Instruction Manual

Instruction Manual
AM.07.360e Edition 2.1
Microprocessor controlled
Constant Current Regulator
Type
MCR³ 2.5 kVA to 30 kVA
Record of Change AM07.360e
Revision Description Editor Checked Date

0.0 Initial description DT 07/07/04
1.0 Final description AHU MR, PC 14/04/05
Spare part correction EV 01/03/06
2.0 List of alarms added CME 11/07/06
Spare part correction EV 30/11/06
2.1 Spare part correction Table 5-3: Power components, EV DT 19/06/07

input
Please, read this carefully before installing the MCR³!
Safety Regulatory safety precautions are applicable in some countries, on some

precautions sites; in absence of such legal prescriptions, the operating and maintenance
personnel should refer to the FAA Advisory Circular AC 150/5340-26
"Maintenance of Airport Visual Aid Facilities" for instructions on safety
precautions. Personnel must observe the safety regulations at all times.
While every practicable safety precaution has been incorporated in this
equipment, the following rules must be strictly observed.
Keep away Operating and maintenance personnel must at all time observe all safety
from live regulations. Neither lamps nor components shall be changed or adjustments
circuits shall be made inside equipment with the light circuit energised.
See FAA Advisory Circular AC 150/5340-26 concerning safety precautions.
See also IEC-61820
Resuscitation Operating and maintenance personnel should familiarise and keep

themselves trained in the resuscitation techniques laid down in the First Aid
Instruction Manual.
Electrostatic Modules and components susceptible to electrostatic damage

Discharge
Electronic modules and components should be touched only when this is
ESD unavoidable e.g. soldering, replacement, etc.
Technicians, operators and all other persons working on the equipment must
first of all eliminate electronic charges from their own bodies just before
touching an electronic module or component. The easiest way of discharging
a human 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 fibre clothing, etc.
They must be laid down on conductive surfaces.
The tip of the soldering iron must be earthed.
Electronic modules and components must be stored and transported in
conductive packaging.
2 / 150
Please, read this carefully before installing the MCR³!
Use This Instruction Manual is the property of

restriction
n.v. ADB s.a .
notice
585, Leuvensesteenweg
B-1930 Zaventem - Belgium
Tel 32 2 722 17 11 Fax 32 2 722 17 64
http://www.adb-air.com
This manual or parts thereof may not be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, nor otherwise, without ADB's prior written consent.
Guarantee N.V. ADB S.A. guarantees that the performance of the equipment described
in this manual, when sold by ADB or its licensed representatives, meets the
requirements of FAA specification AC 150/5345-10E and IEC 61822.
Any defect in design, material or workmanship, which may occur during
proper and normal use over a period of one (1) year from date of shipment,
will be repaired or replaced by ADB free of charge, ex works. Operational
failure resulting from lamp burnt out, improper maintenance or installation,
damage due to runway maintenance equipment, snow ploughs or aircraft
arresting gear hooks is not considered a result of proper use and is beyond
the scope of the warranty.
Warranty does not cover natural wear and tear or damage arising after
delivery owing to faulty or negligent handling, excessive strain, unsuitable
materials for operation, deficient civil engineering work, unsuitable soil
conditions, and such chemical, electrochemical or electrical influences as
were not assumed at the time of the conclusion of the contract.
All liability for consequences of any inexpert alterations or repairs carried out
by Purchaser or a third party shall be waived.
N.V. ADB S.A. shall in no event be liable to Purchaser for any further claims,
particularly claims for damages not affecting the goods themselves.
The above constitutes the limits of ADB’s liabilities in connection with the
constant current regulator covered by this manual.
3 / 150
Table of contents
1 Section 1 General Information and Requirements 7

1.1 Introduction 7
1.2 Technical description 8
1.2.1 Technical data 8
1.2.2 Output circuit values 8
1.2.3 Current regulation limits 9
1.2.4 RV-DV terminals and cut-out SCO 9
1.2.5 Door-open detection (optional) 9
1.2.6 Back-indication signals ON and REG. ERR. 10
1.2.7 Power factor and efficiency 11
1.2.8 Lightning protection 12
1.3 Basic configurations 13
1.3.1 General view 13
1.3.2 MCR³ 2.5 to 10 kVA rated 14
1.3.3 MCR³ 15 to 30 kVA rated 16
1.3.4 MCR³ components 18
1.3.5 User Interface 25
1.3.6 User Interface menus 26
1.4 Brightness steps 37
1.5 Monitoring functions 38
1.5.1 List of alarms made available to the ATC Controller / maintenance base 39
1.6 Remote control and back-indication 41
1.6.1 General 41
1.6.2 Straps and dip-switches 42
1.6.3 Interface module connection 42
1.7 Earth Fault Detector module (option) 43
1.8 Lamp Fault Detector module (option) 44
1.9 Cut-out SCO (option) 45
1.10 Circuit Selector (Option) 46
1.11 Hour Counters (Option) 46
1.12 Equipment required for installation, start-up and troubleshooting but not supplied 47
1.13 Equipment supplied 47
1.14 Nameplate 48
2 Section 2 Installation 49
2.1 Introduction 49
2.2 Installation 50
2.3 Electrical connection 52
2.3.1 Series circuit connection 54
2.3.2 Remote control connection 55
2.3.3 Remote control cable 56
2.3.4 Multiwire 58
2.3.5 J-Bus 64
2.3.6 Signals ON & REG.ERR. (PSL/X7) 65
2.4 Starting procedure 66
2.4.1 Tap selection 68
2.4.2 Tap wiring 70
2.5 Component replacement and software uploads 73
2.5.1 Replacement of modules 73
2.5.3 Replacement of the main contactor 75
2.5.4 Upload of application code 76
3 Section 3 Maintenance 78
4 Section 4 Troubleshooting 79
4 / 150
5 Section 5 Parts List 85
6 Section 6 Drawings 91
7 Section 7 PC Control and Monitoring 110

7.1 Program MCR3_WIN 111
7.2 Overview of the screens 113
7.2.1 MCR3 Control 113
7.2.2 MCR3 Setup 114
7.2.3 MCR3 EFD 128
7.2.4 MCR3 LFD 130
7.2.5 MCR3 IO Settings 133
7.2.6 MCR3 Installation Parameters 141
7.2.7 MCR3 Configuration 143
7.2.8. MCR3 Exit Screen 145
8 Section 8 Appendix 146

8.1 MODBUS settings 146
8.2 Default settings multiwire 147
5 / 150
Table of Pictures
Fig. 1-1: Power factor and efficiency for a MCR³ rated 30 kVA ................................................................11
Fig. 1-2: MCR³ stand-alone unit ................................................................................................................13
Fig. 1-3: MCR³ 2.5 to 10 kVA with EFD module, front view - open ...........................................................15
Fig. 1-4: MCR³ 2.5 to 10 kVA, rear view - open ........................................................................................15
Fig. 1-5: MCR³ 15 to 30 kVA with EFD / LFD modules, front view - open ................................................17
Fig. 1-6: MCR³ 15 to 30 kVA, rear view - open .........................................................................................17
Fig. 1-7: Earth Fault Detector module (MCR³ 15 to 30 kVA).....................................................................43
Fig. 1-8: MCR³ Nameplate ( 4072.03.500E)............................................................................................48
Fig. 2-1: Detail of a typical installation .......................................................................................................51
Fig. 2-2: Multiwire Inputs ...........................................................................................................................60
Fig. 2-3: Multiwire Outputs.........................................................................................................................63
Fig. 2-4: J-Bus connector layout JB / P1, P2, P3 and P4..........................................................................64
Fig. 2-5: Connector layout PSL / X7 ..........................................................................................................65
Fig. 2-6: 2.5 kVA power transformer, top view ..........................................................................................70
Fig. 2-7: Tap adjustment MCR³ 4 to 10 kVA .............................................................................................71
Fig. 2-8: Tap adjustment MCR³ 15 to 30 kVA ...........................................................................................71
Fig. 2-9: Tap wiring ....................................................................................................................................72
Table of Tables
Table 1-1: MCR³ output circuit values .........................................................................................................8

Table 2-1: Mains supply cable sections, fuses… ......................................................................................53
Table 2-2: Maximum voltages (V RMS) for each tap setting, each power and output current .................68
Table 3-1: Preventive maintenance...........................................................................................................78
Table 4-1: The regulator does not turn on.................................................................................................81
Table 4-2: The regulator turns on but de-energises suddenly. .................................................................82
Table 4-3: The regulator does not produce the requested output current. ...............................................83
Table 4-4: Overview of the fuses...............................................................................................................84
Table 5-1: Basic printed circuit boards ......................................................................................................85
Table 5-2: Optional printed circuit boards .................................................................................................86
Table 5-3: Power components, input.........................................................................................................86
Table 5-4: Hardware parts.........................................................................................................................90
Table 5-5: Connectors ...............................................................................................................................90
6 / 150
1 Section 1
General Information and Requirements

1.1 Introduction
The MCR³ The ADB MCR³ is a microprocessor-controlled constant current regulator

specially designed for the supply of airport lighting series loops at various
intensity levels.
Purpose This instruction manual provides general information about installation,

operation, troubleshooting and maintenance. It also contains a parts list.
Scope This manual covers the ADB MCR³ microprocessor-controlled constant

current regulator manufactured in full compliance with:
ICAO: Aerodrome Design Manual, Part 5 paragraphs 3.2.1.4/5/6
FAA : AC 150/5345-10F and L829
IEC: IEC 61822.
Operation The constant current regulators are designed for use in airport series lighting
limits circuits.
They are designed to meet the requirements of the various specifications
mentioned above.
Operation outside the design limitations of these specifications may result in
degradation of performance, damage or failure of regulator components or
hazardous conditions.
All regulators are designed for indoor operation, at an ambient temperature
from -20°C (-40°C on special request) up to +55°C.
(Note: IEC requires only a range from 0°C to +50°C)
All MCR regulators are air-cooled without fans.
Using the regulator at ambient temperatures outside of the specified range
could cause damage. Good ventilation must be provided especially when
operation near the maximum temperature limit is expected.
EMC - The MCR³ is designed to operate in an industrial electro-magnetic

conformity environment, as required by IEC 61822, in accordance with IEC 61000-6-4
and IEC 61000-6-2 (generic standard for industrial environment) with
adapted test levels in accordance with IEC/TS61000-6-5, G (substation
environment, location G).
Accordingly, the MCR³ regulator must not be used in residential, commercial
and light-industrial environment or in harsher environments than substation
environment, location G.
7 / 150
1.2 Technical description
1.2.1 Technical data
Rated powers 2.5/ 4/ 5/ 7.5/ 10/ 15/ 20/ 25/ 30 kVA

Rated input voltages FAA: 220/ 230/ 240/ 380/ 400/ 415 V (±15 %) (*)
IEC: 230/ 400 V (±15 %) (*)
Rated frequencies 50/ 60 Hz (± 7.5 %)
Series circuit current Standard 6.6 A; also 20 A for 25 and 30 kVA.
Remote control and Multiwire, industrial field bus (J-Bus) or combined
monitoring
* 25 and 30 kVA, only for 380/ 400/ 415 V
1.2.2 Output circuit values
Table 1-1 Table 1-1: MCR³ output circuit values
Rated Output Max. RMS Dielectric test on Max. open circuit Max. open circuit
powers current output output circuit - V - RMS output peak voltage (3)
(A) voltage (1) volt.(2)
2.5 kVA 6.6 378 1895 530 750

4 kVA 6.6 606 3030 850 1200
5 kVA 6.6 757 3790 1060 1500
7.5 kVA 6.6 1136 5680 1590 2250
10 kVA 6.6 1515 7575 2120 3000
15 kVA 6.6 2272 11360 3180 4490
20 kVA 6.6 3030 15150 4240 5990
25 kVA 6.6 3788 18940 5300 7490
30 kVA 6.6 4545 22730 6360 8990
25 kVA 20 1250 6250 1750 2470
30 kVA 20 1500 7500 2100 2970
1 50 Hz RMS voltage during 1 min

2 Under worst condition, considered 1.4 times max. RMS output voltage
3 Same conditions as above
8 / 150
1.2.3 Current regulation limits
Limits The current regulation is guaranteed within the limits of ± 1.5 %, under the
following conditions.
Conditions From short circuit to full load

For nominal input voltage ± 10 % (IEC) or +10 %/-5 % (FAA)
For ambient temperatures from -20° - +55°C
For an altitude range from 0 (sea level) to 1000 metres
For a relative humidity range of 10 % RH to 95 % RH without dewing
Up to at least 30 % of lamps transformers with an open circuit in their
secondary side, for a load ranging from at least half-load to full-load
Limitations Operation from -5 % to -15 % (FAA) or from -10 % to -20 % (IEC) 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 a
maximum period of 1 hour to avoid overheating or overstressing of the
components.
Readjustment Although the nominal input voltage is factory-wired, some readjustments are
possible in the ranges 220 - 240 V and 380 - 415 (420 V): consult factory.
1.2.4 RV-DV terminals and cut-out SCO
RV-DV The interlocking of the SCO (optional) cut-out microswitch and the MCR³ RV-
DV terminals allows to energise the regulator after the cut-out contacts are
engaged and to de-energise the regulator before the cut-out contacts are
totally opened.
Interrupting the RV-DV link results in removing the power supply to the logic
circuitry and main contactor coil, thus an almost immediate and safe
interruption of the regulator.
1.2.5 Door-open detection (optional)
LMC / CO12 A door switch (with normally open contact) connecting CO12/1 and 3 (2 and
3 are interconnected on the board) will be detected by the logic.
9 / 150
1.2.6 Back-indication signals ON and REG. ERR.
ON & The back-indication signals ON and REG.ERR. are controlled directly by the
REG. ERR. current control logic CCL and are available on connector PSL/X7.
This 4-terminal spring cage clamp terminal has the following layout:
terminal 1: ON
terminal 2: COMMON (for contacts to terminal 1, 3 and 4)
terminal 3: REG.ERR./NC (normally closed contact)
terminal 4: REG.ERR./NO (normally open contact)
The signal ON corresponds to the control of the main contactor K1.
The signal REG.ERR. (Regulation Error) will be in rest position in case of
current deviation (open circuit, overcurrent, overload, current deviation, etc.)
or in case of loss of input power (power switched off, input voltage too low,
etc.).
10 / 150
1.2.7 Power factor and efficiency
Power Factor According to FAA:

At nominal input power, nominal resistive load and maximum brightness:
• powers up to 10 kVA: 0.90
powers above 10 kVA: 0.95
According to IEC:
At nominal input power, nominal resistive load and maximum brightness: not
less than 0.90
Efficiency According to FAA:

At nominal input voltage and resistive load and max. brightness: 90 to 92 %.
According to IEC:
At nominal input voltage and resistive load and all brightness steps the
average efficiency: not less than 80 %.
Taps By means of output taps on the secondary (high-voltage) side of the power
transformer (PT) the power factor can be optimised in relation to the actual
load at full brightness. The following taps are provided:
• actual load between 100 % and 82 % of nominal (8/8)
• actual load between 81 % and 71 % of nominal (7/8) (*)
• actual load between 45 % and 33 % of nominal (4/8)
actual load between 21 % and 0 % of nominal (2/8) (*)
* : not on MCR³ 2.5 kVA
Benefits of The use of the taps offers the following advantages:

Taps • the power factor will be optimised
• 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 case of open-circuit will be reduced
• the maximum possible output current in case of catastrophic thyristor failure
(short circuit) will be limited
• the power losses will decrease
Example Taps
2/8 3/8 4/8 6/8 7/8 8/8
100 % Efficiency
90
80 Power Factor
70
60
50
40
Load
12 25 37 50 75 87 100 %
Fig. 1-1: Power factor and efficiency for a MCR³ rated 30 kVA
11 / 150
1.2.8 Lightning protection
General Lightning is a natural phenomenon that varies in intensity and frequency

depending on the geographic location.
Therefore the need for additional lightning protection on an installation has to
be examined.
Output The lightning arrestors LA1 and LA2 (fig.1-3 and 1-5) on the output terminals
voltage surge of the series circuit protect the output of the MCR³.
protection
Input voltage Optional lightning arrestors can be installed at the power supply input of the
surge MCR³.
protection
12 / 150
1.3 Basic configurations
1.3.1 General view
Description Each stand-alone MCR³ will accept, in one enclosure, a power rack fitted
with the logic boards, the user interface, a fused input switch (in the low-
voltage unit), and the high-voltage components (in the high-voltage unit). The
stand-alone regulators have optional rolling castors. The bolts to fix the top
plate can be replaced by standard lifting lugs.
Picture Fig. 1-2: MCR³ stand-alone unit
Part Function
1 Low-voltage compartment
2 High-voltage compartment
3 Fused input switch
4 User interface
5 SCO (optional)
13 / 150
1.3.2 MCR³ 2.5 to 10 kVA rated
Dimensions 400 x 600 x 930 mm (width x depth x height)

