1
THE CORE SPLIT: PRIMARY AND SECONDARY
A conventional AGL system rests on a clear separation between the primary series circuit and the secondary circuit. The primary carries the controlled current from the CCR through the primary windings of the isolation transformers. The secondary connects each isolation transformer to one individual fitting.
This distinction underpins design, transformer, cable and connector selection, fault finding, insulation testing, commissioning, photometric troubleshooting and maintenance. FAA specifications treat the series-circuit equipment separately: L-824 underground cable, L-823 connectors, L-830/L-831 isolation transformers and CCRs.
The most important difference
- PRIMARY = COMMON SERIES CIRCUIT
- SECONDARY = INDIVIDUAL FIXTURE CIRCUIT
- This one idea explains a large part of AGL electrical troubleshooting
AGL controlCCRPrimary series circuitIsolation transformerSecondary circuitFixture
2
THE PRIMARY CIRCUIT
The primary circuit is the main series circuit supplied by the CCR. It consists of the CCR, primary series cable, isolation-transformer primary windings, primary connectors, cable joints and accessories, and the return cable to the CCR. It is a series circuit, so the same controlled current flows through the whole path.
CCR
│
PRIMARY SERIES CABLE
│
[IT1] ── cable ── [IT2] ── cable ── [IT3] ── ... ── RETURN TO CCR
IT = isolation transformer (primary winding in the series path)
The transformer is not a normal parallel load across the CCR output. Its primary winding is part of the series path (H1 in, H2 out).
| Primary component | Role |
|---|
| CCR | Supplies regulated series current |
| Primary cable | Carries the series current around the airfield circuit |
| Primary connector | Joins cable to transformer and other cable sections |
| Transformer primary | Forms part of the series circuit |
| Joints / accessories | Maintain continuity of the underground circuit |
| Return cable | Completes the loop back to the CCR |
3
THE SECONDARY CIRCUIT
The secondary circuit is the individual circuit between one isolation transformer and its fitting. Unlike the common primary loop, it is generally an individual load circuit: Transformer 1 → Fixture 1, Transformer 2 → Fixture 2, and so on. This gives electrical isolation between the individual loads.
Transformer secondarySecondary cableSecondary connectorAGL fixture
| Secondary component | Role |
|---|
| Transformer secondary | Produces the required secondary output |
| Secondary cable | Carries power from transformer to fitting |
| Secondary connector | Provides the field connection |
| AGL fixture | Converts electrical energy into the required visual output |
This is why the failure of one fixture's secondary circuit does not necessarily interrupt the complete primary series loop.
4
PRIMARY VS SECONDARY AT A GLANCE
| Parameter | Primary circuit | Secondary circuit |
|---|
| Main purpose | Complete AGL series power circuit | Individual fitting supply |
| Source | CCR | Isolation transformer |
| Configuration | Series | Individual branch / load circuit |
| Main current | CCR-controlled | Determined by transformer and load |
| Main cable | AGL primary cable | Secondary cable |
| Transformer role | Primary winding is in the circuit | Secondary winding supplies the load |
| Typical number | One complete series loop | One per individual fitting |
| Fault impact | Can affect many fittings | Usually affects one fitting |
| Main concern | Circuit continuity and insulation | Individual fitting supply |
| Connector | Primary AGL connector | Secondary AGL connector |
Cable comparison
| Primary cable | Secondary cable |
|---|
| Part of the main series loop | Individual fixture connection |
| Connects CCR and transformer primaries | Connects transformer to fixture |
| Carries regulated series current | Carries individual load current |
| Higher insulation demands (typically 5,000 V-rated L-824) | Lower voltage than primary in typical systems (typically 600 V-rated) |
| Long underground routes common | Usually relatively short |
| Fault can affect several fittings | Usually affects one fitting |
Actual ratings must always come from the approved system design.
5
WHY AGL USES A SERIES CIRCUIT
A series system lets many field fittings share a common circuit supplied by a CCR, which controls the current through the loop. Advantages include controlled current, defined intensity steps, long-distance distribution, individual fixture isolation through transformers, and less dependence on individual parallel supply circuits.
