Providing reliability

and efficiency

in a small,

modular design

ConstantCurrent RegulatorsCCR-10 and CCR-25

A E R O S P A C E

Advantages• High operational reliability

• High efficiency

• Small size

• Modular design

• Plug-in-system

• No readjustment after replacingthe regulator

• Operating controls and displayelements accessible from thefront

• Comprehensive monitoring andprotective functions

ApplicationThe constant current regulators

CCR 10 and CCR 25 (control units)

are specially designed for the power

control of airport lighting circuits of

small, medium and high intensity

ground lighting systems at airports.

The CCR 10 will be combined with

transformer modules TRM 01, TRM

02, TRM 06 or TRM 10 and the CCR

25 will be combined with transformer

modules TRM 01, TRM 02, TRM 06,

TRM 10, TRM 15 or TRM 25 for opti-

mum adaptation from small to large

lamp circuits.

ConstructionThe regulator CCR 10 and CCR

25 (control units) are integrated in a

19” plug-in-unit with the dimension

482 x 132 x 350 mm (W x H x D).

This construction permits a particular-

ly high component density in a

switching and control system.

The unit is designed as a plug-in

system, i.e. the electrical connection

to the cabinet wiring is established

via permanently mounted connectors

when inserting the plug-in-unit.

In contrast to the constant current

regulator CCR 25 the CCR 10 con-

sists of two completely separate

regulator units.

Functional groupsThe regulator unit is split into the following subassemblies:

Electronic plug-in boardsThe plug-in boards are accessible from the front. They contain all

operating controls and display elements and are split into modules.

Power supply boardAll auxiliary supplies for the electronic system, control and signalling are

generated here.

Interface boardThe control commands from the remote control station are all received on

this board and passed on to the electronic system. Interference from the con-trol lines are suppressed by the isolation and voltage restriction of the remotecontrol signals on this board.

An operating mode selector switch permits local operation of the unit.The operating state of the regulator is displayed by means of three LED’s onthe front panel:

Upper LED (green)Regulator under remote control

Middle LED (red)Regulator under local control

Lower LED (green)Regulator has ‘ON’ command

Regulator boardThis board is the control module for the actual regulating function. For

monitoring the regulator, the board has an overcurrent cut-off and a cut-offin the event of a failure of the actual value or an interrupted circuit integratedon this board.

The display elements consist of a measuring instrument on the front panelfor displaying the actual value and one red LED each for displaying the cut-off functions:

Overcurrent cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(I > I max)

Cut-off in the event of open series circuit . . . . . . . . . . . .(I < I min)

A reset button is located on the front panel to release the interlock of thefault cut-off.

Power PartsThyristor actuator

A ‘power block’ is used as a thyristor actuator. This consists of two anti-parallel connected power thyristors integrated within one housing. Thisdesign permits a particularly small type of construction.

A further advantage of this type of construction is that both thyristors dis-charge their heat via a common potential-free heat discharge surface.

This measure enables the high component density of the plug-in unit.

Load contactorThe load contactor ensures the electrical isolation of the power circuits

and the main supply in a switched off condition. In addition, it also ensures areliable emergency cut-off in the event of a fault.

FunctionsThe constant current regulators CCR 10 and CCR 25 feed a series electric

circuit for airport lighting systems via a matching transformer (transformermodules type TRM).

A thyristor actuator keeps the current constant in the series electric cir-cuit via a closed loop control circuit in accordance with the nominal value.

Operation can be effected alternatively via 12 permanently set stages (cate-gories) or flexibly via an 8-bit digital code depending on the configuration ofthe terminal board in the control cabinet. The nominal values are set at theworks in such a way that the output currents at the lamps of the lighting sys-tem give 12 light intensities: maintenance level, 0,01%, 0,03%, 0,1%, 0,3%,1%, 3%, 10%, 30%, 80%, 95% and 100%.

The regulator does not have to be readjusted when a plug-in unit isreplaced. The constant current regulator is switched on either via the remotecontrol inputs (normal operation) or via an operating mode selector switchlocated on the front of the regulator.

Functional sequenceWhen entering one of the (operating)

categories, the load contactor is switchedon and the power channel is thus closed.The thyristor actuator is only releasedwhen the control logic receives the signalthat the power contactor is closed. Amaximum service life is attained for thecontacts because the contactor onlyopens in a deenergized state even whenswitching the regulator.

After the electronic system has beenreleased, the nominal value of the regula-tor switches to the final value specifiedby the category. The control amplifiercontinuously checks this nominal valueagainst the actual value.

Measuring of the actual value iseffected by means of a measuring currenttransformer directly at the output of thepower transformer in the series electriccircuit. The output signal of the trans-former is fed to an analog r.m.s. computerin the regulator and converted into avoltage proportional to the effective valueof the series circulating current. If thecontrol amplifier determines a differencebetween the nominal value and the actualvalue, then the ignition point for thethyristors is modified via the control elec-tronics. Because of the resulting change inthe current-time area, the effective valueof the series circulating current resetsitself to the specified nominal value.