With wheels: height + 100 mm
With lifting lugs: height + 50 mm
With Circuit Selector: height + 500 mm
With bolts M12: height +15 mm
Technical data
Rated powers 2.5 / 4 / 5 / 7.5 / 10 kVA
Rated input voltages 220 / 230 / 240 / 380 / 400 / 415 V (±15 %)
Rated frequencies 50/ 60 Hz (± 7.5 %)
Series circuit current 6.6 A
Remote control and Multiwire, industrial field bus (J-Bus) or
monitoring combined
14 / 150
Pictures Fig. 1-3: MCR³ 2.5 to 10 kVA with EFD module, front view - open
User Interface
Fused input switch
Electronic card cage and mains supply

terminals behind UI panel
Nameplate
Earth Fault Detector module (EFD option)
Output current transformers TI 1 and TI 2
Lightning arrestors LA1 – LA 2
Choke L1
Fig. 1-4: MCR³ 2.5 to 10 kVA, rear view - open
Remote control interface

boards (MW and J-Bus)
Remote control cable, earth

connection of cable screens
Output transformer
Ground studs M6, one on each side

of the regulator
15 / 150
1.3.3 MCR³ 15 to 30 kVA rated
Dimensions 600 x 600 x 1260 mm (width x depth x height)

With wheels: height + 100 mm
With lifting lugs: height + 50 mm
With Circuit Selector: height + 500 mm
With bolts M12: height +15 mm
Technical data
Rated powers 15 / 20 / 25 / 30 kVA.
Rated input voltages 220 / 230 / 240 / 380 / 400 / 415 V (±15 %) (*)
Rated frequencies 50 / 60 Hz (± 5 %).
Series circuit current Standard 6.6 A; also 20 A for 25 and 30 kVA.
Remote control and Multiwire, industrial field bus (J-Bus) or combined
monitoring
* 25 and 30 kVA, only with 380 / 400 / 415 V
16 / 150
Pictures Fig. 1-5: MCR³ 15 to 30 kVA with EFD / LFD modules, front view - open
Nameplate
Earth Fault Detector module

(EFD option)
Output current
transformers TI1 and TI2
Tap S6 through S1 for

adjustment to actual load
Lightning arrestors
LA1 - LA2
SCO (optional)
Fig. 1-6: MCR³ 15 to 30 kVA, rear view - open
Remote control interface

boards (MW and J-Bus)
Remote control cable, earth

connection of cable screen
Output transformer
Ground studs M6
17 / 150
1.3.4 MCR³ components
Diagram Refer to ADB drawing 3229.13.240BA.
Components 1.a X1 - Input terminals

description – Accessible behind the User Interface panel.
Power input The size of the input terminals depends on the input current rating.
Up to 50 A: 16 mm²
Up to 100 A: 35 mm²
Above 100 A: 70 mm²
1.b Wire A02 - Common mode choke

The wires between X1 and F1 are passing through a ferrite core to block the
high frequency common mode currents from the power circuitry.
1.c F1 – Fused main switch
Accessible at the front of the regulator.
Permits to disconnect the regulator from the mains supply.
Fuse value depends on output power and input voltage range of regulator.
Depending on the current range there are two types of fused main switch.
Fuse links in the small cabinet (up to 63 A) are type Neozed DO2 (gL/gG –
slow-blow).
In the big cabinet, from 50 A to 125 A the fuse links are type NH00 (gL/gG –
slow-blow), knife-blade fuses.
1.d F2 - To the F1 fuses switch disconnectors (F2/1 & F2/2) are
connected to protect the low current mains connected wiring.
Note: The fuses F3/1 & F3/2 serve to protect the wiring to measure the
primary voltage of the power transformer.
In case of the Circuit Selector an additional switch disconnector (F4/1 &
F4/2) is added to protect the mains wiring of the Circuit Selector (see 24.
CS/F4).
2. MOV1/A & MOV1/B - (optional) Lightning arrestors (power input)
These lightning arrestors are equipped with a contact to signal if a lightning
arrestor is missing or defective. a local indication “DEFECT” (in small window
on the lightning arrestor) is given if the lightning arrestor is broken.
The lightning protection limits the voltage towards ground. (The voltage
between supply lines is limited to twice the voltage towards ground.)
3. K1 - Input main contactor
Capable of interrupting the maximum input current and provide positive
interruption of the input power circuitry on both supply lines. The contactor
coil is equipped with a transient voltage suppressor network (resistor-
capacitor network).
4. TI 1 - Primary current measurement
By means of a small current transformer providing adequate isolation and
permitting precision measurement of the input current.
18 / 150
Components 5. THP 1 - Series thyristors
description – To obtain the required output current by phase control (closed loop
Power input regulation system).
6. L1 - Series choke
To limit the current rise time for thyristors, output transformer and current
loop. This choke is mounted close to the output power transformer T1.
This choke also limits the harmonics on the current waveform.
7. THP 2 - (optional) Crowbar thyristors
To protect the output circuit from large overloads. Thyristors parallel to load
to derive excessive overcurrents away from load.
This circuit has a small series choke to limit the half cycle short circuit current
below the maximum rated current for the thyristors.
Components 8. T1 - Output power transformer

description – Equipped with primary taps to adapt for a typical input voltage of:
Power output , 220, 240, 380, 400 or 416 V – 50 or 60 Hz.
The secondary taps permit to adapt the load with the following steps:
8/8, 7/8, 6/8, 4/8 or 2/8 (thus 100 %, 87.5 %, 75 %, 50 % or 25 %).
The transformers are designed for 6.6 or 20 A current circuits.
Note: The power transformer for the 2.5 kVA CCR has only secondary taps
for 100 % and 50 %.
The power transformers for the 25 and 30 kVA CCR are limited to the
primary taps: 380, 400 or 416 V – 50 / 60 Hz.
Only for the 25 and 30 kVA CCR, the 6.6 or 20 A versions of the power
transformer are available as standard versions.
9. TI2 - Output current measurement (value)
By means of a small current transformer providing adequate isolation and
permitting precision measurement of the output current.
Two ways of wiring are possible depending on the maximum output current
value: 6.6 A or 20 A.
10. TI3 – (optional) Output current measurement (waveform)
By means of the same small current transformer as described for point 9.
11. MOV2/A & MOV2/B - Lightning arrestors
The lightning arrestor size depends on the output power range of the
regulator.
12. X2 - Output terminals
For output circuit voltages below 1515 V, the output circuit is connected to
screw terminals. (e.g. for regulators up to 10 kVA/ 6.6 A, but also for
regulators 25 and 30 kVA / 20 A).
For output circuit voltages above 1515 V, the series circuit is connected
directly to the lightning arrestors.
In case of the optional SCO the output terminals are replaced by this SCO.
19 / 150
Components 13. PCB1517 - Thyristor Block Module (TBM)
description - This is the interface between the Current Control Logic and the thyristor
Logic gates. It produces the thyristor gate firing signals in accordance with the
requested conduction angle. It provides also fast over-current protection
(reaction in less than half a period for excessive output current peak value or
if the output current reaches more than 125 % of the nominal maximum
value) and asymmetric output voltage monitoring.
Furthermore this board is capable of producing gate-triggering signals for the
crowbar that can prevent over-currents that are due to excessive load
switching from flowing through the load.
14. PCB1521 - Power supply of the logic (PSL)
This power supply is designed to deliver +12 / +5 / -12 V to the boards. It will
be fully operational after only 20 ms and will be capable to keep the +5 V
present for at least one half second to permit fast response of the regulator in
case of short power interruptions. In case the power supply to this board is
interrupted its signal “Power Good” will go low in less than 20 ms leaving
sufficient time to the CCL to prepare a fast restart without loosing control
data. This board provides also, through an autotransformer (100 VA),
230 V AC for the internal 230 V AC components of the regulator. The input
lines have supplementary filtering to reduce the conducted emission of the
regulator.
On this board the logic signals from the Current Control Logic (CCL) are
converted to 230 V AC-control signals.
Furthermore it interfaces several components (current transformer, main
contactor, SCO) with the logic boards of the regulator (low-voltage signals).
15. PCB1516 - Current Control Logic (CCL)
The brightness step request received by the Current Control Logic and the
actual output current are compared and result in the optimal conduction
angle request.
The CCL checks the output current to be in tolerance, checks for over-
current or open- circuit condition and produces the back-indication signals.
Furthermore the CCL also monitors the output circuit and the input
parameters (current and voltage values).
16. PCB1513 - Local Master (LMC)
The Local Master exchanges information via the Local Bus with all the other
modules. This board processes and distributes the messages it receives
from the outer world or from the boards it is connected to.
The LMC is master of the communication on the Local Bus but each slave
has a control line to request transmission of data to the LMC.
One important feature of the Local Bus is the possibility to upgrade the
software of any module.
17. PCB1507 - User Interface (UI)
Through the User Interface it is possible to operate the regulator and to
change parameters in local mode. The User Interface indicates the actual
measurements of output current and the status of the circuit (input current,
power, voltage, output load, output voltage, circuit insulation resistance and
all possible warnings) through selectable screens on the display.
20 / 150
Components 18. PCB1486 - (optional) Multiwire Boards (MW1, MW2 and MW3)
description – The multiwire interface is a straightforward, non-intelligent device with 8 input
Remote and 8 output terminals.
control For a regulator without Circuit Selector, only MW1 and MW2 are used.
interfacing The board provides a simple remote control interface through relays giving
total galvanic isolation between the remote control system and the constant
current regulator.
The multiwire interface is connected to the LMC by a flat cable.
Its presence is detected automatically on connection to the LMC.
In case the internal power supply is not used (external remote control power
supply is available) there is no need to connect this PCB to the mains supply.
Alternatively, the customer can use the internal power supply. This supply is
short-circuit protected by self-repairing polyswitches. Both the positive and
the negative pole of this supply can be used for the common pole.
The multiwire interface exists in 2 versions: 24 V DC or 48 V DC control
signals.
For the control signals any polarity is allowed. Suppression of switching
transients of the coils is done with resistor-capacitor networks.
The back-indication signals are given with simple, potential-free, contacts.
19. PCB1502 - (optional) J-Bus Interface (JB)
This interface board is mounted close to and connected by means of a flat
cable to the LMC. The PCB is equipped with gas arrestors for overvoltage
protection of the external lines. For ease of wiring, there are 4 connectors, 2
for Bus A (standard bus) and 2 for Bus B (redundant bus), permitting one
connector for the cable to the preceding bus user and one connector for the
cable to the next slave on the bus.
For the end units on the bus, the line has to be terminated by means of
resistors (strap connectable to the LMC) to match the load closely to the
characteristic line impedance. This way we obtain a reflection-free, less
disturbance-sensitive communication bus.
The J-Bus interface board is click-mounted in the regulator enclosure. By
disconnecting the flat cable to the LMC and lifting the interface board out of
the regulator it permits to remove the regulator without interrupting the daisy
chain J-Bus connection link of the substation.
21 / 150
Components 20. PCB1519 - (optional) Lamp Fault Detector (LFD)
description – The Lamp Fault Detector checks the load of the circuit. If a pre-settable
Output circuit number of lamp transformers is unloaded (lamp filament interruption) or if a
monitoring load falls below a pre-set level a warning signal is generated.
items Furthermore this module monitors output current, output voltage and output
power independently of the CCL.
21. PCB1514 + PCB1515 - (optional) Earth Fault Detector (EFD)
The Earth Fault Detector checks the insulation of the series circuit towards
ground. If the insulation drops below a pre-settable level, a warning signal is
generated.
The measured insulation value is also available for direct display on the UI
and on the bus.
This board is located in the high-voltage compartment close to the output
terminals.
The measurement range goes from about 10 kOhm TO 250 MOhm.
Components 22. Dongle (optional maintenance part)

description – To change the operational parameters, to check the internal parameters or to
Dongle / update the software of the equipment by means of a personal computer and
Golden Key the dedicated parameterisation software (running under Microsoft Windows).
This item is not part of the regulator. It is a tool for maintenance personnel
and can also be used to configure other ADB equipment.
22 / 150
Components 23. PCB1523 - (optional) Circuit Selector Interface
description – This board is not part of the constant current regulator. It is located in the
Circuit Circuit Selector cabinet. The board converts the logic control signals (12 V
Selector DC) from the Current Control Logic board to coil control voltages.
In case of remote control by multiwire signals the multiwire board MW3
serves as the remote control and back-indication interface for the circuit
selection.
24. CS/F4 – (optional) Fuses to protect the power supply to the auxiliary
transformer
These fuses are located close to the main fuse F1 and are accessible after
removing the User Interface panel.
25. CS/T1 - (optional) Circuit Selector, auxiliary transformer
The coil voltage of the HV contactors is standardized to 230V 50/60Hz. This
autotransformer (250 VA) serves to adapt the MCR³ mains voltage level to
this voltage.
26. CS/K1…K8 - (optional) Circuit Selector contactors
Depending on the cabinet size there are 2 types of high-voltage contactors.
The number of contactors depends on the number of circuits (2 to 8).
The Circuit Selector can be configured (CCL) to permit any circuit to be
selected (simultaneous mode) or only one circuit at the same time (alternate
mode).
For the large cabinet (above 10 kVA) the HV-circuit connection happens
directly to the HV contactor terminals.
In case of more than 4 circuits for the large cabinet, these circuits are to be
connected at the rear of the cabinet.
For the small cabinet (up to 10 kVA) there are separate connection terminals
for the circuit connection.
23 / 150
Concept To obtain ease of manufacturing, maintenance and testing, the complete
power range from 2.5 to 30 kVA is based on 3 standardized groups of
primary power circuit wirings, one for a maximum input current rating of
50 A RMS, another for 63 A RMS and the last one for 125 A RMS. Each
group uses the same (or comparable) components, wire cross-sections and
wiring layout.
Type and size of components 1, 3, 4, 5 and 7 depend on these three current
ratings.
Components 6, 8, 11 and 12 depend on the power rating of the regulator.
Components 2, 9, 10, 13, 14, 15, 16, 17, 18, 19, 20 and 21 are common for
all power ratings.
Component 22 is not part of the product but permits to connect a personal
computer to any regulator and to change the operational parameters, to
check the internal parameters or to update the software of the equipment by
means of the dedicated parameterisation software
Components 23, 24 and 25 are for the optional Circuit Selector and are
independent of the output power.
Components 26 are the HV contactors for the Circuit Selector. The contactor
type depends on the enclosure size.
There are two enclosure sizes (ADB designed, metal sheet parts, welded
together) depending on the output power:
Regulators 2.5 - 10 kVA have a housing with a footprint of 400x600 mm.
Regulators 12.5 - 30 kVA have a housing with a footprint of 600x600 mm.
The enclosure is subdivided in a high-voltage compartment containing
components 6, 8, 9, 10, 11, 12 and 21 and a low-voltage compartment
containing the rest.
At the front of the low-voltage compartment are the power supply input
connections and at the rear side the control cable connections. At the left
side, on the outside of the cabinet, the heatsink for the thyristors is mounted.
The User Interface is located at the front side. The low-voltage compartment
contains internally no high power dissipating components.
The output circuit is connected to the output terminals (or the SCO) on the
front side at the bottom of the high-voltage compartment.
The air inlet of the high-voltage compartment is on the front bottom side
while the hot air exhaust is on the top rear side. The ventilation of this
compartment is assured by with non-forced air-cooling.
For the MCR³ 2.5 to 10 kVA, it is possible to mount one regulator on top of
another in this case wheels are NOT allowed.
Additionally the MCR³ can be equipped with a Circuit Selector (CSM)
mounted on top or underneath the regulator and containing components 23
to 26. The CSM has to be considered as an extension of the MCR³. The
control signals from the CCL to the CSM and and the back-indications from
the CSM to the CCL go through the 26-wire flat cable.
24 / 150
1.3.5 User Interface
General The user interface consists of a 4-line, 40-character display (LCD) and 4
pushbuttons.
The current function of the button is always displayed on the last line of the
LCD just above the pushbutton.
The other lines of the LCD are used to display the regulator data.
For the start menu,
• the 1st and 2nd button permit to switch between local or remote control,
• the 4th button has the function to reset an error condition
• and the 3rd button permits to switch to the next menu.
In this menu, pushing the 1st and 2nd button results in a current step change if
the regulator is operated in local (function STP DOWN and STP UP).
The 3rd and 4th buttons now serve to navigate throught the menus.
The back-lighting is activated on pushing the 1st, 2nd or 3rd button.
To obtain permanent back-lighting of the display: adjust the Display time out
to above 124.5 s. The display will indicate “LOCK” and the back-lighting of
the display will be permanently on. If the back lighting is "on" all the time,
the power supply will not be able to handle short power supply interruptions
>0.5 seconds. Therefore we recommend NOT leaving the backlighting on.
Note that parameter changing is only possible in local control.
Picture User Interface
25 / 150
1.3.6 User Interface menus
START MENU Note: The User Interface will only be operational after the message:
Please WAIT...
has disappeared (in the first line).
This menu displays in the first line the regulator name (maximum 20
characters) and control mode of the regulator: Local, Remote or GK active.
The second line displays the actual output current, actual circuit selection
and indicates if there are any errors (“No errors” or “Errors !”).
The third line displays the actual Step and EFD measurement (if present).
The fourth line indicates the functions for the pushbuttons:
REMOTE LOCAL MENU RESET
Pushbutton Function
REMOTE To switch between remote and local control
LOCAL
MENU To gain access to the other menus
RESET To clear fatal error conditions (overcurrent, open circuit, overload)
Pushing MENU leads you to the second main menu where the pushbuttons
have the following functions:
STP DOWN STP UP MENU BACK
Pushbutton Function
STP DOWN To change the brightness step while the regulator is in Local control
STP UP
MENU To gain access to the other menus
BACK To return to the start menu
Pushing MENU results in a changed functionality for the pushbuttons:

