay
condition is not working. The position of drum switch A1 is moved to position 1 (brightness step 1), if
it desires the CCR operation in step 1 and continuously, if increasing the brightness places in step 2,3,
or 4. Primary coil of Transformator T1 obtain supply voltage 220 Volt and shape series closed via
auxiliary Fuse E3 – E4.

b) Remote Operation
The setting of remote operation is carried out through relay G-K2. The position of Drum switch A1
must be in position “REM”, because of the supply voltage in transformator T1 can not be done by
means of terminal 12, but it must go through contact G-K2, terminal a16 and contact 1 – 1’ on drum
switch A1. Switching brightness CB1 is supplied from contact 1 – 1’ on drum switch A1 and other
side via contact 1 – 1’ and contact 13 – 13’ drum switch A1 and contact 8 – 6 and goes through
normally closed auxiliary contact of contactor brightness CB2, CB3, CB4.

c) Open Circuit Protection

If Open Circuit occurs at output CCR (terminal S1 and S3), no current is induced by transformator
TS and consequently relay D – K1 will trip (OFF). Main contactor CG will also “OFF” because of
contact D (9 - 11) is open due to not operating relay D. Relay A – K3 is still energized via contact A (6
– 7). This condition will remain permanent even though the series circuit closed again. Therefore, if
CCR will be operated again so drum switch A1 must be returned to position “0” at operation local or
switching OFF relay G – K2 at operation remote and procedure operation is repeated from the
beginning [4]. Because of sCCR NBF 1200 is reliability enough and mostly used in small airport
throughout indonesia. Hence, so that CCR NBF 1200 still can be used, PLC based control design is
required to scale up the reliability of its control system in order to CCR can be functioned properly.

Fig. 1. Circuit CCR type NBF 1200

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ICIASGA 2020 IOP Publishing
Journal of Physics: Conference Series 1845 (2021) 012077 doi:10.1088/1742-6596/1845/1/012077

2.1. Desired Condition

Maintaining the reliability and continuity of CCR type NBF 1200 is as the main power supply of
visual aids equipment and one of the various types of CCR that most used at the airport which is
required a new CCR control system design. This design is expected to be a control system that
controlsthe brightness of remote or local options and protection using PLC.Overall, PLC control
relatively has more advantages over electromagnetic control (relay), among others are :
a. Software means that the control function can be easily transformed by changing the program in
software.
b. Implementation project is fast, cabling is relatively simple and neat.

2.2. Control System Design

Here is the diagram block picture from the whole process of manufacturing equipment from the
research that will be made :

Fig. 2. Block diagram of concept design

The concept of equipment design that will be made later is the control of CCR type NBF 1200
using PLC brand LG type Master K120S. In this design, control system of CCR type NBF 1200 is still
electromagnetic that transformed into ladder diagram programmed in PLC, so that in continuity and its
process are easier, and also the work of CCR is more optimal.

2.3. Hardware Design

To make concept of tool design that is required appropriate hardware. The researchers here will
present the hardware design that appropriate with concept of tool design will be made, the following
hardware :
a. PLC LG
b. Relay
c. Contactor
d. Push Button
e. Selector Switch

2.4. Program Design

This PLC is used as a relay replacement and contactor in control system of CCR type NBF 1200.
The establishment of this control system firstly is making program of PLC into ladder diagram, the
establishment program for PLC LG Master K-120 is using an application of KGL-WIN for Windows.
KGL-WIN has several function that can be used to make ladder diagram [5]. The research of making
program is in accordance with the control that researchers have designed in the project form available.

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ICIASGA 2020 IOP Publishing
Journal of Physics: Conference Series 1845 (2021) 012077 doi:10.1088/1742-6596/1845/1/012077

3. Discussion and Analysis

3.1. Brightness Setting
For brightness setting (brightness level) of this CCR type NBF 1200 can be carried out by two
ways, first the remote, it means that the brightness control setting is only done via control desk
located in air traffic controller (tower). Second the local, it means that the brightness control system is
carried out when in maintenance or repair by the technician in the control room of CCR. Brightness
level of this CCR NBF 1200 has 5 steps that consisting of step 1,2,3,4,5 for each has different rating
ampere [6]. Step 1 has smallest rating ampere tat produces smallest brightness level, than step 5 has
the most maximum brightness level (2,8 A for step1, 3,4 A for step 2, 4,1 A for step 3, 5,2 A for step 4
and 6,6 A for step5). In this research, the available electromagnetic control will be changed by PLC
control, therefore researchers need KGL-WIN software to make its ladder, program of brightness level
setting is as follow:

Fig. 3. Ladder of Brightness setting (Remote)

Based on the ladder diagram above, there is P0001 and P0002 in diagram number 27 and 40, P0001
is functioned as input to increase brightness and P0002 is used to decrease the brightness level. This
program is using ADDP, SUBP, And Load Contact, MCS and also timer function.

