6202A SERVICE MANUAL FCE-500 - Global Product Support

'1 \ i \ '

"

SERVICE MANUAL 6202A

" Operation, Installation and Maintenance

FCE-500 Microprocessor-Based Field Code Emulator System

September, 1986 A-09/88-250-2777-1 100038F, 0043F

Replaces

Type L - Form 502A

Type L - Form 5048

Type L - Form 504C

Field Relay Code Systems

UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC./ SWISSVALE, PA 15218


" Operation, Installation and Maintenance

FCE-500 Mic-roprocessor-Based Field Code Emulator System

September. 1986 A-09/86-260-2777-1 l00038f, 0043F

Replaces

Type L - Form 502A

Type L - Form 5048

Type L - Form 504C

Field Relay Code Systems


m UNION SWITCH & SIGNAL

REVISION INDEX

Revised pages of this manual are listed by page number and date of revision:

Page No. Rev. Date Page No. Rev. Date

UNION SWITCH & SIGNAL m Section

I GENERAL 1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.3.1 1.2.3.2 1.2.3.3 1.2.3.4 1.2.3.5 1. 3 1. 3.1 1. 3. 2 1. 3.3

INFORMATION INTRODUCTION COMPONENTS Package

CONTENTS

FCE Storage/Extension Unit and Cable Assembly Card File Printed Circuit Boards Controller PCB Control Delivery PCB Transmitter-Opto PCB Power Supply Converter PCB FRC Interface PCB (Serial or Parallel) SPECIFICATIONS Physical/Mechanical Electrical Miscellaneous

II APPLICATION, INSTALLATION AND ADJUSTMENT 2.1 GENERAL APPLICATION DATA 2.1.1 2.1.1.1 2.1.1.2 2.1.2 2.1. 3 2.1.4 2.1. 5 2.1.6 2.1.6.1 2.1.6.2 2.1.6.3 2.1. 7 2.1.8 2.2 2.2.1 2.2.1.1 2.2.1.2 2.2.1.3 2.2.1.4 2.2.1.5 2.2.1.6 2.2.1.7 2.2.1.8 2.2.1.9 2.2.1.10 2.2.2 2.2.2.1 2.2.2.2 2.2.2.3 2.2.2.4

FCE Equipment Mounting Card File FCE Storage Unit Preparing and Installing Cardfile System Power Requirements System Grounding Installation of Connectors and Cabling Auxiliary Equipment Final Stick Relay Code Line Arresters Cycle Recorder Control Outputs Indication Inputs SPECIAL APPLICATION DATA Type L - Form 502A LCS and Storage Units Introduction Control/Indication Capabilities Unit Mounting Plug Connectors Programming Guidelines Switch and Jumper Settings - Controller PCB Switch Settings - Serial FRC Interface PCB Control Outputs Indication Inputs Cycle Recorder Type L - Form 504B or 504C, LCS and Storage Units Introduction Control/Indication Capabilities Unit Mounting Plug Connectors

i

1-1 1-1 1-1 1-1 1-4 1-4 1-4 1-5 1-5 1-6 1-6 1-6 1-6 1-7 1-7

2-1 2-1 2-1 2-1 2-2 2-2 2-3 2-3 2-3 2-5 2-5 2-6 2-6 2-7/8 2-7/8 2-9 2-9 2-9 2-9 2-10 2-10 2-15 2-15 2-20 2-20 2-20 2-21 2-23 2-23 2-23 2-24 2-24


CONTENTS (Cont'd)

Section

III

IV

2.2.2.5 2.2.2.6 2.2.2.7 2.2.2.8 2.2.2.9 2.2.2.10 2.2.2.ll 2.2.2.12

Programming Guidelines Switch/Jumper Settings Control Outputs Indication Inputs R Relay and Series Line Resistor RP and RPP Relay Code Line Filter Cycle Recorder

FUNCTIONAL DESCRIPTION 3.1 OFFICE/FIELD SYSTEM LOGIC 3.2 GENERAL CONFIGURATION OF CODE UNIT 3.3 FIELD STATION BASIC OPERATION 3.3.1 General 3.3.2 Control Code From Office (502A, 5048 and 504C) 3.3.3 Field-Initiated Indication Code (502A only) 3.3.4 Field-Initiated Indication Code (5048 and 504C only) 3.3.5 Auto Recall Mode (502A, 5048 and 504C) 3.3.6 Field Station Disconnect (5048 and 504C only) 3.4 PCB OPERATIONS AND FUNCTIONS 3.4.1 Controller PCB 3.4.1.1 3.4.1.2 3.4.1.3 3.4.1.4 3.4.1.5 3.4.1.6 3.4.1.7 3.4.2 3.4.3 3.4.4 3.4.5

General Station Address Jumpers Program Switches Toggle Switches LED Indications FRC Interface PCB Signals Card File Bus Signals Control Delivery PCB Transmitter-Opto PCB FRC Parallel Interface PCB (5048 or 504C) FRC Serial Interface PCB (502A)

FIELD MAINTENANCE 4.1 INSPECTION 4.2 CLEANING 4.3 SYSTEM TROUBLE ANALYSIS

IV SHOP MAINTENANCE 5.1 GENERAL 5.2 SYSTEMATIC PCB TROUBLESHOOTING 5.2.1 Controller PCB 5.2.1.1 Test Procedure Comments 5.2.1.2 Required Test Equipment 5.2.1.3 Test Set-Up 5.2.1.4 Procedure

ii

2-33 2-33 2-38 2-38 2-38 2-39 2-40 2-47

3-1 3-1 3-1 3-1 3-1 3-2 3-2 3-5 3-6 3-6 3-6 3-6 3-6 3-7 3-7 3-7 3-9 3-10 3-10 3-ll 3-12 3-13 3-13

4-1 4-1 4-1 4-1

5-1 5-1 5-1 5-1 5-1 5-2 5-2 5-3

•

•

Section

5.2.2 5.2.2.1 5.2.2.2 5.2.2.3 5.2.2.4 5.2.3 5.2.3.1 5.2.3.2 5.2.3.3 5.2.3.4 5.2.4 5.2.5.1 5.2.4.2 5.2.4.3 5.2.4.4 5.2.5 5.2.5.1 5.2.5.2 5.2.5.3 5.2.5.4 5.2.6 5.2.6.1 5.2.6.2 5.2.6.3 5.2.6.4

CONTENTS (Cont'd)

Sequential Delivery PCB Test Procedure Comments Required Test Equipment Test Set-Up Procedures Transmitter-Opto PCB Test Procedure Comments Required Test Equipment Test Set-Up Procedure Power Supply Converter PCB Test Procedure Comments Required Test Equipment Test Set-Up Procedure FRC Parallel Interface PCB Test Procedure Comments Required Test Equipment Test Set-Up Test Procedure FRC Serial Interface PCB Test Procedure Comments Required Test Equipment Test Set-Up Procedure

VI SUPPLEMENTAL DATA 6.1 FCE-500 TO DDL-601BX UPGRADE PROCEDURE 6.1.1 6.1.2 6.2 6.3

APPENDIX A A.l A.2 A. 3 A.4 A. 5 A.6 A.7 A.8

General Procedure RECOMMENDED REFERENCE LITERATURE SCHEMATIC DIAGRAMS

PARTS LIST CARD FILE ASSEMBLY CONTROLLER PCB N451441-4303 SEQUENTIAL DELIVERY PCB N451441-5001 TRANSMITTER-OPTO PCB N085722-1001 FRC PARALLEL INTERFACE PCB N451441-6801 FCR SERIAL INTERFACE PCB N451441-70011 POWER SUPPLY CONVERTER PCB N451441-3303 FCE STORAGE UNIT AND CABLE ASSEMBLY

iii

UNION SWITCH & SIGNAL

5-9 5-9 5-9 5-9 5-10 5-13 5-13 5-13 5-13 5-14 5-16 5-16 5-16 5-16 5-17 5-18 5-18 5-18 5-19 5-19 5-24 5-24 5-24 5-24 5-25

6-1 6-1 6-1 6-1 6-2 6-2

A-2 A-4 A-6 A-8 A-10 A-12 A-14 A-16


Section

APPENDIX B

B.l B.2 B.3 B.4 B.5 B.6 B.7 B.8 B.9

Figure

1-1 1-2 2-1

2-2

2-3 2-4 2-5

2-6 2-7 2-8 2-9 2-10

2-11

2-12

2-13

2-14

2-15

2-16

2-17

CONTENTS (Cont'd)

AUXILIARY EQUIPMENT PARTS LIST AND APPLICATION GUIDE

L-10 RELAY, SHELF AND RACK MOUNTING DN-11 RELAY, SHELF AND RACK MOUNTING DN-22 RELAY, SHELF AND RACK MOUNTING PN-150/250 RELAY, SHELF MOUNTING PN-150/250 RELAY, RACK MOUNTING CAPACITOR/RESISTOR UNIT, SHELF AND RACK MOUNTING CODE LINE LIGHTNING ARRESTER CODE LINE FILTER, SHELF AND RACK MOUNTING P-4 TYPE RELAY, SHELF MOUNTING

ILLUSTRATIONS

FCE-500/Relay Code System Block Diagram FCE-500 Card File PCB Arrangement USSP-11 Surge Suppressor Installation on System Power Input Lines Typical FCE-500 Application to 502A Field Relay Code System Standard FCE-500 PCB External Wiring, 502A Mode Controller PCB Manually Selected Options for 502A Cycle Recorder Layout and Connections for 502A System Systems Typical FCE-500 Application to a 504B Field Relay Typical FCE-500 Application to a 504C Field Relay Standard FCE-500 PCB External Wiring, 504B Mode Standard FCE-500 PCB External Wiring, 504C Mode Controller PCB Manually Selected Options for 504B and 504C Code Line Filter Application for 504B: Without DC Blocking or Carrier Blocking Code Line Filter Application for 504B: With DC Blocking and Without Carrier Blocking Code Line Filter Application for 504B: With DC Blocking and With Carrier Blocking Code Line Filter Application for 504C: Without DC Blocking or Carrier Blocking Code Line Filter Application for 504C: With DC Blocking and Without Carrier Blocking Code Line Filter Application for 504C: With DC Blocking and With Carrier Blocking Cycle Recorder Layout and Connections for 504B or 504C Systems

iv

B-2 B-4 B-6 B-8 B-10 B-12 B-13 B-14 B-15

1-2 1-3 2-4

2-11/12

2-13/14 2-17 2-22

2-25/26 2-27/28 2-29/30 2-31/32 2-35

2-41

2-42

2-43

2-44

2-45

2-46

2-48

Figure

3-1 3-2 3-3 3-4 3-5 5-1 5-2 5-3 5-4 5-5 6-1 6-2 6-3 6-4 6-5 6-6 A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 B-1 B-2 B-3 B-4 B-5 B-6 B-7 B-8 B-9

UNION SWITCH & SIGNAL ffi ILLUSTRATIONS (Cont'd)

FCE-500 Field Station Block Diagram - 502A System FCE-500 Field Station Block Diagram - 504B or 504C System Controller PCB Block Diagram Timing Of Relay-Output PCB Operations Timing of Optical-Input PCB Operations Controller PCB Switch/Jumper Programming ~ecord Control Delivery PCB Troubleshooting Program. Transmitter-Opto PCB. Troubleshooting Program FRC Parallel Interface PCB Test Set-Up FRC Serial Interface PCB Test Set-Up Controller PCB N451441-4305 Schematic Diagram Control Delivery PCB N451441-3601 Schematic Diagram Transmitter-Opto PCB N058722-1001 Schematic Diagram FRC Parallel Interface PCB N451441-6801 Schematic Diagram FRC Serial Interface PCB N451441-7001 Schematic Diagram Power Supply Converter PCB N451441-3303 Schematic Diagram FCE-500 Card File Assembly Controller PCB N451441-4305 Component Layout Control Delivery PCB N451441-3601 Component Layout Transmitter-Opto PCB N085722 Component Layout FRC Parallel Interface PCB N451441-6801 Component Layout FRC Serial Interface PCB N451441-7001 Component Layout Power Supply Converter PCB N451441-3303 Component Layout FCE Storage Unit, Cable Assembly and Wiring Diagram L-10 Relay Mounting DN-11 Relay Mounting DN-22 Relay Mounting PN-150/250 Relay Shelf Mounting PN-150/250 Relay Rack Mounting Capacitor/Resistor Unit Mounting Code Line Lightning Arrester Mounting Code Line Filter Mounting P-4 Type Relay

v

3-3 3-4 3-8 3-11 3-12 5-4 5-11 5-15 5-20 5-25 6-3/4 6-5/6 6-7/8 6-9/10 6-11/12 6-13/14 A-3 A-5 A-7 A-9 A-11 A-13 A-15 A-17/18 B-3 B-5 B-7 B-9 B-11 B-12 B-13 B-14 B-15

ffi UNION SWITCH & SIGNAL

FCE-500 Cardfile

SECTION I GENERAL INFORMATION

1.1 INTRODUCTION (See Figure 1-1)

UNION SWITCH & SIGNAL m

The Field Code Emulator FCE-500 is used to upgrade existing CTC relay-logic field stations to digital logic on a station-by-station basis. The unit can also be used to add new field stations in an existing relay code system. All line coding, addressing, control, and indication operations of the relay code field units are duplicated by the FCE-500. No changes ~re required in the office relay logic. The FCE-500 is designed to be fully compatible with the connector and mounting hardware of the existing field relay code equipment.

The FCE-500 is a standard digital data link code unit containing an FRC Interface (serial or parallel) printed circuit board (PCB), microprocessor (Controller) PCB, power supply converter PCB and a set of relay-output and optical-input PCB's. When a control instruction is processed, the Controller PCB drives the relay-output PCB's. These PCB's are used to operate wayside control relays. When an indication instruction is processed, the Controller PCB scans the optical-input PCB's. These PCB's are designed to receive wayside indication contact inputs on a continuous basis. The Field Relay Code (FRC) Interface PCB connects the de code line data for the FCE-500 Controller PCB. The FRC PCB allows the Controller PCB to communicate with the office relay logic.

Once all relay code field stations have been upgraded with FCE-500 units, the system as a whole can be converted to all-digital operation. This is accomplished, in part, by upgrading the office relay code logic with a DDL-601 Office code unit, and replacing the de code line with a digital carrier modem system. As part of the upgrade process, the FRC Interface PCB in the FCE-500 card file is removed: the FCE-500 is then designated DDL-601BX. A DDL-601BX field code unit is a DDL-6018 unit with an "extended" range of control delivery output times to accomodate the relay timing of the existing code system. Refer to SM-6200 for information on DDL-601BX operation in an all-digital logic system.

This manual describes the FCE-500 that is compatible with 502A, 5048 and 504C relay code systems.

1.2 COMPONENTS

1.2.1 Package (N451583-09XX)

The FCE-500 is housed in a shelf or rack-mountable printed circuit board card file. The card file carries a terminal plug-in board, a code line interface PCB (FRC Interface), one microprocessor logic PCB (Controller), a power supply converter PCB and a set of relay-output and optical-input PCB's arranged according to the application. The general arrangement and functions of the cardfile PCB's are shown in Figure 1-2. Internal circuit connections between boards are made on PCB card edge connectors along the inside of the cardfile rear panel. These connectors share a printed circuit "motherboard", which carries board communications. The PCB's are also connected to a terminal

(Text continued on page 1-4)

6202A, P• 1-1

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=

RELAY CODE OFFICE

•

• OFFICE LINE CODING UNIT

l 1 STORAGE UNIT

l CONTROL CENTER

r

EXISTING RELAY CODE FIELD STATION

I

FCE-500 STATION

DC : CODE LINE

LINE &

START

r-+

4 __ I

• FIELD

LINE CODING STORAGE UNIT

R,RP,RPP RELAYS CYCLE

REC. ETC.

•

() z O Q z ()

d1 • ~ ~ 0 -,... ~ !!! IJJ -I -(/) cil

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"S" UNIT #1

"S" UNIT #2

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210 cil~ o cri~ ,... ~

6 6 z z IJJ

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• ' . WAYSIDE

FINAL STICK RELAYS

WAYSIDE INDICATION CONTACTS

CONTROL BITS*

INDICATION BITS*

FCE-500

POWER SUPPLY CONV.

PCB

j

A

• RELAY·

OUTPUT PCB

CONTROL WORD

j

m ~ m lJ -< ~ c ~ .!!!

() 0 z ~ 0 ,... IJJ =l Cl)

• CONTROLLER

PCB (INCLUDES

ADDRESSES FOR "S" UNITS)

+

EXISTING DC SUPPLY (16 V. NOM.) ....._._

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L__,,.J_ .J FINAL STICK I -r-r1 RELAYS I ...-

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OPTOINPUT PCB (IND.

WORD)

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WAYSIDE INDICATION CONTACTS

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INTER FACE PCB

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A.RP, APP RELAYS CYCLE

REC. ETC.

•

--

CODE LINE 1/0 *

INTERNAL SIGNALS*

EB c z 0 z I ~ ::z: Q!I en Gl z )> ....

"ll .... IQ ~ .., (I)

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(") DJ .., 0..

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'ti (") tp

> .., .., DJ :::, IQ (I) l:I (I) :::, rt"

°' N 0 N > ..

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POWER

0 ~ ON OFF

0 +5 VOLTS

0 0 +12 VOLTS

0 -12 VOLTS

POWER SUPPLY

PCB I I J1

r----...J I APPLICABLE

I POWER SUPPLY CONVERTER PCB:

: -;.4s1«1·3303 -

WORD WORD WORD WORD WORD 1 2 3 4 5 O LED1

O LED2

O LED3

O LED4

h ... N w ... O LED5 ~ z ::u .....

en c:, c:, :z: n en en

~ en O LED& 0 ..... a a ii 0

::u ::u s? ! > > 0 C) C) C) O LED7 t; m m m m c c c c

~ SW8 z z z z :::j :::j :::j :::j n n n n i 0 0 0

~ SW7 !i ..... z z ~ ~ ::u ::u

0 0 0 0

~ SW& .... .... J;; t; en en

-0 SW4

= ~ SW 5

DLVR DLVR DLVR DLVR DLVR (i)) SW 1

0 0 0 0 0 G>) SW2

ADRS ADRS ADRS ADRS ADRS

0 0 0 0 0 @ SW3

:J2 J3 J4 JS JI

I ' .I "'-""'" I APPLICABLE RELAY-OUTPUT PCB: I N451441·3601

I I

J7

;I ... i! !e !~ ~

n 0

!i ::u 0 e ::u .,, n 1111 c

! ... t ... J,,. f!i en

PCB N461441-8801 ONLY

WORD WORD WORD WORD WORD 1 2 3 4 5

h ... N w ~ en z ::u en ..... c:, c:, :z: iii en en en en S! a ..... ..... a 0 0 n ::u ::u ::u ::u ~ > > > > C) C) C) C)

0 m m m m z c c c c en z z z z

:::j :::j :::j :::j

iii z z iii c:, c:, S! 0

" " " n g > ~ > g ::::! 0 0 z z z z en en en en

LOW LOW LOW LOW LOW BYTE BYTE BYTE BYTE BYTE

0 0 0 0 0

HIGH HIGH HIGH HIGH HIGH BYTE BYTE BYTE BYTE BYTE

0 0 0 0 0

i , J8 Jg ~ J11 J1~ I I APPLICABLE OPTICAL-INPUT PCB'S: I I N451«1.3201 I I N085722· 1001 I I I

. .,, :a n z -I m :a .,,

0 ::,:,,. n m

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l 0 CON, NECT

.. 0 z z z ~ 0 0 ..... XMT ..... c c c en en 0 en m m m 0 0 0

REC

0

0

J13 J14 I J1s: J16

r--.J L.--, I STANDARD I

PCB I ', N451441·6801(5048/C) I

OR I N451441-7001(502A) :

c z 0 z I ~ :c • (I)

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plug-in board on top of the card file. These terminals are directly compatible with the existing connectors that interface external equipment such as power supplies, wayside relays etc. Slots Jl3, Jl4 and Jl6 are not used in FCE-500 applications, however PCB connectors are provided in these slots to allow installation of extra optical-input PCB's when the code unit is converted to a DDL-601BX.

1.2.2 FCE Storage Unit and Cable Assembly (N451458-540X and 550X)

The FCE Storage Unit simulates the storage unit of the existing relay code system. It contains a set of plug connectors identical to the top plug connectors of the existing storage unit. However, this unit contains no internal relays or electronics: it is only a wiring connection unit. The functions of the relay code storage units are now handled by relay-output and optical-input PCB's in the FCE-500 card file. Factory-assembled cables are connected to the underside of the FCE Storage Unit terminal board. Plugs at the other end of the cables are inserted in the upper card edge connectors of relay-output and optical-input PCB's in the card file. (The -540X series of assemblies substitute for 502A storage units, while the -550X series substitutes for the 504B and 504C storage units.)

1.2.3 Card File Printed Circuit Boards

1.2.3.1 Controller PCB (N451441-4305)

The Controller PCB performs all logical decisions and calculations for the FCE-500. Its main functions include managing of instructions and data to and from the office (through the FRC Interface PCB) and execution of watchdog and testing routines. It processes wayside controls and indications through the output and input boards in the cardfile. Key components include:

Microprocessor

The principal component of the Controller PCB is a 6809 microprocessor chip. It is an NMOS device operating from a single 5 Vdc power supply.

PROM

There is one 2732 Programmable Read Only Memory (PROM) IC on the PCB. It has a capacity of 32,768 bits or 4K, 8 Bit bytes of memory and is used to store system software.

PIA's

The Controller PCB contains two 6821 Peripheral Interface Adapter (PIA) IC's. The PIA's interface all data and system status information to and from the microprocessor.

PTM's

The Controller PCB contains two 6840 Programmable Timer Modules (PTM's). The PTM's measure the time width of pulses to and from the Office and provide various time-out functions.

6202A, p. 1-4

UNION SWITCH & SIGNAL m RAM

One Random Access Memory (RAM) IC is used on the board for short term or "scratch-pad" memory. It has a capacity of 2048 8-bit words.

LED's

Seven LED's are provided on the Controller PCB for miscellaneous monitoring and board troubleshooting purposes. The LED's are mounted on the foward edge of the board to allow observation in the cardfile.

Toggle Switches

The Controller PCB is equipped with three SPDT toggle switches. These are used to simulate code line data bits during system tests and inhibit processor circuit operation during such tests.

Jumper, Rotary and DIP Switches

The Controller PCB contains two 8-position rotary switches and three Dual In-Line Package (DIP) rocker switches (8 rockers each) on the front edge of the PCB. The board also has seven jumper sockets. These devices are used to configure the FCE-500 unit for the associated code system (i.e., establishing system size and storage unit addresses).

