FAA-AC-150-5345-10F-2005.pdf

U.S. Department of Transportation Federal Aviation Administration Advisory Circular Subject: SPECIFICATION FOR CONSTANT CURRENT REGULATORS AND REGULATOR MONITORS Date: 6/24/05 Initiated by: AAS-100 AC No: 150/5345-10F Change: 1. PURPOSE. This advisory circular (AC) contains a specification for constant current regulators (CCR) and a monitor for use with airport lighting circuits. 2. CANCELLATIONS. AC 150/5345-10E, Specification for Constant Current Regulators and Regulator Monitors, dated 10/16/84, is cancelled. 3. PRINCIPAL CHANGES. The following principal changes are in this specification: a. The addition of Title 47, Part 15, Subpart B, Incidental Radiator, classification, and testing for conducted and radiated interference. b. The addition of crest factor limit testing. c. A change to the output current tolerance of a CCR to ± 0.1 amp (A) for 6.6A and ± 0.3A for 20A. 4. APPLICATION. The specifications contained in this AC are recommended by the Federal Aviation Administration (FAA) in all applications involving development of this nature. For airport projects receiving Federal funds under the airport grant assistance or the passenger facility charge programs, the use of this specification is mandatory. 5. METRIC UNITS. To promote an orderly transition to metric units, this specification includes both “English” and “Metric” dimensions. The metric conversions may not be exact equivalents, and until there is an official changeover to the metric system, the English dimensions will govern. DAVID L. BENNETT Director of Airport Safety and Standards Intentionally Left Blank AC 150/5345-10F June 24, 2005 TABLE OF CONTENTS CHAPTER 1. SCOPE AND CLASSIFICATION.1 1.1 SCOPE.1 1.2 CLASSIFICATION.1 1.2.1 Types.1 1.2.2 Classes.1 1.2.3 Styles.1 1.2.4 Standard Ratings.1 CHAPTER 2. REFERENCED DOCUMENTS.3 2.1 GENERAL.3 2.2 FAA ADVISORY CIRCULARS.3 2.3 FAA STANDARDS.3 2.4 CODE OF FEDERAL REGULATIONS.3 2.5 INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS, AMERICAN NATIONAL STANDARDS INSTITUTE (IEEE/ANSI) PUBLICATIONS. .3 2.6 MILITARY STANDARDS.3 2.7 NATIONAL ELECTRIC MANUFACTURERS ASSOCIATION (NEMA)4 2.8 INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC).4 CHAPTER 3. EQUIPMENT REQUIREMENTS.7 3.1 GENERAL.7 3.2 ENVIRONMENTAL REQUIREMENTS.7 3.3 PERFORMANCE REQUIREMENTS. .7 3.3.1 Regulation.7 3.3.2 Efficiency8 3.3.3 Power Factor.8 3.3.4 Standard Input Voltage.9 3.3.5 Temperature Rise9 3.3.6 Crest Factor.9 3.3.7 CCR Control System.9 3.3.8 Output Current Surge Limitation9 3.3.9 CCR Circuit Isolation. 10 3.3.10 Protective Devices. .10 3.3.11 Input Power Loss. .10 3.3.12 Electromagnetic Interference11 3.4 DETAILED REQUIREMENTS11 3.4.1 Primary Switch11 3.4.2 Operator Controls11 3.4.3 Output Ammeter .11 3.4.4 Output Voltmeter12 3.4.5 Operator Display.12 3.4.6 Terminal Block. .12 3.4.7 CCR Enclosure13 3.4.8 Control Cabinet.13 3.4.9 Capacitors. 14 3.4.10 Wiring Diagram14 3.4.11 Painting and Finishing14 3.4.12 Lightning/Surge Arresters.14 3.4.13 Transient Voltage and Current Protection. .14 i June 24, 2005 AC 150/5345-10F 3.4.14 Warning. .15 3.4.15 Components. .15 3.4.16 Nameplate.15 3.4.17 Instruction Book15 3.5 MONITOR.16 CHAPTER 4. EQUIPMENT CERTIFICATION REQUIREMENTS. 19 4.1 CERTIFICATION PROCEDURES.19 4.2 CERTIFICATION TESTING19 4.2.1 Regulation Test.19 4.2.2 Remote Control Test.19 4.2.3 Temperature Rise20 4.2.4 Efficiency20 4.2.5 Power Factor.20 4.2.6 Crest Factor.21 4.2.7 Altitude. 21 4.2.8 Low Temperature21 4.2.9 Humidity.21 4.2.10 Electromagnetic Interference Tests.22 4.2.11 Basic Impulse Insulation Level (BIL) Tests. 22 4.2.12 Dielectric Tests. 23 4.2.13 Protective Device Tests.23 4.2.14 Leakage Test.23 4.2.15 Output Current Surge24 4.2.16 Monitor Test24 4.3 OUTPUT WAVEFORMS. 