Series AGL vs building (parallel) lighting
| Building lighting | AGL series circuit |
|---|
| Arrangement | Supply feeds each light in parallel | CCR → transformer → cable → transformer → … → return |
| Common quantity | Voltage is common across branches | Circuit current is controlled through the loop |
Because the same current flows through every light, brightness stays uniform whatever the cable length or the number of lights. Confusing series and parallel affects cable sizing, transformer design, fault behaviour, protection, control and troubleshooting.
AC 150/5345-10H specifies CCRs and defines their regulated-current characteristics; see Note 07: Constant Current Regulators.
6
PRIMARY CURRENT, VOLTAGE AND IMPEDANCE
The CCR controls current. Typical primary currents are 6.6 A and 20 A, set by the CCR and the equipment specification (AC 150/5345-10H: Class 1 about 6.6 A, Class 2 about 20 A).
Primary current affects transformer operation, cable losses, circuit voltage, CCR loading, transformer and connector selection, and light intensity. A 6.6 A circuit needs transformers with a 6.6 A primary rating; a 20 A-primary unit cannot be substituted just because the wattage matches.
V ≈ I × Z V = circuit voltage · I = regulated current · Z = effective impedance
Vtotal ≈ Σ voltage drops around the series circuit
Ztotal = Ztransformers + Zcable + Zconnections + other impedance
As circuit length, transformer loading and impedance change, the voltage needed to hold the selected current changes. The CCR must drive current through cable resistance, transformer impedance and connector/contact resistance, so it may develop substantial voltage.
5 kV is a rating, not an operating voltage. The FAA L-830/L-831 transformer specification gives a 5,000 V primary voltage rating. Do not read this as every AGL series circuit running continuously at 5 kV.
7
CABLE: RESISTANCE, LENGTH AND SELECTION
Primary cable is one of the most critical components. AC 150/5345-7F is the FAA specification for L-824 underground electrical cable for airport lighting circuits.
Vdrop = I × R Ploss = I²R Length ↑ → Resistance ↑ → Voltage drop ↑
For a fixed current, higher resistance means higher I²R loss, so a small resistance increase can produce a significant loss increase. The total route length must be accounted for, which is one reason CCR capacity cannot be set from the number of lamps. The same principle applies to the secondary cable: a long or undersized one gives reduced fixture voltage and output, heating and poor performance.
Select primary cable by
- Operating circuit and current
- Voltage / insulation requirement
- Cable length and conductor size
- Resistance
- Installation environment
- Connector compatibility
- Applicable standard and project specification
Select secondary cable by
- Transformer secondary current
- Fixture requirements
- Cable length and insulation
- Temperature
- Mechanical protection
- Connector compatibility
- Installation conditions
8
CONNECTORS AND CONTACT RESISTANCE
AC 150/5345-26E covers L-823 plug and receptacle cable connectors used with underground power cables, isolation-transformer leads and light-fixture leads. A connector must provide electrical continuity, insulation, environmental protection, mechanical integrity, correct polarity/configuration and reliable long-term contact. A primary connector problem can become a series-circuit fault.
Connector resistance risesVoltage drop risesI²R loss risesConnector heating
The connector configuration must match the approved equipment: primary cable → L-823 connector → transformer primary, and transformer secondary → L-823-compatible connection → secondary cable → fixture.
10
ONE LIGHT OUT VS PRIMARY OPEN
One light fails
Say Fixture 3. Possible locations: transformer 3, secondary connector, secondary cable, fixture 3. The complete primary circuit may remain operational. This is one of the most important troubleshooting concepts in AGL.
Primary cable breaks (open circuit)
The series loop is interrupted and current stops everywhere in that loop, so every light on that circuit goes out and the CCR will normally trip on open circuit. There is no "downstream only" effect in a single series loop. The break is then found by splitting the circuit and testing section by section.
CCR → IT-1 → IT-2 ──X── IT-3 → IT-4 (open circuit: loop interrupted, ALL lights on the circuit go out)
Open secondary loads
The transformer primary stays in the series loop even when its secondary load is open. However, enough open or faulted secondary loads can change overall circuit loading and, depending on CCR design, affect CCR operation.
Why primary faults are more serious
| Fault | Likely reach |
|---|
| Primary open circuit | The whole circuit goes dark |
| Primary short or double earth fault across a section | The lights in the bypassed section go dark; the rest stay lit because the CCR holds the current |
| One secondary fault | Usually one fitting |
Why circuits are interleaved: because one open primary loop darkens every light on it, lights on a runway or taxiway are normally shared across more than one circuit in line with the project design, so a single circuit failure does not remove all the lights in an area.