1.2.3.2 Control Delivery PCB (N451441-3601)

US&S provides one standard relay-output PCB for the Control Word locations of the FCE-500 card file (502/504 version): Control Delivery PCB N451441-3601. The card file may contain from one to five of these PCB's, as determined by application.

This PCB is equipped with 16 mercury-wetted (Form C) relays that output control bits to external circuits. One quad exclusive-OR gate is provided for address decoding. One triple NAND gate processes address acknowledgement and data bit load/deliver signals. Four quad latching IC's hold bit prior to delivery. Hex buffer/inverters are used to drive the relays and two LED's.

1.2.3.3 Transmitter-Opto PCB (N085722-1001)

US&S provides one standard optical-input PCB for the Indication Words of the FCE-500 card file: Transmitter-Opto PCB (N085722-1001). From one to five of this PCB will be installed in slots JS through Jl2 of the card'file, as determined by the application. The name "Transmitter Opto" is carried over from a previous application of the N085722-1001 PCB and does not apply to FCE-500 operation.

There are 16 photo-Darlington optical coupler's mounted on this PCB, one for each input line. The couplers allow input of relay contact data, while electrically isolating the relay circuit currents from the board logic. The couplers also provide transient voltage protection and are designed to accept 5 to 32 volts ac or de. Tri-state hex inverter/buffer !C's are used to accept

6202A, p. 1-5


contact data and to allow parallel transmission of the 16 indication bits over the 8 bit motherboard bus to the Controller PCB. A quad exclusive OR gate IC (CMOS) is provided for address decoding, while two NAND gates are used for byte selection among the bits on the tri-state buffers. Two LED's are included for routine monitoring.

1.2.3.4 Power Supply Converter PCB

US&S provides one standard power supply converter PCB f9r the FCE-500: N451441-3303. This is a de/de converter that regulates operating power for the other card file PCB's and power for external equipment, when required by the application. The nominal power input range for the board is 12 vdc from an unregulated source. The full range is 9 to 18 Vdc. Three different output voltages are developed by three converters, including +5 Vdc at 3 amps, +12 Vdc at 1 amp and -12 Vdc at 1 amp. A surge suppressor is installed across the input lines for transient voltage protection, while an input filter is used to eliminate line noise into the converters. An LED is installed across each of the output lines to monitor performance. This PCB also contains the FCE-500 power on/off switch (SPDT toggle).

1.2.3.5 FRC Interface PCB (Serial or Parallel)

The Field Relay Code Interface PCB is used in the FCE-500 system to interface microprocessor-based circuits to the de code line. There are two versions of this PCB.

FRC PCB N451441-6801 is used for the parallel de code line in 5048 and 504C applications. Major components include four mercury-wetted, double pole relays and one optical isolator re. The relays include "XMT" (code line shunt during indication transmissions), "M" (set proper polarity for external "R" relay), "MP" (code line filter control) and •connect• (disconnect circuits in some applications). The optical coupler is used to electrically isolate the Controller PCB from code line signals, while passing on code line data.

FRC PCB N451441-7001 is used exclusively for the serial de code line in the 502A application. It is equipped with the same components as the -6801 board, however there are only three relays ("Connect• relay not used).

1.3 SPECIFICATIONS

1.3.1 Physical/Mechanical

Overall dimensions, system card file:

Overall dimensions, FCE Storage

Card file PCB access:

Card file mounting:

Storage unit mounting:

6202A, p. 1-6

W = 19", H = 15-5/8", D = 10-5/8"

W = 12-13/16", H = 3", D = 6-31/32"

Hinged/removable front cover

Rack (19" standard) or shelf

Shelf

System card file connections:

Storage unit connections:

1.3.2 Electrical

System power supply PCB fuse:

System power supply input:

System power supply outputs:


Plug connector (502A): 75 terminals using three 5" X 5• plug connector boards

Plug Connector (5048 and C): 80 terminals using two 5" X 5", and one 5" X 6" plug connector board

Plug connector: 50 terminals using two 5" x 5" plug conqector boards

5 amp, 32 v

9 to 18 Vdc, 12 Vdc (nom.) @ 5 amps (max.) 5% ripple (max.)

+5 Vdc, @ .2 amps (max.), 2% tolerance, 0.1% regulated line and load •

.:!:ll_Vdc, @ .2 amps (max.), 2% tolerance, 0.1% regulated line and load.

-1.l_Vdc, @ .2 amps (max.), 2% tolerance, 0.1% regulated line and load.

*Excess power available for external application.

Recommended system battery surge: USSP-11, Battery line Surge Suppressor, protection: US&S N451552-0515

1.3.3 Miscellaneous

Data capability:

Remote I/0 isolation:

504B and 504C systems: 7 controls per output board and 7 indications per input board (max.); 35 total controls and 35 total indications (max.)

502A systems: 5 controls per output indications per input total controls and 35 (max.)

board and 7 board (max.); 25 total indications

Relay output (controls) interface with wayside equipment

Optical coupler input (indications) interface with wayside equipment

6202A, P• 1-7


Code unit maintenance aids:

PCB's per unit (card file)

Top part numbers:

Temperature environment:

Logic families:

Communications:

Related literature:

6202A, p. 1-8

Plug-in PCB's, LED's, test points, extender board, Controller PCB diagnostic PROM, TS-200 series test sets

One power supply converter PCB Up to five relay-ouput PCB's One microprocessor PCB Up to five optical-input PCB's One code line interface PCB

Controller PCB: P.S. Converter PCB: Control Delivery PCB: Transmitter-Opto PCB: FRC Parallel Interface PCB FRC Serial Interface PCB Storage Unit (504B/C): Storage Unit (502A):

-40 to +70 oc

N451441-4305 N451441-3303 N451441-3601 N085722-1001 N451441-6801 N451441-7001 N451458-550X N451458-540X

NMOS, 6809 microprocessor, 2732 PROM, Support IC's: CMOS

Half duplex

TS-200 Series Test Sets: DDL-601BX: FCE-500 (506, 506A, 506C, 514):

SM-6171 SM-6200 SM6202

UNION SWITCH & SIGNAL ~ SECTION II

APPLICATION, INSTALLATION AND ADJUSTMENT

2.1 GENERAL APPLICATION DATA

2.1.1 Equipment Mounting

2.1.1.1 Card File

The FCE-500 system cardfile (equivalent of LCS unit) ca~ be mounted on a shelf or in a 20" equipment rack. The cardfile requires a mounting space 19" wide, 10-5/8" deep and 15-5/8• high. Make sure to allow space for handling connectors on the topside terminal board (if these are used in the application). Also, leave a space approximately 17" wide by 12-1;2• deep in front of the cardfile to allow the door to open fully. This door provides access to the internal printed circuit boards. Refer to the special applications section (2.2) for dimensional differences between the card file and the LCS unit it is intended to replace.

If the cardfile is to be shelf mounted, check whether the shelf has front lip which rises above the top surface of the shelf. A lip would restrict the cardfile door and prevent removal of the plug-in PCB's. The lip should be removed if possible, or the shelf should be raised above the lip. The cardfile can be screwed or bolted to the shelf using 9/32• mounting holes. These holes are located in mounting feet on the sides of the unit. Centers of the mounting feet holes are space at 18-3/8•. Use 1/4• screws or bolts for shelf mounting.

If mounting the FCE-500 system cardfile in a rack, use all four four mounting points on the front vertical brackets. These are spaced at 4" x 3• x 4• intervals. This mounting requirement can be met with racks which use universal E.I.A. Standard RS-310 vertical spacing (i.e.: 112• x 5/8" x 5/8" x 112• x 5/8" x 5/8" x etc.). US&S recommends the following equipment:

Item Description US&S Part No.

Equipment Rack 6' 9-5/8" H X 20" W X 12" D US&S R396261

Speed Nut For #12-24 screw and rack frame thick- US&S J480203, ness of .051" to .109• Tinerman No.

C509-1224 or equivalent

Screw #12-24 x 1/2",steel pan head US&S J507261

The cardfile shelf mounting feet, located on each side, must be removed before the cardfile is inserted in the rack. The mounting feet are attached with #10 screws, washers and nuts which can be removed with a screwdriver and wrench.

6202A, P• 2-1


2.1.1.2 FCE Storage Unit

The FCE Storage unit must be shelf mounted. The unit can be screwed or bolted to the shelf using 9/32n mounting holes. These holes are located in mounting feet on the sides of the unit. Centers of the mounting feet holes are spaced at 12-5/16n. Use l/4n screws or bolts for shelf mounting.

The distance from the FCE-500 system cardfile to the FCE Storage unit is limited by the length of the standard connector/cable assemblies provided with each code system application (refer to section 2.2). T~ese assemblies connect the Storage unit plug terminals to the connector edges in the cardfile. The following tabulation shows the maximum physical distance allowed between the cardfile and storage unit:

Storage Unit Max. Physical Sep.

u 5 ft. #2 7 ft. #3 9 ft. #4 11 ft.

2.1.2 Preparing and Installing Cardfile PCB's

The FCE-500 is shipped with the PCB's in separate packages. Install the PCB's according to the instruction label on the inside face of the front cover (see also Figure 1-2). The Controller PCB must be manually programmed (switches and jumpers) to configure the unit for the customer's particular application In addition, the FRC Serial Interface PCB (N451441-7001, 502A applications) must be configured for proper operation on the customer's particular code line. Refer to section 2.2 for all required programming procedures. To install or remove a PCB, loosen the 1/4-turn screws on the cardfile front door and lower the door so that the PCB can be pulled straight out.

CAUTION

DO NOT REMOVE OR INSTALL ANY FCE-500 SYSTEM PRINTED CIRCUIT BOARD WITH POWER ON, OTHERWISE EQUIPMENT DAMAGE AND/OR UNRELIABLE EQUIPMENT OPERATION MAY RESULT.

NOTE

To prevent undesired operation of the Connect and Transmit relays on the FRC Interface PCB, set SW2 on the Controller PCB to OPERATE and SW3 to MARK.

Make certain to close and lock the cardfile front door after the Contoller PCB has been reinstalled. The power supply converter, relay-output and opticalinput boards do not require any initial adjustments. If switch and jumper selections on the Controller PCB are to be changed afterwards, one of the following must occur for the board logic to accept the change:

6202A, p. 2-2


1. Toggle switch SWl on the power supply converter PCB (slot Jl) must be turned off and back on.

2. Reset toggle switch SWl on the Controller PCB (slot J7) must be moved to the RESET position, then back to NORMAL.

3. The Controller PCB watchdog timer circuit must trigger. This will be shown by lighting of the Watchdog LED.

2.1.3 System Power Requirements

FCE-500 system power input specifications are 9 to 18 Vdc input (12 Vdc nominal) at 2 amps maximum, and with a maximum ripple of 5%. The FCE-500 can use the existing power source of relay code system. However, a US&S USSP-11 surge suppressor must be added to the power lines of the existing system, if not already available. This suppressor contains lightning arresters. Its wiring is shown in Figure 2-1.

The FCE-500 system indication input power limits are the same as the operating limits of the system. The maximum current draw of each indication input on the optical-input PCB's is 3 milliamps.

2.1.4 System Grounding

The FCE-500 system requires a solid ground for proper operation. This ground is made by connecting two #6 AWG wires to the ground stud on the back of the FCE-500 system cardfile and running them to the house or case prime ground. Keep these ground wires (a) away from all other wiring as much as possible, (b) as short as possible and (c) with no sharp bends.

2.1.5 Installation of Connectors and Cabling

The FCE-500 accepts the plug connectors of the existing relay code system. These connectors can be used without modifications. When inserting the connectors on the FCE-500, do not apply excessive pressure to the back of the cardfile. The cardfile back panel does not have external support. Excessive pressure on the connectors may cause the equipment to warp.

When the plug connectors are removed for servicing, they are stored on •s• hooks. The •s• hooks will suspend the plug connector above its unit. Mounting of the "S" hooks can be accomplished in either a rack or shelf mount configuration. US&S recommends •s• hook J056179 (Campbell Chain Co. #62 or equivalent).

There are no additional hardware required to shelf mount the "S" hooks. The "S" hooks are mounted in holes drilled into the bottom of the lip of the next higher shelf.

6202A, p. 2-3


16V INSTALLATION (OPERATING) (Maximum Rating for Suppressor: 32 voe@ 15A)

US&S USSP-11 (BATTERY LINE) SECONDARY SURGE SUPPRESSOR ---N451552-0515 ----...._ #9 AWG (MIN)

816

__ 16V

(NOM)

& N16

~ DENOTES TWISTED PAIR

© +

0

_ PRIMEGND &

#9 AWG (MIN)

-;:'" PRIME GND .&.

9 to 20 volt battery.

SYSTEM 816-C

FCE-500 SYSTEM & ASSOCIATED EQUIPMENT

SYSTEM N16-C

Run grounds separate from all other wiring and metal to the prime ground bus, as directly as possible and with a minimum number of bends.

Figure 2-1. USSP-11 Surge Suppressor Installation on System Power Input Lines

The following part is required to rack mount the •s• hooks:


Mounting bar For 20" rack M371705

Mounting bar For 31" rack M341877

A clearance of at least 12" should be allowed between the top of the FCE-500 equipment and the •s• hook. for either shelf or rack mounted equipment.

6202A, p. 2-4

UNION SWITCH & SIGNAL ffi 2.1.6 Auxiliary Equipment

2.1.6.1 Final Stick Relay

The FCE-500 system uses the final stick relays to store controls in the same way as the field relay code system. Refer to section 2.2 for typical wiring of these relays in specific code systems. When the FCE-500 replaces an existing field relay code system, the final stick relays can be used without modification. If a new location is to use an FCE-500, the final stick relays are selected as follows:

US&S recommends the use of the following relay hardware:


Relay DN-11 Neutral Type, I.OK Ohm Coil, 4F-4B Contacts Nl57187

Relay DN-11 Neutral Type, 0.5K Ohm Coil, 4F-4B Contacts Nl57285

Relay DN-22A Neutral Type, I.OK Ohm Coil, 2F-2B Contacts N224890

Relay DN-22A Neutral Type, 0.5K Ohm Coil, 2F-2B Contacts N239397

Relay PN-150B Biased Type, 0.8K Ohm Coil, 6FB Contacts With Front Testing: N322500-702 Without Front Testing: N322500-802

Relay PN-150B Biased Type, I.OK Ohm Coil, 6FB Contacts With Front Testing: N322500-703 Without Front Testing: N322500-803

Relay PN-250B Biased Type, I.OK Ohm Coil, 6FB-6F-3B Contacts With Front Testing: N322554-701

Without Front Testing: N322554-801

Relay PN-250B Biased Type, I.OK Ohm Coil, 8FB-4F-2B Contacts With Front Testing: N322554-702

Without Front Testing: N322554-802

Base PN-150B Type N451376-0302

Base PN-250B Type N438689-003

The final stick relay can be shelf or rack mounted. Appendix B lists all required mounting hardware.

6202A, P. 2-5


2.1.6.2 Code Line Arresters

The code line arresters are used to protect the FCE-500 from high voltage surges on the code line. Refer to section 2.2 for typical wiring of the code line arresters in the specific relay code systems. When the FCE-500 replaces a field relay code system, the existing arresters can be used without modifications. If a new location is to use a FCE-500 system, the arresters are selected as follows:

US&S recommends the use of the following arresters:


Arrester USG-A high voltage type, 500 to 1300 Vdc N451552-0201 firing voltage

Terminal Block USG-A arrester mounting N541552-0303

The code line arresters can be shelf or wall mounted. Appendix B lists all required mounting hardware. The USG-A arrester may be mounted on a wall or on the top of a shelf, but should not be mounted upside down on the under side of a shelf. It may be mounted horizontally or vertically. If mounted vertically, the open end of the cover should be placed down to prevent accumulation of debris inside the cover. Allow a one inch minimum clearance between the open end of the arrester and a flat mounting surface to permit escape of gases.

2.1.6.3 Cycle Recorder

The cycle recorder may be used with FCE-500 when replacing an existing field relay code system, or when installing an FCE-500 at a new location. This device provides a convenient means for measuring and recording time intervals such as code impulses. The two-punch recorder gives a complete record of a entire code on one tape. Odd numbered impulses are recorded by one magnetic punch on one line; even numbered impulses by the another magnet punch on a second line. When the cycle recorder shifts from one line to the other, there will not be an overlap of more than one punch. An overlap of more than one perforation, or loss of perforations, indicates that the cycle recorder needs adjustment. A correct recording is shown as follows:

1 2 3 4 1/2 1/2 1/2 J./2 1/2 OVERLAP < < < < < <

< < < < < l 2 3 4 5

1 2 3 4 1/2 1/2 J./2 1/2 1/2 < < < < <

< < < < < l 2 3 4 5

6202A, p. 2-6


To read a cycle recorder tape, count each perforation as 1/2 cycle and disregard the OVERLAP punch in the count. When using the cycle recorder for measuring code line timing, the right hand punches are for odd numbered pulses and the left hand punches are for even numbered pulses. When using the cycle recorder to measure coding time with the FCE-500 system, observe the limits defined in section 2.2 for the specific code system application. Cycle recorded part numbers are as follows:


Cycle Recorder -- N231678

Cycle Recorder N.C.R. #60D, 1-5/16" wide cash register J773099 Tape paper

The cycle recorder tape tape will fit on existing equipment by removing the paper guide.

2.1.7 Control Outputs

The FCE-500 system uses relay contacts to connect the wayside control final stick relays to microprocessor logic levels of the Controller PCB. The control final stick relays are applied to the FCE-500 system in the same way as the relay code system. Refer to section 2.2 for control output set-ups in the specific code systems.

The FCE-500 system control output power limits are the same as the operating limits of FCE-500 system. The current output of each control output is a function of the resistance of the final stick relay. For example, in the case of an 800 ohm PN-150B relay operating at 16 Vdc, the output current will be 0.02 amps. The maximum current available per output on a relay-output board is 2 amps or 100 VA (resistive load).

2.1.8 Indication Inputs

The FCE-500 system uses optical-isolators to convert wayside indication voltage levels to the microprocessor logic levels of the Controller PCB. These voltages are applied to different cardfile and storage unit plugboard terminals in the same way as the existing field relay code system.

6202A, P• 2-7/8


502A

2.2 SPECIAL APPLICATION DATA

2.2.1 Type L - Form 502A LCS and Storage Units

2.2.1.1 Introduction

The following part numbers describe the FCE-500 systems applied to 502A based code systems:

Description US&S Part No.

FCE-500, 502A Emulator, with no storage unit N451583-0921 FCE-500, 502A Emulator, with 1 storage unit N451583-0922 FCE-500, 502A Emulator, with 2 storage units N451583-0923 FCE-500, 502A Emulator, with 3 storage units N451583-0924 FCE-500, 502A Emulator, with 4 storage units N451583-0925

Figure 2-2 shows a t~cal application of the FCE-500 in a 502A code system. Wires marked with a I are not required in new FCE-500 installations. Figure 2-3 shows the standard 502A wiring between FCE-500 cardfile PCB's, various external terminals and FCE Storage units. The standard cable distances for connecting the cardfile to storage units are as follows:

Cable/Connector Assembly Description US&S Part No.

502A, cardfile to 1st storage unit, length = 5 ft. N451458-5401 502A, cardfile to 2nd storage unit, length = 7 ft. N451458-5402 502A, cardfile to 3rd storage unit, length = 9 ft. N451458-5403 502A, card file to 4th storage unit, length = 11 ft. N451458-5404 502A, cardfile to Xth storage unit, length = 17 ft. N451458-5405*

*This assembly may be added or replaced where adjacent space is not available.

2.2.1.2 Control/Indication Capabilities

The FCE-500 is capable of handling the maximum control and indication limits of the 502A system. Each FCE-500 relay-output PCB outputs five control steps. The first (slot J2) relay-output PCB serves the same function as the LCS part of the 502A. Each additional five control outputs require another relay-output PCB for the FCE equivalent of a 502A storage unit. The limit (five relay-output PCB's, slots J2 - J6) of control outputs available with the 502A-mode FCE-500 is 25 controls.

6202A, P• 2-9


502A

Each optical-input PCB accepts seven indications inputs. The first optical input PCB (slot J8) serves the same function as the LCS part of the 502A code system. Each additional seven indication inputs require another optical input PCB for the FCE equivalent of a 502A storage unit. The limit (five optical-input PCB's, slots J8 - Jl2) of indication inputs available with the 502A-mode FCE-500's is 35 indications.

2.2.1.3 Unit Mounting (Refer also to Sections 2.1.1.1 and 2.1.1.2)

As indicated below, the FCE-500 cardfile is slightly higher and deeper than the 502A LCS unit:

502A Line Coding Storage Unit FCE-500 Card File

23• W x 14-1/2" H x 7-3/8• D 19• W x 15-5/8• H x 10-5/8• D

The FCE Storage unit requires more horizontal space, but has a lower profile:

502A Storage Unit FCE-500 Storage Unit

11-1/2• W X 14-1/2• H x 7-1/4• D 12-13/16" W x 3• H X 6-31/32 8 D

•ff• is the height of unit with external plug connector attached, but without required clearance needed to remove external plug connector. •n• is the depth without clearance for external wires, if required. These spaces differences should be taken into account when preparing to mount the FCE-500 cardfile and any storage units.

2.2.1.4 Plug Connectors (Refer also to section 2.1.5)

If a new location is to use an FCE-500 system, US&S recommends selection of the plug connectors according to the following tabulation:

Type of Unit Position (L to R) US&S Part No.

Card File 1 Nl73240

Card File 2 Nl73242

Card File 3 Nl73219

Storage Unit 1 Nl73240

Storage Unit 2 Nl73246

6202A, p. 2-10

.0. SMD

:IRCUITS qcE

{

<->ZL

(+IYL

TYPICAL APPLICATION OF FCE-500 IN 502A MODE

TO OTHER F !ELOS

(- IZL } LINE ClRCUJT

~---"<•~l~YL~I .

UNlT

FCE-500 - 502A W[TH NO STORAGE UNIT FCE-500 - SOZA W[TH I STORAGE UNIT FCE-500 - 502A WITH 2 STORAGE UNITS FCE-500 - 502A WITH 3 STORAGE UNITS FCE-500 - 502A WITH 4 STORAGE UNITS

PART NO. ----UN451583-092l UN451583-0922 UN45 I 583-0923 UN451583-0924 UN451583-0925

STANDARD CIRCUIT

0"451272-1605

F'CE-500 CAROFILE

GROUND STUD , .. HOOSE PIHi,£

GROUNO

,--------- .. ---------------. -,·----ov

POWER SUPPLY PCB

UN4514"41-3303 CAROFH.E LOCATION JI


~-·---1 CODE

~ I 12J~1lA~iN

------=-----~i ,/ -->-------@--- --+, I r--®=-'L

I I ' -+..+-------®--- ---+- • : ~~~E~~

-.f,o,l-------@-- - --+ ... ... :~~\~ S UNJ1

-.f,o,l-------®------.. + ... PLUG E

--...... ------@--- _ _,. ... ...