DOWN UP START BACK
Pushbutton Function
DOWN To scroll through the start menu line per line and display:
- input voltage and LFD measurement (if LFD present)
UP - output voltage, output loading
- input current
START To gain access to the other submenus
BACK To return to the previous pushbutton menu
Pushing START results in entering a list of submenus with the following

functionality for the pushbuttons:
DOWN UP SELECT BACK
Pushbutton Function
DOWN To scroll through the list of submenus. The asterisk (as first character of the
UP line) indicates the selected item.
SELECT To gain access to the selected submenu
26 / 150
First level submenus are:
MCR3: Control (1.3.6.1)
MCR3: View errors (1.3.6.2)
MCR3: Setup (1.3.6.3)
CSM: Circuit Selector (1.3.6.4)
EFD: Earth Fault Detector (1.3.6.5)
LFD: Lamp Fault Detector (1.3.6.6)
LFD: LFD Calibration (1.3.6.7)
Hour Counters (1.3.6.8)
Display (1.3.6.9)
Each submenu permits again to select lower level submenus down to the
level where the required parameter is displayed.
1.3.6.1 The first submenu is MCR3: Control
* MCR3 Master: Local

Step: OFF
Circuit 1: OFF
Circuit 2: OFF
Circuit 3: OFF
Circuit 4: OFF
Circuit 5: OFF
Circuit 6: OFF
Circuit 7: OFF
Circuit 8: OFF
DOWN UP SELECT BACK
The asterisk indicates the item for which a submenu can be entered by
pushing SELECT..
Pushbutton Function
DOWN To scroll through the list of items to select a further submenu
UP
SELECT To gain access to the selected submenu
Selecting the item MCR3 Master in the displayed list leads to a submenu
where it is possible to toggle between Remote and Local control:
TOGGLE TOGGLE ACCEPT ABORT
Pushbutton Function
TOGGLE To toggle between Local and Remote control
TOGGLE
SELECT To confirm the selection
27 / 150
Selecting item STEP in this list permits to change the step in LOCAL control:
DOWN UP ACCEPT ABORT
Pushbutton Function
DOWN To change the step in local control
UP
ACCEPT To confirm the selection
ABORT To reject the selection
Selecting a Circuit x is only possible in local control if:

• the Circuit Selector is present (hardware detection by logic of CCL)
• and circuit x is enabled (see paragraph 1.3.6.4)
TOGGLE TOGGLE ACCEPT ABORT
1.3.6.2 The second submenu is MCR3: View errors
(Note that the START MENU displays if there are any errors.)
The LCD displays now all the errors having occurred (if there are any) since
the regulator was powered up. The pushbutton functions are:
DOWN UP DELETE BACK

Pushbutton Function
DOWN To scroll through this list
UP
DELETE To clear this list
Note the following messages are possible
Faults Alarm Status
MCR³ Faults
Overcurrent E
Crest factor W
Zero crossing detection W
Open circuit E
Measurement connector disconnected W
Output current deviates W
Overload W
Output current unstable W
Asymetric output current W
Door open E
MOV blown W
AGL disconnected W
Thermal sensor missing W
28 / 150
Mains voltage low W
Mains voltage high W
Mains voltage unstable W
Power loss imminent W
Mains frequency out of range W
CSM disconnected W
CCL calibration error W
CSM error E
EFD Faults
EFD level 1 reached E
EFD calibration is running W
EFD is OFF because MCR³ is OFF W
LFD Faults
LFD level 1 reached E
LFD VA drop level 1 reached E
LFD is calibrating W
REFERENCE calibration not done W
LAMPS REMOVED calibration not done W
W
HOUR COUNTERS faults
Limit exceeded for any current hours couter W
Limit exceeded for threshold hours counter W
Limit exceeded for CSM circuit 1…8 hours counter W
JBUS Faults
BUS A is DOWN E
BUS B is DOWN E
CSM error E
EFD Faults
E= ERROR
W=WARNING
1.3.6.3 The third submenu is MCR3: Setup
29 / 150
With the following submenus: Output current (1.3.6.3.1)
Step data (1.3.6.3.2)
Default mode (1.3.6.3.3)
Supply voltage (1.3.6.3.4)
MCR3 IO (1.3.6.3.5)
Versions (1.3.6.3.6)
Serial Numbers (1.3.6.3.7)
1.3.6.3.1 Output current

Parameters Range Adjustmen Pushbutton menu
t
Nominal output current 6.6 or 8.3 or 12 or 20 Value DOWN UP ACCEPT ABORT
A
Overcurrent level 1 2.0 - 7.5 % 0.1 % DOWN UP ACCEPT ABORT
Overcurrent delay 1 1.0 - 12.0 s 0.1 s DOWN UP ACCEPT ABORT
Overcurrent level 2 4.5 - 25 % 0.1 % DOWN UP ACCEPT ABORT
Overcurrent delay 2 0.0 - 10.0 s 0.1 s DOWN UP ACCEPT ABORT
Step settling speed 0.0 - 2.5 s 0.1 s DOWN UP ACCEPT ABORT
Regulation error value 1.5 – 25% 0.1 % DOWN UP ACCEPT ABORT
Regulation error delay 1.0 - 12 s 0.1 s DOWN UP ACCEPT ABORT
Switch ON delay 0.0 - 1.0 s 0.1 s DOWN UP ACCEPT ABORT
Switch OFF if overload NO / YES Toggle TOGGLE TOGGLE ACCEPT ABORT
Shut-down current 0.00 - 2.40A 0.01 A DOWN UP ACCEPT ABORT
value
Remote reset allowed YES / NO Toggle TOGGLE TOGGLE ACCEPT ABORT
MCR in stopbar mode NORMAL/STOPBAR Toggle TOGGLE TOGGLE ACCEPT ABORT
Note that access to the parameter nominal output current results in the
message:
* Critical parameter
Hit BACK to abort
Hit CONTINUE to proceed
CONTINUE BACK
Because this value changes the regulated output current, the operator is
requested to confirm access to the parameter setting menu.
1.3.6.3.2 Step data

Parameters Range Adj. Pushbutton menu
Number of steps 3 or 4 or 5 or 6 or 7 or 8 Value DOWN UP ACCEPT ABORT
Step 1: 1.8 up to value of next step 0.01 A DOWN UP ACCEPT ABORT
Step 2: Value step 1 up to next step 0.01 A DOWN UP ACCEPT ABORT
Step 8: Value step 7 up to max. value 0.01 A DOWN UP ACCEPT ABORT
Note that a difference of at least 0.1 A is required between two steps for a
6.6 A regulator (0.3 A for a 20 A regulator).
30 / 150
1.3.6.3.3 Default mode
Default mode Use default / Use actual Toggle TOGGLE TOGGLE ACCEPT
ABORT
Default time 3 - 240 s 1s DOWN UP ACCEPT ABORT
Default step OFF,1 ,2 ,3 ,4 ,5 ,6 ,7 or 8 Value DOWN UP ACCEPT ABORT
Default CSM Each circuit: select Value DOWN UP ACCEPT ABORT
and then toggle ON/OFF ON/OFF TOGGLE TOGGLE ACCEPT
ABORT
Note that default selections are only possible with Default mode activated.
Note that disabled circuits cannot be toggled.
1.3.6.3.4 Supply voltage

Nominal supply 220, 230, 240, 380, 400 or Value DOWN UP ACCEPT ABORT
voltage 415 V
Mains frequency 50 or 60 Hz (measured) - DOWN UP ACCEPT ABORT
Fuse range 63 or 125 Toggle DOWN UP ACCEPT ABORT
Mains switch 70 - 80 % 1% DOWN UP ACCEPT ABORT
OFF level
Mains switch 80 - 90 % 1% DOWN UP ACCEPT ABORT
ON level
Mains warning level 110 - 130 % 1% DOWN UP ACCEPT ABORT
Note that access to the parameter nominal supply voltage results in the
message:
Hit BACK to abort
CONTINUE BACK
Note that the mains frequency is a parameter that cannot be adjusted.
The regulator is capable of operating at 50 or 60 Hz. The displayed value is a
result of a measurement by the TBM.
31 / 150
1.3.6.3.5 MCR3 IO
Parameters Display How obtained Pushbutton menu
Multiwire 1 Present / Missing Detection DOWN UP SELECT BACK
Bus A Present / Missing System conf. DOWN UP SELECT BACK
Bus B Present / Missing System conf. DOWN UP SELECT BACK

Arbiter MW only, Disabled… Value DOWN UP ACCEPT ABORT
Local Kill OFF/ON Toggle TOGGLE TOGGLE ACCEPT
ABORT
Temperature limit 40 TO 70°C 1 °C DOWN UP ACCEPT ABORT
Mains protection Present / Missing Toggle TOGGLE TOGGLE ACCEPT
ABORT
Door Open Present / Missing Toggle TOGGLE TOGGLE ACCEPT
ABORT
Note • If multiwire is present, pushing SELECT leads to the following submenus:

o Multiwire input functions: permits to display the control signal function
for each input
o Multiwire output functions: permits to display the back-indication
function for each output
• If Bus is present, pushing SELECT leads to the following submenus:

o Slave number: this message (only displayed for Bus A) indicates the
address of the regulator on the J-Bus (selected on LMC by means of
dip-switches).
o Bus x baudrate: permits to change the baudrate: 9600, 19200 or
38400 Baud.
o Bus x parity: permits selection of EVEN, ODD or NONE.
• Arbiter: determines the remote control signal source and, if required,

governs the priority for different systems. Depending on the factory
configuration following selections are possible:
o Disabled
o MW only
o A only
o B only
o A then B
o B then A
o MW ctrl, A mon
o MW ctrl, B mon
o A then MW
o B then MW
• Multiwire 3 is reserved for Circuit Selector functionality.
• J-Bus baudrate and parity settings for channels A and B are independent.
32 / 150
1.3.6.3.6 Versions
Parameters Display Pushbutton menu
UI version DOWN UP BACK
LMC version Display of currently used software version DOWN UP BACK
EFD version and boot version of the microcontroller DOWN UP BACK
LFD version DOWN UP BACK
CCL version DOWN UP BACK
TBM version DOWN UP BACK
Note The currently active software version is useful information for maintenance and
troubleshooting. In case a module is not detected by the Local Bus the software
version is represented as “ -.--".
1.3.6.3.7 Serial Numbers

Parameters Display Pushbutton menu
UI version DOWN UP BACK
LMC version Display of serial number of module DOWN UP BACK
EFD version and type identification of microcontroller DOWN UP BACK
LFD version DOWN UP BACK
CCL version DOWN UP BACK
TBM version DOWN UP BACK
Note The serial number of the module is useful information for the traceability of the modules.
In case a module is not detected by the Local Bus the serial number is represented as “
-.--".
1.3.6.4 The fourth submenu is CSM: Circuit Selector
CSM: Circuit Selector

CSM installed Missing / Present Toggle TOGGLE TOGGLE ACCEPT ABORT
CSM mode Alternate / Simultaneous Toggle TOGGLE TOGGLE ACCEPT ABORT
Circuit 1 Disabled / Enabled Toggle TOGGLE TOGGLE ACCEPT ABORT
Note Note that access to the parameter CSM installed results in the message:
Hit BACK to abort
CONTINUE BACK
33 / 150
1.3.6.5 The fifth submenu is EFD: Earth Fault Detector
EFD: Earth Fault Detector

EFD Control disabled / enabled Toggle TOGGLE TOGGLE ACCEPT ABORT
EFD Reset error NO / YES Toggle TOGGLE TOGGLE ACCEPT ABORT
EFD ON if MCR3 is YES / NO Toggle TOGGLE TOGGLE ACCEPT ABORT
OFF
EFD Startup 4 - 120 s 0.1 s DOWN UP ACCEPT ABORT
EFD Level 1 1 - 255 MOhm 0.1 DOWN UP ACCEPT ABORT
MOhm
EFD Level 2 0.06 m - 9.99 0.01 DOWN UP ACCEPT ABORT
MOhm MOhm
EFD Calibration Toggle TOGGLE TOGGLE ACCEPT ABORT
Note Rule of thumb for the startup time = 4 s / km cable length (as long as cable
capacitance is less than 0.2 µF/km).
EFD Calibration performs the calibration of the EFD module.
1.3.6.6 The sixth submenu is LFD: Lamp Fault Detector
LFD: Lamp Fault Detector

LFD Control Disabled / Enabled Toggle TOGGLE TOGGLE ACCEPT ABORT
LFD Degraded mode NO / YES Toggle TOGGLE TOGGLE ACCEPT ABORT
LFD Level 1 1 - 4 lamps 1 lamp DOWN UP ACCEPT ABORT
LFD Level 2 3 - 31 lamps 1 lamp DOWN UP ACCEPT ABORT
LFD VA-drop level 1 1 - 19 % 1% DOWN UP ACCEPT ABORT
LFD VA-drop level 2 11 - 50 % 1% DOWN UP ACCEPT ABORT
34 / 150
1.3.6.7 The seventh submenu is LFD: LFD Calibration
LFD: Lamp Fault Detector

LFD View sets To check the different DOWN UP SELECT BACK
circuit combinations
for the LFD
calibration (one out of
8 sets)
LFD Active set Selection of the DOWN UP SELECT BACK
circuit combination
(set) to be calibrated.
As long as none is
selected the display
will indicate “Invalid”
LFD Select CSM Selection of the DOWN UP SELECT BACK
circuits circuit combination for
which the LFD
calibration should be
performed
Warm-up time 10 – 1200s 1s DOWN UP SELECT BACK
Do REFERENCE Start of calibration Toggle DOWN UP SELECT BACK
Calibration
No. of lamps removed 1-31 lamps 1 lamp DOWN UP SELECT BACK
Do LAMPS REMOVED Start of calibration Toggle DOWN UP SELECT BACK
calibration
Erase calibration Erasure of the LFD Toggle DOWN UP SELECT BACK
calibrations for the
active set
35 / 150
1.3.6.8 The eighth submenu is Hour Counters
Depending on the configuration of the regulator, the Hour Counters are

disabled or enabled.
In case the Hour Counters are enabled and for a regulator without Circuit
Selector the following submenus are available (counting “regulator ON” times
or counting “above threshold” times):
Hour Counters
Hrs. Cnt: any current DOWN UP BACK
Hrs. Cnt: above threshold DOWN UP BACK
Hour Limits
Hrs. Lim: any current 1h DOWN UP SELECT BACK
Hrs. Lim: above threshold 1h DOWN UP SELECT BACK
Threshold current 0 - 6.6 A 0.01 A DOWN UP SELECT BACK
In case the Hour Counters are enabled and for a regulator with a Circuit
Selector the following submenu is available (with one Hour Counter per
circuit):
Hour Counters
Hrs.Cnt: Circuit 1 1h DOWN UP BACK
1.3.6.9 The ninth submenu is Display
Default mode
Display contrast 0 100 % 1% DOWN UP ACCEPT ABORT
Display time out 5.0 to 124.5 s (or LOCK) 0.1 s DOWN UP ACCEPT ABORT
Embedded language English None DOWN UP SELECT BACK
Extra language None None DOWN UP SELECT BACK
Note To obtain permanent back-lighting of the display: adjust the Display time-out
to above 124.5 s. The display will indicate “LOCK” and the back-lighting of
the display will be permanently on.
36 / 150
1.4 Brightness steps
Introduction The regulator is delivered with factory programmed default brightness steps.
Each brightness step can be readjusted between the maximum and the
minimum current value with the PC software.
Default values The table below shows the current values for each brightness step in
function of the number of steps.
Imax (A) 6.6

