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Constant Current Regulator

Control System Interface Handbook

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ADB Safegate
977 Gahanna Parkway
Columbus, Ohio 43230 Document No: 110A0481
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Constant Current Regulator

ADB Airfield Solutions : ADB Ferro [Blue Skins] 4-30kW, 6.6A, Ferro, Air-cooled
Control System Interface Guide
Manufacturer:
ADB Airfield Solutions

Model:
ADB Ferro (Blue Skins)
4-30kW, 6.6A, Ferro, Air-cooled

Sample Picture

CCR Control System

CCI CCI
CC CC
B1 B1
B2 B2
Card Cage B3 B3
Motherboard B4 B4
B5 B5
J10 N

S1(PPF)

Pin 16
S2 (PPC) Primary Power Feedback
(48VDC) Primary Power Common
*Note 2
Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
Pin 32
(-48VDC Remote / Local feedback must be active
/GND) high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF
*Note 1

Notes:
1. See drawing 43A2304 for more details of wiring Remote/Local feedback in card cage
2. Internal wiring must be added, wired to spare terminal blocks and should be relabeled

Doc no. 110A0481 2

Constant Current Regulator

ADB Airfield Solutions : ADB LC [Blue Skins] 4-30kW, 6.6A, Ferro, Air-cooled
Control System Interface Guide
Manufacturer:
ADB Airfield Solutions

Model:
ADB LC (Blue Skins)
4-30kW, 6.6A, Ferro, Air-cooled

Sample Picture

CCR Control System

120VAC
CCI CCI
LC CC CC
Switch PCB Relay B1 B1
Kit B2 B2
(S1)
B3 B3
12VDC 1 B4 B4
12VGND 2 KS2 B5 B5
3 N
4
5 *Note 1
S1 (RLF)
6
S2 Primary Power Feedback
Primary Power Common
*Note 2
Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. A KS2 Relay may exist if CCR was formally monitored by Scanning Monitor. Else a Relay Kit will have to
be added. K1 relay must be 12VDC Coil, .5A contact rating.
2. Internal wiring must be added, wired to spare terminal blocks and should be relabeled

Doc no. 110A0481 3

 ADB Airfield Solutions : ADB CCF Signature Series, 4-30kW, 6.6A, Ferro, Air-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
ADB Airfield Solutions

Model:
CCF Signature Series
4-30kW, 6.6A, Ferro, Air-cooled

Sample Picture

CCR S1
S2
Control System
CCI CCI
CC CC
B1 B1
B2 B2
B3 B3
B4 B4
B5 B5
N

120VAC
Primary Power Feedback
FUSE Primary Power Common
F5 Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. A KS2 Relay may exist if CCR was formally monitored by Scanning Monitor. Else a Relay Kit will have to
be added. K1 relay must be 12VDC Coil, .5A contact rating.

Doc no. 110A0481 4

 ADB Airfield Solutions : ADB CCT Signature Series , 4-30kW, 6.6A, Ferro, Air-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
ADB Airfield Solutions

Model:
CCT Signature Series
4-30kW, 6.6A, LC, Air-cooled

Sample Picture

CCR Control System

CCI -48 CCI
LC CC CC
Switch PCB Relay B1 B1
120VAC
Kit B2 B2
(S1)
B3 B3
12VDC 1 B4 B4
12VGND 2 KS2 B5 B5
3 N
CCI -120
4
5 *Note 1
S1 (RLF)
6
S2 (PPF) Primary Power Feedback
Primary Power Common
*Note 2
Primary Power feedback must be active
120VAC high (24VDC or 120VAC) when primary
power is present at the CCR
FUSE
F5 Remote/Local Feedback
Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. A KS2 Relay may exist if CCR was formally monitored by Scanning Monitor. Else a Relay Kit will have to
be added. K1 relay must be 12VDC Coil, .5A contact rating.
2. Internal wiring must be added, wired to spare terminal blocks and relabeled

Doc no. 110A0481 5

 Crouse-Hinds : 30000 SEPCO Series, 10-70kW, 6.6A/20A, Ferro, Oil-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Crouse-Hinds