--------®------+ ... -~------®--- -----+

COOE i --@)- - - - ! 12Sf~~~~H I

I I --@------1--, .&. :

1..,..1'* \ I

STANOARO WIRING DIAGRAM -@- - - - -+, I 1 - --€ci\-- NI

I I y 0451273-1602

NIC -®-----.. .. : L---

-@-----.. ... :

--®-----.. ... : NOTES, I

NIC - NO {NTERNAL CONNECTION -®------+ ... I

£ - EXTERNAL CONNECTION NOT REQUIRED UNLESS UNIT TO SE USED I

::x~~!~~:A~~~A~i\~":! :i~!/!~\:~~~ FIELD RELAY CODE UNIT £ -®-------+ : £ - TERVINAL 67 SHOWN IN TWO PLACES {-®- ~

---------------------,------------J ~ ¥ ~ ~ ~ i i ¥ f ¥ ~ f------------, "" t;;;;;3 l---------------- '--L--------J NIC

Figt

I o ::, <Il

ZL

YLI

22 •

'i 6 i 7 4 -~-·r-·- J7 CONTROLLER

BO ARO

JI 5 ,FACE SO. 441-7001

J_

M ~)>=2"-1---,

1-;-' ---,-/ -,-

1 ~y--<~ ( TX. DATA

-o.--------"---~)) IS : l 1

11

1

BN ~ ( COM. MOOE

ISOLATOR

~)22 11 BK ~(c.M. FEED

>----~>'9 11 I lo ((REC. DATA

~ 21 u,

j;o 9 q q

~ z

.~'(is >I:Y~:-:-E--------------~BK"-----~ 18 ~ 6 7 • RECORDER R

JI PWR. SUP.

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JB INPUT SO. N085722-IOOI

ADDRESS JNOICATION COMMON m COth.40N

\,v ~v"~ ~tHtB~f~,~~v,v\iUtUt " <Il

N-BAT.

" "' 8-BAT.

r----------------------------------------, J9 INPUT 80 NOBS722-l001

lNOICATlON COMMON lD

0 0 0 0 0 0 0 z z z z z z z

~A :,.,

8

vc v0

vE vF v~"'iv1

0fv~-lv~~vr4

"'iv~lv6

"'lv~-----------EXTERNAL 25 ;-- ~ ~ ~ 77° ~ 15 STORAGE • • • • • • • • UNIT #I

r----------------------------------------; JIO INPUT BO N085722·1001

I ND I CA Tl ON COMMON

~ ~ ~ ~ ~ ~ 2

< + l IN ) >------"""18~R--,;------r

74 oi}---"---

...-Ex-~:.-:·_v c-y-o "_E >_'F v-l~olv.~-lv,:"ivi~Jl~:: ::: : : : : : STORAGE • 1 • • • 111 BA.T. c + >

I. A 25

I #)8 BK t - HN ) )----'--='-""---------r- BAT. I - l

6,F

N45144 I -3303

LOGIC COM. )>-----'-•~IB'-"W'-------v'J-,Vl--V9

f--{1~0,--,

z GNO STUD

BASIC LCS N451583-0921

UNt T tt2 BK

~----------------------------------------· ' JI I INPUT 60 N085722·1001

INDICATION COMMON

-------------------------------------------------, NOTE•

I. THE FOLLOWING REPRESENT THE PC. NOS, N45i 583-0921 • FCE 500-502A WI TH NO STORAGE UNIT. N451583-0922 • FCE 500-502A WITH I STORAGE UNIT. N45i 583-0923 • FCE 500-502A WITH 2 STORAGE UNITS, N451583-0924 • FCE 500-502A WI TH 3 STORAGE UNI TS, N451583-0925 • FCE 500-502A WI TH 4 STORAGE UNI TS,

2,@ INDICATES TERMINAL ON TERMINAL BOARD.

3, ; INDICATES TWISTED WIRES

4. ALL WIRES ARE #20 AWG UNLESS OTHERWISE NOTED,

5. 0 INDICATES CONNECTION ON TERMINAL STRIP.

6 • ,,),, INDICATES GROUND STUO,

I I

~----------------------------------------; Jl2 INPUT 80 N085722-1001

INDICATION COMMON "' O o o O o a O z z z z z z z

FigUI


2.2.1.5 Programming Guidelines

The following items must be considered when planning the programming of the FCE-500 for a 502A system:

1. Is Auto Recall desired? When Auto Recall is active, the FCE-500 system will respond with a indication code when a valid control code is

502A

received. This will increase system coding time. lherefore, the decision to use Auto Recall must be based on number of trains and the system response time required.

2. What resistance should the "R" relay be set at? When replacing an existing unit, use the following tabulation to determine the "R" relay resistance:

"R". Relay Resistance

502A LCS Part No. Original FCE-500

N213509 20 Ohms 18 Ohms N253228 31 Ohms 29 Ohms N253229 70 Ohms 70 Ohms

When developing a new location on an existing line, determine the "R" relay resistance at an existing location on that line, then use the same resistance at the new location. On a new line. consult the code line calculation for the value of the "R• relay.

2.2.1.6 Switch and Jumper Settings - Controller PCB (Location J7)

A. LCS Address

The 502A LCS address is set with jumpers on the plug connectors on the FCE-500 cardfile. The address is set as follows:

LCS Address Step Post Address Step Connect Post

2 52 First 51 3 53 Second 59 4 54 Third 49 5 55 6 56 7 57 8 58

6202A, P• 2-15


502A

Examples:

Address 234 - Connect post 51 to 52, post 59 to 53 and post 49 to Address 456 Address 678

- Connect post 51 to 54, post 59 to 55 and post 49 to - Connect post 51 to 56, post 59 to 57 and post 49 to

NOTE

In the 502A address selection process, only three unique long steps are acceptable. The ERROR LED on the Controller PCB (LED 4) will light if more than

54 56 58

or less than three steps are selected as longs, .2!:. if the address selected is the same as an address selected for a storage unit within the same cardfile.

B. First Storage Unit Address

The 502A 1st storage unit address is set with DIP switch SW8 on the Controller PCB (location J7). Figure 2-4 shows the general arrangement and operation of the Controller PCB switches and jumpers for 502A system emulation. The long steps of the address are set by placing the rockers to the open ("l") position. The short steps of the address are set by placing the rockers to the closed ("O") position. ("X" = rocker position not pertinent to any particular function).

SWITCH SW8 Rockers 1st Storage u. Address Step 8 7 6 5 4 3 2 1

2 :llo x 0 0 0 0 0 0 1 3 x 0 0 0 0 0 1 0 4 x 0 0 0 0 1 0 0 5 x 0 0 0 1 0 0 0 6 x 0 0 1 0 0 0 0 7 x 0 1 0 0 0 0 0 8 x 1 0 0 0 0 0 0

For example, address 234 would be set as follows:

SWITCH SW8 Rockers

8 7 6 5 4 3 2 1

x 0 0 0 0 1 1 1

6202A, p. 2-16

CONTROLLER PCB N451441-4305

COMPONENT SIDE (NOT TO SCALE)

4TH STORAGE UNIT ADDRESS

ALWAYS USE 7 JUMPERS.


502A

sw5: SET TO "O" FOR 502A

r-- :-e:-: /~ _· ==========-SW4: SYSTEM SIZE

D SMS

D O = LCS ONLY 3 =3 S. UNITS 1 = 1 S. UNIT 4 =4 S. UNITS 2 = 2 S. UNITS 5-8 = NOT USED

D9MS~M.._S--i-----~,~-S~~~~~~ 234 5678

~-[i]~li]~~~[i]

PCB MAY BE EQUIPPED WITH LOW OR HIGH PROFILE (ROCKER) DIP SWITCHES.

-----OPEN-----

\ } t 3RD STORAGEYUNIT ADDRESS NOT

USED

-----OPEN-----

\..._ _____ y } i 2ND STORAGE UNIT ADDRESS AUTO

RECALL

1 234 5678

tl [i1~ ~ ~ li1 El t1 -----OPEN-----

\ ) l 1 ST STORAG~T ADDRESS

NOT USED SWITCHES SHOWN IN .. OPEN .. POSITION

Figure 2-4. Controller PCB Manually Selected Options for 502A

6202A, p. 2-17


502A

c. Second Storage Unit Address

The 502A 2nd storage unit address is set with DIP switch SW7 on the Controller PCB (location J7). The long steps of the address are set by placing the rockers to the open c•1•) position. The short steps of the address are set by placing the rockers to the closed c•o•) position. Rocker 48 is used for selection of Auto Recall; refer to section G on page 2-19.

SWITCH SW7 Rockers 2nd Storage u. Address Step 8 7 6 5 4 3 2 1

2 ~ - 0 0 0 0 0 0 1 3 0 0 0 0 0 1 0 4 0 0 0 0 1 0 0 5 0 0 0 1 0 0 0 6 0 0 1 0 0 0 0 7 0 1 0 0 0 0 0 8 1 0 0 0 0 0 0

D. Third Storage Unit Address

The 502A 3rd storage unit address is set with DIP switch SW6 on the Controller PCB (location J7). The long steps of the address are set by placing the rockers to the open c•1•) position. The short steps of the address are set by placing the rockers to the closed c•o•) position. c•x• = rocker position not pertinent to any particular function):

SWITCH SW6 Rockers 3rd Storage u. Address Step 8 7 6 5 4 3 2 1

2 .. x 0 0 0 0 0 0 1 3 x 0 0 0 0 0 1 0 4 x 0 0 0 0 1 0 0 5 x 0 0 0 1 0 0 0 6 x 0 0 1 0 0 0 0 7 x 0 1 0 0 0 0 0 8 x 1 0 0 0 0 0 0

E. Fourth Storage Unit Address

The 502A 4th storage unit address is set with the Station Address jumpers on the Controller PCB (location J7). When the jumper is set to the no• side, the address step is short. When the jumper is set to the •1• side, the address step is long. The numbering of the 4th storage unit addresses at the Controller PCB jumpers is as follows:

6202A, p. 2-18

,t

Jumper Pos.

1 2 4 8

16 32 64

F. 502A Mode Selection

4th Storage u. Address Step

2 3 4 5 6 7 8


502A

The 502A mode is selected using rotary switch SW5 on the Controller PCB (location J7). Set this switch to the "O" position for the a 502A system.

G. Auto Recall Selection

The Auto Recall mode for 502A is controlled with rocker #8 of DIP switch SW7 on the Controller PCB (location J7). To activate the Auto Recall mode, set this rocker to the open position. To keep this mode inactive, set rocker #8 to the closed position. Make certain not to readjust any of the other SW7 rockers used to set for other functions.

H. System Size

The size of the 502A system is defined using rotary switch SW4 on the Controller PCB (location J7). The switch settings are as follows:

SW4 Position System Size

0 LCS Unit Only 1 1 Storage Unit 2 2 Storage Units 3 3 Storage Units 4 4 Storage Units 5 Not Used 6 Not Used 7 Not Used

If SW4 is set at position "l", the address for the first storage unit must be properly set, otherwise the system will lock up. This will be indicated with the lighting of LED 4 on the Controller PCB (location J7). The same is true for the remaining storage unit settings. If switch SW4 is set to positions 5, 6, or 7, the system will again lock up (LED 4 on).

6202A, P• 2-19


502A

2.2.1.7 Switch Settings - FRC Serial Interface PCB (N451441-7001)

The code line "R• coil resistance for the 502A system is set on FRC Interface PCB N451441-7001 (location Jl5), using toggle switch SWl (3-position type). The switch options are as follows:

SWl Position "R" Coil Resistance

18 18 Ohms 29 29 Ohms 70 70 Ohms

2.2.1.a Control Outputs

The following tabulation lists relay-output PCB slot and plug connector terminal numbers that pertain to control outputs for 502A mode:

Control Control Cardfile Output Outputs

Slot Function Emulated Terminals Served

J2 LCS Unit 1 to 8 ( 1 to J3 1st Storage Unit 1 to 8 ( 6 to J4 2nd Storage Unit 1 to 8 (11 to J5 3rd Storage Unit 1 to 8 (16 to J6 4th Storage Unit 1 to 8 ( 21 to

2.2.1.9 Indication Inputs

5) 10) 15) 20) 25)

The following tabulation lists optical-input PCB slot and plug connector terminal numbers that pertain to indication inputs for the 502A mode:

Indication Indication Cardfile Input Inputs


JS LCS Unit 9 to 15 ( 1 to 7) J9 1st Storage Unit 9 to 15 ( 8 to 14) JlO 2nd Storage Unit 9 to 15 (15 to 21) Jll 3rd Storage Unit 9 to 15 (22 to 28) Jl2 4th Storage Unit 9 to 15 (29 to 35)

6202A, p. 2-20

2.2.1.10 Cycle Recorder (Refer also to section 2.1.6.3)


502A

Figure 2-5 shows the various connections from the cycle recorder to the FCE-500 for a 502A system. The tabulated numbers represent plug connector terminals on top of the cardfile.

When using the cycle recorder to measure coding time with the FCE-500 system, make certain to observe the following limits:

Received Pulses Minimum Maximum

-Pulse 1 (Indication) 115 ms (7 Cycles) 270 ms (16 Cycles)

Pulse 1 (Control) 280 ms (16.5 Cycles) 535 ms (32 Cycles)

All shorts 50 ms (3 Cycles) 190 ms (11.5 Cycles)

All longs 250 ms ( 15 Cycles) 550 ms (33 Cycles)

Shortest recognized pulse 35 ms (2 Cycles) --Minimum line quiet time re- -- 650 ms (39 Cycles) quired for receive reset

Transmitted Pulses Nominal Value Tolerance

Pulse 1 133 ms (8 Cycles) +0.5, - 0.5 Cycles

Odd Shorts 84 ms (5 Cycles) +0.5, - 0.5 Cycles

Even shorts 108 ms (6.5 Cycles) +0.5, - 0.5 Cycles

Odd longs 350 ms ( 21 Cycles) +o. 5, - 0.5 Cycles

Even longs 417 ms (25 Cycles) +0.5, - 0.5 Cycles

Minimum line quiet time 1033 ms (62 Cycles) +0.5, - 0.5 Cycles required before indic-ation transmission

Minimum line quiet time re- 1369 ms (82 Cycles) +0.5, - 0.5 Cycles quired before indication

" transmission after an indi-cation transmission from this location (SS delay)

6202A, p. 2-21


Notes

The received pulses (first table) represent absolute limits. Deviations beyond these limits will cause improper operation of the FCE-500. Proper operation is only possible if the office and field relay equipment meets service specifications. These specifications are listed in the respective service literature for that equipment.

FCE-500 transmit timing is not adjustable. If.the timing of transmitted pulses is consistently outside the tolerance listed in the second table, either the Controller or FRC Interface PCB is defective. Transmit timing must be measured with all units quiet, except the one under test.

r- - -- - - -- -1 +1 -1 I 105

-2 I I

105

I I I I 1P

1R I I --' -I

115 VOLT [ I AC

I 502A I

LCS UNIT I 67

ON

9 OFF

L __ --- -c--_r-1 PAPER ) _

......._; ..

Figure 2-5. Cycle Recorder Layout and Connections for 502A System

6202A, p. 2-22

..

..


(2.2 SPECIFIC APPLICATION DATA, Continued) 504B and 504C

2.2.2 Type L - Form 504B or 504C, LCS and Storage Units

2.2.2.1 Introduction

The following part numbers describe the FCE-500 systems applied to 504B or 504C based code systems:

Description US&S Part No •

FCE-500, 504B Emulator, with no storage unit N451583-0926 FCE-500, 504B Emulator, with 1 storage unit N451583-0927 FCE-500, 504B Emulator, with 2 storage units N451583-0928 FCE-500, 504B Emulator, with 3 storage units N451583-0929 FCE-500, 504B Emulator, with 4 storage units N451583-0930 FCE-500, 504C Emulator, with no storage unit N451583-0931 FCE-500, 504C Emulator, with 1 storage unit N451583-0932 FCE-500, 504C Emulator, with 2 storage units N451583-0933 FCE-500, 504C Emulator, with 3 storage units N451583-0934 FCE-500, 504C Emulator, with 4 storage units N451583-0935

Figures 2-6 and 2-7 show typical LCS and storage unit applications of the FCE-500 in a 504B and 504C code systems, respectively. Wires marked with a ~ are not required in new FCE-500 installations. Figures 2-8 and 2-9 show the standard 504B and 504C wiring, respectively, between FCE-500 cardfile PCB's, various external terminals and FCE Storage units. The standard cable distances for connecting the cardfile to extension units are as follows:

Cable/Connector Assembly Description US&S Part No.

504B, cardfile to 1st storage unit, length = 5 ft. N451458-5501 506C, cardfile to 2nd storage unit, length = 7 ft. N451458-5502 506C, cardfile to 3rd storage unit, length = 9 ft. N451458-5503 506C, cardfile to 4th storage unit, length = 11 ft. N451458-5504 506C, cardfile to Xth storage unit, length = 17 ft. N451458-5505* 514, cardfile to 1st storage unit, length = 5 ft. N451458-5501 514, cardfile to 2nd storage unit, length = 7 ft. N45l458-5502 514, cardfile to 3rd storage unit, length = 9 ft. N451458-5503 514, cardfile to 4th storage unit, length = 11 ft. N451458-5504 514, cardfile to Xth storage unit, length = 17 ft. N451458-5505*

*Indicates this assembly may be added or replaced where adjacent space is not available

6202A, p. 2-23


504B and 504C

2.2.2.2 Control/Indication Capabilities

The FCE-500 is capable of handling the maximum control and indication limits of the 504B and 504C systems. Each FCE-500 relay-output PCB outputs seven control steps. The first (slot J2) relay-output PCB serves the same function as the LCS part of the 504B or 504C system. Each additional seven control outputs require another relay-output PCB for the FCE equivalent of a 504B or 504C storage unit. The limit (five relay-output PCB's, .slots J2 - J6) of control outputs available with the 504B and 504C-mode FCE-500's is 35 controls.

Each optical-input PCB accepts seven indications inputs. The first optical input PCB (slot JS) serves the same function as the LCS part of the 504B or 504C code system. Each additional seven indication inputs require another optical input PCB for the FCE equivalent of a 504B or 504C storage unit. The limit (five optical-input PCB's, slots J8 - Jl2) of indication inputs available with the 504B and 504C mode FCE-500's is 35 indications.

2.2.2.3 Unit Mounting (Refer also to Sections 2.1.1.1 and 2.1.1.2)

As indicated below, the FCE-500 cardfile is slightly higher and deeper than the 504B and 504C LCS unit:

504B or 504C Line Coding Storage Unit FCE-500 Card File

23• W X 14-1/2• H X 7-3/8 8 D 19• w x 15-5/a• H x 10-5/a• o

The FCE Storage unit requires more horizontal space, but has a lower profile:

506C or 514 Storage Unit FCE-500 Storage/Extension Unit

11-1/2• W X 14-1/2• H X 7-1/4• D 12-13/16 8 W x 3• H x 6-31/32 8 D

•ff• is the height of unit with external plug connector attached, but without required clearance needed to remove external plug connector. •o• is the depth without clearance for external wires, if required. These differences should be taken into account when preparing to mount the FCE-500 cardfile and any storage units.

2.2.2.~ Plug Connectors (Refer also to section 2.1.5)

If a new location is to use an FCE-500 system, US&S recommends' selection of the plug connectors according to the following tabulation:

Unit Type Pos. ( L to R) Part No. Unit Type Pos. (L to R) Part No.

Card File 1 Nl84690 Storage u. 1 Nl84690 Card File 2 Nl84689 Storage u. 2 Nl84691 Card File 3 Nl01931

6202A, p. 2-24

..

..

..

t I

4- I

UNION SWITCH & SIGNAL m 504B

LI } LIN£ L2 crncun

TYPICAL APPLICATION OF FCE-500 IN 504B MODE

FCE-500 CAROFILE

ARRESTERS

/ GROUND STUD

~ HOUSE PRJl,E GROUND

6 ~ A FUSETROHS / STORAGE UNIT r----I i-~~~~~~~~~~~~~~~~~~ ~

R?P

~ TELEPHONE

I I I

I I I I I

FILTER

L-----

l .FOR CIRCUITS ANO EOUIPIENT BETIIJEEN THE FCE-500 UNIT ANO THE CODE LINE. SEE LINE CIRCUIT Pl.AN FOR EACH INSTALLATION. CONNECTIONS TO CARRIER EOUIPI.ENT, ANO 'SPECIAL CONNECTIONS FOR f!ELO STATION DISCOUNT SCHEME, M-!EN USED, ARE ALSO SHOWN ON LINE CJRCUIT Pl.AN,

816 R

CYCLE TIMER CONNECTIONS

m!l2U

-0- TERMINAL

-a:i-- VARISTOR

__m_ REACTOR

-oL 111.lLTIPLE TERMINAl. CONNECTIONS TO All STORAG£ UNITS

-oL lr,IJLTIPLE TERMINAL CONNECTIONS TO LEADING STORAGE UNIT OF EACH GROUP

:8: POLAR STICK DOUBLE COIL RELAY - 0100£

-4-- OPTO ISOLATOR - RESISTOR

CONOENSER

-0-- ORDINARY RELAY

B DOUBLE COIL RELAY

:0 NEUTRAL VlTAL SLOW RELEASE RELAY

--; T I TRANSFER I CONT ACTS

J. POLAR STICK RELAY CONTACTS

:0 NEUTRAL VITAL RELAY

:so)NIC B CONNECT

~

FRC INTERFACE PCB

UN451441-6801

'CAROFILE

LOCATION JIS

RPP r- ------------, -,---- ~----------------, TYPICAL WAYSIDE CONNECT! ONS

~

16 TOPINZT

N (LP~lLri 2

RP

I • ov _I!

: POaER SUPPLY PCB B

~pp I UN4514<11-3303 I CAROfILE LOCATION JI N

l : NIC~}

; FIELD STATION I : £~N :1s OISCONN£CT SC>ltME l I ---..__ IC~ NIC

I 1. ---.. .....

