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AGL 3
Module 6

Aeronautical Ground Lighting

Constant Current Regulators

Contents

1 Purpose

2 The Thyristor Controlled CCR

3 Introduction to CCR Calculations

4 CCR Selection

5 Calculated Allowable Insulation Resistance Value

6 Practical Exercise – CCR Set-up

AGL 3 – Module 6 1 Issue B

Author : Technical Support
Date : Sep 11
 .

1.0 PURPOSE

1.1 To provide power to visual aids such as AGL on airfields, it is essential that airport authorities
select the most suitable equipment designed for that particular purpose, in compliance with
ICAO recommendations.

AGL systems utilise the series circuit.

The common factor in a series circuit is current. By using current isolating transformers at each
light location, it eliminates the problem of system failure should one lamp fail (open circuit).
That would happen if lamps were connected directly into the primary circuit.

A device known as the CCR is used for controlling brilliancy or intensity of AGL series circuits
and hence AGL lights.
They are designed to maintain a set output current level on a series circuit loop ( closed loop )
by altering the voltage output to suit any changing load conditions within certain parameters

Consequently, the CCR has been developed over the years.

There are different types in service, employing a variety of methods to control their output
current.
Over the years there have been three basic types of CCR that maintenance personnel have
been confronted with. They are the :

• Resonant Tuned Circuit

• Magnetic Amplifier
• Thyristor (SCR) type CCR.

1.2 Power Input Requirements

The CCR nameplate provides you with the voltage and power rating. Power requirements may
vary between but ICAO recommend a standard set of CCR Power Ratings ranging from
2.5kVA to 30kVA. The range of input voltage can range from 200volts AC to 440volts AC.

1.3 Current Regulation

Current regulation in the primary series loop is achieved by varying the output voltage of the
CCR main transformer as required to maintain a stable and desired current under varying load
conditions.

Each type has characteristics that allow them to monitor and compare their output currents.
This gives them the ability to instantly correct the output level as necessary to maintain the
constant current in the High Voltage Series Circuit at whatever lamp brilliancy level is selected.

Manufacturers are always looking at different ways of powering and controlling the visual aid
circuits in accordance with the latest directives issued by the aviation authorities.
Research into ways of overcoming the effects of problems such as Harmonics is ongoing.

The latest development is based on the use of TRANSISTORS to control the current in the
primary winding of the power transformer. These are now emerging into the industry so there
will be another type for maintenance personnel to contend with.

Due to the procurement processes adopted in today’s business environment, it is possible that
all of the types mentioned could be installed at a single airport.

AGL 3 – Module 6 2 Issue B

Author : Technical Support
Date : Sep 11
 .

1.4 Brilliancy and RMS Current Limits

CCR’s are designed to maintain a constant current output not withstanding variations of field
circuit loading and input voltage.
Theyshould be set-up according to the requirements of ICAO and the manufacturers
recommendations.

Any reduction or increase in light output caused by poor regulation of the output current of a
CCR can have serious flight safety implications.

Therefore it is essential to maintain the requested current values within set tolerances.
Any monitoring system incorporated into the CCR should create an alarm if any CCR falls
outside the tolerance standards laid down.

1.5 CCR Characteristics

Constant Current Regulators should have the characteristics as laid down in the following
standards :
 ICAO – Aerodrome Design Manual Part 5
 FAA – AC 150/5345-10E and L829
 Eurpean Standard – EMC EN 50081-1 and EMC EN 50082-2 for industrial
environments
 STNA ( France ) requirements

For the purpose of these notes we will concentrate on the thyristor controlled CCR
manufactured by ADB Siemens and known as the MCR Mark 2 ( micro-processor controlled
CCR )

2.0 THE THYRISTOR CONTROLLED CCR ( MCR )

The Thyristor controlled CCR uses an SCR ( Silicone Controlled Rectifier ) to provide the
primary method of controlling current in the primary series circuit.

+ • A thyristor with forward polarity will

gate
Thyristor conduct a current, the moment a small
voltage is applied to the gate.

-
Short Pulse • With reverse polarity it will act as a
diode and will not conduct, even with a
voltage applied to the gate.