11
PRIMARY CIRCUIT LOAD AND DESIGN
Primary load depends on more than the number of lamps: transformer rating, fixture load, transformer and cable losses, number of fittings, open secondary loads, circuit impedance and operating current.
Rule
- AGL circuit design = complete electrical circuit calculation
- Not number of lights × wattage
Primary circuit design sequence
Lighting functionNumber of fixturesFixture wattagesTransformer typesPrimary currentCircuit lengthCable characteristicsImpedance / loadSelect CCRCheck transformers and connectorsTest
Secondary circuit design sequence
FixtureWattageTransformerSecondary currentSecondary cableConnectorCable lengthVoltage drop / performanceFixture operationPhotometry
12
INSULATION, MOISTURE AND FAULT TYPES
A primary circuit can be electrically continuous and still be defective: continuity good, insulation bad, caused by moisture, cable damage, a poor joint, transformer insulation failure or connector contamination. Continuity testing alone never proves a healthy primary circuit.
The insulation system includes cable, transformer, connector and joint insulation; a defect in any one can affect the circuit. Underground and outdoor operation exposes it to moisture, which reduces insulation resistance and causes leakage current, corrosion, tracking, connector failure and transformer faults. That is why specialised AGL cable, connectors and sealed transformers are used (L-824, L-823).
Primary cable fault types
- Open circuit: broken conductor or joint
- Short circuit: unwanted low-resistance connection
- Earth fault: insulation failure leaking to ground
- High-resistance joint: voltage drop and heating
- Intermittent fault: changes with movement, temperature or moisture
Secondary circuit fault types
- Open cable
- Shorted cable
- Damaged connector
- Fixture failure and driver failure
- Transformer secondary failure
- Water ingress
Primary short circuit and earth faults. A CCR regulates current, so a short across part of the loop does not normally raise the current: the lights in the bypassed section go dark and the CCR may operate its protection. A series circuit is floating (not earthed), so a single earth fault usually does not stop the circuit, but a second earth fault at another point can bypass part of the loop and stress the insulation. Protection should respond according to the approved system design.
13
CABLE JOINTS
Joints are critical points in an underground AGL circuit. A poor joint causes high resistance, moisture ingress, insulation failure, intermittent operation or series-circuit interruption.
Joint inspection
- Correct joint kit
- Correct cable preparation
- Proper conductor connection
- Adequate insulation
- Water sealing
- Mechanical protection
- Correct identification
- Test result recorded
14
CONTROL, BRIGHTNESS AND PHOTOMETRY
The control system does not normally control each secondary fitting independently. The CCR is the key interface between control and the field series circuit.
ATC / control roomALCMS / control systemCCRPrimary series circuitTransformersFixtures
The CCR changes the primary current. A lower step gives lower primary current and lower fixture output; a higher step does the reverse. Actual brightness-current values depend on the CCR classification and approved system.
CCR currentTransformerSecondary supplyFixtureOptical outputPhotometry
An electrical problem can therefore become a photometric one: incorrect current → incorrect fixture output → photometric deviation.
LED fixtures. LED fittings have electronic drivers. Verify secondary current and voltage, transformer, connector, driver characteristics, CCR compatibility and manufacturer requirements. Do not assume an LED fixture can replace any older fitting on the existing transformer.
15
COMMISSIONING
Primary circuit, before energisation
- Visual: cable installation, joints, transformer connections, connectors, labels, equipment condition
- Electrical: continuity, insulation, earthing/bonding where applicable, correct circuit identification
- CCR: correct current, brightness steps, output, monitoring
- Field: transformers, fixtures, secondary circuits, photometric performance where required
Secondary circuit, each fitting
- Correct connection and fixture
- Correct orientation
- Correct operation and intensity
- No abnormal heating
- No visible damage
16
TESTING AND SAFETY
Primary circuit test sequence
- Isolate the system safely.
- Identify the circuit.
- Verify the cable and transformer arrangement.
- Continuity test the primary loop and each secondary path.
- Insulation test the primary to earth, with the CCR and any sensitive equipment disconnected from the circuit first.