3.2. Increasing Brightness Position Remote

The command to increase the brightness is showed in ADDP function that utilized to total the
wordbool data number whose results are stored in register D0000 amount of 5 (five) of these
restrictions program using andload contact, these restrictions are the amount of brightness on CCR
consisting of 5 (five) steps where step 5 is maximum brightness with a current of 6,6 Ampere flowing
to the series of runway lights.

3.3. Decreasing Brightness Position Remote

To decrease the brightness with input P0002 is using SUBP program, this command is the opposite
of ADDP command if SUBP program functioned to reduce wordbool data number. If this function is
activated so data in D0000 will be reduced by 1 (one) and the result will be saved in the same register
(D0000) [6]. Input P0002 decreasing the data value in D0000 and this reducing is able to be saved in
value D0000 + 1 (one), because the minimal step value of brightness is 1 (one). If the value is less than
number 1 (one) so this command will not be executed. In the program of andload contact point is
functioned to activate an input according to data condition in D0000. If the output condition connected
to brightness contactor is affected by the amount of data in D0000.
If D0000 = 2 so M0000 will active, D0000 + 3 so M00001 will active, D0000 = 4 so M0002 will
active and if D0000 = 5 so M0003 will active [7]. The function of M in this ladder program is relay
internal that used to meet the need of existing relay number.

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ICIASGA 2020 IOP Publishing
Journal of Physics: Conference Series 1845 (2021) 012077 doi:10.1088/1742-6596/1845/1/012077

Function of M0000 to M0007 in this application connected to output P0040 to P0043 that designed to
manage step brightness connected directly with brightness contactor.
The following is ladder diagram :

Fig. 4. Ladder of Output of Brightness Regulator Coil

3.4. Increasing and Decreasing Brightness of Local Position

For brightness setting in local position is not much different from Remote position because in
summary this ladder has the same function starting from ladder diagram number 85 (eighty five) to
number 129 (one hundred twenty nine). The distinctions are P0004 used to increase brightness and
P0005 to decrease brightness as well as relay internal (M Function) used is not the same as ladder
diagram remote position that starting from M0004 to M0007. The output coil used is P0040 to P0043
connected with brightness contactor. The following is the picture of its ladder diagram :

Fig. 5. Ladder of Brightness Regulator (Local)

3.5. The Remote and Local Setting

The program of ladder diagram is made separately in order to manage remote and local position,
the researchers used MCR function namely MCS and MCSCLR. In PLC program, the instruction’s
use of MCR is always in pairs. If the first MCR is ON, the ladder lines below will be executed
normally until second MCR. If the first MCR is OFF so the relay internal or output on the block will
also be OFF except if latch function is used for its relay. Technically, this MCR function in PLC is
implemented into two functions namely :
a. MCS (Beginning of Block)
b. MCSCLR (End of Block) [7]

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ICIASGA 2020 IOP Publishing
Journal of Physics: Conference Series 1845 (2021) 012077 doi:10.1088/1742-6596/1845/1/012077

3.6. Remote Position

In this ladder diagram design P0000 is input ladder for selecting the remote position which if
P0000 pressed so all programs among MCS 0 to MCSCLR 0 can be executed. Generally, the
configuration is MCS (MCSCLR) No.Block, No Block is integer between 0 (zero) to 8 (eight).
Integer 0 (zero) and 1 (one) are used in this program. This program between MCS and MCSCLR
contains of brightness setting in remote position 5 (five) step for input P0001 to increase step and
P0002 to decrease step.