Imin (A) 1.8
Brightness step No of steps
selection 3 4 5 6 7 8
1 4.8 3.3 2.8 2.7 2.2 2.8
2 5.5 4.4 3.4 3.4 2.8 3.1
3 6.6 5.5 4.1 3.9 3.4 3.4
4 “ 6.6 5.2 4.5 4.1 3.9
5 “ “ 6.6 5.4 5.2 4.6
6 “ “ “ 6.6 6.4 5.5
7 “ “ “ “ 6.6 6.4
8 “ “ “ “ “ 6.6
Imax (A) 20
Imin (A) 5.5
Brightness step No of steps
selection 3 4 5 6 7 8
1 14.5 10 8.5 8.2 6.7 8.5
2 16.7 13.3 10.3 10 8.5 9.4
3 20 16.7 12.4 11.8 10.3 10.3
4 “ 20 15.8 13.6 12.4 11.8
5 “ “ 20 16.4 15.8 13.9
6 “ “ “ 20 19.4 16.7
7 “ “ “ “ 20 19.4
8 “ “ “ “ “ 20
37 / 150
1.5 Monitoring functions
Output current The MCR³ creates an alarm message and switches off when the output
monitoring for current drops below the minimum output current. The restart of the MCR³ is
open circuit only possible after troubleshooting and reset (reset button is 4th button on
user interface in start menu).
Output current The MCR³ creates an alarm message and switches off when the output
monitoring for current is higher than one of the two preset levels and after the
overcurrent corresponding delay of each level. The restart of the MCR³ is only possible
after troubleshooting and reset (reset button on the front panel).
Mains supply Undervoltage: if the mains supply voltage drops below a certain (user-
voltage adjustable) level, the MCR³ switches off.
monitoring When the mains supply voltage has reached a higher (user-adjustable) level
again, the MCR³ restarts automatically.
Overvoltage: an alarm will be generated when the mains supply voltage
reaches a (user-adjustable) level.
Monitoring of In case of overload the output current may be lower than required.
overload The MCR³ can be programmed by the user to consider this as an open-
circuit condition and to switch off in this case, requiring local reset.
(The default reaction is not to switch off the MCR³!)
38 / 150
Monitoring of A fast response network fires back the thyristors if the peak value of the
output current output current reaches a value greater than twice the maximum peak value
surge in normal operation. The thyristors remain in the off-state for at least one
limitation period followed by smoothly increasing the firing angle from zero back to the
normal value.
At the instance the peak is detected, the optional crowbar will be switched
on during one half-period to prevent any overcurrent in the field circuit
Monitoring of During operation, due to load switching or sudden load variation, the output
output current current may exceed 125 % of the nominal maximum.
for To improve the reaction time of the regulator a fast rough current
overcurrents measurement circuit (approximated RMS value) is used to readjust the
conduction angle (half the value) as soon as the overcurrent is about 115 %
of the nominal current.
1.5.1 List of alarms made available to the ATC controller / maintenance base
Faults Alarm Status
MCR³ Faults
Overcurrent E
Crest factor W
Zero crossing detection W
Open circuit E
Measurement connector disconnected W
Output current deviates W
Overload W
Output current unstable W
Asymetric output current W
Door open E
MOV blown W
AGL disconnected W
Thermal sensor missing W
Mains voltage low W
Mains voltage high W
Mains voltage unstable W
Power loss imminent W
Mains frequency out of range W
CSM disconnected W
CSM error E
E= ERROR
W=WARNING
39 / 150
Faults Alarm Status
EFD Faults
EFD calibration is running W
EFD is OFF because MCR³ is OFF W
LFD Faults
LFD is calibrating W
REFERENCE calibration not done W
LAMPS REMOVED calibration not done W
W
HOUR COUNTERS faults
Limit exceeded for any current hours couter W
Limit exceeded for threshold hours counter W
Limit exceeded for CSM circuit 1…8 hours counter W
JBUS Faults
BUS A is DOWN E
BUS B is DOWN E
CSM error E
EFD Faults
E= ERROR
W=WARNING
To make the warnings available to the tower, this option should be activated via
the U/I.
40 / 150
1.6 Remote control and back-indication
1.6.1 General
Basics The MCR³ permits the combination of multiwire and J-Bus (single or dual)
systems. The LMC is equipped with the RS485 interfacing circuitry for the J-
Bus and permits the connection of up to 3 multiwire interface boards.
The microcontroller of the LMC processes the J-Bus communication and
controls the data transfer over the Local Bus between the different modules.
In case a multiwire board is connected to the LMC this module is recognized
on powering up and depending on the configuration of the system the remote
control is executed via with the MW modules or via J-Bus.
Multiwire In case a multiwire is connected to the LMC this module is recognized by the
logic.
Up to 3 modules can be used.
All inputs and outputs of MW1 and MW2 are configurable.
MW3 is reserved for the circuit selection operation
Each multiwire board contains 8 inputs and 8 outputs, each individually
configurable.
Two versions exist: 48 V DC or 24 V DC remote control voltage. The internal
remote control voltage can be wired so that any polarity is permitted of the
relay coils.
For an external remote control voltage source any polarity is allowed.
(Suppression of switching transients of the coils is done with resistor-
capacitor networks.)
The internal remote control source is floating towards ground level and short-
circuit protected by self-repairing polyswitches. The maximum current is
200 mA for 48 V DC and 400 mA for 24 V DC. Note that the output voltage of
this power supply is fully dependent on the input voltage.
Remote control input characteristics:
Remote control voltage 48 V DC 24 V DC

Minimum voltage 40 V DC 21.6 V DC
Maximum voltage 65 V DC 35 V DC
Current consumption about 9 mA at about 16 mA
per relay input 48 V DC at 24 V DC
The back-indication signals are given with simple, potential-free contacts.

If necessary, the positive pole of the internal remote control voltage can be
connected to the common of the back-indication signals by means of a strap.
The maximum contact load is:
• AC – 110 V - 0.5 A – 60 VA
• DC – 110 V - 0.5 A – 30 W
41 / 150
J-Bus RS485 signals: differential mode, 5 V (max.) signals.
Possible over 2 or 4 wires.
The RS485 signals are isolated from the other board signals (500 V DC
level) and the 0V of the RS485 signal is available on the terminal block.
Cable length of the J-Bus is limited to 1200 m for copper wire.
Operation is possible with a single J-Bus or A dual J-Bus version (factory
programmed).
The dual J-Bus makes the control system fully redundant up to the CCR.
The J-Bus can be configured (by setting the switches on the LMC) for 2-wire
or 4-wire communication.
The 0V of the isolated power supply for the RS458 serial bus must be
interconnected between all the MCR³’s. This 0V is kept close to the ground
level by means of a power zener diode
J-Bus A MCR³ is always a “slave” on the J-Bus. There can be a maximum of 31

Master/ Slave MCR³s on one bus section with one common bus master.
Signal ON & These back-indication signals are given with simple, potential-free contacts.
REG.ERR. The maximum contact load is:
(PSL/X7) • AC – 110 V – 2 A – 220 VA
• DC – 110 V – 2 A – 60 W
1.6.2 Straps and dip-switches
For a detailed description of strap setting and dip-switch setting:

see section 6.
1.6.3 Interface module connection
For a detailed description of the interface module connection:

see section 2.3.
42 / 150
1.7 Earth Fault Detector module (option)
Principle The Earth Fault Detector module measures the insulation resistance
between the series circuit and the ground or the cable screen with the
regulator switched to the supply, even when not running. A stabilised,
current-limited voltage of 500 V DC is applied between the series circuit and
the ground or cable screen, irrespective of the operating voltage, via a high-
voltage resistor. The insulation resistance is determined on the basis of the
resulting leakage current.
Measurement The measurement range is from 10 kOhm to 0.5 GOhm. The insulation
range resistance can be displayed on the User Interface.
Two levels Two alarm levels are available.

Level 1 can be set from 1 MOhm to 225 MOhm.
Level 2 can be set from 60 kOhm to 10 MOhm.
Alarm If the insulation value drops below the alarm level, an “earth-fault” error
message is displayed on the User Interface and a back-indication signal is
generated. If the insulation level returns above that level, the alarm remains
latched. Reset is possible with the “RESET EFD” button on the User
Interface (submenu EFD) or via a remote control command.
PC settings For the settings and calibration, refer to section 7.
Picture Fig. 1-7: Earth Fault Detector module (MCR³ 15 to 30 kVA)
EFD HV resistors
EFD logic
43 / 150
1.8 Lamp Fault Detector module (option)
Theory The Lamp Fault Detector module (LFD) measures the reactive power
required to saturate the unloaded lamp transformers of the series loop by
integrating the series loop voltage (obtained through the voltage transformer)
during a measuring window (derived from the output current and voltage
measurement).
The measured voltage with all the lamps of the series loop intact is
compensated to obtain a zero-volt reading.
With a defined number of lamps in open circuit the module can be calibrated
to obtain a read-out corresponding to the number of lamps deactivated.
Restrictions To obtain acceptable measurements by the LFD, the following restrictions

apply:
• All lamp transformers have to be of the same rating and type because the
LFD detects unloaded lamp transformers, not lamp power. This means
also that defective lamps shorted out by cut-outs will not be detected.
• Low reactive and constant loadings:
• The cable capacitance towards ground should be less than 1 µF and
should be equally distributed over the loop. (Note: The cable capacitance
towards ground can be checked. Without output current but with the EFD
operational, a multimeter with an internal resistance of 10 MOhm is
connected to the output of the MCR³. A reading of 400 V DC corresponds
to a perfect insulation of the cable. After disconnecting the 500 V DC
source of the EFD the discharging time of the cable capacitance through
the multimeter from 400 V DC to 147 V DC is measured. The measured
voltage should decrease in about 10 seconds for a cable capacitance of
1 µF from 400 V DC to 147 V DC (=0.37x400). If the initial voltage has
already dropped to 330 V DC this means that the cable leakage
resistance equals about 10 MOhm. The discharge time in this case will
be about 5 seconds for a cable capacitance of 1 µF.)
• No non-linear loads (guidance signs, BRITE, serial-to-parallel adapter...).
Poor contacts at primary or secondary of lamp transformers will also
cause arcing and non-linear loading.
• Only two circuits or circuit combinations can be calibrated. For other
circuit combinations the readings will be neglected. The LFD is not
compatible with Circuit Selectors or switching, variable loads.
Tolerances If the above mentioned restrictions are fulfilled, the tolerance will be:
• for 0 to 5 burnt lamps : + 1 lamp
• for 6 to 10 burnt lamps: + 2 lamps
PC settings For the settings and calibration refer to section 7.
44 / 150
1.9 Cut-out SCO (option)
Cut-out SCO As an option, the MCR³ regulator can be delivered with a cut-out SCO
mounted onto the bottom part of the front panel.
The purpose is to isolate safely the series circuit from the CCR during
maintenance or testing operations. It also allows periodical isolation
resistance measurement series circuit to ground without disconnecting the
series cable.
Refer to instruction manual AM.06.455e.
Mode of The table below describes the different working positions.

operation Switch off the constant current regulator before manipulating the cut-out.
Position A Position B Position C

Mode of Allows the Maintenance can The series circuit insulation relative to
operation regulator to deliver be done safely on ground can be measured by applying the
current to the the series circuit. measurement voltage, max. 9000 V DC,
series circuit. between the measurement terminal (7)
and the ground strip.
Microswitch Microswitch Microswitch
Diagram Series
CCR Series CCR
CCR Series Circuit
Circuit
Circuit
Measurement
Ground Ground socket
Cover
Handle horizontal turned 90° ccw. turned 90° cw. from position A
from position A
The series connected to the shorted and disconnected from the CCR, shorted and
circuit is CCR grounded connected to the measurement terminal
The CCR is delivering current shorted and shorted and grounded
to the series circuit grounded
The microswitch activated and not activated and activated and allows the CCR to be ON
(2) is allows the CCR to inhibits the CCR to
be ON be ON
The cover can be locked with can be locked with can be locked with the key
the key the key
1. The position of the cover intermediate between B and C, i.e. turned 180°
from position A, cannot be used and the cover cannot be plugged into the
body.
2. An activated microswitch means that the normally open contact is closed
and that the normally closed contact is open. For interlocking with the
CCR, only the normally open contact will be used.
45 / 150
1.10 Circuit Selector (Option)
Circuit Additionally the MCR³ can be equipped with a Circuit Selector mounted
Selector underneath the regulator.
The Circuit Selector is to be considered as an extension of the MCR. The
control signals from the CCL to the CSM and the back-indications from the
CSM to the CCL go through a 26-wire flat cable.
Depending on the power rating of the regulator there are two types of high-
voltage contactors. The number of contactors depends on the number of
circuits (2 TO 8).
The power supply for the coils of the high-voltage contactors is derived from
the input power of the regulator. By means of a transformer this input voltage
is adapted to a typical coil voltage of 230 V AC.
The Circuit Selector can be configured (CCL) to permit any circuit to be
selected (simultaneous mode) or only one circuit at the same time (alternate
mode).
For the large cabinet (above 10 kVA) the HV circuit connection happens
directly to the HV contactor terminals.
In case of more than four circuits for the large cabinet, these circuits (5 to 8)
are to be connected at the rear of the cabinet.
For the small cabinet (up to 10 kVA) there are separate connection terminals
for the circuit connection.
1.11 Hour Counters (Option)
Hour counters As an option, the regulator MCR³ can be delivered with Hour Counters.
The Hour Counter can be configured to measure the “ON” time (Hour
counting starts as soon as the MCR³ is switched ON) or to measure the
operating time above a preset level.
In case of a Circuit Selector there is one Hour Counter per circuit available.
46 / 150
1.12 Equipment required for installation, start-up and troubleshooting but not
supplied
Tools • True RMS Voltmeter

(Note that the output voltage of the 30 kVA / 6.6 A regulator can reach
about 4600 V at full load. An isolating measurement transformer for use on
the 5000 V AC line is recommended in this case.)
• Multimeter
• Insulation tester "Megger" 500 V or 1000 V to test the series circuit

insulation
• Clamp or A-meter true RMS scale 10 and 30 A.

(Note that the current regulation is + 1 %. To make an acceptable re-
adjustment of the output current the precision of the meter should be
better than 0.5 % for the adjusted value.)
• Complete set of tools for electrician and mechanic (no special tool
required), with screwdrivers and spanner set (ring or socket spanners)
• Allen key 8 mm (front and rear panel, door lock)
Connection • Screened remote control cable (between regulator and marshalling panel
equipment or control desk)
• Earth wire to ground the cabinet (ground reference for the output lightning
arrestors)
• Feeder cable
• Series loop supply cable
1.13 Equipment supplied
Packaging Each unit is individually packaged in a durable crate.

On this crate the nameplate of the equipment is attached to permit
identification without unpacking the crate.
47 / 150
1.14 Nameplate
Picture Fig. 1-8: MCR³ Nameplate ( 4072.03.500E)
MCR³
a1 50/60Hz
Rep. Function Rep. Function

a Supply voltage f Type of remote control
a1 FAA or IEC performance h Options
b Max. input current i Serial number
c Output power j Bar code = code number
d Nominal output current
e Max. output voltage
Values
Output power Output current Supply voltage
c d a e
2.5 kVA 6.6 A 220/ 230/ 240 378
4 kVA 6.6 A 220/ 230/ 240 606
5 kVA 6.6 A 220/ 230/ 240 757
7.5 kVA 6.6 A 220/ 230/ 240 1136
10 kVA 6.6 A 220/ 230/ 240 1515
15 kVA 6.6 A 220/ 230/ 240 2272
20 kVA 6.6 A 220/ 230/ 240 3030
2.5 kVA 6.6 A 380/ 400/ 415 378
4 kVA 6.6 A 380/ 400/ 415 606
5 kVA 6.6 A 380/ 400/ 415 757
7.5 kVA 6.6 A 380/ 400/ 415 1136
10 kVA 6.6 A 380/ 400/ 415 1515
15 kVA 6.6 A 380/ 400/ 415 2272
20 kVA 6.6 A 380 3030
20 kVA 6.6 A 400/ 415 3030
25 kVA 6.6 A 380/ 400/ 415 3788
30 kVA 6.6 A 380/ 400/ 415 4545
25 kVA 20 A 380/ 400/ 415 1250
30 kVA 20 A 380/ 400/ 415 1500
b: input current see table 2-1
48 / 150
2 Section 2
Installation
2.1 Introduction
Introduction This section provides instructions for the installation of the MCR³ regulators.
Refer to the substation drawings and specifications for specific installation
instructions.
Unpacking Unpack the crate upon receipt and examine the regulator to make sure that
no damage has occurred during shipping. Note any exterior damage to the
crate, which might lead to the detection of equipment damage. When
handling the regulator, care should be taken to maintain the regulator in the
upright position.
If damage to any equipment is noted, a claim form should be filed with the
carrier immediately. Inspection of the equipment by the carrier may be
necessary.
Installation The regulator has to be installed in a well-ventilated room with sufficient

criteria clearance for personnel to inspect and maintain the regulator.
The person that installs the regulator should refer to the specific installation
plan for implantation.
For special models, refer also to the appropriate manuals (outside, portable,
rack-mounted version).
49 / 150
2.2 Installation
Regulator If the regulator is equipped with rolling castors, it can simply be pushed to the
with wheels right location in the substation, provided the floor is flat and level.
Adequate precautions should be taken to avoid overbalancing the regulator if
there are obstacles on the floor such as wires or small unevenness.
Note that the 4 to 10 kVA regulators do not have a square footprint.
Regulator The regulator can be lifted by lifting lugs (Optional). The bolts to fix the top
without plate are then replaced by four lifting lugs M12 – ADB P/N 7015.20.120.
wheels CAUTION:
Always use the four lifting lugs and adequate lifting cables to lift the load.
Take the necessary precautions to prevent personal injuries during the lifting
of the regulator. Prevent sudden movements or swinging of the load.
Ventilation Air outlets are provided at the rear of the regulator.

