Centralised smart monitoring for CCR / AGL transformer networks — real-time visibility across every light on your airfield.
AGL transformer failures in a CCR series circuit can cause partial or total loss of runway lighting with little or no warning. Today's maintenance teams rely on manual inspection and reactive fault-finding.
TransGuard changes that. By placing intelligent sensors at every transformer and aggregating data to a central master controller, your team moves from reactive to predictive maintenance — knowing of degradation before a lamp goes dark.
Continuous secondary voltage measurement at each transformer ensures lamps operate within specification and highlights early insulation or winding faults.
Real-time CCR series loop current monitoring detects open-circuit conditions and deviations from set-point, helping prevent cascading failures.
Per-transformer load current tracking provides a precise health index, flagging lamp degradation or unexpected load changes long before failure.
Integrated thermal sensing on each transformer core detects overheating caused by overloads, blocked drainage or embedded moisture ingress.
Onboard hygrometer continuously evaluates moisture levels inside the transformer enclosure — essential for underground and subsurface installations.
A composite health score derived from all measured parameters delivers instant actionable status — green, amber, or red — for each unit in the field.
Live display in the airfield operations centre or equipment room. Real-time status map of the entire CCR circuit visible at a glance via LAN.
Maintenance teams and OEM service centres access historical logs, trend analysis, and alerts remotely — enabling predictive maintenance from anywhere in the world.
Threshold-based alarms triggered automatically when parameters drift outside safe limits, with configurable escalation to email, SMS or SCADA integration.
Uses proven narrow-band Power Line Communication technology (e.g. Semitech SM2400) to transmit sensor data over the existing CCR wiring. No additional cabling required.
A cyclic ring communication protocol implemented on FPGA delivers deterministic, high-reliability data collection across the entire CCR circuit with proprietary IP protection.
Snap-on slave units attach to existing AGL transformers already installed in the airfield. Minimal disruption to operations; no re-cabling required. Ideal for airport upgrade programmes.
TransGuard electronics are embedded at the transformer manufacturer's production line, delivered as a pre-wired, pre-tested assembly — simplifying installation and commissioning.
A fully integrated product combining AGL transformer and monitoring electronics in a single sealed unit. One SKU, one warranty, one supplier — the simplest solution for new builds and major expansions.
TransGuard is available for pilot programmes and technical evaluation. Contact us to discuss your airfield's requirements and arrange a proof-of-concept demonstration.
This section presents the complete architectural diagrams for the TransGuard monitoring system, covering the overall CCR network topology, Slave unit configurations (Type A and B), and Master controller block diagrams for both communication variants.
The complete CCR/AGL monitoring topology showing the relationship between the control tower, CCR unit, Master controller, and Slave monitoring nodes distributed across the airfield. The dashed blue line marks the boundary between the equipment room and the airfield.
The Constant Current Regulator drives a series AC loop at fixed current through all AGL transformers on the circuit. This daisy-chain topology means any transformer fault affects all downstream lamps — making monitoring essential.
One Master unit per CCR circuit, co-located in the equipment room alongside the CCR. It aggregates data from all Slave nodes over the PLC bus, then forwards status to the on-site display via LAN and to the cloud for remote access.
One Slave per transformer, deployed in the field. Slaves are powered directly from the CCR loop — no separate supply cable required. Data is transmitted back to the Master over the existing CCR wiring using Power Line Communication.
Separates the protected equipment room (left) from the exposed airfield environment (right). Slave units must be rated for harsh outdoor or in-ground conditions.
Block diagram and connection schematic for the Slave monitoring node using a standard N-PLC modem chip (e.g. Semitech SM2400). Captures voltage, current, temperature and humidity; communicates to Master over the CCR wiring via OFDM modulation.
The Slave draws power from the CCR lamp circuit. The same block performs secondary voltage and current sensing on the lamp load.
High-resolution analogue-to-digital converter digitises voltage and current waveforms for transmission and local health computation.
The host microcontroller runs the sensing logic and hands data frames to the PLC modem (e.g. Semitech SM2400) for transmission over the CCR wiring.
A dedicated sensor module (yellow block) feeds environmental readings directly to the CPU, independent of the analogue power path.
The SM2400 is the proposed PLC modem IC for the Type A Slave. It connects directly to the AC power line via a coupling transformer and line driver, and interfaces with the host CPU over UART or SPI.
| Interface | UART / SPI to host MCU |
| Line voltage | AC 275 V or DC 400 V |
| Frequency band | 155 kHz – 490 kHz (FCC) |
| OFDM speed | 466 kbps max |
| XXR mode | 5 kbps (extreme noise) |
| Protocol | G3-PLC FCC / XXR |
| Supply | 3.3 V (5 V tolerant I/O) |
| Package | 64QFP — 45 × 45 mm |
The SM2400 handles all PLC physical-layer complexity — OFDM modulation, noise cancellation, and channel estimation — allowing the host CPU to operate via simple UART commands. This minimises firmware complexity and accelerates time to market for the Type A variant.
The Type B Slave replaces the CPU+Modem stack with a single FPGA implementing both data acquisition and the proprietary cyclic ring communication protocol. The field-connection schematic is identical to Type A; only the internal block diagram differs.
Type A uses a CPU + off-the-shelf MODEM chip. Type B consolidates both functions into a single FPGA running a proprietary ring protocol — creating defensible IP at the same per-unit production cost at volume. Ring speed: up to 500 kbps.
The Master unit sits in the equipment room alongside the CCR. It aggregates all Slave data, serves the local on-site display over LAN, and pushes data to the cloud for remote access. Type A uses a CPU+Modem; Type B uses an FPGA.
Both variants share the same external interface: LAN for on-site display and cloud connectivity, and Power & Battery Backup for continuous operation even during mains events. The Master is the single integration point for the entire airfield lighting monitoring system.
Whether you're interested in a pilot program, technical data sheets, or OEM integration, our airfield specialists are ready to assist.
Aviation Technology Center, Suite 400
Industrial Way, Airfield Hub
support@agltransguard.tech
+1 (555) AGL-GUARD