25 CHAPTER 5. PRODUCTION TEST REQUIREMENTS.27 5.1 PRODUCTION TESTING27 ii AC 150/5345-10F June 24, 2005 CHAPTER 1. SCOPE AND CLASSIFICATION. 1.1 SCOPE. This specification details the requirements for constant current regulators and a monitor system for use with airport series lighting circuits. 1.2 CLASSIFICATION. 1.2.1 Types. L-827 Regulator Monitor. L-828 - Regulator without monitoring. L-829 - Regulator with monitoring. NOTE: Multiple regulators may be bussed together into switchgear configurations, but each regulator must meet the requirements of this specification. In addition, each regulator must have disconnects to isolate it from primary and control power. 1.2.2 Classes. Applicable to regulators only: Class 1 - 6.6 amperes (A) output current. Class 2 - 20.0 A output current (see Note 1 in paragraph 1.2.4). 1.2.3 Styles. Applicable to regulators only: Style 1 - 3 brightness steps. Style 2 - 5 brightness steps. 1.2.4 Standard Ratings. Standard ratings are as follows: NOTE: Other voltages, frequencies, or sizes of regulators may be supplied to suit local site conditions, but must meet all the requirements in this specification. Standard Sizes (kW out) Standard Voltages (Volts ac in) Standard Freq. (Hz) 1, 2, 4, 7.5, 10, 15, 20, 25, 30, 50, 70 208, 220, 240, 480, 2400 60 Hz 1 June 24, 2005 AC 150/5345-10F NOTES: 1. 50 and 70 kW CCRs are not available for new designs replacement equipment only. 2. 2400 volt input CCR not available for new designs - replacement equipment only. 2 AC 150/5345-10F June 24, 2005 CHAPTER 2. REFERENCED DOCUMENTS. 2.1 GENERAL. The following is a list of documents referenced in this advisory circular. 2.2 FAA ADVISORY CIRCULARS. AC 150/5345-53 Airport Lighting Equipment Certification Program AC 150/5345-47 Isolation Transformers for Airport Lighting Systems 2.3 FAA STANDARDS. FAA-STD-019d Lightning and Surge Protection, Grounding, Bonding and Shielding Requirements for Facilities and Electronic Equipment 2.4 CODE OF FEDERAL REGULATIONS. Code of Federal Regulations (CFR) Title 47, Telecommunications, Section 15.13, Incidental Radiators 2.5 INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS, AMERICAN NATIONAL STANDARDS INSTITUTE (IEEE/ANSI) PUBLICATIONS. ANSI/IEEE C57.12.00-2000 IEEE Standard General Requirements for Liquid Immersed Distribution, Power, Regulating Transformers ANSI/IEEE C57.12.01-1998 IEEE Standard General Requirements for Dry-Type Distribution and Power Transformers Including Those with Solid Cast and/or Resin Encapsulated Windings ANSI/IEEE C57.12.90 01 May 1999 Standard Test Code for Liquid Immersed Distribution, Power and Regulating Transformers ANSI/IEEE C57.12.91 01 May 2001 Standard Test Code for Dry-Type Distribution and Power Transformers IEEE C62.41-1991 IEEE Recommended Practice on Surge Voltages in Low-Voltage AC Power Circuits IEEE C62.45 IEEE Recommended Practice on Surge Testing for Equipment Connected to Low-Voltage (1000 V and Less) AC Power Circuits 2.6 MILITARY STANDARDS. MIL-STD-810F Department of Defense Test Method Standards for Environmental 1 January 2000 Engineering Considerations and Laboratory Tests 3 June 24, 2005 AC 150/5345-10F 2.7 NATIONAL ELECTRIC MANUFACTURERS ASSOCIATION (NEMA). NEMA 250-1997 Enclosures for Electrical Equipment 2.8 INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC). IEC 60529 Degrees of Protection Provided by Enclosures (IP Code) Copies of FAA ACs may be obtained from: Department of Transportation General Services Division M-45 Washington, DC 20590 Phone: (202)267-3115, 3161, and 8329 Website: www.faa.gov/airports_airtraffic/airports/resources/advisory_circulars/ Copies of FAA Standards may be obtained from: Federal Aviation Administration