Air intakes are provided at the bottom and the front of the regulator.
The top cabinet and the high-voltage compartment have separate air outlets
and intakes.
To avoid overheating of CCR components, take care never to block these
ventilation grids.
The heatsink for the thyristors is located at the top of the left side wall seen
from the front.
Note that this heatsink will become hot during operation of the regulator.
To obtain adequate ventilation, a minimum clearance of about 0.5 m from the
rear of the regulator to the wall is required.
Side by side, the regulators are to be installed at a minimum distance of 5 cm
from each other.
50 / 150
Removable Top, front and rear panels are removable. They can only be mounted in one
panels way.
The front and rear panels have ventilation grids. At the bottom, the side walls
have air inlets and the bottom plate has ventilation slots.
Each of these removable panels is grounded with a green/yellow wire
equipped with a fast-on connector. This wire must be disconnected before
taking the panel away and it is mandatory to reconnect it on the panel
when re-installed.
The auxiliary fuses, optional input lightning arrestors and power supply
connection terminals are located behind the User Interface panel.
Cable routing The side channels of the enclosure can be used to route and fix the cables.
Seen from the front: the front left hand channel is reserved for mains supply
wiring and the front right hand channel for low-voltage signals.
Seen from the rear: the rear left hand channel is reserved for remote control
signals and the rear right hand channel for the high-voltage connection of the
optional Circuit Selector.
Cut-out SCO As an option, the regulator MCR³ can be delivered with a cut-out SCO
mounted onto the bottom part of the front panel.
Refer to the instruction manual AM.05.455e for more information.
Picture Fig. 2-1: Detail of a typical installation
51 / 150
2.3 Electrical connection
Warning Only personnel qualified to work on high-voltage equipment is allowed

to perform installation and operation.
Before connection, check if the supply voltage of the regulator corresponds
to the local supply voltage.
Panels to The power supply connection terminals are accessible behind the User
remove Interface panel in the top cabinet.
Notice that the User Interface has two electrical connections (power supply
of the logic and Local Bus flat cable). These wires must be disconnected on
removing the User Interface panel and have to be connected before the User
Interface panel is re-installed.
The remote control terminals are located in the top cabinet, at the rear side
and are accessible by means of the removable rear panel.
The output terminals are accessible from the front, at the bottom behind the
removable front panel.
Refer to the previous page for the precautions to take.
Grounding Although the supply cable includes a ground wire, additional safety
grounding is required. Use one of the ground studs M6 on each bottom side
of the regulator (in the middle, accessible from the side wall and the bottom).
The grounding wire must have a cross-section of at least 16 mm² and be as
short as possible.
Mains supply The minimum section of the mains supply cable (see table 2.1) is valid under
cable following conditions:
• mean ambient temperature of 35°C
• PVC insulated cables
• cable separation at least 1x the cable diameter
• cable length from the low-voltage distribution board to the MCR³ is about
15 m
52 / 150
Table 2-1 Table 2-1: Mains supply cable sections, fuses…
Input supply voltage 220 / 230 / 240 V

Output Fuse in fused Input current (max.) Section Strip- Section Strip- External
power switch supply ping earth ping fuse
(kVA) Rating Type 220V 230V 240V wire mm (mm) wire mm (mm)
² ²
2.5 20 A Neozed 14 13 13 4 16 4 16 25 A
4 25 A Neozed 22 21 21 6 16 6 16 35 A
5 35 A Neozed 28 27 26 10 16 10 16 50 A
7.5 50 A Neozed 42 40 39 16 16 16 16 63 A
10 63 A Neozed 56 54 51 25 22 16 18 80 A
15 100 A NH00 80 76 73 35 22 16 18 100 A
20 125 A NH00 106 102 97 50 22 25 18 125 A
Input supply voltage 380 / 400 / 415 V

Output Fuse in fused Input current (max.) Section Strip- Section Strip- External
power switch supply ping earth ping fuse
(kVA) Rating Type 380V 400V 415V wire mm (mm) wire mm (mm)
² ²
2.5 20 A Neozed 8 8 7 4 16 4 16 25 A
4 20 A Neozed 13 12 12 4 16 4 16 25 A
5 20 A Neozed 16 15 15 4 16 4 16 25 A
7.5 25 A Neozed 24 23 22 6 16 6 16 35 A
10 35 A Neozed 32 31 30 10 16 10 16 50 A
15 50 A NH00 46 44 42 16 18 16 18 63 A
20 80 A NH00 62 58 56 25 22 16 18 80 A
25 80 A NH00 77 73 70 35 22 16 18 100 A
30 100 A NH00 90 86 83 50 22 25 18 125 A
Notes The power supply cable can be routed through the front left hand channel
(seen from the front) from the bottom up to the low-voltage compartment and
be fixed to the channel wall by means of nylon straps.
Up to a wire section of 35 mm² the connection is executed with screw
terminals. For higher cross-sections, 70 mm² bolt terminals (socket or ring
spanner 13 mm) are used for the connection.
Check that the connecting wires do not hinder the mounting of the User
Interface and that the mains wiring does not mix with low-voltage signal
wiring.
53 / 150
2.3.1 Series circuit connection
Description The series circuit cables enter the cabinet through the bottom plate of the
regulator at the rear for the big cabinet and at the front or the rear for the
small cabinet.
These cables shall be routed such that they do not touch the transformer
winding because the latter can become extremely hot. (Transformer winding
material is designed to withstand temperatures up to 180°C.)
These cables are to be routed by preference at the right-hand side of the big
cabinet (seen from the front) and shall be routed and fixed to prevent mixture
of low-voltage wiring with the series circuit wiring.
For the small cabinet (or the big cabinet, 20 A series circuit current): connect
the series cables to the output terminals (screw terminal block).
For the big cabinet (6.6 A loop current): connect the series cables to the
lightning arrestors; do not remove the other wires connected to them (stud
diameter = 10 mm).
If the series cable is screened or armoured it is mandatory to connect the
screen or the armature to the ground inside or outside the regulator
Refer to the instruction manual AM.05.455e for the connection of the series
circuit in case of the optional SCO.
If an optional Circuit Selector is present, the high-voltage connection wires
from the Circuit Selector are routed through the rear right-hand side channel
(seen from the rear) to the output terminals of the regulator. The series
circuits are connected to the corresponding terminals of the Circuit Selector.
Note In case of the optional Circuit Selector, if a circuit is disabled but the high-
voltage contactor is energised, the output of the inhibited circuit has to be
short-circuited. Otherwise this could result in an open-circuit condition.
54 / 150
2.3.2 Remote control connection
Description The remote control cable(s) can be routed through the rear right-hand
channel (seen from the front) from the bottom up to the low-voltage
compartment and be fixed by means of nylon straps to the channel wall.
For strain relief and grounding of the cable screen there is a cable clamp
usable for cable diameters ranging from 7 up to 16 mm, click mountable on
the grounded rail at the rear of the card cage. (Use one cable clamp per
cable.) If this grounding clamp is mounted it is not recommended to connect
the screen also to terminal 12 (PE).
The connection of the remote control signals is by means of pluggable
spring-terminals.
For multiwire, connectors P1 and P2, the connector type is WAGO 231-
312/026-000 cage-clamp connector (ADB code number 6112.33.112).
For J-Bus, connectors P1 to P4 are WAGO 231-306/026-000 cage-clamp
connector (ADB code number 6112.32.518).
For the back-indication signals “ON” and “REG. ERR.” the connector PSL /
X7 is a WAGO 231-304/026-000 cage-clamp connector (ADB code number
6112.32.517).
These WAGO cage-clamp connectors accept wires of 0.08 to 2.5 mm² (28 –
12 AWG). Recommended stripping length: 6 mm.
(Connector spring activation is possible with screwdriver blade 3.5x0.5 mm
or with operating lever WAGO 231-131.)
55 / 150
2.3.3 Remote control cable
Multiwire We recommend a screened cable with screen connected to the ground at

both ends to limit high frequency disturbance.
Each signal requires a wire. We recommend also a separate wire for the
commons (input and output) for each multiwire board.
Twisted pairs are not obligatory for this kind of signals but using one wire for
the signal and the other wire of that pair as return gives minimal voltage drop
and optimal coupling between these two wires. (This, however, requires an
intermediate terminal in the regulator to interconnect the return wires.)
Combining the remote control and back-indication signals in one cable is
only possible if there is no (or only low level) isolation required between
these signals (as in the case of one common energy source for remote
control and back-indication signals).
To determine the required cross-section of these cable wires:
• Check the tolerances of the power supply.
• The maximum permitted voltage drop on the line is the difference of the
minimum available power supply voltage minus the minimum required
voltage for the load.
• Consider for copper wires a typical resistance of 0.1 Ohm/m for diameter
0.5 mm (about 0.2 mm²) and 0.04 Ohm/m for diameter 0.8 mm (about
0.5 mm²). This is a typical value at ambient temperature of 55°C.
• Check the required load current in each line.
• Determine the number of signals that may exist at the same time.
Size the cable to obtain less or equal than the maximum permitted voltage
drop with the required load current.
E.g.: Maximum cable length in case of copper wire if only one remote control
signal will be transmitted at any time.
(If two signals may be sent at the same time then the common wire has to be
doubled in diameter or the maximum cable length will be only 2/3 of the
indicated value.)
Diameter Power supply tolerance 48 V DC 24 V DC

0.5 mm -5 % 3 km 0.65 km
(0.2 mm²) -10 % 1.7 km -
0.8 mm -5 % 7.5 km 1.5 km
(0.5 mm²) -10 % 4 km -
usable for cable diameters ranging from 7 up to 16 mm, click-mountable on
the grounded rail at the bottom of the compartment. (Use one cable clamp
per cable.) If this grounding clamp is mounted it is not recommended to
connect the screen also to terminal 12 (PE).
56 / 150
J-Bus We recommend a screened cable with screen connected to the ground at
both ends to limit high frequency disturbance.
The factor (number of pairs) depends on the installation: transmission over
two or four wires, combination of J-Bus A and J-Bus B in 1 cable or in 2
separate cables. (Notice that there is at least 1 wire required for the
interconnection of the 0V-signal.)
Signals Tx+ and Tx- form a pair and (in case of 4 lines) signals Rx+ and Rx-
form the other pair.
Signals for J-Bus A and J-Bus B may not be mixed in one pair.
Because this is a data-transmission cable with a very low power signal the
wire cross-section is less important, but a minimum diameter of 0.5 mm
(0.2 mm²) is required for mechanical strength.
In all cases the screen or the armour must be connected to the earth lug
(PE) of the cabinet.
suitable for cable diameters ranging from 7 up to 16 mm, click-mountable on
the grounded rail at the bottom of the box. (Use one cable clamp per cable).
If this grounding clamp is mounted it is not required in additition to connect
the screen also to terminal 6 (PE).
Signals ON & We recommend a screened cable with screen connected to the ground at
REG.ERR. both ends to limit high-frequency disturbance. The best screening result is
obtained by grounding the cable on entering the cabinet.
The wire cross-section depends on the load connected to this terminal block.
The cable insulation level depends on the operation voltage level of the load.
57 / 150
2.3.4 Multiwire
Description The function of each input and output terminal is defined in the configuration
software (Menu MCR3: IO / Multiwire). Configuration of this terminal block
has to be known to make the right connections.
Attributing a certain function to several terminals would result in only one
terminal given the correct operation.
There can be a maximum of 3 multiwire PCBs attached to the LMC.

Their presence is detected by the system.
They are identified as MW1, MW2 and MW3.
MW3 is reserved for Circuit Selector functionality.
Seen from the rear side of the regulator: MW1 is the one farthest on the left,
MW2 is on its right-hand side and MW3 is the one farthest to the right.
If an attempt is made to attribute a function to a contact that has already

been attributed to some other contact, then only the last attribution will be
executed. The contact that had the function originally will become FREE.
It is possible to set each contact individually (input and output) to POSITIVE

or NEGATIVE logic. E.g. if an output contact is attributed to a certain function
and if the condition of that function becomes TRUE, then the contact closes
in positive logic, but opens in negative logic. The same is true for INPUT
functions, in positive logic applying a voltage to a contact starts the
corresponding function whereas in negative logic, the function is executed
when the contact opens.
Input connector (P2)
MW1 and MW2 Possible input functions are:
Function Function description

Free This terminal is unused.
ON/OFF Separate ON/OFF control signal
Step 1
Step 2
Step 3
Step 4 Brightness step selection
Step 5
Step 6
Step 7
Step 8
Reset EFD error Reset of EFD alarms, level 1 and level 2
Use LFD degraded mode LFD alarm level 1 back-indication cancelled with this signal
Allow WRITE via bus This external signal permits the bus to change parameters under
multiwire control (only in case of the following arbiter setting:
“Multiwire control, Bus A monitoring” or “Multiwire control, Bus B
monitoring”).
58 / 150
MW3 Possible input functions are:

Circuit 1
Circuit 2
Circuit 3
Circuit 4 Circuit selection
Circuit 5
Circuit 6
Circuit 7
Circuit 8
Wiring: see next page.
59 / 150
12 12 12
11 11 11
10 10 10
9 9 9
8 8 8
7 7 7
6 6 6
5 5 5
4 4 4
3 3 3
2 2 2
1 1 1
Fig. 2-2: Multiwire Inputs
60 / 150
Output connector (P1)
MW1 and Possible output functions are:

MW2

Step 1 obtained
Step 2 obtained
Step 3 obtained
Step 4 obtained Back-indication of actual step
Step 5 obtained
Step 6 obtained
Step 7 obtained
Step 8 obtained
Overcurrent alarm Regulator has switched OFF due to overcurrent in the loop.
Open circuit alarm Regulator has switched OFF due to open circuit in the loop.
EFD warning level EFD, level 1 has been exceeded (fault condition may actually
not be present anymore).
EFD alarm level EFD, level 2 has been exceeded (fault condition may actually
not be present anymore).
LFD warning level LFD, level 1, preset quantity of burnt lamps has been reached
or preset value of VA drop has been surpassed. (This warning
disappears if the condition is no longer detected.)
LFD alarm level LFD, level 2, preset quantity of burnt lamps has been reached
or preset value of VA drop has been surpassed. (This warning
disappears if the condition is no longer detected.)
Lamp life warning Preset time for the lamp life is exceeded.
Local Bus error LMC detects that one or more modules on the Local Bus are
no longer communicating.
Bus A down LMC detects that there are no messages received on Bus A.
Bus B down LMC detects that there are no messages received on Bus B.
Overtemperature When the inside temperature of the regulator (measured on the
LMC) exceeds the programmed maximum temperature, this
terminal is activated. As soon as the temperature drops under
the limit on all devices, the terminal is inactivated again.
MOV blown alarm The optional lightning arrestor protection of the input voltage is
missing or needs replacement.
Notify that warnings will only be available if option is activated via U/I. Otherwise, only
errors will be available!
61 / 150
MW3 Possible output functions are:

Circuit 1
Circuit 2
Circuit 3
Circuit 4 Circuit selection
Circuit 5
Circuit 6
Circuit 7
Circuit 8
CSM fault Actual detected circuit selection deviates from request.
Wiring: see next page.
Note Internal connections

The connector J1 is for the power supply (230 V AC) of the multiwire.
P3 is a flat-cable connector to the LMC.
62 / 150
12 12 12
11 11 11
10 10 10
9 9 9
8 8 8
7 7 7
6 6 6
5 5 5
4 4 4
3 3 3
2 2 2
1 1 1
Fig. 2-3: Multiwire Outputs
63 / 150
2.3.5 J-Bus
Connectors For ease of wiring, there are 4 connectors, 2 for Bus A and 2 for BUS B. P1
and P2 are for the connection to the preceding / next user respectively. P3
and P4 are for Bus B.
If the LMC to which the bus will be connected is the last on the bus, the bus
should be terminated (see section 6: LMC for line termination of the J-Bus).
Note Internal connection

The flat-cable connector P6 is for internal distribution of the bus signal.
The wiring of connectors P1, P2, P3 and P4 is as follows:
Tx + 1
Rx + 2
Tx – 3
Rx – 4
0V 5
PE 6
Fig. 2-4: J-Bus connector layout JB / P1, P2, P3 and P4
During the installation care must be taken that the bus polarity is
homogenous, i.e. that all the contacts of the same type are on the same wire
in all connected units.
The use of a twisted pair for Tx+ and Tx- and for Rx+ and Rx- is imperative.
Note that if a polarity is inverted on the bus, this will not cause damage, but
the communication will not be established. A clear give away are the LEDs
indicating bus communication (see LMC): instead of lighting up at each
message received, they will remain permanently ON.
In case the transmission is executed via 2 wires (instead of 4 wires), the pair
has to be connected to Tx+ (1) and Tx- (3). Note that, in this case, the
selection on the LMC (Local Master) has to be for a 2-wire system (see
LMC).
64 / 150
2.3.6 Signals ON & REG.ERR. (PSL/X7)
The wiring of connector X7 is as follows:
ON 1
COMMON 2
REG.ERR. / NC 3
REG.ERR. / NO 4
Fig. 2-5: Connector layout PSL / X7
65 / 150
2.4 Starting procedure
Caution Read the safety instructions and check if the installation complies with
section 2.3. Do the following preliminary checks:
• grounding
• mains supply cable, routing, wiring and voltage
• series circuit cable, routing, wiring and insulation resistance to earth
• remote control cable, routing, wiring and voltage
In order to obtain a fast response of the regulator the last request is

memorized. This means that the regulator will start producing the same
output current that was valid on powering down.
The same rule applies for remote or local control.
Once all the information is obtained by the User Interface, this User Interface
can be switched to local or remote control.
Therefore, if the powering-down status of a regulator is unknown; the series
circuit has to be disconnected prior to switching the regulator on, in order to
prevent a regulator to produce output current.
With the series circuit disconnected, a regulator that would try to reproduce
output current will switch off in open-circuit condition.
By then the brightness step request can be cancelled in local control and the
failure condition be reset.
Procedure The first start-up will be done in local control only. It is advised, as far as
possible, to disconnect (unplug) the remote control. We recommend to start
the regulator first with its output short circuited
Step Action
1 Open the fused input switch (fig. 1-2).
2 Disconnect the series circuit (if already connected) and short the
output terminals. Put an AC current clamp around the shorting
wire to measure the output current. Warning: High Voltage!
3 Switch ON the regulator supply on the low-voltage distribution
board and measure the input voltage on the mains supply
terminals. The measured voltage must match the input voltage
indicated on the nameplate (within tolerances).
4 Check if the input fuses are correctly positioned.
5 Close the fused input switch. Note: The regulator memorizes its
last selection. If the regulator was switched off without selecting
brightness step “OFF” the last selection will be recalled at the
moment of energizing. The display on the User Interface will
indicate the actual measured output current and the selected
brightness step.
6 Select the brightness steps by means of the User Interface and
compare each reading on the display with the reading of the
external A-meter.
The value of the actual measured output current depends on the
number of programmed steps (see section 1.4).
7 Switch the regulator OFF by selecting the brightness step “OFF”
(0) and open the fused input switch.
66 / 150
8 Remove the short circuit on the output and switch the regulator
ON (close the fused main switch and select any brightness step).
The main contactor will switch ON and after a short period OFF.
The display will indicate the open circuit error message.
9 Switch the regulator OFF by selecting the brightness step “OFF”
(0) and open the fused input switch.
Connect the series circuit to the regulator. Switch ON the
regulator and check the output current. Check that the regulator is
not in overload.
With the maximum output current, check that the main input
voltage is not less than the minimum tolerated value.
10 Proceed with the adjustment of the output transformer secondary
taps to the actual load (see section 2.4.1).
11 Calibration of the EFD and LFD option, if installed (see section 7).
67 / 150
2.4.1 Tap selection
Target Adjustment of the regulator to the installed load by adjusting the tap setting.
Three 1. Measurement of the output voltage directly on the output terminals