I T • The thyristor only requires a small

voltage pulse at the gate and then it is
thrust into saturation. It will continue to
pass a current while the biasing is in
the forward direction, even though the
Thyristor blocked T applied pulse has stopped.

Principle of Thyristor operation :

AGL 3 – Module 6 3 Issue B
Author : Technical Support
Date : Sep 11
 .

Fig. a)
V in V OUT

Fig. b)
V OUT
V in

Fig. c)
V in

• Fig a) : The thyristor can be used to chop an AC signal, but only passes current in the forward
direction.
• Fig b) : The thyristor only passes current in the reverse direction

• Fig c) : If the thyristors are connected in parallel then current will pass in both directions

BLOC K DIAGRAM OF A REGULATOR

CONBTROLLED BY SERIAL THYRISTORS

7/8
V prim 6/8 Output to
Input V sec
Airfield
4/8
supply Circuit
2/8 I se

I prim. TI
Thyristor
Tower Trigger
( Remote ) Circuit
Control
Setpoint
Board
Local
Feedback

AGL 3 – Module 6 4 Issue B

Author : Technical Support
Date : Sep 11
 .

2.1 Brightness Steps

100 % S5 6.6 A )
30 % S4 5.2 A )
10 % S3 4.1 A ) Defined settings
3% S2 3.4 A ) iaw ICAO
1% S1 2.8A )

Actual Intensity / Current Settings in accordance with FAA

2.2 Operating Characteristics

Limitations :

• Operation from -5% to -15% of nominal input voltage with full load can cause too low
output current at maximum brightness step

• Operation at +15% of the nominal input voltage will be restricted to maximum 1 hour
period to avoid over-heating or over-stressing of the components

Features :

• Incorporates an open-circuit device which quickly locks out the primary voltage and
requires re-setting of the regulator

• Allows intensity settings to be changed without de-energising the regulator

• Incorporates a security device that sets the regulator out of service or assures a
reduction of the current in case of an over-current

• Indicates a ground fault while permitting the circuit to operate normally when a single
fault prevails

CCR’s supplying power to airfield lighting circuits must guarantee current regulation within the
limits of +/-1% in the following conditions :

• From short circuit to full load

• For nominal input voltage within +/- 15% - see limitation for additional comment
AGL 3 – Module 6 5 Issue B
Author : Technical Support
Date : Sep 11
 .

• For ambient temperatures from -20 to + 55 degrees celcius

• For a relative humidity range of 10% RH to 95%RH without condensation
• Up to at least 30% of lamp transformers with an open circuit on their secondary side,
for a load ranging at least half-load to full-load ( ie. Lamp failure )

They shall have an Efficiency at nominal input power, nominal resistive load and maximum
brightness at :
• 90% for CCR’s up to 10kVA
• 94% for CCR’s above 10kVA

The Power Factor at nominal input voltage and resistive load and maximum brightness is from
90% to 92%

However, because CCR’s are manufactured to a set range of power outputs, it is necessary to
more closely to match the power requirements of the particular circuit to the output of the CCR.
This achieved ‘ on-site’ by means of the provision of tappings on the secondary side of the
output power transformer of the CCR. This will increase the efficiency of the CCR and the
following benefits will be realised :

• The power factor will be optimized

• The main input current will decrease
• The harmonic content in the main input current and in the output current will decrease
• The maximum output voltage ( in the field circuit ) in the case of an open-circuit will be
lower

Additional facilities such as Earth Fault detection and Lamp Fault detection are also available
but users must decide whether these options are required. These facilities are then added at
manufacture.

Earth fault detection ( EFD ) levels are defined by ICAO in ADM Part 5. This is the calculated
value of the Insulation Resistance of the circuit. An example is explained in Module 10 of these
AGL3 notes.

3.0 INTRODUCTION TO CCR CALCULATIONS

3.1 It is important to ensure that that the CCR is closely matched to the actual value of the circuit it
will supply.
Consequently, the following issues are considered :
 The actual calculated load of the circuit
 The available and appropriate sizes of CCR
 To optimise the overall CCR/field circuit by selecting the correct output tappings on
the CCR output transformer to fine-tune the CCR to the calculated load of the
primary circuit as close as possible
In addition, it is important to set-up alarm levels as appropriate.
Eg.
 Lamp Fault Detection
 Earth Fault Detection

In this session, Students will get the opportunity to :

 Calculate the load of a circuit
 Calculate the ICAO level of Insulation Resistance

4.0 SELECTING CCR’s

AGL 3 – Module 6 6 Issue B
Author : Technical Support
Date : Sep 11
 .