L--------------------------------~ I I €9----l ' l I RP I

,~l , : £<._ ', I

NIC~NIC

INPUT PCB IND I f I I CONTROLLER PCB

I I UNOB5772-IOOJ

UN451441-43()5' CARDFILE IND 2 CAROFILE LOCATION LOCATION J7 J8 FOR LCS UNIT INC 3

J9 FOR S UNIT I

JlO FOR S UNIT 2 IND•

Jll FORS UNIT 3

~ W AR 86 NIC =! ~ z r-----> ,----!-

PO 816 NIC IT w ,-----

___ ._16 LOP ... ASPR

!!

I R-IN ~ R INPUT

Jl2 FORS UNIT <I IND 5

IN06 =~~~~======~~~~============~==============~~~~~========~~========~~====~~~~~~~~~~~ I

INC 7

WIRED

~ I I

I

~_;___ : - ..-~ I COO£ I !,..-.

.IL-.@-- L"~~'U~i., I NIC ""'

ADO 2 e"/ ---, ; / l TER "/ ®------+ I r--@::--ft- NIC ~ A003 e I I , ' ,,, ®----~ • ' ' ·--·. " ADO 4 e ,£;\_ I I LCS UNIT'S

/. ~ - - - _. .... .... I PLUG BOARO-

AOO , e" 1 ~·~.~:~· .. LOCATION I ~ @r----. + + I PLUG BOARD

ADO 6 e..: ®-----.. + + ADO 7 e" /. ®-------+ + ADO 8 r;.{ (6a)--------+

ONLY

IN FCE-500

CAROFILE

JB

ID.§

OUTPUT PCB

UN451441•3601

CAR0FILE LOCATION

CONTROL ••

STEP LONG DELIVERY I --~---- 1 snc, I

·~======~==============================-------~-~~·------~-• I

2 I I i I II I I @ 2 • · o •

1

•

" ~

J2 FOR LCS UN[T

JJ FOR S UN[T I J4 FOR S UNIT 2 JS FOR S UNIT 3 J6 FOR S UNIT 4

UNIT

I I I I I I @--t----------

I i ~ II.PR

16 2i~

15 .------------------------_.!_.!_ _____ ...!.._ __ _

L_ ___ 7 13~--------------------------1~-t------;--1 USR

PART NO. STANDARD CIRCUIT

0<151272-1606


STANDARD WIRING DIAGRAM

0451273-1603

i I IS Nl6

I

I I 23;------------~ ~

NIC --@)-----~-, : fn i :

OR .!!!

FCE-500 - 5048 WITH NO STORAGE UNIT FCE-500 - 5048 WITH I STORAGE UNIT FCE-500 - 5046 WITH 2 STORAGE UNITS FCE-500 - 5048 WITH 3 STORAGE UNITS FCE-500 - 5048 WITH 4 STORAGE UNITS

UN4S 1583-0926 UN451583-0927 UN451583-0928 UN451583-0929 UN4Sl 583-0930 {

-®-----I r--®- NIC ; .

1....-1.-r• I I

--@-----4- I : ~---------------..1 r-------------r-----------~-~--~~, NdTES1

NIC - NO INTERNAL COHHECTION

.£_ - EXTERNAL CONNECTION NOT REQUIRED UNl.ESS UNIT TO SE USED AS 1NTERCHANGEABt.E PART WITH TYPE 5048 FJELD RELAY CODE UNIT <EXCEPTION PIN 27 TO RP RELAY +I TERIO

I I I •

@)------.. ~ I I

@-----.. + ...

sw. @

SIG. ;

@ I AR J e •1•-0-

SW. SIG.

@@ @ @

Nl6

Lo-1-8-J ON-22A

®-----.. + +

'------------¥ ¥ f ¥ f ¥ f ¥~'~ff¥¥ f ff f #-------, . "" l :=.=~~i~ @ @

© © © 0

®1• It © I © 18

© © ©

l±±i ~·I· . ["" • .L-... 1L..S1.

···--t-.r+~··· ~8161 I • l

Circuit Drafting No. QS2 (67, 6) I : I 12J{1Ji~~,

FIG 9. SMD NIC L-------------------L--------~ L. sJ1Rr1t.fJRNDs\'=ttlAlONsT~S _L ____ ~l~~a:ORr~nr.J'~Pr ___.

Figurle 2-6. Typical FCE-500 Application to 504B Field Relay Code System

6202A, p. 2-25/26

''<'

"'


LI } LINE

L CIRCUIT

TYPICAL APPLICATION OF FCE-500 IN 504C MODE

FCE-500 CAROFILE

ARRESTERS

/

RPP

~ TELEPHONE

t FOR CIRCUITS ANO EOUJPt.E:NT BETWEEN THE FCE-500 UNIT ANO THE CODE LINE, SEE LINE CIRCUIT PLAN FOR EACH INSTALLATION, CONNECTIONS TO CARRIER EOUIPIENT, ANO SPECIAL CONNECTIONS FOR FIELD STATION DISCOUNT SCHEt.E, MiEN USED, ARE ALSO SHOWN ON LINE CIRCUIT PLAN,

FRC INTERFACE PCS

UN451441-6801

'CAROflLE

LOCATION JIS

~ RPP

···~ RPP ~Q_l~.!!L2.! ~Q_~~-.7.!

RP RPP

; FIELD STATION O I SCONNECT SCHEWE.

GROUND STUD ~

ov

POW\£R SUPPL 't PCB

UN45l441-3303 CAROFILE LOCATION JI

HOUSE PRil,E GROUND

B CONNECT ~~~=====1_~_ (/

INPUT PCB IND 1

CONTRot.LER PCB ,

I I UN085712-1001

UN45!44t-4305 CARDflLE '""' CAROFILE LOCATION LOCATION J7 JS FOR LCS UNIT IND 3

J9 FOR S UNIT l

JIO Frut S UNIT 2 !NO • JI I FOA: S UNIT 3

6 ~ A FUSETRONS ,! STORAGE UNIT

..

TYPICAL WAYSIDE CONNECTIONS

NlC 16~.--t---------._ , __ __.!!!.! .:... ~ f PO ... t

NIC~

LRGPR RACiPR ASPR !§

Jl2 FORS UNIT 4 816 R

7172 IR-IN ~

I R INPUT

NIC

~YCLE TIMER ONNECT IONS ~

IND 5 ~

INO 1

!NO 6 ~ I I I I I © I ~J ___ , - : • ·- ~ I ' ASPR ~ j ~----L'2J~'~~~.. NIC~ :-rl ~ ~ ~· 8 ''/ ' • - ' • t

- . .;t ..----~ i r--®c-'- .,, .. + I

-0--cn-_:.iii!L

-(Y-

-oL-B

-4-

m!!Q!,!i

TERMINAi.

VARISTOR

REACTOR

lot.IL TJ PLE TERM! MAL CONNECTIONS TO ALL STORAGE UNI TS

IAILTIPLE TERMINAL CONNECTIONS ro LEADING STORAGE UNIT Of EACH GROUP

POUR STICK DOUBLE COIL RELAY

DIODE

OPTO ISOLATOR

--W-- RESISTOR

--0---

B ts:

~

J.

CONDENSER

ORDINARY RELAY

DOUBLE CO[L RELAY

NEUTRAL VtTAL SLOW RELEASE RELAY

T I TRANSFER l CONT ACTS

POUR Sl'ICK RELA\' CONTACTS

r:::5:: NEUTRAL ,VITAL RELAY

OUTPl.;JT PCB UN451441-360J CAROflLE LOCATION J2 FOR LCS UNIT J3 FOR S UNIT I J4 FOR S UNIT 2 JS FOR S UNIT 3 J6 FOR S UNIT 4

/. ®------+ I I ' ......... . AOO 4 c;,?' .. I I WIRED ONLY ON <::;/ '&<'- I I LCS UNIT'S

CAROFILE-<. ADOS e~ ~-----+ + + I PLUG BOARO

LOCATION I /. ®---- l ~0

~.~~~io ON

WIRED

ONLY

IN FCE-500

ADO 6 e"/ --+ + + 1 PLUG 80ARO

~ ®------+ ... ~ ADD7 e T ~ @--------+- ~ ADOS B T

JS

fil

~ CONTROL ®-------->= co• -,- . + , m

9

CK J ll , I I I • .. : : : ~·.r·--1-,---------

l::' • ' ' ' : - : : : 11 i~i---___JD Nl6

I 1• ~ I.IPR Nll<:.A WI.PR

Dwc::A L...f

+------------,16 2~

+----------~15 ,-----------------------_!,.-_! _____ 2_ __ _

L----,,7 13 I I

UNIT

FCE-500 - 504C WITH NO STORAGE UNIT FCE-500 - 504C WITH I STORAGE UNIT FCE-500 - 504C WITH 2 STORAGE UNITS FCE-500 - 504C WITH 3 STORAGE UNITS

PART NO. ---- STANDARD CIRCUIT

0451272-1607

S£RVICE MANUAL 6202A

STANDARD WIRING DIAGRAM

0451273-1603

USR

~--------~··•»-------------<

~----------'•23)-------------

NIC -@-----L., : & ; :

""

fil.§.

~

OR

FCE-500 - 504C WI TH -4 STORAGE UN I TS

UN451583-093 I UN45 I 5B3-0932 UN451583-0933 UN-451583-0934 UN45l 583-0935 {

--@---0---1 r---@-- NIC . ;

1.-1..-1• I I

--@-------+I: ~---------------~ r-------------r-------------------. -, NOTES a

NlC - NO INTERNAL CONNECTION

_£, - EXTERNAL CONNECTION NOT REQUIRED UNLESS UNIT TO BE USED AS INTERCHANGEABLE PART WITH TYPE S0-4C F IELO RELAY COOE UNIT !EXCEPTION PIN 27 TO RP RELAY +I TERM)

I I I @------+ + I I

I @-------+ ....

sw. SIG. I @ I

.. J e ···-o-SW. SIG~

8@ ••• I ~ I AR2 I LLJ-+-O-J ON-22A

e •••-...!-.t.I""-~··· ®------+ ......

•----------------~ f ff ff f ¥~'~ff f f f f ff f--------1 . . .. l ::.=~~i~ I I I SETTJNG

8 @ @

© © © : '":1 @ I

© ..

@ @

© © ©

@ I ""I

~~ ... I LVBl6

I I 1

Circuit Drafting No. Qs2· (67, 6) FIG 7. SMD NIC L---------------- ·--L- (234 SHOWN) -I.. sJrT~CJ 6R"0s1fcfJAlONs.Jl:.s _L ____ T~1~f~1f/Mif1g~pr -----

Typical FCE-500 Application to 504C Field Relay Code System

83

Figul 2-7,

6202A, p. 2-27/28

,,..

0451272-1606, Rev. 0

7! R<r ® 75 R- #I 8 GN @

#18 R @ R-IN

27 CONNECT #I 8 V i'

~-------<>--~JIS INTERFACE SO.N45144J -6SOI

..

JI PWR. SUP.

OC/OC

ll_K

< + l !N ) #I B R I ,A

J7 CONTROLLER

BOARD

"' g v '

v v "

"' v z

49

·-BAT. ( + >

50 I <->IN )) t #18 BK _,.,

6,F BAT.(-)

N451441-3303

LOGIC COM.) #18 W z

GNO STUD

UNION SWITCH & SIGNAL 83

,a '~"' '"· ~osm-' oo, j l I " oo ""' "" "'"" -,oo,

~-v{~2VI~3r\vli",vli'6It·it-~F:~~::~ ·vi~' VIi2It~i·1~rtri7 'VFUJ.IJ[111·",l"tp1~1R"'I~"1~'rl~>r1~U;fll\l)l~l~x alO>-OCO>o COO>-OCD>O er ~N ~~ BN ~3:3:3:3.~ BN ;;:::

_J2 63 _64 65 66 67 68 I 2 3 4 5 6 7 ~ • • • • • • • • • • • • • j I 9 I 9 IO 20 ll I 2 I 3 I 4 I 5 23 22 21

i15l le\ r.-, (.) ii5 : • • • • • • • • • • • •

BK

8-BAT.

BK N-BA T.

r---------------------------------------- ADD ON Fool N451583-0927----------------------------------

,s , ~"' '" ~"'"'. '""' I [ ; " """"' "" "'" .. " -,w, J '~'"''

00 ,_ ; : ; : : : 6 J 1 I II I ~ r:n E1 lcfl :j :j :j g r,n~

...... v. V- v. v, ~, ~, ~, ~. ~. ~. ~, ·,,,,. ~, 1,,(1. r, 1J: 1. J. r. r. I, r, uJ: ... w,aa,c • /J,=1/:J,J/::::'~:f J~~I;R~~ltllltl;R!l,f lf~l~ STORAGE • 1111111 t~ . I t t t . t t . 1111 UNIT #I ,

r---------------------------------------- ADO ON F<JFl N451583-0928----------------------------------

I I I I I I I I I I I I I I I I

JI O INPUT 80 N085722-I 001

INDICATION COMMON ~ ~ i i i ; i J [----1-~I I lr I ~ r:n" rrcn'"f~ :j E 0 r,nVi, v v v v ~ v v v v v v v v v l f_l f !.f 1 I I I I I !_f_!_)_1

_r ff l°-----+-f F ~ :i§f'I-f :§i:ro1:1:Q1:====P3=:c::

8

::J::v: :~=,~f)f~'~'~Ip~1R~1·!15J1

6

!I7

=~'~i)[)[)[x=~ EXTERNAL 50 :--12 i"°" :;- 6 6 7 49 ;;-- 19 ;--; W ~ ;-T ;-;-- 14 ;-;- ;;- U ;;-, /17 STORAGE • • @ • • • • • • ) • • • (!: • • o • o • • • UNIT #I ,

I ' r-------------. --------------------------- ADO ON FOJ1 N451583-0929 ---------------------------------

1 1 . --------------------~"'"'!. ~~!.'~"-"'------------------------ ----! "' '~"' '" """'"'-'"" l I I I I I i ,s 't''"'""""'.., E"'~ ~ ~ J \\ J

INDICATION COMMON - N ~ v "' "' ~ r-=11 :1 1Jl "' ~ "' "' ~ rn· "' ~ ...... v. v. v. v, U, U. t U, , , . , . [Jk "r, 1,J, U. U. r, U,.t1:. ·.

NOTE, I. THE FOLLOWING REPRESENT THE PC. NOS.

N451583-0926 = FCE 500-5048 WITH NO STORAGE UNIT. N451583-0927 = FCE 500-5048 WITH I STORAGE UNIT. N451583-0928 = FCE 500-5048 WITH 2 STORAGE UNITS, N451 583-0929 = FCE 500-5048 WITH 3 STORAGE UN I TS, N451583-0930 = FCE 500-5048 WITH 4 STORAGE UNITS,

2. @ INDICATES TERMINAL ON TERMINAL BOARD.

3. l INOICATES TWISTED WIRES

4. ALL WIRES ARE #20 AYIG UNLESS OTHERWISE NOTED.

5, 0 INDICATES CONNECTION ON TERMINAL STRIP,

6 • ,,h INDICATES GROUND STUD,

1 """"" 1,~·1,J.=l//J/= ====~=~·==J~~f ;R~Iltl!1ltf ;R!ljl}1/n

STORAGE • 11 4 1111 t~ ' t • • t • • t • t 11 t UNIT #I

" r---------------------------------------- ADO ON roil N451583-0930 ---------------------------------

'""""'00,:~:"' '"-~"';'~' i i i i JI [""1~ I I I I ~ r-=nJ6 E1Pur=n441~0~ E E ~ rn~1 ~ - - .. ,, v v v v v v v v v v v '"' I l fj r 1 r l I I I I I ! _r-1_11

' r r f r1~01:>1:§i:Q1:1:01:====i#E3=:c::8:~J::v:P.:;:'~i'~iM=,~1~1p~1Ri1j15116~17=~'}}'J[)})}'~ EXTERNAL STORAGE UN[T #l

--, I 2 3 4 5 6 7_ 49 ' 9 19 10 20 11 12 13 14 15 23 22 i7l /77 • • • • • • • • ! • • • • • • • • • • • •

File 2-8. Standard FCE-500 PCB External Wiring, 504B Mode

6202A, p. 2-29/30

D451272-1607, Rev. 1

M

@LI #18 BNf

@Fl #I 8 'f

~F2 #18 BU

®l2 #18 W

@R• •t 8 0

@R- #18 GN

iiiR-JN #18 R

~ CONNECT #I 8 V

Jl5 INTERFACE BD.N451441-6801

,.: ~i .. ~~ "' 1 >--- < .... x ~ "' "'! cl ::, ::,

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J7 CONTROLLER

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2,@ INDICATES TERMINAL ON TERMINAL BOARD.

3. ; INDICATES TWJSTEO WIRES

4. ALL WIRES ARE #20 AWG UNLESS OTHERWISE NOTED,

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6 • ,.h INDICATES GROUND STUD.

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Jl2 INPUT BO N085722-l001

Figre 2-9. Standard FCE-500 PCB External Wiring, 504C Mode

6202A, P• 2-31/32


5048 and 504C

2.2.2.5 Programming Guidelines

The following items must be considered when planning the programming of the FCE-500 for 5048 or 504C systems:

1. Is Auto Recall desired? When Auto Recall is active, the FCE-500 system will respond with a indication code when a valid control code is received. This will increase system coding time. Therefore, the decision to use Auto Recall must be based on number of trains and the system response time required.

2. Use a station code preference plan based on geographical layout and list the plan on a code and function sheet, or on the wayside plans. The proper address preference based on geographical layout is as follows, with the location closest to the office listed first:

Office Continue Continue Continue

357 578 235 268 358 567 237 245 356 568 238 247 378 678 236 248 36.7 457 234 246 368 458 257 End of Line 345 456 258 347 478 256 348 467 278 346 468 267

2.2.2.6 Switch and Jumper Settings

A. LCS Address

The 504B or 504C LCS address is set with jumpers on the plug connectors on the FCE-500 cardfile. The address is set as follows:

LCS Address Step Post Address Step Connect Post

2 62 First 69 3 63 Second 70 4 64 Third 29 5 65 6 66 7 67 8 68

6202A, p. 2-33


504B and 504C

Examples:

Address 234 - Connect post 69 to 62, post 70 to 63 and post 29 to 64 Address 456 - Connect post 69 to 64, post 70 to 65 and post 29 to 66 Address 678 - Connect post 69 to 66, post 70 to 67 and post 29 to 68

Note

In 504B/504C address selection, only three unique long steps are acceptable. The ERROR LED on the Controller PCB (LED 4) will light if more than or less than three steps are selected as longs.

B. First Storage Unit Address

The 504B or 504C 1st storage unit address is set with DIP switch SW8 on the Controller PCB (location J7). Figure 2-10 shows the general arrangement and operation of the Controller PCB switches and jumpers for 504B or 504C system emulation. The long steps of the address are set by placing the rockers to the open c•1•) position. The short steps of the address are set by placing the rockers to the closed c•o•) position. ("X" = rocker position not pertinent to any particular function).

SWITCH SW8 Rockers 1st Storage u. Address Step 8 7 6 5 4 3 2 1

2 •X 0 0 0 0 0 0 1 3 x 0 0 0 0 0 1 0 4 x 0 0 0 0 1 0 0 5 x 0 0 0 1 0 0 0 6 x 0 0 1 0 0 0 0 7 x 0 1 0 0 0 0 0 8 x 1 0 0 0 0 0 0

For example, address 234 would be set as follows:

SWITCH SW8 Rockers

8 7 6 5 4 3 2 1

x 0 0 0 0 1 1 1

c. Second Storage Unit Address

The 504B or 504C 2nd storage unit address is set with DIP switch SW7 on the Controller PCB (location J7). The long steps of the address are set by placing the rockers to the open ("l") position. The short steps of the address are set by placing the rockers to the closed ("O") position. Rocker i8 is used for Auto Recall selection; refer to section G on page 2-37.

6202A, p. 2-34

CONTROLLER PCB N451441-4305

COMPONENT SIDE (NOT TO SCALE)

4TH STORAGE UNIT ADDRESS

ALWAYS USE 7 JUMPERS.

z w ~

LOWP.

D SW5

D swsSW4


5048 and 504C

SWS: SYSTEM MODE

SET TO "1" FOR 5048 OR 504C

SW4: SYSTEM SIZE

'~f • c::::::::i •

5• • 3

0 • LCS ONLY 1 • 1 S. UNIT 2 • 2 S. UNITS

3 •3 S. UNITS 4 =4 S. UNITS

5-8 • NOT USED

D SW6

1 234 5678

,.._,.____--... ~ ~ ~ [i] ~ ~ ~ ~ SW7

HIGH P.

PCB MAY BE EQUIPPED WITH LOW OR HIGH PROFILE (ROCKER) DIP SWITCHES.

-----OPEN

\ J t 3RD STORAGE~NIT ADDRESS NOT

USED

-----OPEN

\ J l y

2ND STORAGE UNIT ADDRESS AUTO

RECALL

1234 5678

E]~eJ~El~El~ -----OPEN-----_____ )

--.......-1 ST STORAGE UNIT ADDRESS i \

NOT USED

SWITCHES SHOWN IN "OPEN " POSITION

Figure 2-10. Controller PCB Manually Selected Options for 5048 and 504C

6202A, p. 2-35


5048 and 504C

SWITCH SW7 Rockers 2nd Storage u. Address Step 8 7 6 5 4 3 2 1

2 0 0 0 0 0 0 1 3 0 0 0 0 0 1 0 4 0 0 0 0 1 0 0 5 0 0 0 1 0 0 0 6 0 0 1 0 0 0 0 7 0 1 0 0 0 0 0 8 1 0 0 0 0 0 0

D. Third Storage Unit Address

The 5048 or 504C 3rd storage unit address is set with DIP switch SW6 on the Controller PCB (location J7). The long steps of the address are set by placing the rockers to the open c•1•) position. The short steps of the address are set by placing the rockers to the closed c•o•) position. c•x• = rocker position not pertinent to any particular function):

SWITCH SW6 Rockers 3rd Storage u. Address Step 8 7 6 5 4 3 2 1

2 ... x 0 0 0 0 0 0 1 3 x 0 0 0 0 0 1 0 4 x 0 0 0 0 1 0 0 5 x 0 0 0 1 0 0 0 6 x 0 0 1 0 0 0 0 7 x 0 1 0 0 0 0 0 8 x 1 0 0 0 0 0 0

E. Fourth Storage Unit Address

The 504B or 504C 4th storage unit address is set with the Station Address jumpers on the Controller PCB (location J7). When the jumper is set to the •o• side, the address step is short. When the jumper is set to the •1• side, the address step is long. The numbering of the 4th storage un~t addresses at the Controller PCB jumpers is as follows:

6202A, p. 2-36

Jumper Pos.