- Check any fault condition.
- Reconnect equipment as approved.
- Energise and verify the CCR.
- Verify field operation.
Continuity checks that the path is complete (CCR output → cable → transformer primaries → return, or transformer secondary → cable → connector → fixture); an open circuit can interrupt it or leave a fitting OFF. Insulation testing covers primary to ground, cable, transformer, connector and joint insulation, and the secondary cable, transformer secondary, fixture and connector condition. Test voltages and acceptance criteria must come from the applicable standard, approved project method statement and manufacturer instruction.
Protect connected electronics. Sensitive electronic or LED equipment must not be subjected to an insulation test unless the approved procedure specifically allows it.
Primary circuits can involve hazardous voltages. De-energise → Isolate → Lockout/Tagout → Verify absence of voltage → Discharge/secure as required → Test → Work. Never assume switching the CCR OFF alone has made the circuit safe. The secondary side is usually lower voltage but must be treated as live until verified otherwise. Follow the airport electrical safety procedure.
For the full commissioning and test-record workflow see Note 14: AGL Testing & Commissioning; for the electrical chain see Note 05.
17
FAULT-FINDING
Field rule
- ALL lights on the circuit off: Power → Control → CCR (and its protection) → open primary loop
- MANY lights off but others still lit: the loop is intact, so look for a shorted or bypassed primary section or a shared cause (for example water in a pit or junction)
- ONE light off: Secondary circuit / transformer / fixture (start locally)
Many lights OFF (others lit)
Identify affected sectionPrimary cable in that sectionJoints and connectorsInsulation testTransformersIndividual secondaries
One light OFF
FixtureFixture connectorSecondary cableTransformer secondaryTransformerPrimary connection
Starting with the most localised likely fault saves time.
| Problem | First investigation |
|---|
| Entire circuit OFF | CCR / input / control / open primary loop |
| Many lights OFF, others lit | Shorted or bypassed primary section, or a shared cause |
| One light OFF | Fixture / secondary |
| CCR trips | Primary circuit / fault / protection |
| Low fixture output | Secondary / transformer / fixture |
| Low insulation | Cable / joint / transformer / moisture |
| Intermittent light | Connector / cable / fixture |
| Connector heating | Contact resistance / poor connection |
| Abnormal CCR voltage | Circuit impedance / loading |
| Several adjacent lights OFF | Shorted or bypassed primary cable section, or a common pit/junction fault |
Worked examples
25 of 80 taxiway fittings OFF, the rest lit
The loop is still continuous, or the other 55 would be dark too. Suspect a common cause first: a shorted or bypassed primary section, a double earth fault, or water in a shared pit or junction. It is unlikely that 25 unrelated fixtures failed together.
1 centreline light OFF, neighbours ON
Investigate the fixture, secondary connector, secondary cable and isolation transformer before assuming a CCR failure.
18
COMMON MISTAKES
Treating the circuit as parallel
Series-circuit AGL uses a different architecture.
Choosing a transformer by wattage only
Primary current and frequency are equally important.
Ignoring cable length
Cable resistance affects circuit voltage and losses.
Ignoring connector resistance
A poor connector can become a significant fault.
Testing only continuity
A circuit can have continuity and poor insulation.
Assuming one light failure means CCR failure
Start with the individual secondary circuit.
Secondary: wrong transformer, connector or cable
Also ignoring LED-driver requirements.
Insulation-testing connected electronics
Check the approved procedure first.
Selection checklists
Primary circuit
- CCR: output current, steps, capacity, monitoring, input supply
- Cable: type, conductor size, insulation rating, total length, route, jointing method
- Transformers: quantity, wattage, primary and secondary current, frequency, type
- Connectors: primary connector, cable size, transformer lead, environmental protection
- Testing: continuity, insulation, circuit identification, CCR output, functional test
Each secondary (fitting)
- Correct transformer and secondary current
- Correct secondary cable, length and connector
- Correct fixture
- Polarity / orientation where applicable
- Sealing and mechanical protection
- Functional test completed
Quick Revision
QUICK REVISION
Remember
- PRIMARY = common series circuit · SECONDARY = individual fixture circuit
- CCR controls primary current · transformer isolates and transfers power · fixture produces light
- Primary: CCR → Series current → Primary cable → Transformer primary → Return
- Secondary: Transformer secondary → Secondary cable → Connector → Fixture
- Many lights off: go upstream · one light off: go local
- Vdrop = I × R · Ploss = I²R · V ≈ I × Z
AGL SYSTEM
│
CCR
│
PRIMARY SERIES CIRCUIT
┌──────────┼──────────┐
IT1 IT2 IT3
│ │ │
Secondary Secondary Secondary
│ │ │
Fixture Fixture Fixture
Keyword Reference
AGL SERIES CIRCUIT: KEY TOPICS
AGL series circuit working principle
In an AGL series circuit the CCR drives one controlled current through the primary cable and the primary windings of every isolation transformer in the loop. Each transformer passes power to its own light, so every light sees the same current whatever the circuit length. Brightness changes by changing that current.