The following points are checked formonitoring the operating state of the regu-lator and the series electric circuit:

� If the current is in a range necessaryfor operating the lighting equipment,then a service signal is given to theremote control station. The regulatoris fitted with a display instrument forverification purposes. The light inten-sity is given in % on the scale andcorresponds with the series circulat-ing current which has been specifiedfor this. A direct verification of theoperating state of the lighting systemis thus given.

� In order to prevent the lamps in thelighting circuit from being destroyedby an overcurrent, the regulator isfitted with an electronic protectivecircuit.

If the current reaches a level whichis dangerous for the lamps, thenthe circuit actuates an ‘emergencycut-off’ of the regulator via the cur-rent-time integral. The regulator isinterlocked so that it cannot beswitched on again and the ‘I > Imax.’ LED lights up as a display.

The regulator is released bypressing the ‘reset’ key on thefront of the regulator.

• If the actual value fails, then theregulator automatically switchesoff. This circuit also secures thesystem against operation with anopen series circuit.

In this case the ‘I < I min. ‘ lights up.

All monitoring circuits obtain theirmeasured values decoupled fromthe r.m.s. computer and thus alsocheck for a failure of the analogcomputer. The cut-offs described

above result in the service signalbeing switched away.

This is processed into a fault sig-nal in the remote control station.

An additional control unit (‘regula-tor lock-out’) permits the switch-ing off of the series current with-out influencing the (operating)category and without switching offthe load contactor.

Technical DataCCR 10 CCR 25

Performance specifications

Maximum current of the thyristor actuator 50 A 80 A

Input voltage alternatively without adjustment at plug-in unit 231/240 V 231/240 V or 400/415 V

Frequency 50 Hz (optionally 60 Hz) 50 Hz (optionally 60 Hz)

Apparent input power 10 kVA max. 25 kVA max.

Efficiency (including transformer module type TRM) better than 90% better than 90%

Power factor

- uncompensated depending on the operating category 0,36 to 0,85 ind. 0,36 to 0,85 ind.

- compensated by automatic multi range compensation better than 0,9 ind. const. better than 0,9 ind. const.

Control precision ≤ 2 % ≤ 2 %

Ramp-up time approx. 300 ms approx. 300 ms

Radio interference suppression time EN 55011, Class A EN 55011, Class A

Ambient temperature range min. -5°C up to 55° C min. -5°C up to. 55° C

Relative air humidity up to 95% up to 95%

Dimensions (W x H x D) 482 x 132 x 350 mm 482 x 132 x 350 mm

Technical functions in key wordsCCR 10 CCR 25

Control voltage + 18 V DC ≤ U≤ 32 V DC + 18 V DC ≤ U≤ 32 V DC(nominal + 24 V DC) (nominal + 24 V DC)

Status signals Service signal + 24 VDC/20 mA Service signal + 24 VDC/20 mAand potential-free contact and potential-free contactSignals local control, Signals local control,potential-free contact potential-free contact

Auxiliary supplies None NoneAll auxiliary supplies are generated All auxiliary supplies are separately in the plug-in unit for generated separatelyeach unit in the plug-in unit

Categories 12 permanently set power 12 permanently set powerstages according to the relative stages according to the relativelight intensities of 100 %, 95%, light intensities of 100 %, 95%,80%, 30%, 10%, 3%, 1%, 0,3%, 80%, 30%, 10%, 3%, 1%, 0,3%,0,1%, 0,03%, 0,01%, maintenance 0,1%, 0,03%, 0,01%, maintenancestage, regulator lock-out, control stage, regulator lock-out, controlpossible on the plug-in unit by possible on the plug-in unit bymeans of an integrated means of an integratedoperating mode selector switch operating mode selector switch

Recording of the actual value Measuring transformers in the Measuring transformers in theseries circuit for a nominal series circuit for a nominalcurrent of 6,6 A with conditioning current of 6,6 A with conditioningby an analog r.m.s. computer by an analog r.m.s. computer

Protection against Over current in series circuit Over current in series circuitEvaluation of the current-time Evaluation of the current-timeintegral with a cut-off and integral with a cut-off andinterlocking against recurrent interlocking against recurrentswitching on of the regulator switching on of the regulator

Protection against failure of operation on an open series Monitoring of the output signal Monitoring of the output signalcircuit and of the actual value of the r.m.s. computer with of the r.m.s. computer with

cut-off and interlocking against cut-off and interlocking againstrecurrent switching on in the recurrent switching on in theevent of a failure event of a failure

Airport SystemsHoneywellP.O. Box 21111Phoenix, Arizona 85036-1111U.S.A.Phone: +1-602-436-5599Fax: +1-602-436-6661

Airport Systems GmbHHoneywellIndustriestrasse 23-3322880 WedelGermanyPhone: +49 (0) 41 03/8004-0Fax: +49 (0) 41 03/8004-599

P61-0003-000-000May 2001

Printed in U.S.A. on recycled paper© 2001 Honeywell International Inc.

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