1 2 4 8

16 32 64

F. 5048 or 504C Mode Selection

4th Storage u. Address Step

2 3 4 5 6 1 8


5048 and 504C

The 5048 or 504C mode is selected using rotary switch SW5 on the Controller PCB (location J7). Set this switch to the "l" position for either the 5048 or 504C system.

G. Auto Recall Selection

The Auto Recall mode for 5048 or 504C is controlled with rocker #8 of DIP switch SW7 on the Controller PCB (location J7). To activate the Auto Recall mode, set this rocker to the open position. To keep this mode inactive, set rocker #8 to the closed position. Make certain not to readjust any of the other SW7 rockers set for other functions.

H. System Size

The size of the 504B or 504C system is defined using rotary switch SW4 on the Controller PCB. The switch settings are as follows:

SW4 Position System Size SW4 Position System Size

0 LCS Unit Only 4 4 Storage Units 1 1 Storage Unit 5 Not Used 2 2 Storage Units 6 Not Used 3 3 Storage Units 7 Not Used

If SW4 is set at position "l", the address for the first storage unit must be properly set, otherwise the system will lock up. This will be indicated with the lighting of LED 4 on the Controller PCB (location J7). The same is true for the remaining storage unit settings. If switch SW4 is set to positions 5, 6, or 7, the system will again lock up (LED 4 on).

6202A, p. 2-37


504B and 504C

2.2.2.7 Control Outputs

The following tabulation lists relay-output PCB slot and plug connector terminal numbers that pertain to control outputs for the 504B or 504C:

Control Control Cardfile Output Outputs


J2 LCS Unit 9 to 15 & 19 to 23 ( 1 to 7) J3 1st Storage Unit 9 to 15 & 19 to 23 ( 8 to 14) J4 2nd Storage Unit 9 to 15 & 19 to 23 (15 to 21) J5 3rd Storage Unit 9 to 15 & 19 to 23 (22 to 28) J6 4th Storage Unit 9 to 15 & 19 to 23 ( 29 to 35)

2.2.2.8 Indication Inputs

The following tabulation lists optical-input PCB slot and plug connector terminal numbers that pertain to indication inputs for 504B or 504C:

Indication Indication Cardfile Input Inputs


J8 LCS Unit 1 to 7 ( 1 to 7) J9 1st Storage Unit 1 to 7 ( 8 to 14) JlO 2nd Storage Unit 1 to 7 (15 to 21) Jll 3rd Storage Unit 1 to 7 (22 to 28) Jl2 4th Storage Unit 1 to 7 (29 to 35)

2.2.2.9 R Relay and Series Line Resistor

The R relay is the Receive Data interface to the code line for the FCE-500. Refer to Figures 2-6 and 2-7 for typical wiring of the R relay'and associated equipment in 504B and 504C systems. When the FCE-500 is used to replace an existing field relay code system, the R relay and associated equipment can be used without modification. If a new location is to use an FCE-500 system, the R relay and associated equipment are selected as follows:

6202A, p. 2-38


- 5048 and 504C

US&S recommends the use of the following relays and series line resistor:


Relay P4 Type, 1900 ohm coil N216112

Plug Connector P4 Type Nl09134

Resistor 2-Watt (minimum), wire wound --

Select a resistance value for the series line resistor that limits current flow through the P4 relay coil to 2 to 3 milliamps.

The R relay is shelf mounted. Appendix 8 lists all required mounting hardware.

2.2.2.10 RP and RPP Relay

If a field station disconnect function is required by the application, the FCE-500 system uses the RP and RPP relays in the same manner as the relay code system. When the FCE-500 is used to replace an existing relay code system with field station disconnect, the existing RP and RPP relays, and associated equipment, can be used without modification. If a new location is to use an FCE-500 with field station disconnect, the RP and RPP relays and associated equipment are selected as follows. (Refer to Figures 2-6 and 2-7 for recommended applications of this equipm~nt).

For the 5048 or 504C systems, US&S recommends the use of the following relays in conjunction with a standard capacitor/resistor unit:

Item

Relay (for RP)

Relay (for RP)

Relay (for RPP)

Relay (for RPP)

Capacitor/Resistor Unit

Description

Type L-10, dual 150/400 Ohm Coil

Type L-10, dual 150/400 Ohm Coil, equipped for plug connection

DN-11, Slow Release, 1500 Ohm Coil

DN-22, Slow Release, 1500 Ohm Coil

3000 mFd Capacitor and 30 Ohm Resistor

US&S Part No.

N234555

N234555-001

N262767

N234820

N266187

6202A, p. 2-39


5048 and 504C

This equipment will give a field station disconnect time of approximately 10 seconds at 70 deg. F., and should be satisfactory for most installations. If a greater disconnect time is required, additional capacitor/resistor units may be added in parallel to reach the desired value.

The RP and RPP relays, and the capacitor/resistor unit can be shelf or rack mounted. Appendix 8 lists all required mounting hardware.

2.2.2.11 Code Line Filter

The code line filter is a de pass/voice and carrier blocking unit that allows voice and carrier signals to be overlayed on the de line used by the code system. When the FCE-500 is used to replace a field relay code system, the code line filter can be used without modification. If the FCE-500 is to be installed at a new location, a code line filter is required. If there is no carrier or voice overlay on the code line, the filter is not required. The code line filter is selected as follows:


Code Line Filter Without de-blocking capacitors or N237446 carrier-blocking reactors

Code Line Filter With de-blocking capacitors, without N235113 carrier-blocking reactors

Code Line Filter With de-blocking capacitors, and with N235112 carrier-blocking reactors

If there is voice overlay on the code line and the voice communication devices have built-in de blocking, use code line filter N237446.

If there is voice overlay only on the code line, and the voice communication devices do not have built-in de blocking, use code line filter N235113.

If there is voice and carrier overlay on the code line, and the voice communication devices do not have built-in de blocking, use code line filter N235112.

Figures 2-11, 2-12 and 2-13 show the various connections from the code line filter to the FCE-500 for a 5048 system. Figures 2-13, 2-14 and 2-15 show the equivalent connections for a 504C system. The tabulated numbers represent plug connector terminals on top of the cardfile.

6202A, p. 2-40


504B

(J) z 0 j:: 0 r-, w z z I 0 I ~i 0 r----...I -, < a: I z w I a: ~ w

I ~ u: I w w z I I I ::i w I

I 0 I ... 0

L U> 0 --- - 1 alS

I IO

I ......

I I I I

l I a: L __

~ '\. '\. ') ~

') I I I

m ~ I I 1 ~ ;z ~ ...I ..... 1 L ..... ..... alS

w--- r0- -I~ r-- ~ z I I I I g 0 ::i .... ~

) '~ I 0 I ~

o ___

r ~ ~'1 t\l '? I alS

I :5 ~ U>

_J I ......

L------I I

L-------- _ _j

Figure 2-11. Code Line Filter Application for 504B: Without DC Blocking or Carrier Blocking

6202A, p. 2-41


5048

(J) z 0

@ z z 0 (.)

...I < z a:

~ I I I

L

L __

a: w ~ u:: w z ::::i w 0

8

r· I I u.1 I ~

I I

I

I J. I ~

I l a:

~r------/ ....

iL ~

', ') ( l I I

.... I I I c, <1 ~I L I ~ ~

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- ., I I I I

.., I I I

L

L __

,---

r I 1

I I I I L ____ . _____ .J

w z 0

C\I :I: (.) a. - -- -- ------·--o--f 1----6--

- -- - -- - -- --o-f r-0--.... w (.) z

0 :I: a.

Figure 2-12. Code Line Filter Application for 5048: With DC Blocking and Without Carrier Blocking

6202A, p. 2-42

Cl) z 0

~ w z z 0 0 ...I <( z a: w ~ w

w- - - ,. z

o:::i I ~8 I o--..-r

I I I I I I I I I I L

L __

a: w ~ u::: w z :::i w 0

8

r· I I 11.i I ~

I I

I

I I I

~r----

l a:

', ') ') I

~I I I CD ;z .... L_ .... .... I~ ) \~

( ~ ; ') I I

l ______ -

L _______ _


-1 I I I I

1 I I I

L

I L_

r, I I r I I

_J I I

__ J

5048

Figure 2-13. Code Line Filter Application for 504B: With DC Blocking and With Carrier Blocking

6202A, p. 2-43

83


504C

CD z Q. ~ 0 w z z 0 0 ...J < z a: w ~ w

I I I

w---z 0 ::i ~w

0 0 o __ _

Ill ...J

,--. I

I il ~r----I I I

T ~- - -- -/ ....

~ LL u. :::!: ~ t\l

l, a: --,§ a: - - - -, r ', l L _____ I __ _J

I I I -:- I I ~I L r<>- -I

)

... (0

all It) .....

0 CX)

Figure 2-14. Code Line Filter Application for 504C: Without DC Blocking or Carrier Blocking

6202A, p. 2-44

en z 0 j::: () w z z 0 ()

..J <( z a: w ... x w

~---r 0::::;

I 1-W 0

8-r--+-I

L

a: w ... ..J u:: w z ::::; w 0 0 ()

ID ..J

j

r· I I I I I I

I I I l '

~i ~r----,,.... - - -- -

/ .... .... LL LL ::!: ::!: v C\I

a: --,~ a: ---, ' ) L _____ I_ ') I

";" I I ~I L ro-- -

I )

~ C\I

:5

I

;

w z 0

~ ~ --- -- --------o--t l----0-

- -- - - - - -- --o--f J---0-.... ()

w z 0 J: a.


504C

co ell ll) ,....

0 CX)

r ;::!: _ _J

~ ell --- ~

CX) --- ,.... ell

le

Figure 2-15. Code Line Filter Application for 504C: With DC Blocking and Without Carrier Blocking

6202A, P• 2-45


504C

Cl) z 0 i= (..) w z z 0 (..)

..J <( z a: w !i< w

I I I

w---.,. z

o:::i I 1-8 I 0- ..--r

I I I I I I I I I I L

L __

r-, I

I ~1 u. -~r---- U)

I "° It)

I ,...

I

-- - 0 Cl)

l, a: --,~ a:: -- - 1 r ', ') L _____ I __ _J

I I I -;- I I ~ L_

I )

Figure 2-16. Code Line Filter Application for 504C: With DC Blocking and With Carrier Blocking

6202A, p. 2-46


504B and 504C

2.2.2.12 Cycle Recorder (Refer also to section 2.1.6.3)

Figure 2-17 shows the various connections from the cycle recorder to the FCE-500 for a 504B or 504C system. The tabulated numbers represent plug connector terminals on top of the cardfile.

When using the cycle recorder to measure coding time with the FCE-500 system, make certain to observe the following limits:

Received Pulses Minimum Maximum

Pulse 1 (Indication) 115 ms (7 Cycles) 270 ms (16 Cycles)

Pulse 1 (Control) 280 ms (16.5 Cycles) 535 ms (32 Cycles)

All shorts 50 ms (3 Cycles) 190 ms (11.5 Cycles)

All longs 250 ms (15 Cycles) 550 ms (33 Cycles)

Shortest recognized pulse 35 ms (2 Cycles) --Minimum line quiet time re- -- 650 ms (39 Cycles) quired for receive reset

Transmitted Pulses Nominal Value Tolerance

Pulse 1 133 ms (8 Cycles) +0.5, - 0.5 Cycles

Odd Shorts 84 ms (5 Cycles) +0.5, - 0.5 Cycles

Even shorts 108 ms (6.5 Cycles) +0.5, - 0.5 Cycles

Odd longs 350 ms ( 21 Cycles) +0.5, - 0.5 Cycles

Even longs 417 ms (25 Cycles) +0.5, - 0.5 Cycles

Minimum line quiet time 1033 ms (62 Cycles) +0.5, - 0.5 Cycles required before indic-ation transmission

Minimum line quiet time re- 1369 ms (82 Cycles) +o.5, - 0.5 Cycles quired before indication transmission after an indi-cation transmission from this location (SS delay)

6202A, p. 2-47

E:l3 UNION SWITCH & SIGNAL

Notes

The received pulses (first table) represent absolute limits. Deviations beyond these limits will cause improper operation of the FCE-500. Proper operation is only possible if the office and field relay equipment meets service specifications. These specifications are listed in the respective service literature for that equipment.

FCE-500 transmit timing is not adjustable. If.the timing of transmitted pulses is consistently outside the tolerance listed in the second table, either the Controller or FRC Interface PCB is defective. Transmit timing must be measured with all units quiet, except the one under test.

115 VOLT [ I AC ----+---i

504B,504C LCS UNIT

I I I

72 ---------1

n--------ON

9 OFF

L------r--rJ PAPER ) L-.---J

Figure 2-17. Cycle Recorder Layout and Connections for 5048 or 504C systems

6202A, p. 2-48

SECTION III FUNCTIONAL DESCRIPTION

3.1 OFFICE/FIELD SYSTEM LOGIC

UNION SWITCH & SIGNAL ffi

Refer to service manuals SM-502A, SM-504B, SM-504C for functional descriptions of the relay code systems emulated by the FCE-500.

3.2 GENERAL CONFIGURATION OF CODE UNIT

The minimum FCE-500 code unit operating set-up in a typical relay code application requires a Controller PCB, a power supply converter PCB, at least one relay-output PCB, one optical-input PCB, and an FRC Interface PCB (serial or parallel). When the FCE-500 replaces a field relay code station with storage units, one additional relay-output and one additional optical-input PCB will be required for each storage.

From one to five relay-output PCB's are inserted in cardfile slots J2 to J6 (see Figure 1-2). A relay-output PCB installed in slot J2 obtains the Line Coding Storage (LCS) unit Control Word address by four internal Program Bit inputs on the corresponding "B" connector. Additional relay-output PCB's are installed in slots J3 through J6. These assume control functions of storage units: each PCB replaces one such unit.

From one to five optical-input PCB's are inserted in cardfile slots J8 through Jl2. An optical-input PCB installed in slot J8 obtains the LCS Indication Word address at that slot by four internal Program Bit inputs. A voltage source provides the indication inputs to these PCB's. Additional opticalinput PCB's are installed in slots J9 through Jl2. These assume indication functions of storage units: each PCB replaces one such unit. When the battery source to an indication input is switched on, the bit is read as a logic •1•. When the source is switched off, the bit is read as a logic •o•.

An FRC Interface PCB is installed in slot Jl5 of the FCE-500 cardfile in all applications. The FRC Parallel Interface board N451441-6801 is only used in the 504B and 504C-eumlating systems. The FRC Serial Interface board N451441-7001 is only used in the 502A-emulating system. When the FCE-500 is converted to a DDL-601BX, this PCB is removed. The slot may then be used for additional indication inputs.

3.3 FIELD STATION BASIC OPERATION

3.3.1 General

Figure 3-1 is a block diagram of a typical FCE-500 system used for 502A emulation. Figure 3-2 is the equivalent diagram for a 504B or 504C system emulation. To meet minimum operating requirements, the basic FCE-500 field location contains the following:

6202A, p. 3-1


a. Code Line d. Battery Source b. Code Line Lightning Protection e. Battery surge suppressor

The FCE-500 unit c. 8 R8 Relay and Associated Hardware f.

In 5048 and 504C systems, the field station disconnect circuit and code line filter are optional, according to the application.

3.3.2 Control Code From Office (502A, 5048 and 504C)

Under normal conditions, with no data being processed, the code line is inactive and Ll is positive with respect to L2. The Line (•R•) relay is energized and the Received Data signal to the Controller PCB is at a logic 1.

When the office begins transmitting control data, the code line potential goes to zero. The 8 R8 relay will de-energize and the Controller PCB will begin processing data. Received data is decoded and checked for station address and format. If the data has the correct address and format for that station, the Controller PCB reformats the data and delivers it to the appropriate relayoutput PCB(s). The relay output PCB(s) deliver their control bits to the corresponding external relays.

3.3.3 Field-Initiated Indication Code (502A only)

NOTE

Some signal names from the Controller PCB, such as •common Mode• are carried over from a different application of this PCB and are not related to FCE-500 operations. Refer only to signal names on the circuits between the Controller and the FRC Interface.

When the status of an indication input changes at the FCE-500 location, the system will attempt to transmit this new indication back to the office. The FCE-500 is subject to the same restrictions or preference conditions as the prior relay code field station. These include:

a. On simultaneous starts of field stations, the station closest to the office in the code line takes preference.

b. Office transmissions will take priority and lock-out all field transmissions.

c. During a transmission by another field location, a current increase in the code line, or open line, will still cause a lock-out to the FCE-500 station.

In all of the above cases, the Controller PCB memory will retain any indication code that has yet to be transmitted to the office. When the code line goes back to normal or reset, the FCE-500 will again try to initiate a transmission.

6202A, p. 3-2

'-..1 I .... IQ c: I"! Cl)

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...... •

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rF~ - --- -,:~..,-----' ! PROTECTION

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"R" RELAY

I "R" I B>--, i

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FILTER

L__ -11 I B I BATTERY I I _[___ SURGE BATTERY -

SOURCE --N SUPRESSOR

L2

L1

--+ TO OTHER

FIELD STATIONS

---- ------, CONTACT

PROTECTION

OPTO ISOLATOR

"XMT" RELAY

MASTER "M"

RELAY

FRCINTERFACE PCB FOR

502A STYLE

5VOLT BUFFER

I I I I

XMT DATA

COM· MON

MODE

REC I DATA

I -- _ _j

TO PCB's

....-~~~~-............... ~~~~~--( SV +12V ·12V )

POWER SUPPLY

FCE-500 SYSTEM

502A

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TO EXTERNAL CONTROL RELA VS

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PCB

CONTROLS

INDICATIONS

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OPTICAL INPUT PCB

I INPUTS FRO

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CONTACT PROTECTION

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MASTER "M"

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5048/C

SVOLT BUFFER

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SEND

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BATIERY

SOURCE

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BATIERY SURGE

SUPPRESSOR

11 TO PCB's

,------~-------( SV H2V -12V )

POWER SUPPLY

FCE-500 SYSTEM 5048/C

c 0 N T R 0 L L E R

p c B

TO EXTERNAL CONTROL RELAYS

( ...... ;.; ...... )

RELAY OUTPUT

PCB

CONTROLS

INDICATIONS

OPTICAL INPUT PCB

D

JI

,JIBdJ INPUTS FROM

EXTERNAL SOURCE

EE c z 0 z I ~ :c Ir> en (5 z )> ....


When the code line is normal and an indication change is acknowledged, the Controller PCB will energize two relays on the FRC Interface PCB, the Master (•M•) and the Transmit c•xMT") relays. An "XMT• relay contact opens and closes the code line, and the "Mn relay opens and closes the code line to all other field stations further along the line. Indication data is then transmitted to the office by applying and removing energy on the code line. The condition of the line is monitored by the "R" relay for completion and verification of the transmitted message.

3.3.4 Field-Initiated Indication Code (5048 and 504C only)

NOTE

Some signal names from the Controller PCB, such as "Common Mode• are carried over from a different application of this PCB and are not related to FCE-500 operations. Refer only to signal names on the circuits between the Controller and the FRC Interface.

When the status of an indication input changes at the FCE-500 location, the system will attempt to transmit this new indication back to the office. The FCE-500 is subject to the same restrictions or preference conditions as the prior relay code field station. These include:

a. On simultaneous starts at one station, station code preference will be in effect.

b. Office transmissions will take priority and lock-out all field transmissions.

c. During a transmission by another field location, the code line pole change will still cause a lock-out to the FCE-500 station.

In all of the above cases, the Controller PCB memory will retain any indication code that has yet to be transmitted to the office. When the code line goes back to normal or reset, the FCE-500 will again try to initiate a transmission.

When the code line is normal and an indication change is acknowledged, the Controller PCB will energize two relays on the FRC Interface PCB, the Master ("M") and the Transmit c•xMT") relays. An "XMT• relay contact shunts the code line and the •M" relay contacts condition the "R" relay for proper polarity after the office pole-changes the code line. Indication data is then transmitted to the office by applying and removing a shunt from the code line. The condition of the line is monitored by the "R" relay for completion and verification of the transmitted message. An additional "M" contact is used for shunting of a resistor in the code line filter, during a transmission. As the code line is being shunted by one "XMT" contact, another contact of this relay will open, removing the source voltage for deenergization of the •R• relay. This keeps the timing constant.

6202A, p. 3-5


3.3.5 Auto Recall Mode (502A, 504B and 504C)

The FCE-500 incorporates an Auto Recall capability. Auto Recall allows the system to return an indication code independent of an indication bit change, after it has received a valid control code message. The receipt of a control code will recall an indication code. Refer to Section 2.2 for the switch setting of the Auto Recall Mode for the various system applications.

3.3.6 Field Station Disconnect (504B and 504C only)

Certain faults at a field station can cause that station to interfere with other stations that are operating in a normal manner. Equipment can be furnished, when desired, to enable the operator to eliminate the faulty station. The operator presses the STATION DISCONNECT button for a prescribed time, which prevents all field stations from transmitting indication codes. The operator then recalls the stations, one at a time, to determine the faulty one. All other field stations may be reactivated by means of the recall (faulty station kept in the inactive condition).

When an FCE-500 system receives a valid control or recall code, the Contoller PCB initiates a signal that momentarily picks the •coNNEcT• relay on the FRC Interface board. The CONNECT relay contact picks the field disconnect circuitry to its normal condition.

3.4 PCB OPERATIONS AND FUNCTIONS

3.4.1 Controller PCB N451441-4305 (See Figures 3-3 and 6-1)

3.4.1.1 General

The Controller PCB consists basically of the microprocessor, peripherals (PROM, RAM, PTM's, PIA's) and additional support !C's. The 6809 microprocessor is the exclusive controlling chip on the board. Its clock signal is generated by 4.0 Mhz crystal XTAL l; the chip divides this frequency by four. The resulting 1 MHz signal is used to sequence various operations.

The microprocessor and its peripherals communicate over a 16 line address bus (AO to Al5), an eight line data bus (DO to D7) and a five line control bus (IRQ, FIRQ, E, RESET, R/W). Address lines Al2 to Al4 are used to select the RAM, PTM's PIA's or latches for addressing. These lines control a decoder IC which selects one of eight lines (SEL 1 to SEL 8) on the address decoder bus. Line Al5 is used exclusively for PROM addressing. The IRQ (interrupt request) line is used by the PIA's and PTMl to flag the microprocessor when they require serv1c1ng. The FIRQ line {fast interrupt request) is only used for microprocessor servicing of PTM-2. The E {enable) control line is the basic clocked output from the microprocessor and is used to sequence peripheral operations. The RESET line is used to place the microprocessor, PTM's and PIA's in a reset condition. A reset is generated at power-up or when the SYSTEM toggle switch (SWl) is momentarily moved to the RESET position. (If SWl is held in the RESET position, the processor program is inhibited from executing). The microprocessor uses the R/W (read/write) line to inform the peripherals when it is requesting a read (data received from peripherals) or

6202A, p. 3-6


write (data sent to peripherals) operation. All other unused microprocessor control lines are disabled by pull-up resistors.