Model:
30000 Series [SEPCO]
10-70kW, 6.6A/20A, Ferro, Oil-cooled

Sample Picture

CCR N
120VAC
71
72
Control System
73 CCI
74 CC
*NOTE 1 B1 B1
B2 B2
B3 B3
B4 B4
B5 B5

Primary Power Feedback

Primary Power Common
Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. Older Crouse-Hinds and SEPCO Series should always be field verified for interface accuracy. If new
variations of CCR’s are determined, information should be forwarded to Project Engineering Group for
addition to CCR Interface Handbook

Doc no. 110A0481 6

 Crouse-Hinds : 31000 Series, 4-30kW, 6.6A, Ferro, Air-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Crouse-Hinds

Model:
31000 Series
4-30kW, 6.6A, Ferro, Air-cooled

Sample Picture

CCR (CC)
120VAC
XCP
N
Control System
CCI CCI
CC
B1(B10) B1
B2(B30) B2
12VGND B3(B100) B3
B4 B4
B5 B5

Option SP1 (RLF)

S446 Kit SP2
(Optional)
*Note 2
Primary Power Feedback
? Primary Power Common
? Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
*Note 1 Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. Limited information is available regarding the S446 Kit required to create the Remote/Local feedback
signal. This information should always be field verified for interface accuracy. If interface information
becomes available, this data should be forwarded to Project Engineering Group for addition to CCR
Interface Handbook
2. Internal wiring must be added, wired to spare terminal blocks and should be relabeled

Doc no. 110A0481 7

 Crouse-Hinds : 31060 Series, 10-70kW, 6.6A/20A, Ferro, Oil-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Crouse-Hinds

Model:
31060 Series
10-70kW, 6.6A/20A, Ferro, Oil-cooled

Sample Picture

CCR N
Control System
120VAC CCI CCI
CC CC
B1(B10) B1
B2(B30) B2
B3(B100) B3
B4 B4
B5 B5

Option XCP
S446 Kit XOS
(Optional)
Primary Power Feedback
? Primary Power Common
? Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
*Note 1 Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. Some older models may require the S446 Kit. Limited information is available regarding the S446 Kit
required to create the Remote/Local feedback signal. This information should always be field verified
for interface accuracy. If interface information becomes available, this data should be forwarded to
Project Engineering Group for addition to CCR Interface Handbook

Doc no. 110A0481 8

 Crouse-Hinds : 82860 Series, Small & Large, 4-30kW, 6.6A, 20-70kW,20A, Ferro, Air & Oil-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Crouse-Hinds

Model:
82860 Series, Small & Large
4-30kW, 6.6A, Ferro, Air-cooled
20-70kW, 20A, Ferro, Oil-cooled

Sample Picture

CCR Control System

Option 23 Kit 120VAC
CCI CCI
CC CC
Opt 23 Terminal Block
B1 B1
1 B2 B2 IRMS (120)
2 B3 B3 IRMS (N)
3 B4 B4
4 B5 B5
5 N
6
7
8 SP1 (RLF)
9 SP2 Primary Power Feedback
10 Primary Power Common
*Note 2
Primary Power feedback must be active
*Note 1 high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
PCB 31716 Remote/Local Common

S1 Remote / Local feedback must be active

high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
*Note 3 any local step including OFF

Notes:
1. An Option 23 Kit may exist if CCR was formally monitored by Crouse-Hinds system. Else, the
Contractor must include in their pricing the purchase and installation of these kits. Card must be
added and configured in the CCR card cage
2. Internal wiring must be added, wired to spare terminal blocks and should be relabeled
3. Refer to manual to adjust S1 switch settings to assure proper configuration and enable OPT23 options
Doc no. 110A0481 9
 Crouse-Hinds : 31360 Series, Small, 4-10kW, 6.6A, Ferro, Air-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Crouse-Hinds

Model:
31360 Series, Small
4-10kW, 6.6A, Ferro, Air-cooled

Sample Picture

CCR Control System

120VAC
CCI CCI
CC CC
Option 23 Kit B1 B1
B2 B2
B3 B3
Opt 23 Terminal Block
B4 B4
1 B5 B5
2 N
3
4
5 SP1 (RLF)
6 SP2 Primary Power Feedback
7 Primary Power Common
*Note 2
8 Primary Power feedback must be active
9 high (24VDC or 120VAC) when primary
10 power is present at the CCR