methods are (This might require the use of an isolation step down transformer)
possible Warning: High Voltage!
2. By means of the MCR³ output voltage measurement
3. By means of the conduction angle measurement
Preliminary For each method a preliminary visual check will be made on the series
check circuit.
Switch the regulator ON at a convenient brightness and check that all the
lamps of the circuit are operational. If not, take corrective actions until all
lamps are OK.
Check that the mains voltage is at its nominal value.
First method Output voltage measurement
Step Action
1 Switch the MCR³ ON to the max. brightness step 6.6 A or 20 A.
2 Measure the RMS output voltage at the output terminals after
about 10 minutes. Determine the correct tap using table 2-2,
choose the tap with the nearest higher voltage than the measured
RMS output voltage.
Switch the MCR³ OFF and wire the chosen tap (see section 2.4.2).
Warning: High Voltage!
3 Switch ON the regulator at the maximum brightness for about 10
minutes and check that the output current is not lower than the
maximum value. If the output current is too low, wire to the next
higher tap.
4 Close the MCR³ taking into account the requirements given in
section 2.2.
Table 2-2 Table 2-2: Maximum voltages (V RMS) for each tap setting, each power
and output current
PWR/ Iout Tap 8/8 7/8 6/8 4/8 2/8
2.5 kVA/ 6.6 A 378 - - 190 -
4 kVA/ 6.6 A 606 530 450 300 150
5 kVA/ 6.6 A 757 660 565 375 185
7.5 kVA/ 6.6 A 1136 990 850 565 280
10 kVA/ 6.6 A 1515 1320 1130 755 375
15 kVA/ 6.6 A 2272 1980 1695 1130 560
20 kVA/ 6.6 A 3030 2645 2260 1505 745
25 kVA/ 6.6 A 3788 3305 2825 1880 935
30 kVA/ 6.6 A 4545 3965 3390 2255 1120
25 kVA/ 20 A 1250 1090 930 620 310
30 kVA/ 20 A 1500 1310 1120 745 370
68 / 150
Second Output voltage measurement by means of the User Interface (or PC
method software).
This is less accurate than measuring with a voltmeter but will be sufficiently
accurate for the tap setting.
Use the values in table 2-2 to adjust the tap setting.
Third method You can also use the PC software (see section 7) to determine which tap to
select by using the conduction angle reading.
Procedure Conduction angle reading
Step Action
1 Wire the 8/8 tap and switch the regulator ON to the maximum
brightness.
2 Connect the PC to the regulator, open the program and go to the
menu “MCR3 Setup”. In the sub-menu “MCR3 Input/Output
measurements” select the “Thyristor conduction angle” reading.
3 Read the thyristor conduction angle and select the tap according to
the table below:
If the thyristor conduction select the tap
angle is
between 115° and 130° 7/ 8
between 90° and 115° 6/ 8
between 67° and 90° 4/ 8
<67° 2/ 8
4 Switch the regulator OFF and wire the chosen tap.

5 Switch ON again at maximum brightness and check the “thyristor
conduction angle”.
If the thyristor conduction then
angle is
< 145° the chosen tap is correct.
> 145° go to the next higher step.
69 / 150
2.4.2 Tap wiring
Tap wiring To wire the tap, proceed as follows.

2.5 to 30 kVA (2.5 to 30 kVA: a spare strap is provided on S5.)
Note that the 2.5 kVA has only two possible tap settings: half and full load.
Step Action
1 Remove the front panel and disconnect the ground wire.
2 Wire the tap according to fig. 2-9.
3 Switch the regulator ON at the maximum brightness step for about
10 minutes.
4 Check that the output current is not below the maximum value.
If it is too low, wire to the next higher step and check again till the
output current attains its maximum value.
5 Close the MCR³ taking into account the requirements given in
section 2.3.
Picture Fig. 2-6: 2.5 kVA power transformer, top view
P10
P9 S1
P8 S2
P7 S3
P6 S4
P5 S5
P4 S6
P3
P2
P1
70 / 150
Fig. 2-7: Tap adjustment MCR³ 4 to 10 kVA
Terminal identification label Tap S6 through S1 for adjustment to actual load
Picture Fig. 2-8: Tap adjustment MCR³ 15 to 30 kVA
Spare strap
71 / 150
Picture Fig. 2-9: Tap wiring
S1 wire m1 S1 wire m1
S2 S2
82 to 100 % 71 to 81 %
(8/8) (7/8)
S3 S3
S4 wire m2 S4
S5 S5 wire m2
strap B strap B
S6 S6
S1 S1 wire m1
S2 wire m1 S2
59 to 70 % 22 to 46 %
(6/8) (4/8)
S3 S3
strap A
S4 S4 wire m2
S5 wire m2 S5
strap B strap B
S6 S6
S1 wire m1
S2
8 to 22 %
(2/8)
S3
strap B
S4 wire m2
S5
S6
72 / 150
2.5 Component replacement and software uploads
Material This equipment contains electrostatic sensitive devices.

handling Please take care not to damage components by electrostatic discharges.
precautions Electronic modules and components should be touched only when this is
unavoidable, e.g. for soldering, replacement etc.
Before touching any component of the cabinet you should bring your body to
the same potential as the cabinet by touching a conductive earthed part of
the cabinet.
Electronic modules or components must not be brought in contact with highly
insulating materials such as plastic sheets, synthetic fibre clothing etc. They
must be laid down on conductive surfaces.
The tip of the soldering iron must be earthed.
Electronic modules and components must be stored and transported in
conductive packing.
Take care not to cause electrostatic discharges on plugging or unplugging
connectors on the boards (e.g. Dongle connection to LMC), i.e. also Dongle
and PC must be at the same potential as the equipment.
2.5.1 Replacement of modules
Procedure Disconnect the power to the MCR³.

Take note of connector positions and switch coding.
All boards are mounted with nuts (M3 – socket or ring spanner: 5.5 mm) on
standoffs.
All the boards for the remote control interfacing are located at the rear of the
top cabinet.
The EFD boards (logic and HV resistor) are mounted in the HV compartment,
close to the output terminals and are accessible from the front door. (Note
the slots in the HV resistor board. They serve to fix the HV connecting wires
so they cannot touch low-voltage parts in case the connection is broken.)
The Circuit Selector interface board is located in the Circuit Selector cabinet.
In the small cabinet (up to 10kVA) it is accessible from the rear, and in the
big cabinet from the front.
All the other boards - PSL, LMC, CCL, TBM and LFD - are mounted on a
removable card cage.
Caution Be careful when removing the PSL.

The rest energy of capacitor C6 can be lethal. Discharge this capacitor prior
to handling this board to prevent injuries or component damage.
See section 6: PSL for further explanation.
Be careful of the 500 V DC voltage present on the EFD boards and the high-
voltage wiring. The energy of this source is limited but still sufficient to startle
a person coming in contact with it.
Always take car to discharge the series circuit loop, and connect the series
circuit to the ground at both sides, prior to touch any HV part.
73 / 150
Procedure Set the dip-switches of the replacement board exactly in the same position
(continued) as the removed board.
Mount the replacement board and re-install the connectors.
If possible, check the installed software. If required, make an upload of the
most recent software version.
If measurements of the module are necessary, it is required to adjust the
parameter settings in accordance with the MCR³ (input voltage, input fuse
range, regulator power, tap setting).
Check always the parameter setting “CS installed / not installed"
Check the operation of the board.
74 / 150
2.5.2 Replacement of the thyristor pack

Please note the connections.
The connection of the gates is done with fast-on tabs 2.8/0.8.

Please note that the position of these gates may differ for different brands
(see drawing 3229.13.240BA).
A heat-conducting paste between thyristor pack and heatsink is required to

keep the junction temperature of the thyristors as low as possible. Apply a
thin layer of heat-conducting paste (e.g. DOW CORNING 340) on the flat
mounting surface of the thyristor pack. Clean the heatsink thoroughly prior to
mounting the thyristor pack.
The mounting of the thyristors on the heatsink and the power connection is
done with M5 screws. These screws have to be mounted with an adequate
mounting torque.
Recommended mounting torques according to the manufacturer data sheets:
Manufacturer Thyristor model Mounting torque in Nm (lb in)
Heatsink Terminal
EUPEC TT92N 3.4-4.6 (30.1-40.7) 3.6-4.4 (31.9-38.9)
EUPEC TT162N 5.1-6.9 (45.1-61) 5.4-6.6 (47.8-58.4)
SEMIKRON SKKT92E 2.55-3.45 (22.6-30.5) 2.55-3.45 (22.6-30.5)
SEMIKRON SKKT162E 4.25-5.75 (37.6-50.9) 4.25-5.75 (37.6-50.9)
2.5.3 Replacement of the main contactor

Take note of the connections.
The contactor is clip-mounted on a rail (symmetric 35 mm rail).
It is kept in position on this rail by means of two end blocks.
Recommended mounting torques according to the manufacturer data sheets:
Contactor model Mounting torque in Nm (lb in)
Coil terminals A1 & A2 Power terminals L1 - L4 and T1 - T4
3RT1326 0.8-1.2 (7.1-10.6) 2-2.5 (17.7-22.1)
3RT1336 0.8-1.2 (7.1-10.6) 3-4.5 (26.5-39.8)
3RT1344 0.8-1.2 (7.1-10.6) 4-6 (35.4-53.1)
Check that the coil transient protection block is mounted correctly on top of
the contactor.
A transient suppressor RC network is mounted on the output terminals of the
contactor to prevent switching transients from disturbing the logic circuitry.
75 / 150
2.5.4 Upload of application code
The Dongle The Dongle is the interface between the MCR³ and a PC running the MCR³
configuration program under one of the Window brands (operating system:
Windows98, WindowsNT, Windows2000, WindowsXP). It is normally only
used during installation, adjustment of system parameters and potentially
repair.
By means of the Dongle it is possible to upload software to the MCR³ boards
containing a microcontroller.
The Dongle is connected to the LMC on the female DB9-connector and to a
COM port (male DB9) of a PC (RS232 connection). The Dongle receives its
power from the LMC.
Note that when the Dongle is connected to a laptop running the configuration
software, then all MCR³ control is transferred to the laptop. This means that
changing brightness or parameters via the User Interface will not be possible
and the remote control by multiwire or bus is disabled.
Shortly after connecting the Dongle the UI will display “GK active”.
The actual brightness step and circuit(s) stay selected.
In this case control will only be possible by means of the configuration
software.
After unplugging the Dongle the message “GK active” stays displayed until
the Dongle is fully disconnected from the LMC. The LMC requires some time
to notice that the Dongle is disconnected. By interrupting the power supply
for several seconds (until the display goes blank) this transition time can be
reduced.
To disable the Dongle without unplugging the serial link to the LMC: in the
window “Configuration/Communication port” switch to “DEMO”-mode instead
of a COM port.
Upload There are 6 different types of PCB with on-board intelligence in the regulator:
LMC, UI, CCL, TBM, EFD, LFD.
All these boards are equipped with a FLASH EEPROM device for storing the
application code in replacement of the EPROMs of older types of equipment.
This allows the user to install new code in the equipment without having to
replace EPROMs on the boards. Also the Dongle is equipped with a FLASH
EEPROM permitting easy installation of new code.
If it is necessary to update the software, the customer will receive from ADB
a floppy disk, a CD or an e-mail with the new code in a proprietary format (file
extension: UPL). This file must be copied by the customer to the same
directory on his PC where the configuration software is located.
He then connects the Dongle between PC/serial port and regulator/
LMC/CO5 and starts the configuration software, which will automatically
detect the presence of new upload software. In the configuration menu there
is a header for uploading new software. Clicking on it opens a window that
shows all upload versions available on the PC.
76 / 150
Upload The first step is the transmission of the upload to the Dongle, where it is
(continued) temporarily stored. Then the destination device is switched to upload mode,
this means that the CPU stops executing the normal application and jumps to
the boot-loader code. (reserved EEPROM zone in the micro-controller
containing this fixed code). At that point the laptop transmits the new code to
the devices concerned where it is stored in RAM. After termination of the
transfer, the integrity of the code is checked in several ways and then the
command is given to reprogram the FLASH memory. When the transfer is
complete, the code is checked again in the FLASH and if correct, the device
goes into reset and restarts with the new code.
During the upload operation, the user/operator can monitor its execution on
the PC. After its termination, he can consult the list of the software versions
currently active on the system and verify that the upload was executed
correctly.
An upload can take up to several minutes depending on the file volume.
Although many precautions are taken in this automatic sequence, there are
critical moments during which e.g. a power failure might lead to an unusable
system because only part of the FLASH is reprogrammed. If this happens,
the CPU itself will detect at the next power-up that the application is
incomplete and go into boot-loader mode. The customer must then restart
the upload.
As a last resort, a strap is provided on each PCB to force the CPU in boot-
loader mode and wait for the upload of a new application.
Note that the user can find out if a PCB is running in application or in boot-
loader mode by looking at the RUN LED. If there is a fixed flashing sequence
of ½ s ON and ½ s OFF, then the CPU is running in application mode. If the
RUN LED flashes at a higher rate, then the CPU has switched to boot-loader
mode.
77 / 150
3 Section 3
Maintenance
Introduction The MCR³ regulators have been developed using future-oriented technologies
and in view of reducing the maintenance tasks to a minimum.
This section establishes the maintenance procedures required for the MCR³
regulator. The maintenance tasks must be performed on a securing basis to
insure optimum performance, minimise service interruption and avoid major
breakdowns.
Caution Only personnel authorised to work on high-voltage equipment should perform

maintenance on the regulators.
Operate the regulator under local control when performing maintenance
tasks. This will prevent the regulator from being accidentally turned on and
causing serious injury or death.
Table 3-1 Table 3-1: Preventive maintenance
Check Action
Operational • the operation of the • Use a PC to log the data, if
regulation on all desired.
brightness steps
• all readings
Electrical • the input voltage • If the regulator voltage is not
within the tolerances, notify
the power company to correct
the voltage.
• the output current • Record and adjust if out of
(RMS value) tolerance; use a RMS-reading
A-meter.
Visual • the wiring of the • Repair damaged or loose
regulator and circuit wires.
• Replace damaged
components.
• the housing for rust • Clean and repaint rust spots.
spots and damage. • Repair eventual damages.
• the housing for dust • Clean by blowing dry air over
accumulation the dirty components, PCBs…
78 / 150
4 Section 4
Troubleshooting
Important Only personnel qualified to work on high-voltage systems should be

precaution! permitted to troubleshoot on the regulator.
If the regulator de-energises the output suddenly, the circuit might have
been interrupted by an overcurrent, open circuit or undervoltage
condition. Before inspecting the output circuit, place the local control in
the OFF position. Without this precaution, a rise on the power line may
produce an ON cycling and re-energise the regulator, resulting in an
output voltage of several hundreds or thousands of volts that may cause
serious injury or death.
Preliminary Before any operation or adjustment check for the obvious:

checks •User Interface indications (or back-indication signals)
•power supply voltage off
•fused input switch
•blown input fuses and blown auxiliary fuses
•loose connections
•charred or burned components
•openings in wiring
79 / 150
Guideline As a guideline for troubleshooting, use tables 4-1 to 4-3. Three different
cases are treated:
Table What to do if the regulator

Table 4-1 does not turn on
Table 4-2 turns on but de-energises suddenly
Table 4-3 does not produce the requested output
Display and See section 1.3.6 for the interpretation of the indications on the User
LEDs info Interface.
Several LEDs are available on the boards to indicate the operation of the
modules. See section 6 for the function of these LEDs.
In general terms:
The LED RUN blinking at a rate of once per second indicates that the
microcontroller is operational.
If this LED RUN blinks at a much higher rate this means that the
microcontroller is in boot-loader mode and a software upload is required.
The LEDs indicating bus activity are blinking at the communication rate
during transmission or reception.
The busses operate on a voltage source isolated from the logic supply. The
LED for this isolated power supply should always remain lit.
PC: With the help of the program MCR3_WIN it is easy to check the operation of
MCR3_WIN the Local Bus, the modules and the parameter setting.
See section 7 for a detailed description of this program.
Fuses Table 4-4 gives an overview of the fuses (main fuses, fuses on the power
module, etc.) in the MCR³.
80 / 150
Table 4-1 Table 4-1: The regulator does not turn on.
Observations Possible cause Solutions

No local indications • power supply to the • Power supply
board interrupted, check:
- fuses of the fused
switch (fig. 1-2)
- auxiliary power fuses in
the top cabinet (F3/F4
fig. 1-12 and 1-13)
- PSL defective (fig. 1-12
and 1-13)
- internal fuses on PCBs
Indication "Error" and • power supply level • Check the power supply.
the main contactor in too low (less than Correct if possible the
the power module the pre-set value) voltage level.
(K on drawing 3229. • Check the calibration of
13.240BA) is not the input voltage
energised. measurement.
• fuse PSL/F1 blown • Check the wiring and

main contactor coil.
Replace the fuse.
• failure in the CCL or
PSL module or • Check the wiring.
wiring Replace the defective
module.
Main contactor (K) is • failure in the CCL or • Check the wiring.
energised but no TBM module Replace the defective
output current is module.
generated.
81 / 150
Table 4-2 Table 4-2: The regulator turns on but de-energises suddenly.