PIA 2 interfaces all signals pertaining to the FCE-500 relay-output and optical-input PCB's. Lines PBO through PB7 from the PIA output control bits and input indication bits. A tri-state transceiver (IC12) buffers these lines. The station address bits are also output from PBO to PB6, through the IC16 buffers. When these bits match the bits developed with the station address jumpers, AND gate IC21 sends an interrupt to the PIA.

PIA 1 is used for FRC Interface PCB data. It also accepts five switch inputs (DIP switch SW6) for several program options, and drives LED's that monitor the system status. Code line inputs are made through the 5 volt buffer IC15. Separate drivers are used for the Transmit Data and Request To Send outputs to the FRC interface PCB. The Controller PCB watchdog circuitry consists of a retriggerable one-shot timer (IC22) which is normally retriggered by the microprocessor in repeated, discrete time intervals. If the microprocessor fails to retrigger IC22, the watchdog circuitry will generate a signal that attempts to reset the microprocessor for normal operation. A watchdog LED (LED 7) monitors the output of the watchdog circuit. This LED will flash whenever the watchdog reset occurs.

!C's 9, 10, and 11 are transparent latch !C's that input program options from the rotary (SW4, SW5) and DIP (SW6, SW7, SW8) switches directly to the microprocessor. When selected by the address decode line, these latches output the switch positions in a "O" = switch closed, "l" = switch open format. SW4 and SW5 are octal coded switches that use three switch contacts to generate eight binary bits patterns.

3.4.1.2 Station Address Jumpers

The seven Station Address jumper locations on the Controller PCB are only used in certain applications of the FCE-500 system. Refer to Section 2.2 for this information. The Controller PCB circuits require jumpers at all jumper locations, even if they are not used for a particular programming function.

3.4.1.3 Program Switches

All FCE-500 program switch functions are determined by the PROM software. When the code unit is upgraded to a DDL-601BX, new software is incorporated which may change the functions of some of these switches (i.e. modem communications control). Refer to Section 2.2 for the specific settings of these switches with each application.

3.4.1.4 Toggle Switches

The tabulation at the top of page 3-9 describes the functions of the three toggle switches on the Controller PCB. These switches will be used for modem testing when the FCE-500 is uprgraded to DDL601BX. During routine operation, SW2 is left in the OPERATE position and SW3 is left in the MARK position.

6202A, p. 3-7

°' N 0 N > ..

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XMIT LED (1)

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TTL XMIT

I ...

EIA

DRIVE .. (2)

COMMON MODE RELAY

WATCHDOG

RESET

"'

TOGGLE SWITCHES

• MESSAGE REC.AND FORMAT LED'S (4) lJ m

~ 0 > i!

... I P1A

DATA

CONTROL ...... 2K X 8

..... DATA ADD

ADDRESS i-- RAM

SELECT

.. ' "' j. I+-

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XTAL CLOCK

STATION ADDRESS DRIVE

, PIA2

STATION DATA

ADDRESS'-... CONTROL JUMPERS

. .

- ADDRESS

- SELECT

.4KX8 PTM 1

ADD DATA DATA

PROM CONTROL

4 .. ..... ADDRESS

j~ SELECT

MICRO· PTM2 PROCESSOR DATA

CONTROL CONTROL

i,- ADDRESS

DATA ,..... t ADDRESS

. ,..,.. SELECT .

ADDRESS BUS

CONTROL BUS

DATA BUS

CHIP-SELECT BUS

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-

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o-

2-WAY rBUFFERS

CONTROL/ INDICATION

I BITS

. DELIVER LED

I

BUFFERS PCB ADDRESS ~

OUTPUT CONTROL.

BOARD PRESENT

(OPTO PCB'S ONLY)

TRAN SP. SWITCHES

LATCH +-- SW4, SW5 SW6

TRAN SP. I+-- SW7 LATCH

TRAN SP. +-- swa LATCH

'

EB c z i5 z I ~ :r: et en c5 z > ...

Switch No .

SWl

SWl

SWl

SW2

SW2

SW3

SW3

UNION SWITCH & SIGNAL m Position Function

RESET (momentary) Microprocessor, PTM's and PIA's simultaneously reset.

RESET (hold) Logic inhibited, SW2 and SW3 active.

NORMAL Logic in routine system operation.

ON Connect relay "Up" (SWl in RESET).

OPERATE Connect Relay "down" (SWl in RESET).

SPACE

MARK

Transmit relay "up"; code line shunted (SWl RESET)

Transmit relay "down"; code line not shunted (SWl in RESET)

3.4.1.5 LED Indications

The functions of the seven LED's on the Controller PCB are listed in the following tabulation:

LED No. Name

1 LINE DETECT

2 RECEIVE DATA

Function

Code line voltage

Reports incoming data

3 ~ESSAGE ACCEPT Station addressed

4 ERROR

5 DELIVER

6 TRANSMIT

7 WATCHDOG

Misc. errors such as configuration set-up error and Controller PCB hardware faults.

Delivery of controls from code unit

Indicates reconnect pulse delivery.

Timing out of watchdog timer.

Behavior·

On steady when code line is not energized.

On steadily when valid data is being received or transmitted.

Flashes on after accepting a complete and correct control message.

Normally off. Flashes when interna' error occurs. Stays on if address has been programmed incorrectly.

On steady during delivery time.

On steadily when reconnect pulse i~ being delivered.

Stays off under normal conditions.

6202A, p. 3-9


3.4.1.6 FRC Interface Signals

There is one input from the FRC Interface PCB (serial or parallel) to the Controller PCB, and three outputs to the FRC PCB. The external lines between these devices are given names related to FCE-500 operation. The pin-outs on the Controller PCB keep names related to modem/digital code system operations (future FCE-500 upgrade to DDL-601BX). The following tabulation describes this interface:

Controller PCB Line Pin-Out Desiqnation

Request to Send Connect Control (5048 and c only)

Transmit Data Transmit Data

Common Mode Relay M-Relay Control (Front Contact)

Common Mode Relay M-Relay Control (Heel) Feed

Receive Data Rec. Data

3.4.1.7 Card File Bus Signals

Tvoe of Siqnal

EIA output level, short 1.0 second pulse latch.

EIA output level.

0-volt return through contact.

0-volt feed from FRC PCB.

TTL input, logic

Function

Pulse CONNECT relay for field disconnect latch.

Energize/deenergize XMT relay to shunt code line in proper format.

Energize FRC PCB M relay during transmit sequence.

Source Feed

R relay data: Logic 1 = relay pick Logic O = relay drot

The cardfile bus signals are divided into eight control/indication bit lines and eight PCB control lines. These lines are common to all relay-output and optical-input PCB's in the cardfile. The control/indication bit lines will not carry data unless the PCB control lines have been enabled (refer to paragraph 3 of section 3.4.1.1). All lines carry CMOS level signals.

Four PCB addressing lines (Address Bit 2X) are included in the control lines. Their function is to present various 4-bit word addresses to relay-output or optical-input PCB's in the cardfile; these addresses are selected by the office to execute tasks with specific Control and Indication Words. Each PCB has a characteristic cardfile slot address; when the word address matches the slot address, the PCB is enabled.

The Address Bit 20 line is not used for PCB address selection. This line is referred to as the •Byte Pointer•. Each relay-output or optical-input PCB is capable of executing 16 bits for external functions. Since there are only eight control/indication lines on the bus, the bits are presented in consecutive eight-bit bytes. The Byte Pointer is used to select the bits 0-7

6202A, p. 3-10


byte or the bits 8-15 byte. Data Strobe is an enable function. In conjunction with the Address Bit 20, it is used to steer the proper byte or Control Word into latch circuits on the relay-output PCB. The Deliver line is used to enable the 16 control bit outputs of the relay-output PCB(s) "Deliver Set-Up", and •Req.-Service Int.• are not used in FCE-500 system operation.

3.4.2 Control Delivery PCB N451441-3601 (See Figure 6-2)

The PCB cardfile slot is provided a pre-assigned, programmed word on the bus connector (Program Bit 2x). The IC11/IC12 address decode logic compares this address with the 4-bit binary word address generated by the Controller PCB (Address Bit 2x). If the two addresses agree, LED 1 (ADDRESS) is lit. The Controller PCB then sets up the first eight control bits (0-7) with the byte pointer (Address Bit 20) at a logic •o•. When the Controller toggles the Data Strobe signal, the data (low byte) is loaded into two quad latches, IC2 and IC3. Then, the second byte is set up with the byte pointer line at a logic •1•. A second Data Strobe signal is sent, loading the data (high byte) into the other quad latches, IC7 and IC8. The Controller PCB then strobes a series of deliver pulses, and LED 2 (DELIVER) lights at this time. When this deliver pulse occurs, the information stored in the 16 quad latches is transferred to the 16 mercury-wetted relays. Their contacts now represent the control bit information received from the Controller PCB, and are delivered to the external circuits.

NOTE

The 502A version of the FCE-500 utilizes eight of the 16 relays for its five control bits. The 5048 and 504C versions utilizes 12 of these 16 relays for its control bits.

The time given for total operation of each board is approximately four seconds. Figure 3-4 shows the timing of Controller PCB signals on the bus, to the Control Delivery PCB •

.-------------4 SEC.---------------.i

WORD ADDRESS LOW-BYTE v HIGH-BYTE

DATA STROBE

CONTROL DATA

.. 32 PULSES-----1•~1

DELIVER _____ nnnnn.f f.

NOT TO SCALE

Figure 3-4. Timing Of Relay-Output PCB Operations

6202A, P• 3-11


3.4.3 Transmitter Opto PCB N085722-1001 (See Figure 6-3)

The PCB cardfile slot is provided a pre-assigned, programmed word on the bus connector (Program Bit 2x). The IC5-IC7 address decode logic compares this address with the 4-bit binary word address generated by the Controller PCB (Address Bit 2X). When the two agree, gates ICl and IC2 are enabled for the first eight inputs (0 - 7) with the byte pointer (Address Bit 20) at a logic •o•. The Board Present line is also enabled, verifying for the Controller PCB that an optical-input PCB is in the addressed slot. LED 1 (WORD •o•) is lit when the first eight bits are selected. This is a rapid event which may not be observable on the LED. When the byte pointer is switched to a logic •1•, the gates for inputs 8 - 15 are enabled and LED 2 is lit (WORD 1). The Address Disable and Output Inhibit circuits are not actively used by the Controller PCB in the FCE-500 system. On the bit O input, diode Dl is used for half-wave rectification of ac type inputs. Diode 034 assures a current limit of 2.2 milliamps over the PCB's input voltage range (5 to 32 volts ac or de).

NOTE

In the FCE-500 system, only the first seven bits are used for indication information on each optical-input PCB. The second byte or word on this PCB is used for the station address of the LCS unit and is only active in cardfile slot JS. All other storage unit addresses are programmed with the switches and jumpers on the Controller PCB.

Figure 3-5 shows the general timing of Controller PCB signals on the bus to the Transmitter-Opto PCB.

WORD ADDRESS LOW-BYTE :v HIGH-BYTE

I I I

BYTE POINTER I I I

I I I

INDICATIONS i 1ST 8 BITS u 2ND 8 BITS

BOARD PRESENT -+t I+< 4µS

Figure 3-5. Timing of Optical-Input PCB Operations

6202A, p. 3-12


3.4.4 FRC Parallel Interface PCB N451441-6801 (See Figure 6-4)

The FRC Parallel Interface PCB is designed to isolate the Controller PCB logic from noise on the code line during communications. Optical isolator ICl and relays RLY-1 through RLY-4 are used for this purpose. Ll and L2 are the two code line inputs to this board. The acceptable input range on these lines is 12 to 240 volts de. Overvoltage protection is provided by MOV devices Vl and V2. A RC network Cl, C2 and Rl2 are also across the code line to protect the contacts of the relays.

The state of the external "R" relay contact (line or receive data) is read at contacts Al4 and Al5 on the PCB. (Battery positive is applied to this contact). ICl converts the "R" relay status to standard TTL 5 volt logic. Buffer IC2 lights LED 4 (REC) and delivers the received data to the Controller PCB via PCB contact Al9.

The FRC Parallel Interface PCB accepts three functions from the Controller PCB, including Transmit Data (XMT), Common Mode and Request-to-Send (REQ.). XMT Data is an EIA level input signal repeated by relay RLY 1 through transistor driver Q2. One of the RLY-1 relay contacts is used to apply and remove a short between Ll and L2 (code line shunt for transmission of indication message back to the office). The Common Mode input is the return of the common mode feed (de common) through a relay contact on the Controller PCB. When the Controller PCB's Common Mode relay is energized, RLY-2 (Mor Master relay) will also energize. Req.-to-Send is an EIA level signal from the Controller PCB that indicates a valid field station address. This signal is a 1 second pulse and is repeated by RLY 4 ("Connect") through transistor driver Ql. Each function on the -6801 FRC interface PCB has an LED indicator for monitoring.

3.4.5 FRC Serial Interface PCB N451441-7001 (See Figure 6-5)

The FRC Serial Interface PCB is designed to isolate the Controller PCB logic from noise on the code line during communications. Optical isolator IC2 and relays RLY-1 through RLY-3 are used for this purpose. Pins 6 and 7 are the two code line inputs to this board, and pin 4 is the series output. The acceptable input range on these lines is 12 to 240 volts de. Overvoltage protection is provided by MOV devices Vl and V2. A RC network RlO, C5 and R9, C4 are also located across the code line to protect the contacts of the relays.

The state of the •R• relay (line or receive data) is normally energized on the PCB. (Battery positive is applied to the "R" contact). IC2 converts the •R• relay status to standard TTL 5 volt logic. Buffer ICl lights LED 3 (REC) and delivers the received data to the Controller PCB via PCB contact Al9.

The FRC Serial Interface PCB accepts two functions from the Controller PCB, Transmit Data (XMT) and Common Mode. XMT Data is an EIA level input signal repeated by relay RLY 3 through transistor driver Ql. The XMT relay contact is used to open and close the code line for proper field transmission to the office. The Common Mode Input is the return of the Common Mode feed (de

6202A, P• 3-13


common) through a relay contact on the Controller PCB. When this relay is energized, RLY-2 c•M• or Master relay) also energizes. The •M• relay contacts are used to (a) open the series code line to field stations further out on the line, and (b) increase the code line current from the office for field transmission acknowledgement. Each function on the FRC Serial Interface PCB has an LED indicator for monitoring.

6202A, p. 3-14

..

4 .1 INSPECTION

SECTION IV FIELD MAINTENANCE


FCE-500 equipment should be periodically inspected in conjunction with inspections of related equipment, in accordance with the customer's preventive maintenance schedule. The inspection should include the following:

1. Check the mounting of the cardfile and storage units. Tighten any loose mounting fasteners.

2. Make certain the cardfile front cover is secure. If loose, lower the cover and check that all PCB's are fully inserted in their slots. Also check that rear card edge connectors are tight.

3. Examine PCB's for loose or missing components, broken component leads, evidence of burning, cracked circuit board material, and broken copper tracks. (Power should be turned off before removing or installing any PCB.)

4. Make certain all plug-connector couplers or plugs are firmly connected to the terminal board and that all nuts are tight.

5. Check for frayed or broken wires on the plug-connector plug or under the plug-connector terminal board.

4. 2 CLEANING

Do not use any kind of solvents, detergents or abrasive cleaners on the cardfile or internal components. Dust accumulated on the outside of the cardfile should be removed with a vacuum cleaner, if possible. Do not use vacuum cleaner inside the cardfile.

4.3 SYSTEM TROUBLE ANALYSIS

Before making any checks on the FCE-500 itself, make certain all associated equipment is working properly and that all local cabling is in good condition. Verify that all voltages necessary for system operation are present such as code line, battery voltage, "R" relay input and associated logic power supply output voltages. Power supply output voltages may be read from test points on the foward edge of the board. Readings should be 1 0.5 Vdc of nominal. Recheck all switches and jumpers on the Controller PCB and plug connector jumpers for proper selection per the application.

With the system powered up, make the following observations on the FRC Interface PCB (serial and parallel):

1. When the code line is not carrying data, the REC led should be lit steadily.

2. The REC LED should flash when the code line is active or communicating.

6202A, P• 4-1


3. When the field station is powered up, it should transmit the indication inputs to the office when the code line is clear. checked by observing flashing of the XMT, Mand REC LED'~·

current This can be

Spare printed circuit boards and miscellaneous components should be kept on hand. Replacement of all plug-in components or boards should be conducted before considering removal of the FCE-500 unit.

6202A, p. 4-2

5.1 GENERAL

SECTION IV SHOP MAINTENANCE


The maintenance procedures provided in this section should only be attempted by qualified and properly equipped personnel. A faulty FCE-500 unit or PCB{s) may be returned to US&S for repair. To obtain the proper Returned Material Report (RMR) Form, contact the US&S district sales representative, or:

Union Switch & Signal Division American Standard Inc. 1789 South Braddock Avenue Swissvale, PA 15218 Attn: Customer Service Department

Telephone: (412/273-4000) TWX: 710-664-2096 Telex 86-6448

US&S designed test sets are used for troubleshooting of some of the FCE-500 printed circuit boards. These are as follows:

NAME

TS-205

TS-203

TS-204

APPLICABLE PCB's

Control Delivery N451441-3601

Power Supply Converter N451441-3303 Transmitter-Opto N085722-1001

Controller N451441-4305

The FRC Interface PCB (serial or parallel) requires general-purpose test equipment.

The TS-200 series test sets are only used to localize a PCB problem in a functional sense; the maintainer must continue with standard component-performance and circuit continuity tests to pinpoint the source of the problem. The design and general operating characteristics of the test sets are discussed in SM-6171. No attempt should be made to troubleshoot any FCE-500 PCB without these test sets. Except for the PROM !C's on the Controller PCB, all PCB components may be replaced from sources other than US&S, provided component values, tolerances, etc. are noted carefully (see Appendix A).

5.2 SYSTEMATIC PCB TROUBLESHOOTING

5.2.1 Controller PCB (N451441-4305)

5.2.1.1 Test Procedure Comments

The TS-204 is used to store a 16K (2K x 8) bit test PROM IC which is substituted for the service PROM on the Controller PCB. The test PROM contains diagnostic software which runs the boa~d through a limited hardware examination. Three toggle switches on the set are used to select specific areas of the board for diagnostics. The TS-204 also contains a digital LED

6202A, P• 5-1


display which provides various codes representing the results of individual diagnostics routines. Nominal test codes are given with each procedure step. When the actual code does not agree with the nominal code, an error code interpretation table (Table 4-1) may be consulted to determine the general nature and location of the problem. The table gives the numbers of Controller PCB IC's pertaining to each tested area, however these IC's are only listed as a guide to follow-up troubleshooting.

The Controller PCB test procedure is divided into four parts. In the first part (steps 1 and 2) the board power circuits are given _continuity and voltage checks. The second part (step 3) consists of EIA and TTL communications interface voltage checks. The third part (step 4) is a general performance check of the microprocessor and peripherals, conducted by the Test PROM software. This is the first part of the test procedure to use the TS-204 digital display. The fourth part (steps 5 through 19) consists of tests of the program switches and jumpers.

The first three parts of the Controller PCB test procedure should be run in the indicated order to verify the basic operating condition of the board. The part-four tests do not have to be run in order and may also be repeated on a selectively as required. There is a remote possibility the service PROM is the source of the fault, in which case the TS-204 would show nominal test results. A spare service PROM may be used to verify the condition of the original.

5.2.1.2. Required Test Equipment

TS-204 Test Set

Digital or Analog Electronic Voltmeter (Qty.= 1)

5.2.1.3 Test Set-Up

Description

N451400-3202, includes test PROM N451575-0701

a. Remove the Controller PCB from the cardfile (power supply converter PCB power OFF).

b. Remove the service PROM (IC26) from the board; avoid placing the PROM under bright lights.

c. Take the test PROM from the TS-204 holder and install in the IC26 socket.

d. Record the programmed positions of the various switches and jumpers so that they can be reset to the original positions after testing. Figure 5-1 provides a chart for recording these positions.

6202A, p. 5-2

UNION SWITCH & SIGNAL ffi e. Set the switches on the Controller PCB as follows:

SWl SW2 SW3 SW4

RESET ON SPACE Position "O"

SW5 SW6 SW7 SW8

Position "O" All closed (•0 11 side) All closed (•0 11 side) All Closed ("O" side)

STATION ADDRESS JUMPERS All to ·o· side

f. Plug the TS-204 into standard 120 Vac source, with the POWER switch OFF.

g. Insert the Controller PCB into the test set edge connectors with the component side facing the test set control panel.

CAUTION

DO NOT INSTALL OR REMOVE THE CONTROLLER PCB FROM THE TS-204 WITH TEST SET POWER ON, OTHERWISE COMPONENT DAMAGE MAY RESULT.

5.2.1.4 Procedure

Operation Verification

1. Measure the resistance between 1. v.o.M. should show the the following pairs of test points:

Common Lead +v Lead

TP2 TPl greater than 15 ohms TP3 TPl greater than lK ohms TPl TP4 greater than lK ohms TP3 TP4 greater than SK ohms

2. Turn on TS-204 power and measure 2. Meter should show the voltages on the following test voltages: points, as referenced to TP2 (OV)

TPl +5 Vdc, +/- 0.5 Vdc TP3 -12 Vdc, +/- 0.5 Vdc TP4 +12 Vdc, +/- 0.5 Vd'c TPll 0 Vdc, +/- 0.5 Vdc

following:

following

6202A, P• 5-3


CHECK BOX 00 TO RECORD POSITION OF JUMPER · OR SWITCH

0 0 0 0 0 0 0

0000000-0 0 0 0 0 0 0

0000000~ 0 0 0 0 0 0 0

JUMPERS

SW6 SW7

co00 co OD "-00 .... oo

'°OD '°DO inOO ffi inOO z w

Q.

•OD o Q.

•DO o

Moo Moo NOD NOD -DD -DO

CHECK BOX 00 TO RECORD POSITION OF JUMPER OR SWITCH

0 0 0 0 0 0 0

0000000-0 0 0 0 0 0 0

0000000~ 0 0 0 0 0 0 0

SW6

r.o00 .... oo

1'°00 linOO ffi! 1•00 g;I

!Moo 1\

INog II

JUMPERS

SW7

co OD .... oo '°OD inOO ffi

a. •OD 01

l·Moo NOD

1-oo '

0 :1 0

~

1

D•=•D SW5 5 3

0 • 0 0

0 ~ 0

~

1

0 • = • 0 SW4 5 3

0 • 0 0

swa

co OD .... OD '°DO inOO ffi

Q.