*Note 1 Remote/Local Feedback

Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. An Option 23 Kit may exist if CCR was formally monitored by Crouse-Hinds system. Else, the
Contractor must include in their pricing the purchase and installation of these kits. Card must be
added and configured in the CCR card cage
2. Internal wiring must be added, wired to spare terminal blocks and should be relabeled

Doc no. 110A0481 10

 Hevi-Duty : 644 Series , 10-70kW, 6.6A/20A, SCR, Air & Oil-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Hevi-Duty Electric

Model:
644 Series
10-70kW, 6.6A/20A, SCR Saturable Reactor
Ferro, Oil-cooled

Sample Picture

CCR Control System

120VAC CCI CCI
CC CC *Note 3
CCR Control
PCB B1 B1
B2 B2
B3 B3
8A B4 B4
7A B5 B5
Installed Jumper
6A N
PPF
5A
4A
N 3A
Primary Power Feedback
*Note 1 Installed Jumper Primary Power Common
Primary Power feedback must be active
120VAC high (24VDC or 120VAC) when primary
power is present at the CCR
FUSE FU2 *Note 2
Remote/Local Feedback
Remote/Local Common
3A
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Wire to spares TB’s and relabel

FU2

Notes:
1. Jumper needs wired from 3A on CCR Control PCB to spare terminal block and relabeled (N).
2. Jumper needs wired from FU2 to spare terminal and relabeled PPF (Primary Power feedback)
3. CCR may require both CC and B1 signals to turn on to Brightness step 1. Field verify by applying
jumper from CCI to CC and see if CCR turns on to Step 1. If so, B1 signal not required for control.
Doc no. 110A0481 11
 Hevi-Duty 57990 Series, 10-70kW, 6.6A/20A, SCR, Oil-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Hevi-Duty Electric

Model:
57990 Series
10-70kW, 6.6A/20A, SCR Saturable Reactor
Oil-cooled

Sample Picture

CCR 120VAC
71 (N)
72 (PPF)
Control System
*Note 2 73 (CCI) CCI
74 (CC) CC *Note 3
B1(B10) B1
B2(B30) B2
B3(B100) B3
B4 B4
B5 B5

SP1
SP2

Primary Power Feedback

Primary Power Common
Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

*Note 1
Notes:
1. The Neutral and the Primary Power terminal blocks may not be pre-wired and require field
modifications to the internal wiring to wire these signals.
2. Some older series of Hevi-Duty CCR’s have different terminal block labels. Always field verify the
interface connections during site visit
3. CCR may require both CC and B1 signals to turn on to Brightness step 1. Field verify by applying
jumper from CCI to CC and see if CCR turns on to Step 1. If so, B1 signal not required for control.
Doc no. 110A0481 12
 Manairco: MR/MSR Series 2-50kW, 6.6A/20A, Ferromagnetic, Air-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Manairo

Model:
MR & MSR Series
2-50kW, 6.6A/20A, Ferromagnetic
Air-cooled

Sample Picture

CCR TB1
Control System
CCI CCI
CC CC
B1 B1
B2 B2
B3 B3
B4 B4
B5 B5
N

TB2
1
GRD Primary Power Feedback
Primary Power Common
*Note 1
Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. Depending on Manairco model, Spare terminal block may not exist and require field modifications of
internal wiring to locate Primary Power feedbaclk signal (120VAC). If TB2 does not exist, PPF should be
field verified and documented and forwarded to Project Engineering to create new interface diagram

Doc no. 110A0481 13

 Flight Light: 4-10kW, 6.6A, Ferro, Air-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Flight Light (Formerly Hevi-Duty)
Model:
4-10kW, 6.6A, SCR Saturable Reactor
Air-cooled