Fig. 6. Ladder of Position Remote Regulator

3.7. Local Position

In summary, the ladder diagram below has the similarity with the ladder above, the distinction is
input ladder to select the block used P0003 (input local position) which if pressed will execute the
ladder between MCS 1 to MCSCLR 1 namely number ladder 85 (eighty five) to 129 (one hundred
twenty nine) which contains the setting of brightness 5 (five) step to increase used input P0004
and to decrease used P0005. In this block used integer 1 (one) to distinguish the block above. The
following is the detail picture of its ladder diagram :

Fig. 7. Ladder of Local Position Regulator

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ICIASGA 2020 IOP Publishing
Journal of Physics: Conference Series 1845 (2021) 012077 doi:10.1088/1742-6596/1845/1/012077

3.8. Protection to CCR NBF 1200

CCR NBF 1200 is like other equipment which has also protection (safety) system such as open
circuit, over current and short circuit. This protection protects CCR if there is interference in system.
As a substitute to the existing system, researchers made protection control with ladder language. In
electromagnetic system condition is installed if occurs open circuit in output (terminal S1 and S3),
there is no current induced by Current Transformer TS and caused relay D – K1 will trip (OFF) then
CCR is off. If occurs open circuit interference, before turning off the CCR occurs time delay (timer)
that including Resistor and capacitor series functioned to assure the interference. Based on condition
installed then researchers make ladder to control the interference protection in CCR, the following is
ladder diagram :

Fig. 8. Ladder CCR protection

Ladder diagram above is series substitute on control protection to CCR interference, the principle’s
work is input P0006 as a substitute of standby relay that will activate relay internal M0008. If M0008
is active then M0009 will also be active and activate M0010, so output coil P0044 will be active. If
CCR series is in close circuit (normal condition) there is no interference then P0007 will deactivate
TON T001 so P0044 is still active.
If there is interference in CCR in the form of open circuit then P0007 connected with relay sensor
protection interference will be opened the contact so that TON will count the time until 20 seconds
then will turn of P0044. This decision of time 20 seconds will be adjusted with the condition of
electromagnetic control system installed that is still using RC series (combination of resistor and
capacitor) as time delay if occurs interference in CCR will count the time before turning off the main
circuit breaker which ultimately turning off the whole system of CCR NBF 1200. In manufacturing the
implementation of ladder program using ladder (instruction) PLC brand LG K120 S needs to allocate
the input and output addresses that will be connected physical equipment and the internal relay. This
allocation tool is aimed to facilitate cabling design so the possibility mistakes can be minimized.
The followings are allocation addresses of input and output :

Table 1. Address I/O PLC

Address Input /
Function
Output
P0000 For selector switch selects local position or remote where P0000 for local and
P0003 P0003 for remote
P0001 For input in local position where P0001 to increase brightness and P0002 to
P0002 decrease brightness
P0004 For input in remote position where P0004 to increase brightness and P0005 to

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ICIASGA 2020 IOP Publishing
Journal of Physics: Conference Series 1845 (2021) 012077 doi:10.1088/1742-6596/1845/1/012077

Address Input /
Function
Output
P0005 decrease brightness
P0006 For relay control where P0005 for standby and P0007 for relay safety of open
P0007 circuit
P0040 Output connected with contactor brightness are P0040 to P0043 and P0044 for
P0041 main CB
P0042
P0043
P0044

4. Conclusions
a. This control system design can enhance the reliability of CCR type NBF 1200 which still use
electromagnetic control due to PLC control program execution, response time is faster and
reliable.
b. Software means that the control function can be easily transformed by changing the program in
software
c. Implementation design is faster, cabling is relatively simple and neat as well as integrated
monitoring.

Refferences
[1] ICAO A and Volume I 2004 Aerodrome Design and Operations, Annex 14 to the Convention
on International Civil Aviation
[2] Anon 1994 Constant Current Regulator and Sequence Flashing Light (DGAC Indonesia)
[3] Systems I C 2006 Introduction to Programmable Logic Controllers ( PLC ’ s ) Industrial
Control Systems Fall 2006 The Need for PLCs • Hardwired panels were very time consuming
[4] Adrien De Backer (ADB) Manual Book CCR NBF 1200 (Zaventem Belgium)
[5] Master K. User’manual LG Programmable Logic Controller (LG Industrial System)
[6] Anon ADB Safegate, Data Sheet, Reliance poer CSF, Constant Current Regulator,
Frroresonant Air Cooled
[7] Setiawan I 2006 Programmable Logic Controller dan Teknik Perancangan Sistem Kontrol