•OD o Moo NOD -DO

0 ~ 0

~

1

D•=•D SW5 5 3

0 • 0 0

0 ~ 0

~

1

D• = •D SW4 5 3

0 • 0 0

swa

\r.ooo .... DO <DOD I

linDO ~. 1·00 0

1MOO I jNDD 1-00


0 0 0 0 0 0 0

0000000-0 0 0 0 0 0 0

'.JOO ODDO 9 0 0 0 0 0 0 0

SW6

co OD .... DO '°OD inOO ffi

Q. ..,DO o

Moo NOD -oo

JUMPERS

SW7

r.oOO .... oo '°OD inOO ffi

a. ..,DO o

..,oo NOD -oo


0 0 0 0 0 0 0

0000000-0 0 0 0 0 0 0

000000[]9 0 0 0 0 0 0 0

JUMPERS

SW6 SW7

r.o00 '11 .... oo <DOD ,I

I

inoo ~I •DO 0 ! t~o: II

Ir.coo 1 .... 00 i '°DO I in OD ffi I Cl. i"'DO ol I I

;MOO I !Noo I

1-00 I

O SJ O

~

1

D• = •D SW5 5 3

0 • 0 0

0 ~ 0

~

1

D• =~D SW4 5 3

0 • 0 0

swa

r.oCO .... LO <000 1()00 z

~ •DO O

Moo NOD -oo

O SJ O

~

1

D•=•D SW5 5 3

0 • 0 0 0

0 • 0

~

1

D• = •D SW4 5 3

0 • 0 0

SW8

r.o00 .... DO '°OD in00 ffi

a. •DO o

Moo I

/NOD !

Figure 5-1. Controller PCB Switch/Jumper Programming Record

6202A, p. 5-4

Operation

3. Position toggle switches SWl, SW2 and SW3 as follows and read voltages on PCB edge "A" pins 6, 7, 8 and 9:

SWl

RESET RESET RESET

SW2

ON ON OPERATE

SW3

SPACE MARK MARK

3.

4. Move toggle switch SWl on the 4. Controller PCB to the NORMAL position and observe the TS-204 digital display and board LED's.

5. Move Controller PCB toggle switch 5. SWl to the RESET position.

6. Set TS-204 switches S2 and Sl to 6. •o• and so to •o•, then move PCB toggle SWl to NORMAL.

UNION SWITCH & SIGNAL m Verification

Meter should show the following voltages(+/- 0.5 Vdc) on the pins:

Pin No.: 6 7 8 9

+5 +5

0

+5 0 0

+6* +6* -6* -6* -6* -6*

*5 to 7 Vdc, + 1 Vdc

All seven PCB LED's should flash in a regular, sequential pattern and the TS-204 should run through and repeat the following sequence:

1. 999 (initial display) shows shows for approx. one sec.

2. Various numbers flash quickly 3. 601 (successful test) shows

shows for approx. one sec. 4. 127 (reset) shows for approx.

one second.

If the digital display stops on an error code number, or does not display any numbers, refer to Table 5-1 (p. 5-8) for error code definitions.

6202A, p. 5-5


Operation

7. Position SW6 rockers to the following positions and observe the test set digital display (1 = open, 0 = closed):

1

0 1 1 1 1 1 1 1

2

0 0 1 1 1 1 1 1

3

0 0 0 1 1 1 1 1

SW6 Rockers

4

0 0 0 0 1 1 1 1

5

0 0 0 0 0 1 1 1

6

0 0 0 0 0 0 1 1

7

0 0 0 0 0 0 0 1

8

0 0 0 0 0 0 0 0

8. Move PCB toggle SWl to RESET.

9. Set TS-204 switch so to •1•, switches Sl and S2 to •o•, then PCB toggle SWl to NORMAL.

7.

8.

9.

Verification

TS-204 should display the following codes; if an error code is displayed, refer to Table 5-1 for error code definitions. (Each readout is a binary sum, with rocker 1 the LSB.)

Nominal Readout:

000 001 003 007 015 031 063 127

10. Set SW7 rockers to same positions as step 7, then with all rockers to the •1• position. Observe the test set digital display.

10. TS-204 should display the same codes as shown in step 7, plus "255" for the all-"l's" setting. If an error code is displayed, refer to Table 5-1 for error code definitions.

11. Move PCB toggle SWl to RESET. 11.

12. Set TS-204 switches SO and S2 to 12. "O" and Sl to •1•, then move PCB PCB toggle SWl to NORMAL.

13. Set SW8 rockers to the same posi- 13. tions as step 7, then with all rockers to the "l" position. Observe the test set digital display.

14. Move PCB toggle SWl to RESET. 14.

15. Set TS-204 switches so and Sl to 15. "l" and S2 to "O", then move PCB toggle SWl to NORMAL.

6202A, p. 5-6

TS-204 should display the same codes as shown in step 7, plus "255" for the all-"l's" setting. If an error code is displayed, refer to Table 5-1 for error code definitions

UNION SWITCH & SIGNAL m Operation Verification

16. Set Controller PCB switches 16. TS-204 should display the follow-SW4 and SW5 as follows: ing codes. If error code is dis-

played, refer to Table 5-1 for error code definition. (Each readout contains the respective

Rotary Switches positions of the switches.)

SW5 SW4 Nominal Readout -- --.. 0 0 000

0 1 001 1 2 012 2 3 023 3 4 034 4 5 045 5 6 056 6 7 067 7 0 070

17. Move PCB toggle SW! to RESET. 17. --18. Set TS-204 switches so and Sl to 18. --

"O" and S2 to 11 1•, then move PCB toggle SW! to NORMAL.

19. Position the Station Address 19. TS-204 should display the follow-jumpers as follows and observe ing codes. If error code is dis-TS-204 display (0 = jumper played, refer to Table 5-1 for jumper to 11 0 11 side, 1 = jumper error code definition. (943 is an to 11 1 11 side). is an error code. The other read-

outs correspond to the generated Jumpers station addresses.)

64 32 16 8 4 2 1 Nominal Readout

0 0 0 0 0 0 0 943 0 0 0 0 0 1 1 003 0 0 0 0 1 1 1 007 0 0 0 1 1 1 1 015 0 0 1 1 1 1 1 031 0 1 1 1 1 1 1 063 1 1 1 1 1 1 1 127

6202A, p. 5-7


CODE

101 102 103 104 105 106 111 127 201 202 203 204 205 206 207 208 209 210 211 212 342 4XX 667 800 801 802 803 804 805 806 807 808 809 810 888 901 902 903 904 905 906 907 908

Table 5-1. TS-204 Test Set Error Codes

DEFINITION

PTM-1, timer il accuracy error PTM-1, timer i2 accuracy error PTM-1, timer i3 accuracy error PTM-2, timer il accuracy error PTM-2, timer i2 accuracy error PTM-2, timer i3 accuracy error RAM error Watchdog circuit does not reset microprocessor EIA carrier detect line stuck low EIA CTS line stuck low EIA AVI data line stuck low EIA receive data line stuck low EIA carrier detect line stuck high EIA CTS line stuck high EIA AVI data line stuck high EIA receive data line stuck high EIA RTS line stuck low EIA RTS to send line stuck high EIA transmit data line stuck low EIA transmit data line stuck high Common mode relay drive error Control/indication bit linesl Deliver, deliver set-up error 2

Interrupt error Carrier detect interrupt error AVI data interrupt error Receive data interrupt error Request service interrupt error PTM-1, timer il interrupt error PTM-1, timer i2 interrupt error PTM-1, timer i3 interrupt error PTM-2, timer il interrupt error PTM-2, timer i2 interrupt error PTM-2, timer i3 interrupt error Microprocessor internal fault TTL carrier detect line stuck high TTL carrier detect line stuck low TTL AVI or RTS line stuck low TTL AVI or RTS line stuck high TTL receive data line stuck high TTL receive data line stuck low TTL CTS or transmit data line stuck high TTL CTS or transmit data line stuck low

1 Any digit may appear in •x•

IC4 IC4 IC4 IC5 IC5 IC5 IC6

FAULTY IC'S?

IC8, 14, 18, 19, 22 IC24 IC23 IC23 IC24 IC24 IC23 IC23 IC23 IC3, 18, 20, 25 IC3, 18, 20, 25 IC3, 13, 20, 25 IC3, 13, 20, 25 IC3, 14 IC2, 12

ICl, 2, 3, 4, 5 ICl, 3 ICl, 3 ICl, 3 ICl, 2 IC4 IC4 IC4 IC5 IC5 IC5 I Cl IC3, 15 IC3, 15

IC3, 15 IC3, 15

2 If the DELIVER LED is not cycling, the error is in the Deliver function. Otherwise, the error is in the Deliver Set-Up function.

6202A, p. 5-8


Table 5-1. TS-204 Test Set Error Codes (Cont'd)

CODE DEFINITION FAULTY IC'S?

909. Board present data bit stuck high3 IC2, 17 910. Board present data bit stuck low3 IC2, 17 942 Sta. addr. decode reads more than one address IC16, 21 943 Sta. addr. decode reads no address IC16, 21 . Data Strobe Error3 IC13 X66 Word Addressl

Buffer or PIA fault (PCB LED's cycle twice)4 Microprocessor, RAM or test PROM fault4 I Cl, 6, 26

1 Any digit may appear in "X" 4 No display 3 Decimal point flashes

5.2.2 Control Delivery PCB (N451441-3601)


The test procedure for the Control Delivery PCB requires the TS-205 Test Set. This set is designed to simulate all Controller PCB inputs, including card file addressing and loading/strobing of data bits. The set also monitors and display the relay contact outputs, using LED's.

The objective of the test procedure is to run the PCB through a wide range of addressing, data bit and byte-control configurations and verify that relay outputs correspond correctly to data inputs. The test procedure is presented in the form of an illustrated truth table (Figure 5-2). The table lists test set switch positions and LED responses from both the test set and the PCB. Test set LED's are depicted in their panel arrangement. When test set outputs do not correspond to inputs, as shown in figure, the associated input and output lines/components are isolated for follow-up testing.

5.2.2.2 Required Test Equipment

This test procedure requires the TS-205 test set (N451441-3101).

5.2.2.3 Test Set-Up

1. Remove PCB from cardfile (power supply converter PCB power OFF).

2. Plug test set into standard 120 Vac source, POWER switch OFF.

3. Insert PCB in the slot that includes part number suffix "3601". The PCB is inserted with the component side facing the test set controls.

6202A, P• 5-9


CAUTION

DO NOT INSTALL OR REMOVE THE CONTROL DELIVERY PCB FROM THE TS-205 WITH TEST SET POWER ON, OTHERWISE COMPONENT DAMAGE MAY RESULT.

4. Turn test set power on.

5. Operate LAMP TEST button to verify test set LED's.

6. Move the BOARD SELECT switch to the position corresponding to the part number suffix for the board.

5.2.2.4 Procedure (See Figure 5-2)

a. Board Addressing

Position the ADDRESS BIT and PROGRAM BIT switches for board addressing tests, according to the ADDRESS BIT AND PROGRAM BIT columns in Figure 5-2. The ADDRESS BIT switches simulate word address inputs from the Controller while the PROGRAM BIT switches simulate the program address obtained from the cardfile slot. In those steps where the switches are properly matched, the ADDRESS LED on the board should light. These switches are only reset after each even numbered step because two steps (1 & 2, 3 & 4, etc.) are required to load data bits. When an addressing test is successful, the ADDRESS LED should remain on for the rest of the step until the ADDRESS BIT and PROGRAM BIT switches are reset.

b. Input Bits Set-Up

Position the eight INPUT BITS switches on the test set according to the INPUT BITS column. Input bit loading is accomplished in two steps. In the odd numbered steps, load the first eight bits of data by setting the ADDRESS BIT 2° switch (equivalent to the Controller PCB byte pointer) to "O" and momentarily pressing the DATA STROBE pushbutton (indicated with arrow on the chart). In the even numbered steps, load the second byte of data by setting ADDRESS BIT 2° to "l" and pressing DATA STROBE again.

c. Relay Actuation

Move the DELIVER switch (DEL in Figure 5-2) to the "l" position to output all 16 bits in parallel. This happens in every even-numbered step since only eight bits of data are loaded in the odd numbered steps. The DELIVER LED on the PCB should stay on until the DELIVER switch on the test set is returned to "O".

6202A, p. 5-10

NOTE

Due to PCB inhibit circuitry and switch bounce from the test set, this step may have to be repeated several times to initiate relay sequencing.

UNION SWITCH & SIGNAL m RELAYS LEO'S

ADDRESS PROGRAM AOOR. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS 16 BIT BIT AODR. INPUT BITS BIT DATA HO DEL

STEP 2' 2' 2' 2' 2' 2' 2' 2' LED 0 1 2 3 4 5 8 7 2• STRB. DEL. NC LEO DEL

1 0 0 0 0 0 0 0 0 • 0 0 0 0 0 0 0 0 0 J_ 0 •••••••••••••••• • -0000000000000000

2 0 0 0 0 0 0 0 0 • 0 0 0 0 0 0 0 0 1 J_ 1 SAME AS STEP 1 • 0

3 0 0 0 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 J_ 0 SAME AS STEP 1 • -

4 0 0 0 1 1 1 1 0 0 0 0 0 0 0 0 0 0 1 J_ 1 SAME AS STEP 1 0 0

5 0 0 0 1 1 1 1 0 0 1 1 1 1 1 1 1 1 0 J_ 0 SAME AS STEP 1 • -. 6 0 0 0 1 1 1 1 0 0 11111111 1 J_ 1 0000000000000000 0 0

•••••••••••••••• 7 0 0 0 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 J_ 0 SAME AS STEP 1 • -

8 0 0 0 1 1 1 1 0 0 0 0 0 0 0 0 0 0 1 J_ 1 SAME AS STEP 1 0 0

9 0 0 0 0 1 1 1 0 • 1 1 1 1 1 1 1 1 0 J_ 0 SAME AS STEP 1 • -10 0 0 0 0 1 1 1 0 • 1 1 1 1 1 1 1 1 1 J_ 1 SAME AS STEP 1 • 0

11 0 0 0 1 1 1 1 1 • 1 1 1 1 1 1 1 1 0 J_ 0 SAME AS STEP 1 • -

12 0 0 0 1 1 1 1 1 • 1 1 1 1 1 1 1 1 1 _L 1 SAME AS STEP 1 • 0

13 0 0 1 0 J_ • -1 1 0 1 0 1 0 1 0 1 0 1 0 0 o. SAME AS STEP 1

14 0 0 1 0 1 1 0 1 0 1 0 1 0 1 0 1 0 1 J_ 1 O•O•O•O•O•O•O•O• 0 0 •O•O•O•O•O•O•O•O

15 0 0 1 1 1 1 0 0 0 0 1 0 1 0 1 0 1 0 _l 0 SAME AS STEP 1 • -

16 0 0 1 1 1 1 0 0 0 0 1 0 1 0 1 0 1 1 J_ 1 •O•O•O•O•O•O•O•O 0 0 O•O•O•O•O•O•O•O•

O LED LIT

• LED DARK

j__PRESS DATA STROBE MOMENTARILY

Figure 5-2. Control Delivery PCB Troubleshooting Program.

6202A, p. 5-11


~ ~ ~ ALL PCB'S ALL ALL ALL ·3601 ONLY ~ ~ --- - RELAYS LED'S ADDRESS PROGRAM ADDR. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

BIT BIT ADOR. INPUT BITS BIT DATA NO DEL STEP 2' 2' 2' 2' 2' 2' 2' 2' LEO 0 1 234567 2• STRB. DEL. NC LEO DEL

17 0 1 0 0 1 0 1 1 0 1 1 1 1 1 1 1 1 0 _! 0 SAME AS STEP 1 • -(PRECEDING SHEET)

18 0 1 0 0 1 0 1 1 0 1 1 1 1 1 1 1 1 1 J_ 1 SAME AS STEP 6 0 0

19 0 1 0 1 1 0 1 0 0 0 1 1 1 1 1 1 1 0 j_ 0 SAME AS STEP 1 • -

20 0 1 0 1 1 0 1 0 0 0 1 1 1 1 1 1 1 1 _! 1 eOOOOOOOeOOOOOOO O•••••••O•••••••

0 0

-----CONTINUE BINARY COMBINATIONS OF ADDRESS BIT ANO PRO· GRAM BIT SWITCHES UNTIL COMPLETING ADDRESS 15 (STEPS 39/40). ADDRESS 1 STARTED ON STEP 11/12. REPEAT INPUT BITS FOR STEPS 17/18 ANO 19/20.

37 1 1 1 0 0 0 0 1 0 1 1 1 1 1 1 1 1 0 j_ 0 SAME AS STEP 1 • -38 1 1 1 0 0 0 0 1 0 1 1 1 1 1 1 1 1 1 j_ 1 SAME AS.STEP 6 0 0

39 1 1 1 1 0 0 0 0 0 0 1 1 1 1 1 1 1 0 J_ 0 SAME AS STEP 1 • -

40 1 1 1 1 0 0 0 0 0 0 1 1 1 1 1 1 1 1 j_ 1 SAME AS STEP 20 0 0

O LED LIT

• LED DARK

_l PRESS DATA STROBE MOMENTARILY

Figure 5-2. Control Delivery PCB Troubleshooting Program (Cont'd).

6202A, p. 5-12

UNION SWITCH & SIGNAL m d. Relay Output Indications

When the board is initially addressed, all 16 N.C. RELAYS LED'S should light. PCB relays are automatically energized in the normally-closed position. When the DELIVER switch is operated, the RELAYS LED's should change to a pattern which matches the INPUT BITS switches. RELAYS LED's 1 - 7 should match the positions of the INPUT BITS switches sent on the first DATA STROBE, while LED's 8 - 16 should match the bits sent on the second DATA STROBE. An INPUT BITS switch set at •1• should light the corresponding N.O. RELAYS LED. An INPUT BITS switch set at •o• should light the corresponding N.c. RELAYS LED. Only one LED of each pair should light at any time.

e. Close Out

After each even-numbered step (one complete relay loading and delivery), move the DELIVER switch back to •o•. All N.O. RELAYS LED'S should go dark.

5.2.3 Transmitter-Opto PCB (N085722-1001)


The Transmitter-Opto (N085722-1001) PCB is tested in the TS-203 test set. The TS-203 is designed to simulate all Controller PCB inputs to the PCB, including cardfile addressing and loading/reading of data bits. The set also simulates the low current indication contact inputs from wayside circuits, and operates the Address Disable and Output Inhibit circuits. Although Address Disable and Output Inhibit are not used by the Controller PCB, they do not pertain to the internal operation and testing of the board. The CONNECTOR SELECT knob, METER TEST pushbutton and digital display are not used in these tests.

The test procedure is to runs the PCB through a variety of addressing, byte-control and indication bit configurations, and verifies that bits received by the board correspond with those output to the Controller PCB. The procedure is presented in an illustrated truth table (Figure 5-3). The table lists test set switch positions and LED responses from both the test set and the PCB. When test set outputs do not correspond to inputs, as shown in the diagram, the associated input and output lines/components may be faulty.


This test procedure requires the TS-203 test set N451400-2201 •.

5.2.3.3 Test Set-Up

a. Remove PCB from cardfile (power supply converter PCB power OFF).

b. Plug TS-203 into standard 120 Vac source with POWER switch OFF.

c. Set all LOW BYTE and HIGH BYTE switches in the •o• position and the OUTPUT INHIBIT and ADDRESS ENABLE switches in the •o• position.

6202A, p. 5-13


d. Insert PCB into test set edge connector marked "3201" with component side facing control panel.

CAUTION

DO NOT INSTALL OR REMOVE THE INDICATION-OPTO OR TRANSMITTER-OPTO PCB FROM THE TS-203 WITH TEST SET POWER ON, OTHERWISE COMPONENT DAMAGE MAY RESULT.

e. Turn TS-203 power ON.

f. Operate LAMP TEST button to verify the OUTPUTS LED's.

g. Throw each of the LOW BYTE and HIGH BYTE switches to verify adjacent LED's. Do the same for the OUTPUT INHIBIT and ADDRESS ENABLE LED's.

5.2.3.4 Procedure (See Figure 5-3)

a. Input Bits Set Up

Position the eight LOW BYTE and eight HIGH BYTE switches as indicated in the first two columns of Figure 5-3. These correspond to the 16 indication inputs provided by external circuit contacts. When a BYTE switch is set to the "l" position, the adjacent LED should come on, otherwise the LED should be off.

b. Board Addressing

Position the ADDRESS BIT and PROGRAM BIT switches for board addressing tests, according to the ADDRESS BIT AND PROGRAM BIT columns. The ADDRESS BIT switches simulate word address inputs from the Controller, while the PROGRAM BIT switches simulate the program address obtained from the cardfile slot. Also, move the ADDRESS ENABLE switch (ADD ENA in the figure) to the "l" position. When the BOARD PRESENT LED lights (BRO PRS on chart), the address test is successful.

c. Input Bits Loading

Move the ADDRESS BIT 20 switch (byte pointer) to LOW. This places indication bits O - 7 on the output data lines. The WORD O LED should light at this time. Next, move the ADDRESS BIT 20 switch (byte pointer) to HIGH. This places indication bits 8 - 15 on the output data lines. On the Transmitter-Opto PCB, the WORD 1 LED should light at this time. OUTPUT INHIBIT is kept off at this point to allow delivery'of both bytes.

d. Output Bits Indications

When ADDRESS BIT 20 is set to LOW, the seven OUTPUTS LED's on the test set should match the positions of the LOW BYTE switches. When ADDRESS BIT 20 is set to high, the OUTPUTS LED's should match the positions of the HIGH BYTE switches. In both cases, a BYTE switch set to "l" should cause the corresponding OUTPUTS LED to light. A BYTE switch set to "O" should leave the corresponding OUTPUTS LED off.

6202A, p. 5-14

STEP LOW BYTE HIGH BYTE

0 1 2 3 c 5 & 7 I I 10 11 12 13 14 15

1 •••••••• --------0 0 0 0 0 0 0 0 ..., ....