ACM-20 - NAS Documentation Control Center 800 Independence Avenue, SW Washington, DC 20591 Phone: (202) 548-5502 Fax: (202) 548-5501 Website: www.faa.gov/cm/dcc.htm Copies of Codes of Federal Regulations (CFRs) may be obtained free of charge from: Website: www.gpoaccess.gov/cfr/index.html Copies of American National Standards Institute (ANSI) publications may be obtained from: American National Standards Institute W. 42 Street, New York, NY 10036 Phone: (212) 642-4900 and 764-3274 Website: www.ansi.org Copies of military standards and specifications publications may be obtained from: DAPS/DODSSP Building 4, Section D 700 Robins Avenue Philadelphia, PA 19111-5094 Phone: (215)697-2179 Fax: (215)697-1460 4 AC 150/5345-10F June 24, 2005 Website: www.dodssp.daps.mil Copies of NEMA documents may be obtained from: Internet: www.nema.org or: NEMA 1300 North 17th Street Suite 1847 Rosslyn, VA 22209 Phone: (703) 841-3200 Copies of IEC documents may be obtained from: Internet: E-standards store - webstore.ansi.org 5 June 24, 2005 AC 150/5345-10F Intentionally Left Blank 6 AC 150/5345-10F June 24, 2005 CHAPTER 3. EQUIPMENT REQUIREMENTS. 3.1 GENERAL. The equipment requirements are grouped into four categories: environmental, performance, detail, and monitoring requirements. 3.2 ENVIRONMENTAL REQUIREMENTS. The equipment must be designed for continuous operation under the following conditions: a. Temperature range from -40 degrees to 131 degrees Fahrenheit (F) (-40 degrees to 55 degrees Celsius (C). b. For monitoring circuitry, the temperature range is from 32 degrees to 131 degrees F (0 degrees to 55 degrees C). c. Relative humidity range from 10 to 95 percent. d. Altitude range from zero to 6,600 feet above sea level (2,000 meters). 3.3 PERFORMANCE REQUIREMENTS. 3.3.1 Regulation. 3.3.1.1 Resistive Loading. The CCR must maintain the output current per Table 1 while powering any load from short circuit to 100 percent load. a. For all CCRs, regulation must be maintained over the full range of environmental conditions specified in paragraph 3.2 and the input voltage range specified in paragraph 3.3.4. 7 June 24, 2005 AC 150/5345-10F Table 1. CCR Output Current Class Style Step Nominal output amperes (A) root mean square (RMS) Allowable range (A RMS) 3 6.6 6.5 - 6.70 2 5.5 5.4 - 5.6 1 1 1 4.8 4.7- 4.9 5 6.6 6.50 - 6.70 4 5.2 5.1 - 5.3 3 4.1 4.0- 4.2 2 3.4 3.30 3.50 1 2 1 2.8 2.7 2.9 5 20.0 19.7 - 20.30 4 15.8 15.5 - 16.1 3 12.4 12.1 - 12.7 2 10.3 10.0 - 10.6 2 2 1 8.5 8.2 - 8.8 3.3.1.2 Reactive Loading. The CCR output current must be per Table 1 for all current steps when the CCR is connected to series isolation transformers with between 0 and 30 percent of the secondary windings open circuited. 3.3.2 Efficiency. The efficiency of a CCR operated at its rated input voltage with 100 percent load at unity PF must not be less than the values shown in Table 2. Table 2. CCR Efficiency CCR size kilowatts (kW) Minimum overall Efficiency (percent) Less than 30 90 30 92 50 93 70 94 3.3.3 Power Factor. a. The PF for CCRs 10 kW or less, must not be less than 0.90. b. The PF must not be less than 0.95 for CCRs larger than 10 kW. c. The PF must be measured with the equipment operating at: (1) Its maximum intensity setting, (2) Its rated input voltage, 8 AC 150/5345-10F June 24, 2005 (3) Its rated load at unity PF. 3.3.4 Standard Input Voltage. The CCR standard input voltage must be single phase, 60 Hz alternating current (ac). a. All CCRs must operate per paragraph 3.3.1 when the input voltage is from 95 to 110 percent of its nominal value. b. CCRs may be provided with different voltage taps from which the correct supply voltage may be selected. c. The CCR must be designed to withstand momentary increases of voltage up to 120 percent of the nominal input voltage (duration of over-voltage not longer than 50 milliseconds (ms) at no more than once per minute) without shutdown or damage. 