When selecting CCR’s , we must consider the :

 Load demanded by each secondary circuit ( lamp + secondary leads )
 Load felt on the primary circuit due to each secondary circuit ( secondary circuit +
isolating transformer losses )
 Load on the whole primary circuit ( primary cable + number of secondary circuits &
isolating transformers )

Example :

Let us assume an airfield circuit consisting of 100 X 45 watt light fittings at a length of 8 kilometres.
The primary cable is 8mm² and the secondary cable is 4mm² with the length of each secondary
circuit @ 30 metres.

Calculations :

It is normal to consider the overall circuit in two distinct stages :

1. each secondary circuit load
2. overall primary circuit load

1. Secondary Circuit load :

Load of 1 X 45W fitting = 45W

Length from transformer to fitting = 30 metres

Cross-sectional area = 4mm²
Resistance in secondary circuit = 2 x cable resistivity x l
cross-sectional area of secondary cable

( declared resistivity = 18x 10-³ ohms mm²/metre )

Resistance in each secondary = 2 x 18 x 10-³ x 30 = 0.27 ohms

4
Losses in each secondary circuit = I²R = 0.27 x 6.6² = 11.76 W

Total Power demand from secondary = 45 + 11.76 = 56.76W

( lamps + cabling )

2. Primary Circuit load :

Power at the primary side ( from each secondary circuit )

Power = secondary power x 1.25
= 56.76 x 1.25 = 73.79W
( Note : 1.25 = efficiency coefficient of the isolating transformer )

Total primary power demand of lamps etc = primary power ( from secondary circuit ) x number of
lamps
= 73.79 x 100 = 7379W

Total length of primary circuit is 8 kilometres

Note : Advised knowledge due to resistivity of 8mm² primary cable = R = 24 ohms

Losses in primary circuit = I²R = 6.6² x 24 = 1045W

Total load in Circuit = 7379 + 1045 = 8424W

AGL 3 – Module 6 7 Issue B

Author : Technical Support
Date : Sep 11
 .

3. CCR size :

Assuming the ICAO standard of selecting CCR’s @ 80% of nominal value :

Circuit calculated load @ 8424W

By selecting a 12.5 kW CCR = 12.5 x 80% = 10kW

Therefore the 10kW CCR is selected for this circuit !

( Note : If we had assumed a 10kW CCR would have been acceptable, let us calculate the
allowable circuit load for a 10kW CCR : 10 x 80% = 8kW …….. too small !!! )

5.0 CALCULATED ALLOWABLE INSULATION RESISTANCE VALUE

ICAO ( ADM Part 5 ) states that the insulation resistance value of each individual circuit shall
depend upon the earth leakage current values allowable as follows :

 2µA for each transformer in the circuit

 1µA for each 100 metres of cable ( this figure allows for the standard connectors &
splices )

For example :

Let us take a runway centreline containing 133 light fittings with a circuit length of 10kms.

1. Maximum leakage current for transformers = 133 x 2 = 266µA

2. Maximum leakage current for cabling etc = 10 x 1000 = 100µA

100
3. Total allowable leakage current for the circuit = 266 + 100 = 366µA

Assuming 5kV is the voltage level in the circuit ( circuit components are designed to withstand
5kV, therefore we use this figure in our calculations )

4. Insulation Resistance = 5000 V = 13.7 Megohms

366 µA

5 Recommended Alarm Levels for CCR’s :

 Level 1 @ 2 x Calculated value = 2 x 13.7 = 27.4 Megohms

 Level 2 @ 0.5 x Calculated value = 0.5 x 13.7 = 6.8 Megohms

( Note : Maximum value of Level 1 allowable is 150 Megohms regardless of the

calculated value )

6.0 PRACTICAL EXERCISE

The students will undertake practical training and exercises using an ADB 7.5kW MCR
connected to a small circuit consisting a variety of AGL lighting equipment.

AGL 3 – Module 6 8 Issue B

Author : Technical Support
Date : Sep 11