AGL series circuit types
AGL series circuits are grouped by the lights they feed, for example runway edge, centreline, threshold, taxiway, approach and sign circuits. They may differ in current rating, number of brightness steps and whether they are a single loop or a split system.
AGL series circuit functions
The functions of an AGL series circuit are to deliver constant current to many lights, isolate each light from the primary, allow brightness control and keep working when one light fails, as the transformer secondary opens without breaking the loop.
AGL series circuit components
The main components are the CCR, the primary cable, isolation transformers, connectors and joints, the fixtures and the earthing system. The control and monitoring system switches the circuit and reports its status.
AGL series circuit requirements
Requirements for an AGL series circuit come from the standards and project specification: correct current, reliable insulation, suitable cables and connectors, protection, earthing, monitoring and layout that allows the airfield to operate safely when part of a circuit fails.
AGL series circuit design
Designing an AGL series circuit means dividing the lights into circuits, finding the load and cable resistance, and selecting the CCR size and the cable. Circuits are usually arranged so a single failure does not remove too many lights from one area.
AGL series circuit installation
Installing an AGL series circuit includes laying and joining primary cable, fitting transformers and connectors, connecting the CCR and earthing the system. Joints and connectors need particular care, because they are common points of failure.
AGL series circuit maintenance
Maintenance of an AGL series circuit includes periodic insulation and resistance checks, inspection of connectors and joints, CCR checks and record keeping. Condition trends in the records show deterioration before a failure occurs.
AGL series circuit troubleshooting
Troubleshooting a series circuit starts with the symptom: all lights out points to power, control or CCR, while one light out points to the lamp, transformer or secondary. Isolate, measure and locate the fault before repairing, then retest.
AGL series circuit testing procedure
A series circuit test sequence starts with isolating and making the circuit safe, then visual checks, insulation resistance and continuity or loop resistance tests, followed by energising and checking the current. Follow the approved test plan for methods and limits.
AGL series circuit selection guide
Selecting equipment for a series circuit means matching the CCR, cable, transformers and connectors to the circuit current, voltage, load and environment. Check that every part is compatible with the others.
AGL series circuit technical guide
This technical guide view of the series circuit links the working principle to design, installation, testing and fault finding. Learn the primary and secondary split first, because most fault logic follows from it.
AGL series circuit standards
Series circuit standards include the aerodrome lighting provisions of ICAO and national authorities, FAA equipment specifications, IEC and Indian standards for cables, connectors and equipment. The project specification names the ones that apply.
AGL series circuit preventive maintenance
Preventive maintenance of a series circuit follows a planned schedule: inspect and test insulation and loop resistance, check connectors, joints and the CCR, and record results. Planned work finds problems before they cause outages.
Exam & Interview
EXAM / INTERVIEW QUESTIONS
What is the AGL primary circuit?
The CCR-fed series circuit containing the primary cable and the primary windings of the isolation transformers.
What is the secondary circuit?
The individual circuit connecting an isolation transformer to its AGL fixture.
Why is the primary circuit a series circuit?
The primary windings of the isolation transformers are connected into a continuous series loop supplied by the CCR.
Why are isolation transformers used?
To provide electrical isolation and transfer power from the primary series circuit to individual fittings.
What controls primary current?
The CCR.
Is primary current always equal to secondary current?
No. It depends on the transformer configuration.
Can one secondary light fail while the primary circuit continues operating?
Yes. A secondary-side or fixture failure does not necessarily open the primary series loop.
What happens when the primary cable opens?