3.3.5 Temperature Rise. The temperature rise of the transformer portion of the CCR must not exceed the maximum transformer safe operating temperature and the maximum insulation temperature permitted in the hottest spot of the windings when operated at its maximum operating temperature (131 degrees F or 55 degrees C). Temperature rise measurements are performed at room temperature (77 degrees F or 25 degrees C). 3.3.6 Crest Factor. The crest factor for L-828 and L-829 CCRs must be less than 3.2 with regulator output loading per paragraph 3.3.1. 3.3.7 CCR Control System. a. The control system must stabilize the CCR output current at any selected intensity within 5.0 seconds, and hold the output current stable within ± 0.1A for 6.6A CCRs and ± 0.3 A for 20A CCRs. b. The control system must provide both local and remote control. c. The equipment must function properly when operated by a circuit with a round-trip length of 10,000 feet (3,000 m) using #19 American Wire Gauge (AWG) control cable. d. The operating voltage for the remote control system must not exceed 120 V ac or +48 V dc. 3.3.8 Output Current Surge Limitation. a. The equipment must be designed so that switching the equipment on and off, changing brightness steps, or opening/shorting the output will not produce current surges that will damage the CCR or any equipment connected to its output. b. If a start-up time delay is used, no more than 2.0 seconds must elapse from CCR turn-on to current present at the output terminals. 9 June 24, 2005 AC 150/5345-10F c. The CCR must not generate a transient of over 120 percent of the nominal current for more than 250 milliseconds at any step or setting after the load is switched with a 50 percent resistive component. The preceding must also be true when the load includes an inductive component at a PF of 0.6. 3.3.9 CCR Circuit Isolation. a. The input power circuit must be electrically isolated from the output circuit. b. With open circuit protection disabled, the peak output voltage of an open-circuited CCR must not exceed two times the rated wattage divided by the rated current or 4,250 volts, whichever is greater. 3.3.10 Protective Devices. 3.3.10.1 Open-Circuit Protection. a. The CCR must include an open-circuit protective device to open the primary switch (see paragraph 3.4.1 for primary switch description) within 2.0 seconds after an open circuit is detected in the regulator output circuit. b. The protective device must reset within 2.0 seconds after the CCR control switch is turned off and re-energized. Alternatively, if a reset switch is provided, it may be used to reset the protective device and re-energize the regulator. c. The protective device must not be tripped by load circuit switching or other transients. 3.3.10.2 Over-current Protection. a. CCRs must include an over-current protective device that opens the primary switch when the output current exceeds 100 percent (6.6 or 20 A) by 5 percent. b. The protective device must operate within 5.0 seconds after an over-current of 5 percent and within 1.0 second after an over-current of 25 percent. c. The protective device must reset within 2.0 seconds after the regulator control switch is turned off and re-energized. Alternatively, if a reset switch is provided, it may be used to reset the protective device and re-energize the regulator. d. The over-current protection must not be activated by momentary (0.25 second) over-current events that are caused by load circuit switching or other transients. 3.3.11 Input Power Loss. If there