Sample Picture

CCR Control System

120VAC CCI CCI
CCR Control CC CC
PCB B1 B1
B2 B2
B3 B3
8A B4 B4
7A B5 B5
Installed Jumper
6A N
5A
4A
N 3A
Installed Jumper Primary Power Feedback
Butt splice to
*Note 1 feedback wire
Primary Power Common
Primary Power feedback must be active
120VAC high (24VDC or 120VAC) when primary
power is present at the CCR
FUSE FU2 *Note 2
Remote/Local Feedback
Remote/Local Common
3A
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

FU2
Wire to spares TB’s and relabel

Notes:
1. Jumper needs wired from 3A on CCR Control PCB to spare terminal block and relabeled (N).
2. Jumper needs wired from FU2 and butt spliced /labeled to PPF wire (Primary Power feedback)

Doc no. 110A0481 14

 Honeywell: Stackable CCR (Old Style), 4-30kW, 6.6A, Thyristor Controlled, Air-cooled
Constant Current Regulator
Control System Interface Guide

Manufacturer:
Honeywell
Model:
Stackable CCR (Old Style)
4-30kW, 6.6A, Thyristor Controlled
Air-cooled

Sample Picture

CCR Control System

120VAC CCI CCI
Installed Jumper
CC CC
B1 B1
*Note 1
B2 B2
B3 B3
B4 B4
B5 B5
N
Local Control
Door Switch

120VAC Installed Jumper Primary Power Feedback

P14 Butt splice to
feedback wire
Primary Power Common
*Note 2 Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. Jumper needs wired from CC to B1 for CCR to turn on at Step 1 by only energizing CC
2. Jumper needs wired from Door switch P14 (position 14) and butt spliced /labeled to RLF wire
(Remote / Local feedback)

Doc no. 110A0481 15

 Honeywell: Stackable CCR (New Style), 4-30kW, 6.6A, Thyristor Controlled, Air-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Honeywell Distributed

Model: Control Device

Integrated in door
Stackable CCR (New Style)
Integrated Computer Control Module
4-30kW, 6.6A, Thyristor Controlled
Air-cooled
Part# example: W30A6B480BB
Sample Picture

J22 TB CCR INT AC

Control System
(On Door) 120VAC CCI CCI
Installed Jumper
CC CC
B1 B1
*Note 1
B2 B2
B3 B3
IRMS (120)
B4 B4
IRMS (N)
1 B5 B5
Return
15 N
-24V

18 +24VDC (When Active)

Installed Primary Power Feedback
Jumper -24VDC
Primary Power Common
Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR
*Note 2
+24VDC (When Active)
Remote/Local Feedback
-24VDC
Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
any local step including OFF

Notes:
1. Jumper needs wired from CC to B1 for CCR to turn on at Step 1 by only energizing CC
2. Jumper needs wired from J22 terminal 1 to terminal 18. Primary Power feedback (PPF=24VDC when
active) is wired to terminal 1, Remote/Local feedback (RLF=24VDC when active) is wired to terminal 15
Programming Distributed Control Device to provide feedback signals:
1. Program password: 0000 2. Remote reset: Yes
3. Option 1=0 4. Indication of faults: contact closed
5. Single lamp ctrl/mtrng: No 6. Serial Interface: Not used
7. PIO command: ON-input 8. Strobe: Not used

Doc no. 110A0481 16

 Liberty: Stackable CCR, Freedom Series , 4-30kW, 6.6A, Ferro, Air-cooled
Constant Current Regulator
Control System Interface Guide
Manufacturer:
Liberty
Model:
Stackable CCR
Freedom Series
Integrated Computer Control Module
4-30kW, 6.6A, Ferro, Air-cooled
Sample Picture

CCR Control System

120VAC CCI CCI
Installed Jumper
CC CC
B1 B1
B2 B2
B3 B3
B4 B4
B5 B5
Return
N
-24V

Primary Power Feedback

Primary Power Common
Primary Power feedback must be active
high (24VDC or 120VAC) when primary
power is present at the CCR

Remote/Local Feedback
Remote/Local Common
Remote / Local feedback must be active
high (24VDC or 120VAC) when CCR is in
Remote and low ( 0 V) when CCR is in
*Note 1 any local step including OFF

Notes:
1. No details for Primary Power and Remote/Local Feedback available at this time

Programming Distributed Control Device to provide feedback signals:

1. Not available at this time

Doc no. 110A0481 17