The series path is interrupted and current stops, so all the lights on that circuit go out and the CCR open-circuit protection normally operates.
What is the main difference between primary and secondary cable?
Primary cable forms the common series circuit; secondary cable connects an individual transformer to its fitting.
Why is cable resistance important?
It affects voltage drop, power loss and the total electrical requirement of the series circuit.
What is the basic primary chain?
CCR → Primary Cable → Transformer Primary → Primary Cable → Return.
What is the basic secondary chain?
Transformer Secondary → Secondary Cable → Connector → Fixture.
Why does the CCR output voltage change?
The CCR regulates current and develops the voltage the connected circuit impedance requires, within its design limits.
Why can a primary cable fault affect many lights?
The fixtures share one series loop. An open circuit darkens the whole circuit, and a short or double earth fault can bypass the lights in a section.
Why is a secondary fault usually localised?
Each transformer normally serves an individual fitting through its own secondary circuit.
What happens when secondary loads are disconnected?
The primary transformer remains in the series circuit, but enough disconnected loads can alter total circuit loading and electrical behaviour.
What matters more in primary-circuit design: voltage or current?
Both matter, but the CCR's controlled parameter is the series current; voltage capability follows the total circuit requirement.
Why must transformer primary current match the CCR circuit?
The primary winding is part of the series circuit and must be designed for the actual regulated current.
How to test an AGL series circuit?
Isolate the circuit and make it safe, then check it visually. Test insulation resistance and continuity or loop resistance of the primary cable and connectors, then energise and check the CCR output current at the brightness steps. Follow the approved test plan, standard and manufacturer data for methods and limits.
Final Study Takeaway
FINAL STUDY TAKEAWAY
The primary is the common CCR-controlled series circuit: CCR + primary cable + transformer primaries + connectors + return. The secondary is the individual fitting circuit: transformer secondary + secondary cable + connector + fixture. The primary controls and distributes the series current, the isolation transformer provides the interface and isolation, and the secondary supplies the individual fixture.
AGL circuit knowledge = CCR + Primary cable + Series circuit + Isolation transformer + Secondary cable + Connector + Fixture + Testing + Photometry.
Field Insight
ENGINEERING & EXPERT NOTES
RS
By Rahul Sharma
Airfield Ground Lighting Specialist
Treat the Primary as Hazardous Until Proved Dead
SafetyA series circuit can hold dangerous voltage even when lights appear off. Follow isolation and test-for-dead procedures every time.
Section the Circuit to Find the Fault
Fault LocationSplitting the primary into parts and testing each narrows the search far faster than walking the whole route.
Read Current and Voltage Together
DiagnosisA circuit holding current but needing more voltage than before is telling you resistance has grown. Log both at each step.
Most Secondary Trouble Is at the Connector or Lead
SecondaryCheck terminations and secondary cable before replacing a transformer or a fixture.
References
REFERENCES & FURTHER READING
These notes are a study aid. Verify details against the primary sources below (FAA-based systems).
| # | Source | Use it for |
|---|
| 1 | FAA AC 150/5345-10H – Constant Current Regulators and Regulator Monitors | CCR classes, regulated current, brightness steps. |
| 2 | FAA AC 150/5345-47C – Series to Series Isolation Transformers | L-830/L-831 types, ratings, construction, testing. |
| 3 | FAA AC 150/5345-7F – L-824 Underground Electrical Cable for Airport Lighting Circuits | Primary cable specification. |
| 4 | FAA AC 150/5345-26E – L-823 Plug and Receptacle, Cable Connectors | Connectors for cables, transformer leads and fixture leads. |
| 5 | FAA AC 150/5340-30J – Design and Installation Details for Airport Visual Aids | Installation guidance and recommendations. |
| 6 | FAA AC 150/5340-26C – Maintenance of Airport Visual Aid Facilities | Series-circuit safety, insulation-resistance testing and troubleshooting. |
| 7 | ICAO Annex 14, Volume I, Chapter 8 (Electrical Systems) and ICAO Doc 9157 Part 5 | International practice for series circuits, secondary power and cabling; check the current edition. |
Check the editions. For any airport, check the approved project drawings, airport technical specification, national authority requirements, equipment certification and manufacturer's instructions together with the applicable FAA/ICAO requirements.
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