Protection of the • too fast acting or • Check values on drawing
power supply to the too low level 3229.13.240BA
CCR became and in manual.
operational. • power supply • Check the wiring to the
wiring or CCR CCR and the internal
components wiring; check the fused
switch and the terminals.
CCR produced • one thyristor not • Check the wiring to the
considerable more operating or short- thyristor gates and
noise and the fuses circuited inspect the TBM.
of the fused switch
blew. • failure in thyristor • Replace the TBM.
control pulses
• one thyristor • Replace the TBM.
interrupted
Indication • overcurrent • Check the maximum
"Overcurrent error" output current and, if
necessary, readjust.
• Check the overcurrent
alarm level and, if
necessary, readjust.
Indication • An open circuit in • Check the series loop for
"Open circuit error” the loop occurred. an interruption.
• CCR malfunction • Check the thyristors, the
wiring of the transformer
and the choke, the main
contactor, the output
current measurement
transformer and TBM.
Indication • open circuit in the • Check the load of the
"Overload error” loop . series loop.
• CCR malfunction • Check the power
components, the wiring
and the parameter setting
of TBM and CCL.
82 / 150
Table 4-3 Table 4-3: The regulator does not produce the requested output
current.

Always maximum • maximum brightness • Disconnect the remote
output current step always selected control line for the max.
brightness step and
check the remote
control signals.
• failure of the logic • Check the parameter
setting and the CCL.
All steps above but • one brightness step • Check the remote
none below a certain always selected control signals.
step can be selected • failure of the logic • Check MW or CCL.
Only the minimum • failure of the remote • If the module operates
brightness step is control line correctly in local, then
selected. check the remote
control line.
• failure of the logic • Check MW or CCL.
The output current is • CCR is overloaded • Check the output
not reached and transformer tap, the
signal "I fault" is power supply voltage
given. and the load.
No output current • input voltage too low • Check input voltage
and parameter setting
of the regulator.
• failure of the logic • Check local control,
Local Bus, MW, LMC,
CCL or TBM.
No display at all and • power supply failure • Check mains power
none of the LEDs lit supply, fuses, wiring
on the boards. and PSL.
83 / 150
Table 4-4 Table 4-4: Overview of the fuses
Fuses Position Reference

Main fuses F1 (*) Fused switch Fig. 1-2 rep 3
Auxiliary fuses F2, F3 and F4 (**) Behind the User Interface panel
Internal fuses on the boards: see below.
(*) See diagram 3229.13.240BA, page 2, for the value in accordance with
power rating and input voltage.
These fuses have a visual indication in case of overload:
• for type NEOZED (up to 63 A): the centre point of the fuse
• for type NH00 (up to 125 A): the spring clip on top of the fuse.
(**) See section 5: Parts List for the value of these fuses.
F2 serves to protect the internal auxiliary mains wiring.
F3 protects the wiring of the voltage measurement circuit (primary voltage of
transformer T1).
F4 protects the wiring of the mains to the Circuit Selector (HV contactor coil
control voltage).
On the boards:
Miniature glass fuses (DIA 5 L20):
PCB Fuse Type Protects

1521 PSL/F1 T 1A DIA 5 L20 the power supply (230 V AC) for the main contactor, the
(PSL) logic supply (PSL) and the coil for the SCO lock.
PSL/F2 T 1A DIA 5 L20 the power supply (230 V AC) of the multiwire modules.
1523 CS/F1 T 4A DIA 5 L20 the mains supply to the coils of the contactors K1 to K8.
(CS)
Some boards have polyswitch resettable fuses (PPTC: Polymeric Positive

Temperature Coefficient Devices). These devices do not require replacement
after a fault event, and allow the circuit to return to the normal operating
condition after the power has been removed and/or the failure causing the
overcurrent is eliminated.
PCB Fuse Protects
1516 VR1 the control voltage (+12V) to check the back-indication signals of the Circuit
(CCL) Selector.
VR2 the control voltage (+12 V) to the relays CS / K1 to K4.
VR3 the control voltage (+12 V DC) to the relays PSL/K1, K2 and K3.
the control voltage (+12 V) to the relays CS / K5 to K8.
VR4
1486 VR1 the 24 V DC or 48 V DC internal remote control signals supply of the
(MW) VR2 regulator.
VR3 VR1 and VR3 are mounted in case of 24 V DC.
Only VR2 is mounted in case of 48 V DC.
84 / 150
5 Section 5
Parts List
Introduction This section covers the main replaceable parts for the MCR³ regulators.
Caution Replacement of electronic components may be done, only with original spare
parts delivered by ADB. Not doing so can result in severe damage to the unit
and hazardous conditions for the user or the operator.
Reference A reference code number is assigned to each part contained in the

designation equipment. When ordering, always mention the reference code number of
the ordered part and also the serial number, type, power rating, input voltage,
frequency, number of brightness steps, output current, which are indicated
on the nameplate of the regulator.
Recomm. On major airports or when an important quantity of regulators are installed, it

spare parts is recommended to have one or more regulators in standby inside the
substation, to allow quick replacement of a defective unit. This procedure is
recommended when it is desirable to reduce the downtimes caused by
maintenance, troubleshooting and repair procedures.
Other parts should be kept in stock to cope with repair: fuses, lightning
arrestors, PCBs, terminals and connectors, fused input switches, circuit
breaker, power packs and others.
Orders All spare parts orders shall be addressed to ADB or our local representative.
n.v. ADB s.a.
585, LEUVENSESTEENWEG
B - 1930 ZAVENTEM, BELGIUM
Tel.: 32/2/722.17.11
Fax: 32/2/722.17.64
Table 5-1 Table 5-1: Basic printed circuit boards

(reference on drawing 3229.13.240BA)
Basic printed circuit boards

Order quantity
Ref. ADB part Description (per)
number
UI 1593.14.000 PCB1507 – User Interface 1
LMC 1593.14.113 PCB1513 – Local Master Circuit 1
CCL 1590.03.541 PCB1516 – Current Control Logic 1
TBM 1593.14.213 PCB1517 – Thyristor Block Module 1
PSL 1593.14.400 PCB1521 – Power Supply Logic 1
85 / 150
Table 5-2 Table 5-2: Optional printed circuit boards
(reference on drawing 3229.13.240BA)
Optional printed circuit boards Order quantity

Ref. ADB part Description (per)
number
MW1, MW2, MW3 1593.13.510 PCB1486 – multiwire board 24 V DC 1
MW1, MW2, MW3 1593.13.520 PCB1486 – multiwire board 48 V DC 1
JB 1590.03.490 PCB1502 – J-Bus Interface 1
EFD 1590.03.521 PCB1514 – Earth Fault Detector, logic 1
board
EFD RES. 1590.03.530 PCB1515 – Earth Fault Detector, resistor 1
board
LFD 1590.03.551 PCB1517 – Lamp Fault Detector, logic 1
board
CS 1590.03.561 PCB1523 – Circuit Selector board 1
DONGLE 1440.00.010 PCB1505.1 - DONGLE 1
Table 5-3 Table 5-3: Power components, input
Power components, input fuses Order quantity

Ref. ADB part number Description (per)
Fused switch F1 6132.00.210 5SG7 fused switch – fuse interrupter 10
for Neozed fuses (small cabinet)
Fused switch F1 6130.54.460 Input fuse for 5SG7 – 20 A - Neozed, 2
2 per fused switch
Fused switch F1 6130.57.360 Input fuse for 5SG7 – 25 A – Neozed, 2
2 per fused switch
2 per fused switch
2 per fused switch
2 per fused switch
Fused switch F1 6132.00.220 NH00 fused switch – fuse interrupter 2
(big cabinet)
Fused switch F1 6130.63.366 Input fuse for NH00 – 50 A -NH00, 2
2 per fused switch
Fused switch F1 6130.68.330 Input fuse for NH00 – 80 A - NH00, 2
2 per fused switch
2 per fused switch
2 per fused switch
Note For the selection of the input power fuses refer to table 2-1.
86 / 150
Power components, input Order quantity
(per)
Ref. ADB part Description
number
Fused switch 6112.45.203 Fuse holder for symmetric rail 35 mm, 2
F2, F3, F4 fuses DIA 6.3 L 32
Fused switch 6130.27.005 Fuse M1.6A HBC DIA 6.3 L 32 10
F2, F3 (medium)
Fused switch 6130.37.180 Fuse T4A HBC DIA 6.3 L 32 (slow- 10
F4 (optional) blow)
PSL / F1 6130.26.134 Fuse T1A HBC DIA 5 L20 (slow-blow) 10
PSL / F2
CS – F1 6130.37.132 Fuse T4A HBC DIA 5 L20 (slow-blow) 10
(optional)
MOV1/A, MOV1/B 6134.03.010 Lightning arrestor for mains input 2
(optional)
CS – T1 6300.03.160 Autotransformer 250 VA for Circuit 1
(optional) Selector
K1 6148.45.580 Main contactor - 50 A 1
K1 6148.45.630 Main contactor - 63 A and 80 A 1
K1 6148.45.600 Main contactor - 100 A and 125 A 1
For K1 6148.45.590 Main contactor, RC coil protection - up 1
to 80 A
For K1 6148.45.610 Main contactor, RC coil protection - 1
100 A and 125 A
For K1 6322.99.055 Mains filtering at contactor contacts, all 1
or power ratings
6322.99.065
T.I.1 6302.03.200 Input current measurement transformer 1
200/0.2 A
THP-1, THP-2 6351.85.320 Thyristor pack CRPTT90GK (up to 1
50 A)
THP-1, THP-2 6351.85.330 Thyristor pack CRPTT165GK (above 1
50 A)
Wire A2 6304.10.600 Common mode choke, ferrite core 1
OC/2
Note For the selection of the main contactor and the thyristor pack refer to
table 2-1.
87 / 150
Power components, output Order quantity
(per)
number
LA1-LA2 6314.32.750 Lightning arrestor for 2.5 kVA - 10 kVA 2
- 6.6 A - Siemens B32K750
LA1-LA2 6134.03.322 Lightning arrestor for 15 kVA - 6.6 A. 2
Qty 2x1 - G.E. 3kV-XEP
LA1-LA2 6134.03.622 Lightning arrestor for 20 to 30 kVA- 2
6.6 A. Qty 2x1 - G.E. 6kV-XEP
T.I.2, T.I.3 6302.03.180 Output current measurement 1
transformer for 6.6 A. 50 / 0.05 A
Spare parts for optional Circuit Selector Order quantity

(per)
number
SCO 1475.92.030 Cut-out SCO 1
CS – K1…K8 6148.47.510 High-voltage contactor, up to 1515 V / 1

6.6 A RMS
CS – K1…K8 6148.45.229 High-voltage contactor, up to 4545 V / 1
6.6 or 1515 V / 20 A RMS
CS – K1…K8, 6148.98.250 RC coil protection, for contactors up to 1
RC coil protection 1515 V RMS
CS – K1…K8, 6148.45.238 RC coil protection, for contactors up to 1
RC coil protection 4545 V / 6.6 A or 1515 V / 20 A RMS
CS – K1…K8, 6148.45.484 Auxiliary contact, for contactors up to 1
Auxiliary contact 1515 V RMS
CS – K1…K8, 6148.45.236 Auxiliary contact, for contactors up to 1
Auxiliary contact 4545 V / 6.6 A or 1515 V / 20 A RMS
88 / 150
Power components, transformers Order quantity
(per)
number
T1 1476.03.195 Power transformer, 2.5 kVA, 6.6 A 1
T1 1476.03.742 Power transformer, 4 kVA, 6.6 A 1
T1 1476.03.762 Power transformer, 7.5 kVA, 6.6 A 1
T1 1476.03.843 Power transformer, 25 kVA, 20 A 1
T1 1476.03.833 Power transformer, 30 kVA, 20 A 1
Note Wiring depends on input voltage.
Power components, choke Order quantity

(per)
number
L1 1476.02.500 Series choke, 2.5 kVA 1
L1 1476.02.504 Series choke, 4 kVA 1
L1 1476.02.507 Series choke, 7.5 kVA 1
Note Wiring depends on input voltage.
89 / 150
Table 5-4 Table 5-4: Hardware parts
Hardware parts
Ref. . ADB part Description

number
Wheels (optional) 7015.35.240 Wheel 2
Wheels (optional) 7015.35.250 Wheel with wheel lock 2
Lifting lugs 7015.20.120 lifting lugs M12 4
(optional)
PCB 7510.08.300 Standoffs for PCBs M3 L10 10
PCB 7154.04.010 Nut Hex M3 for PCB mounting 100
Wiring 6126.83.810 Cable clamp, up to DIA 8 mm 10
Wiring 6126.83.820 Cable clamp, for DIA 7 up to 16 mm 10
Table 5-5 Table 5-5: Connectors
Hardware parts

number
PSL/X7 6112.32.517 4-pole cage-clamp 1
MW1-2 or 3 / P1 or 6112.33.112 12-pole cage-clamp 1
P2
JB / P1, P2, P3 or 6112.32.518 6-pole cage-clamp 1
P4
Cage-clamp 6112.32.500 Connector accessory, operating lever, 10
231-131
90 / 150
6 Section 6
Drawings
Introduction Overview of the printed circuit boards: silk screens, switch settings, LED
functions and remarks.
Electrical diagram 3229.13.240BA.
Local Bus This bus is used for communication between all modules and the LMC.
The LMC is master of this communication.
Note that the Local Bus connection on the TBM is only used for software
uploads of this board. The TBM is connected primarily to the CCL and
connects to the LMC through the CCL.
The Local Bus connection uses RS485 protocol, in differential mode, 5 V

(max.) signals over 2 wires.
These RS485 signals are isolated from the other board signals (500 V DC
level).
Line The line termination resistors (150 to 850 Ohm) are only to be placed on the
termination modules that are at the extremities of the line, to prevent line reflections.
resistors J-Bus
In case of a 2-line system (J-Bus or Local Bus) only the straps of the used
channel are to be set, thus only on the line “Transmit / E”.
In case of a J-Bus 4-line system the straps on the lines “Transmit / E” and
“Receive / R” have to be set.
Make sure that only the line termination resistors at the end of the line are
placed. When other straps are also placed, the signals on the line are
weakened. This can cause an incorrect functioning of the MCR³!
Local Bus
For the Local Bus the line termination is done on the TBM and the LMC.
LED RUN In general terms:

The LED RUN blinking at a rate of once per second indicates that the
microcontroller is operational.
If this LED RUN blinks at a much higher rate this means that the
91 / 150
TBM – PCB1517 –1593.14.212
92 / 150
Dip-switches - TBM
S1 Local Bus - Line termination

Switch Function
1 ON: Transmit / E – pull up 680 Ohm
2 ON: Transmit / E – line termination 150 Ohm
3 ON: Transmit / E – pull down 680 Ohm
S2 Various functions
Switch Function
1 Recall default parameters
2 CCL-TBM communication, parity:
For 115200 Bd: 0 = even / 1 = odd
For 38400 Bd: 0 = even / 1 = no parity
3 ON: Lock in boot-loading mode
4 CCL-TBM communication, baudrate: 0 = 115200 Bd /
1 = 38400 Bd
5 Local Bus – 0 9600 1 19200 0 38400 1 9600
6 baudrate: 0 Bd 0 Bd 1 Bd 1 Bd
7 Local Bus – 0 NO 1 NO 0 ODD 1 EVEN
8 parity: 0 parity 0 parity 1 parity 1 parity
Switch Function
1 Not used
2 Not used
3 Not used
4 Not used
5 Not used
6 Not used
7 Not used
8 Not used
LEDs
LED Function
D1 Local Bus – isolated 5 V present
D2 Microcontroller – RUN
D3 Local Bus – TXD
D5 Local Bus – enabled
Note Strap J5 has to be installed in case of an input voltage range of 208 to 240 V.
In case of an input voltage range 380 to 415 V, the strap J5 has to be
removed.
Incorrect placing of strap J5 will cause inaccurate output voltage monitoring.
Strap J4 is only for factory use (removed for normal operation).
Factory Factory setting of the switches:

setting S1 - all ON
S2 - 1:OFF 2:OFF 3:OFF 4:ON 5:OFF 6:ON 7:ON 8:ON
93 / 150
PSL – PCB1521 – 1593.14.400
Test points - PSL

Test point Function
TP1 +12 V DC - Relay control common
TP2 Ground, relative to +12 V DC signal
TP3 Relay control signal - K1 (main contactor)
TP4 Relay control signal - K2 (regulation error)
TP5 Relay control signal - K3 (SCO locking)
TP6 5 V AC1 - input voltage reference, AC signal
TP7 5 V AC2 - input voltage reference, AC signal
Caution Capacitor C6 will remain charged at about 70 V DC long after disconnecting the
power supply. To prevent any damage or electrical shock it has to be discharged
by means of a power resistor. (Remaining energy in capacitor about 2 Joule. A
resistor of about 1000 Ohm / 3 W across the capacitor terminals will discharge
the capacitor to below 24 V in less than half a second.)
94 / 150
CCL - PCB1516 – 1590.03.541
95 / 150
Dip-switches - CCL
SW1 Local Bus - Line termination

Switch Function
SW2 Various functions

Switch Function
1 Recall default parameters
2 CCL-TBM communication, parity:
For 115200 Bd: 0 = even / 1 = odd
For 38400 Bd: 0 = even / 1 = no parity
3 ON: Lock in boot-loader
4 CCL-TBM communication, baudrate: 0 = 115200 Bd / 1 = 38400 Bd
5 Local Bus – 0 9600 Bd 1 19200 0 38400 1 9600
6 baudrate: 0 0 Bd 1 Bd 1 Bd
LEDs
LED Function
DS1 Microcontroller – RUN
DS2 Local Bus – isolated 5 V present
DS3 Local Bus – TXD

setting SW1 - all OFF
SW2 - 1:OFF 2:OFF 3:OFF 4:ON 5:OFF 6:ON 7:ON 8:ON
96 / 150
LMC - PCB1513 – 1593.14.111
97 / 150
Dip-switches - LMC
SW1 J-Bus A - Line termination and 2- or 4-wire transmission selection

Switch Function
4 OFF = 2 wire / ON = 4 wire
5 ON: Receive / R – pull up 680 Ohm
6 ON: Receive / R – Line termination 150 Ohm
7 ON: Receive / R – pull down 680 Ohm
8 Not used
SW2 J-Bus B - Line termination and 2- or 4-wire transmission selection

Switch Function
4 OFF = 2 wire / ON = 4 wire
5 ON: Receive / R – pull up 680 Ohm
6 ON: Receive / R – line termination 150 Ohm
7 ON: Receive / R – pull down 680 Ohm
8 Not used
SW3 Local Bus and Sync line - Line termination

Switch Function
1 ON: Local Bus - Transmit / E – pull up 680 Ohm
2 ON: Local Bus - Transmit / E – line termination 150 Ohm
3 ON: Local Bus - Transmit / E – pull down 680 Ohm
4 Not used
5 ON: Sync line - Transmit / E – pull up 680 Ohm
6 ON: Sync line - Transmit / E – line termination 150 Ohm
7 ON: Sync line - Transmit / E – pull down 680 Ohm
8 Not used
SW4 J-Bus slave number (composed by the switches in the position OFF)
Switch Hexadecimal value Decimal value
1 01 hex 1
2 02 hex 2
3 04 hex 4
4 08 hex 8
5 10 hex 16
6 20 hex 32
7 40 hex 64
8 80 hex 128
98 / 150
SW5 Local Bus – Enabling or disabling of modules
Switch setting on LMC permits disabling of the detection of the optional units.
(Local Bus to these units will be deactivated.)
Switch Function
1 ON: UI enabled
2 ON: EFD enabled
3 ON: LFD enabled
4 Not used
5 Not used
6 Not used
7 Not used
8 ON: GK enabled

Switch Function
1 ON: Local Kill
2 ON: E2P init
4 Not used
5 Local Bus – 0 9600 1 19200 0 38400 1 9600 Bd
6 baudrate: 0 Bd 0 Bd 1 Bd 1
7 Local Bus – 0 NO 1 NO 0 ODD 1 EVEN Parity
8 parity: 0 parity 0 parity 1 parity 1
SW7 Not used
LEDs
LED Function
DS1 J-Bus A – isolated 5 V present
DS2 J-Bus B – isolated 5 V present
DS5 Sync line signal
DS6 Local Bus – RXD
DS7 J-Bus A – RXD
DS8 J-Bus A – TXD
DS9 J-Bus B – RXD
DS10 J-Bus B – TXD
DS11 Microcontroller - RUN

settings SW1 - all OFF
SW2 - all OFF
SW3 - 1:ON 2:ON 3:ON 4:OFF 5:OFF 6:OFF 7:OFF 8:OFF
SW4 - J-Bus slave number
SW5 - Depending on the presence of the modules
SW6 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON
99 / 150
UI - PCB1507 – 1593.14.000
Dip-switches - UI

Switch Function
4 Not used
100 / 150
Switch Function
1 Not used
2 Not used
3 ON: Lock in boot-loader mode
4 Not used
5 Local Bus – 0 9600 1 19200 0 38400 1 9600
LEDs
LED Function
D2 Local Bus – RXD
D4 Microcontroller – RUN
D5 Local Bus – isolated 5 V present

101 / 150
Multiwire - PCB1486 – 1593.13.510 & 1593.13.520
Note The multiwire board delivers a remote control voltage usable to control the
relays of this board.
It is protected with polyswitch fuses.
This internal remote control voltage is brought to the terminal block P2:
terminal P2/10: positive pole.
terminal P2/11: negative pole.
With strap W5 installed, the internal remote control voltage (negative pole
also internally wired to P2/11) is connected to the common of the remote
control line (P2/9).
With strap W6 installed, the positive pole of the internal remote control
voltage is connected to the common pole for the back-indication signals.
102 / 150
J-Bus Connection - PCB1502 – 1590.03.490
This small PCB provides the interconnection of the user J-Bus(ses) with the
LMC.
The PCB is equipped with gas arrestors for overvoltage protection.
103 / 150
LFD - PCB1519 – 1590.03.551
DIP-switches - LFD
S1 Local Bus - Line termination

Switch Function
4 Not used
Switch Function
1 Not used
2 Not used
3 ON: Lock in boot-loader mode
4 Not used
5 Local Bus – 0 9600 1 19200 0 38400 1 9600
LEDs
LED Function
104 / 150
setting S1 - all OFF
S2 - 1:OFF 2:OFF 3:OFF 4:OFF 5:OFF 6:ON 7:ON 8:ON
EFD Logic - PCB1514 – 1590.03.520
Dip-switches – EFD

Switch Function
4 Not used

Switch Function
1 Not used
2 Not used
4 Not used
5 Local Bus – 0 9600 1 19200 0 38400 1 9600
105 / 150
LEDs
LED Function
DS2 Ohm-test activated
DS3 Output disconnected

Caution The EFD produces a voltage of 500 V DC. This voltage is connected to the
output circuit of the regulator, thus all high-voltage components will have this
voltage level relative to ground. The energy is limited but still sufficient to
startle a person coming in contact with it.
EFD-Res - PCB1515 – 1590.03.530
106 / 150
Circuit Selector – PCB1523 – 1590.03.561
Test points – CS
Test point Function
TP1 Ground, relative to +12 V DC signal
TP2 +12 V DC signal for relay control – K1 to K4
TP3 +12 V DC signal for relay control – K5 to K8
LEDs
LED Function
DS1 Relay K1 energised / Circuit 1 short-circuited
107 / 150
Dongle – PCB1505.1 – 1444.00.010
The Dongle is the interface between the CCR and a PC running the CCR
configuration program under one of the Window brands. It is normally only
used during installation, adjustment of system parameters and repair, if
necessary.
It connects on the one hand to the connector CO5 of the LMC and on the
other hand to the COM port of the PC on which the regulator configuration
software is running. Both connections use RS232.
When the Dongle is connected to the system and to the PC and the regulator
configuration software is running, then the LMC relinquishes bus mastership
in favour of the Dongle. Control through the User Interface is no longer
possible.
The Dongle receives its power from the LMC.
DB9 Male LED - LEDs for RXD & TXD LED - RUN
to PC Isolated Communication to LMC
power supply
Communication to PC
LEDs for DB9 Female
TXD & RXD SW1 to LMC
1 8
SW1 Baudrate and parity settings
Switch Function
1 PC link (RS232) - 0 9600 1 38400 0 19200 1 9600
3 PC link (RS232) - 0 NO 1 EVEN 0 NO 1 ODD
5 Local Bus - 0 9600 1 38400 0 19200 1 9600
7 Local Bus - 0 NO 1 EVEN 0 NO 1 ODD
LEDs LED – Isolated Power supply: indicates the presence of the isolated
supply. It must always remain lit.
LED – RUN: This LED flashes at a rate of 1 flash per second during normal
operation. If it blinks at a much higher rate this means that the
Bus LEDs: All these LEDs are normally OFF and light up for a short time
during transmission or reception.

setting SW1 - 1:ON 2:OFF 3:ON 4:OFF 5:ON 6:OFF 7:ON 8:OFF
108 / 150
Electrical Diagrams (3229.13.240BA)
109 / 150
7 Section 7
PC Control and Monitoring
Preliminary The regulator does not require the use of a PC to operate.
Use The PC with the dedicated ADB software and the Dongle is required to
modify parameters, in particular for the adjustment of the lamp fault detection
module and for the Circuit Selector.
It can also be used to control the regulator.
Caution! If the PC with the Dongle is connected to the LMC, local control will only be
possible by means of this software. The User interface will give back-
indications but brightness control or parameter access will be disabled.
110 / 150
7.1 Program MCR3_WIN
With a connected Dongle, an operational regulator and the program

MCR3_WIN started, the communication between PC and regulator enters an
infinite loop.
The program performs two tasks:
• a regular and automatic data exchange with the MCR³
• possibility to change parameter settings, control and calibration of the
MCR³ by means of a screen interface using a menu
Structure of The screen is divided in windows with a menu bar at the top.
the screen
To the left, the status window is always present and shows:
• the output current (as a thermometer-like vertical bar graph and as a
numeral value)
• the mains voltage
• the luminosity in %
• the currently active step
• the selected circuits (if the CS option is installed)
• the number of burnt lamps (if the LFD option is installed)
• the insulation resistance of the series circuit (if the EFD option is
installed)
• the status of the J-Bus
The display in the right-hand window can be selected by the user via the
menu bar at the top of the screen.
Eight different dialogue screens are accessible: Control, MCR3 Setup, EFD,
LFD, IO, Installation, Configuration and Exit.
Some screens contain more lines than visible in one window. A scroll bar at
the right side of the window permits to scroll through these screens.
Parameters can be changed by clicking on the text or the value.
A small window appears to make a selection between various settings or to
enter a value.
The small window on the bottom left displays informative messages.
The small window on the bottom right shows warnings and alarm messages.
Note Calibration of the current, voltage and power measurements:

See menu “MCR3 Setup” / “MCR3 Input/Output measurements” / “Calibration”
Rough calibration is possible with regulator in short circuit.
Fine-tuning is possible with full load.
After the calibration procedure of “input voltage”, ”input current”, ”input
power”, ”output voltage”, ”output current” or ”output power” has been
selected, the MCR³ (CCL) starts a zeroing of the measurement. After this is
finished, the MCR³ switches on at the maximum brightness step and asks for
the reading to be entered. Wait until the regulation and the measurement are
stabilized and enter the reading. Check if the calibration is concluded
successfully.
111 / 150
Calibration of After the EFD calibration has been started, the module itself checks the
the EFD status without any leakage current and the status with the maximum leakage
current. After successful conclusion of this calibration the module will
measure correctly the leakage current of the field circuit and translate this to
a corresponding leakage resistance.
Control of the regulator (brightness step and circuit selection) is also possible
in the status window by selecting a displayed brightness step or circuit
selection.
To exit the program, select the window EXIT and answer YES or click on the
screen-button in the right top corner:
Caution Via menu “Installation / MAXIMUM OUTPUT CURRENT” the parameter

“Maximum output current” can be changed. This is considered to be a factory
adjustment! Changing this parameter requires calibration of output current
and output power to obtain correct readings.
112 / 150
7.2 Overview of the screens
7.2.1 MCR3 Control
113 / 150
7.2.2 MCR3 Setup
114 / 150
115 / 150
116 / 150
117 / 150
118 / 150
119 / 150
120 / 150
121 / 150
122 / 150
123 / 150
124 / 150
125 / 150
126 / 150
127 / 150
7.2.3 MCR3 EFD
Note Rule of thumb for the startup time = 4s / km cable length (as long as cable
capacitance is less than 0.2µF/km).
128 / 150
129 / 150
7.2.4 MCR3 LFD
130 / 150
131 / 150
132 / 150
7.2.5 MCR3 IO Settings
133 / 150
134 / 150
135 / 150
136 / 150
137 / 150
138 / 150
139 / 150
140 / 150
7.2.6 MCR3 Installation Parameters
141 / 150
142 / 150
7.2.7 MCR3 Configuration
143 / 150
144 / 150
7.2.8. MCR3 Exit Screen
145 / 150
8
Section 8
Appendix
8.1 MODBUS settings
Hardware present Bus A

Bus B
Arbiter Arbiter
Local kill Local kill
Default Breakdown mode
Default mode
Default step
Default step REIL
Bus Slave number
Bus A Time-out
Baudrate
Parity
Bus B Time-out
Baudrate
Parity
146 / 150
8.2 Default settings multiwire
Back-indication signals multiwire 1
P1 Function
1 Step 1 obtained
2 Step 2 obtained
3 Step 3 obtained
4 Step 4 obtained
5 Step 5 obtained
6 MCR3 is ON
7 Regulation error
8 Overtemperature alarm
9 Common
10 GNDext
11 Vext+
12 PE
P1 Function
1 Overcurrent alarm
2 Open-circuit alarm
3 EFD warning level
4 EFD alarm level
5 LFD lamps warning level
6 LFD lamps alarm level
7 LFD VA warning level
8 LFD VA alarm level
9 Common
10 GNDext
11 Vext+
12 PE
P1 Function
1 Circuit 1 active
2 Circuit 2 active
3 Circuit 3 active
4 Circuit 4 active
5 Circuit 5 active
6 Circuit 6 active
7 Circuit 7 active
8 Circuit 8 active
9 Common
10 GNDext
11 Vext+
12 PE
147 / 150
Remote control signals multiwire 1
P2 Function
1 Step 1
2 Step 2
3 Step 3
4 Step 4
5 Step 5
6
7
8
9 Common
10 Vext+
11 GNDext
12 PE
P2 Function
1 Reset EFD error
2 Use LFD degraded mode
3 Allow WRITE via bus
4
5
6
7
8
9 Common
10 Vext+
11 GNDext
12 PE
P2 Function
1 Circuit 1
2 Circuit 2
3 Circuit 3
4 Circuit 4
5 Circuit 5
6 Circuit 6
7 Circuit 7
8 Circuit 8
9 Common
10 Vext+
11 GNDext
12 PE
148 / 150
149 / 150

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AM.07.360e Edition 2.1

Revision Description Editor Checked Date

1.0 Final description AHU MR, PC 14/04/05

Spare part correction EV 01/03/06

2.0 List of alarms added CME 11/07/06

Spare part correction EV 30/11/06

2.1 Spare part correction Table 5-3: Power components, EV DT 19/06/07

Safety Regulatory safety precautions are applicable in some countries, on some

Resuscitation Operating and maintenance personnel should familiarise and keep

Electrostatic Modules and components susceptible to electrostatic damage

Use This Instruction Manual is the property of

1 Section 1 General Information and Requirements 7

7 Section 7 PC Control and Monitoring 110

8 Section 8 Appendix 146

Table 1-1: MCR³ output circuit values .........................................................................................................8

General Information and Requirements

The MCR³ The ADB MCR³ is a microprocessor-controlled constant current regulator

Purpose This instruction manual provides general information about installation,

Scope This manual covers the ADB MCR³ microprocessor-controlled constant

EMC - The MCR³ is designed to operate in an industrial electro-magnetic

1.2.1 Technical data

Rated powers 2.5/ 4/ 5/ 7.5/ 10/ 15/ 20/ 25/ 30 kVA

* 25 and 30 kVA, only for 380/ 400/ 415 V

1.2.2 Output circuit values

Table 1-1 Table 1-1: MCR³ output circuit values

2.5 kVA 6.6 378 1895 530 750

1 50 Hz RMS voltage during 1 min

Conditions From short circuit to full load

1.2.4 RV-DV terminals and cut-out SCO

1.2.5 Door-open detection (optional)

Power Factor According to FAA:

Efficiency According to FAA:

* : not on MCR³ 2.5 kVA

Benefits of The use of the taps offers the following advantages:

General Lightning is a natural phenomenon that varies in intensity and frequency

1.3.1 General view

Picture Fig. 1-2: MCR³ stand-alone unit

Dimensions 400 x 600 x 930 mm (width x depth x height)

Electronic card cage and mains supply

Earth Fault Detector module (EFD option)

Output current transformers TI 1 and TI 2

Lightning arrestors LA1 – LA 2

Fig. 1-4: MCR³ 2.5 to 10 kVA, rear view - open

Remote control interface

Remote control cable, earth

Ground studs M6, one on each side

Dimensions 600 x 600 x 1260 mm (width x depth x height)

* 25 and 30 kVA, only with 380 / 400 / 415 V

Earth Fault Detector module

Tap S6 through S1 for

Fig. 1-6: MCR³ 15 to 30 kVA, rear view - open

Remote control interface

Remote control cable, earth

Diagram Refer to ADB drawing 3229.13.240BA.

Components 1.a X1 - Input terminals

1.b Wire A02 - Common mode choke

Components 8. T1 - Output power transformer

Components 22. Dongle (optional maintenance part)

Picture User Interface