I.Q 2 SAME AS STEP 1 --------

s:: .., (I) 3 SAME AS STEP 1 ------ - -U1 I w • 4 SAME AS STEP 1 ------ - -. 8 .., QI

5 oeoeoeo• eoeoeoeo 1 0 1 0 1 0 1 0 0 1 0 1 0 1 0 1 ::s

[ll

a 6 SAME AS STEP 5 SAME AS STEP 5 .... rt ("!" (I) 7 eoeoeoeo oeoeoeo• .., I

0 1 0 1 0 1 0 1 1 0 1 0 1 0 1 0

.§> 8 SAME AS STEP 7 SAME AS STEP 7 ("!"

0

I'd (") tXI

9 -------- 0000000·0 1 1 1 1 1 1 1 1

8 10 .., ------- - SAME AS STEP 9

0 s:: O" .....

~

11 ------- -(I) [ll :::,-0 12 ------·- -0 ("!" .... ::s 13 ------- -I.Q

I'd .., 14 ------- -0

O'I I.Q

N ..,

0 QI

N a :J>' .. 't:I

15 -------- v 16 --------. U1 I

NOTES: e LEO DARK OLEO LIT

..... U1

.

AOORESS PROGRAM AOD LOW HI ADD BRO BIT BYT BYT

2 2 2 2 2 2 2 2 ENA PRS Zo LED LED

0 0 0 0 0 0 0 0 • • LOW • • 0

O O 0 0 0 0 0 0 0 • LOW • • 1

0 0 0 0 1 1 1 1 • • LOW • • 0

0 0 0 0 1 1 1 1 0 0 LOW 0 • 1

0 0 0 0 1 1 1 1 0 0 LOW 0 • 1

0 0 0 0 1 1 1 1 0 0 HIGH 0 0 1

0 0 0 0 1 1 1 1 0 0 HIGH • 0 1

0 0 0 0 1 1 1 1 0 0 LOW 0 • 1

1 0 0 0 1 1 1 1 0 • HIGH • 0 1

0 1 0 0 1 1 1 1 0 • HIGH • 0 1

0 0 1 0 1 1 1 1 0 • HIGH • 0 1

0 0 0 1 1 1 1 1 0 • HIGH • 0 1

1 1 1 1 1 0 0 0 0 • HIGH • 0 1

1 1 1 1 0. 1 0 0 0 • HIGH • 0 1

1 1 1 1 0 0 1 0 0 • HIGH • 0 1

1 1 1 1 0 0 0 1 0 • HIGH • 0 1

RUN ALL OTHER BINARY COMBINATIONS OF ADDRESS ANO PRO· GRAM SWITCHES (15 TOTAL). ANY INPUT BIT CONFIGURATION ACCEPTABLE.

OUT INH

• 0

• 0

• 0

• 0

• 0

• 0

• 0

• 0

• 0

• 0

• 0

• 0

• 0

• 0

• 0

• 0

OUTPUTS

0 1 2 3 C 5 6 1

•••••••• SAME AS STEP 1

SAME AS STEP 1

.SAME AS STEP 1

oeoeoeo•

eoeoeoeo

SAME AS STEP 5

SAME AS STEP 6

•••••••• SAME AS STEP 9

-

v c z 0 z I ~ ::c 11!1 UI c5 z ), r

m


5.2.4 Power Supply Converter PCB N451441-3303 (TS-203 Test)


The TS-203 checks all +5, +/- 12 Vdc outputs points on the Power Supply Converter PCB. This includes 16 contacts on the •B• connector edge (logic level voltage to other cardfile PCB's): 9, 10, 16, 17, 19, 20, 21 and 22. On the •A• connector edge, eight contacts are checked: 1, 6, T, 18, v, 20, x, 22 and z. A four digit (7 segment type) display indicates voltages at these points. When the CONNECTOR SELECT knob is moved between the three left-hand voltage positions, outputs are displayed from the •A• connector edge contacts. The right-hand positions provide outputs from the •B• contacts. The TS-203 is equipped with resistors which simulate the load from other FCE-500 PCB's. The ADDRESS DISABLE, OUTPUT INHIBIT, ADDRESS, PROGRAM etc. switches do not participate in these test procedures and may be left in any position.


Item

TS-203 Test Set

Oscillosope (Suggested Models: Textronix 453, 465, 515, 545, 7603)

DC Power Supply (Suggested Model: Harrison 64438 or equivalent)

5.2.4.3 Test Set-Up

Specifications

US&S N451441-2201

- Frequency range: de to 30 MHz - Time base: .02 msec./div. to

12 sec./div. - Time base accuracy: 1% - Dual channel inputs with chopped or

alternate operation - ac or de coupling - External sweep mode - Accuracy: +3% - Veritcal amp. sensitivity: .05 V/div.

- 8 to 20 volts, 0 to 10 amps - Line reg: 0.01% +/- 2 millivolts - Load Reg. - 0.01% +/- 200 millivolts

Ripple and noise: less than 500 millivolts RMS

- Stability: 0.15% +/- 90 millivolts

1. Remove PCB from cardfile (operating power OFF).

2. Plug TS-203 into standard 120 Vac source with POWER switch OFF.

3. Insert PCB into test set edge connectors marked •3301• with component side facing test set controls.

6202A, p. 5-16

UNION SWITCH & SIGNAL m CAUTION

DO NOT INSTALL OR REMOVE THE POWER SUPPLY CONVERTER PCB FROM THE TS-203 WITH TEST SET POWER ON, OTHERWISE COMPONENT DAMAGE MAY RESULT.

4. Connect de power supply (power OFF) to TS-203 "banana• jack plugs c•+• to red terminal, •-• to black terminal).

5. Turn on test set power (make certain SW! on PCB is OFF).

6. Momentarily press the METER TEST pushbutton; all segments of all four digits, a•+• sign and a decimal point should light.

5.2.4.4 Procedure

Operation

1. Turn on external power supply and adjust to 8 Vdc.

2. Turn PCB SW! switch on.

3. Move CONNECTOR SELECT knob to •A• side, 11 -12• position.

4. Move CONNECTOR SELECT knob to •+5• position.

' 5. Move CONNECTOR SELECT knob to • -12• position.

6. Move CONNECTOR SELECT knob to •B• side, •+12•, •+5• and •-12• positions.

7. Adjust oscilloscope controls as follows:

1.

2.

Verification

LED's 1, 2 and 3 should light with equal brightness. If none light, check fuse and replace (SW! OFF) if necessary. If only one or two LED's light, continue with Steps 3 through 6 to check individual converter modules.

3. Meter should show •-12•, + 0.38.

4. Meter should show •+5•, + 0.17.

5. Meter should show •-12• + 0.38.

6. Same results should be obtained as steps 3, 4 and 5.

7. --

- Vertical attenuation: 20 millivolts/Div. - Coupling: ac or ac - Horizontal time base: 10 millisec./Div. - Trigger level: Auto - Trigger: CH! - Scope: + - Probe: !OX (use short ground clip on

scope probe).

6202A, p. 5-17


Operation

8. Connect oscilloscope Common to TP2.

9. Connect oscilloscope probe to TPl.

10. Move probe to TP3, then TP4.

11. Turn PCB SWl switch off.

8.

9.

Verification

Ripple in oscilloscope waveform should not exceed 600 millivolts.

10. Same ripple maximum should be obtained as in Step 9.

11. --

12. Adjust de power supply to 16 Vdc. 12.

13. Turn PCB SWl back on.

14. Repeat steps 3 through 6.

13. --

14. Same results as shown in steps 3 through 6 should be obtained.

5.2.5 FRC Parallel Interface PCB N451441-6801


The FRC Parallel Interface PCB test procedure (section 5.2.5.4) is divided into two parts. In steps 1 through 25, continuity is checked on relay circuits, using a variety of operating states. Toggle switches are used to simulate some Controller PCB inputs during these tests. In steps 26 through 28, the "R• relay output (to the Controller) is checked, using an oscilloscope. A function generator is used to simulate the •R• relay input.


Item

Oscillosope (Suggested Model: Textronix 465)

DC Power sut~l~ (Qty= 2, Suggested Model: HP o B):

6202A, p. 5-18

Specifications

- Frequency range: de to 30 MHz - Time base: .02 msec./div. to

12 sec./div. - Time base accuracy: 1% - Dual channel inputs with chopped or

alternate operation - ac or de coupling - External sweep mode - Accuracy: +3% - Veritcal amp. sensitivity: .05 V/div.

- 0 to 20 Vdc@ 0 to 1.5 amps.


Item Specifications

Function Generator (Suggested Model: - Frequency range: 10 Hz to 10 KHz Wavetek 112): - Output amplitude: 10 volts peak to

peak - Frequency accuracy: 2% - Output impedance: 50 ohms

v.o.M. (Suggested Model: Simpson 260) - Ohmmeter accuracy: ±. 5% reading at center scale

- Resistance range: 0 to 10 megohms

Card Edge Connector Kit, 44-pin: - US&S N451170-1001

Toggle Switch (Qty= 3) - DPDT

5.2.5.3 Test Set-Up

a. Remove PCB from cardfile (power off).

b. Stand PCB vertically (mercury relay contact arrow up).

c. Connect test equipment according to Figure 5-4, but leave card edge connector disconnected from PCB.

d. Turn on both power supplies. Adjust #1 power supply to 5 Vdc + 1% and power supply #2 to 12 Vdc + 1%. Turn both supplies off.

e. Turn on function generator and adjust to produce a square wave output, 24 volts peak to peak.

f. Turn off function generator and attach card edge connector to the FRC Interface PCB. Do not turn on any test equipment until instructed in the test procedure.

5.2.5.4 Test Procedure


1. Set switches Sl, S2 and S3 to the 1. All LED's on the board should be off position. dark.

2. Use V.O.M to measure the res is- 2. v.o.M. should show a short circuit tance between the following pairs between each pair of pins. of PCB pins:

2A and 3A 4A and 6A 5A and 7A 9A and lOA 12A and 13A

6202A, p. 5-19


FUNCTION H i---------------------------<,14A GENERATOR

60Hz 24V P/P

SR.WAVE L~----------------------<~15A

i----:.i. PROBE OSCILLOSOPE

OFF S1 ON~SA c ¢,A

OFF S2 ON~1A ,-0 OFF

~3- ~-ON...,,.~OA ~

POWER (+)t----i~-------------__. SUPPLY

#1 5VDC (-)-

POWER (+)t---1.,._--------------------<,198 SUPPLY

#2 12VDC (-)t---4~------------------<i~72B

~

Figure 5-4. FRC Interface PCB Test Set-Up


UN451441 ·6801

3. Measure resistance between the following pairs of pins:

3. v.o.M. should show open circuit between each pair of pins.

lA and 3A 4A and SA 6A and 7A 8A and 9A llA and 12A

4. Turn switch Sl to the on position. 4.


6202A, p. 5-20

2A and 3A 4A and 7A SA and 6A 8A and 9A 12A and 13A

5.

LED 1 on the PCB should light.

v.o.M. should show short circuit between each pair of pins.

Operation


lA and 3A 4A and SA 6A and 7A 9A and lOA llA and 12A

7. Turn switch S3 to on position.

6.

7.


V.O.M. should show open circuit between each pair of pins.

LED's 1 and 2 on the PCB should light.

8. Turn switch SWl to off position. 8. LED 1 on the PCB should go dark (LED 2 on only).


2A and 3A 4A and 6A 5A and 7A 9A and lOA llA and 12A


lA and 3A 4A and SA 4A and 7A 5A and 6A 8A and 9A 12A and 13A

11. Turn switch S2 to on position.

12. Turn switch S3 to off position.

13. Measure resistance between following pairs of pins:

lA and 3A 4A and 5A 4A and 6A SA and 6A 5A and 7A 9A and lOA 12A and 13A

the

9. V.O.M. should show short circuit between each pair of pins.


11. LED's 2 and 3 on the PCB should light.

12. LED 2 on the PCB should go dark (LED 3 on only).

13. v.o.M. should show' short circuit between each pair of pins.

6202A, p. 5-21


Operation


2A and 3A 8A and 9A llA and 12A

15. Turn switch Sl to on position.


lA and 3A 4A and 5A 8A and 9A

17. Turn switch S2 to off position.


2A and 3A 4A and 7A 5A and 6A SA and 9A


lA and 3A 4A and 5A 9A and lOA

20. Turn switch Sl to off position.


6202A, p. 5-22

2A and 3A 4A and 6A 5A and 7A 9A and lOA 12A and 13A

Verification

14. V.O.M. should show open circuit between each pair of pins.

15. LED 1 on the PCB should light.

16. v.o.M. should show short circuit between each pair of pins.

17. LED 3 on the PCB should go dark (LED 1 on only).



20. All LED's on the PCB should be dark.


Operation


lA and 3A 4A and SA BA and 9A llA and 12A

23. Turn all three test switches to the on position.


lA and 3A 4A and SA 6A and 7A 4A and 6A BA and 9A llA and 12A


2A and 3A 9A and lOA 12A and 13A



23. LED's 1, 2 and 3 should light.



26. Turn on scope and attach probe 26. Scope should show zero volts. to pin 19A or TP3.

27. Turn on function generator. 27. LED's 1, 2 and 3 should be on. LED 4 should flash very rapidly (appears to be on steady). Scope should show a 60Hz pulse wave with a positive level at 5 Vdc and negative level at O Vdc. The positive pulse width should not be less than 3.5 milliseconds.

28. Turn off and disconnect all test 28. --equipment.

6202A, p. 5-23


5.2.6 FRC Serial Interface PCB N451441-7001


The FRC Serial Interface PCB test procedure (section 5.2.6.4) is divided into three parts. Steps 1 through 4 check the impedance of the "Rn relay and input circuit. Steps 5 through 9 check the contacts of the Master and Transmit relays. Steps 10 through 22 the interface to the Controller PCB, in conjunction with the circuits which convert relay level signals to logic level signals. A five volt power supply is used to simulate ~ine voltage, while a separate 12 volt supply provides system voltage.


Item

DC Power Supply (Qty= 2, Suggested Model: HP 62008):

Specifications

- 0 to 20 Vdc@ 0 to 1.5 amps.

v.o.M. (Suggested Model: Simpson 260) - Ohmmeter accuracy: ± 5% reading at center scale

- Resistance range: 0 to 10 megohms

Card Edge Connector Kit, 44-pin: - US&S N451170-1001

Toggle Switch (Qty= 2) - SPST or SPOT

5.2.6.3 Test Set-Up

a. Remove PCB from cardfile (power off).

b. Stand PCB vertically (mercury relay contact arrow up).

c. Connect test equipment according to Figure 5-5, but leave card edge connector disconnected from PCB.

d. Turn on both power supplies. Adjust #1 power supply to 5 Vdc + 1% and power supply #2 to 12 Vdc + 1%. Turn both supplies off.

e. Set switches Sl and S2 to the off position and attach card edge connector to the PCB. Do not turn on any test equipment until instructed in the test procedure.

6202A, p. 5-24


~-:_I_~-~-~_:_:'_,1~~:::::::::::::::::::::::::::::~+-~_A_:-::::::::{: ~ << 7A

S1 ON I o----c<; < 18A

["°:o: OFF I - <<22A

S2 _r,,. -

ON I Q.....---<< 21A

0-0FF I << 13A

I ------<~< 14A

I << 15A

I --<~<16A

I << 19A

POWER SUPPLY

#2 12VDC

I N451441-7001

(+)i------------------1.._---+---c,-<19B

I (-)t---------------------+---~~<22B

I NOTE: BOARD MUST BE SET VERTICALLY FOR OPERATION.

Figure 5-4. FRC Serial Interface PCB Test Set-Up

5.2.6.4 Test Procedure

Operation

1. Turn on both power supplies (Sl and S2 should be off).

2. Set SWl on the PCB to position 18 and read the ammeter.

3. Move SWl to position 29 and read the ammeter.

4. Move SWl to position 70 and read the ammeter.

5. Connect voltmeter leads on PCB pins 7A (+) and 4A (-).

1.

2.

3.

4.

5.

Verification

LED's 1 and 2 should be off, LED 3 should be on.

Ammeter should show 278 milliamps, + 20 % •

Ammeter should show 172 milliamps + 20%.

Ammeter should show 71 milliamps + 20%.

Voltmeter should show O volts.

6202A, p. 5-25


Operation

6. Move switch Sl to on position. 6.

7. Move switch S2 to on position. 7.

8. Move switch Sl to off position. 8.

9. Move switch S2 to off position. 9.

10. Connect voltmeter neg. lead to 10. pin 16A and pos. lead to pin 13A.


12. Move voltmeter pos. lead to 12. pin 19A.

13. Move switch Sl to off position. 13.

14. Move voltmeter pos. lead to 14. pin 15A.

15. Move switch S2 to on position. 15.


17. Move switches Sl and S2 to off 17. position.

6202A, p. 5-26

Verification

Voltmeter should show 5 Vdc, + 5%. Ammeter should show O -amps. LED's 1 and 3 should be off, and LED 2 should be on.

Voltmeter should show 0 Vdc. Ammeter should show O amps. LED's 1 and 2 should be on, and LED 3 should be off.

Voltmeter should show O Vdc. Ammeter should show 71 milliamps, + 20% • LED's 1 and 3 should be -on, and LED 2 should be off.

LED's 1 and 2 should be off, and LED 3 should be on.

Voltmeter should show 12 Vdc, + 2%.

Voltmeter should show O Vdc. LED's 1 and 3 should be off, and LED 2 should be on.

Voltmeter should show O Vdc.

Voltmeter should show 5 Vdc, + 10% • LED's 1 and 2 should be off, and LED 3 should be on.

Voltmeter should show O Vdc.

Voltmeter should show O Vdc. LED's 1 and 3 should be on, and LED 2 should be off.

Voltmeter should show 12 Vdc, + 2%. LED's 1 ano 2 should be -on, and LED 3 should be off.

Voltmeter should show O Vdc. LED's 1 and 2 should be off, and LED 3 should be on.

UNION SWITCH & SIGNAL ffi Operation Verification

18. Set SWl on PCB to position us. 18. Same results as step 17.

19. Set SWl on PCB to position #29. 19. Same results as step 17.

20. Move switch Sl to on position. 20. Voltmeter should show 12 Vdc, + 2% . LED's 1 and 3 should be -off, and LED 2 should be on.

21. Set SWl on PCB to position us. 21. Same results as step 20. ..

22. Turn off power supplies before 22. --disconnecting test leads.

6202A, p. 5-27

SECTION VI SUPPLEMENTAL DATA

UNION SWITCH & SIGNAL m 6.1 FCE-500 TO DDL-601BX UPGRADE PROCEDURE

6.1.1 General

This section provides a DDL-601BX station. been replaced with a unit is installed in

the procedure for converting an FCE-500 field station to In this procedure, it is assumed that the code line has

digital carrier system modem and that the field modem the equipment rack.

US&S provides FCE to DDL conversion kit X451584-1102. This contains a new PROM IC {containing the digital code system functions software), a new card file name plate and a new label for the inside of the card file front cover, identifying DDL-601BX card slots and the Controller PCB manually selected functions.

6.1.2 Procedure

CAUTION

MAKE CERTAIN THAT ALL POWER SOURCES ARE KEPT OFF UNTIL ALL UPGRADE PROCEDURES ARE COMPLETE, OTHERWISE EQUIPMENT DAMAGE MAY RESULT.

1. Remove the cable connectors from the Controller PCB and the FRC Interface PCB's.

2. Remove the Controller and FRC Interface PCB's from the card file.

3. Remove the PROM from IC26 and install the DDL-601BX PROM {N451575-0604) from the conversion kit.

-4. Reprogram all DIP and rotary switches on the Controller PCB for the new digital code system functions, according to the instructions in section 5.3 of service manual 6199.

5. Reinstall the Controller PCB in the card file.

6. Attach the modem interface cable to the modem and the Controller PCB. Refer to SM-6199 sections 4.3 through 4.5 for connector/cable assembly ordering/construction information.

7. Attach a new cable indentification tag to the connector on the Controller PCB. Refer to SM-6199 section 4.14 for tag instructions.

8. Reset the carrier control switches on the Controller PCB as follows: SWl to NORMAL, SW2 to OPERATE and SW3 to either position. This sets up the Controller PCB for normal modem communications. Refer to SM-6200, section 2.4.1.5 for test mode instructions using these switches.

6202A, p. 6-1


9. Apply the new card file plan label (kit, M451559-8301) to the inside of the front cover.

10. Attach the new code unit name plate in place of the existing FCE-500 plate.

11. Turn on code unit power and perform routine system start-up checks.

6.2 RECOMMENDED REFERENCE LITERATURE

The following publications provide additional data on the Controller PCB components:

M6809 Programming Reference Manual, Motorola Semiconductor Products, Inc.

Microprocessor Applications Manual, Motorola Semiconductor Products, Inc.

Motorola CMOS Data, Motorola Semiconductor Products, Inc.

Signetics Bfpolar & MOS Memory Data Manual, Signetics Corporation.

The TTL Data Book, Texas Instruments, Inc.

6.3 SCHEMATIC DIAGRAMS

This section provides the complete schematic diagrams for all FCE-500 plug-in printed circuit boards. Refer to Section III for operating descriptions and Appendix A for component specifications and part numbers.

6202A, p. 6-2

+5 +5 rczq

+5 CONNECTOR A

+5 011 TP16 ~ -12v I~

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+5

TP15

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I z 6821

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4 PAI PA2

6 PA3 PA4 PAS

q PA6 PA7 !CJ

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Jq CA2

RESET~ ENABLE ZS

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9 /REQUEST TO SEND <CAI

S I TRANSMITTED OAT A <BAI

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RI I -"IV

IM

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PR83510

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MARK ~ IIC20hll ~eT~ ~~ =:.--• 13 4011

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D451626-1601, Rev. 6

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R32 101<

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I R36 ~ ) 01 6J.qK 2N3q06 !/SW 2K ±Ir.

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l THR V+r+l2V R37 voo 21il.0K GNO I/SW ±1%

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CONT /IND BIT 3 / 4. a·

CONT/IND BIT 4 /5,E

CONT/IND BIT 5 /6,F

CONT /IND BIT 6 l7 , H

,CONT/IND BIT 7 /S,J

ADDRESS BIT 2 e ADDRESS BIT 2 l

ADDRESS BIT 2

ADDRESS BIT

ADDRESS BIT

DELIVER SET-UP

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~

SW4

SW5

SWG

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7 .--__,_.., swe

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m

Fi<liure 6-1. Controller PCB N451441-4305 Schematic Diagram

6202A, P• 6-3/4

ill

D451315-6601

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027

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Control Delivery PCB N451441-3601 Schematic Diagram

83

6202A, P• 6-5/6

p

,.

0085722-02, Rev. B

UNION SWITCH & SIGNAL m C~!;TOR

CDN!IISTOR

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u I · )

}SPAU

015 I I I TO l'LL PINS II I I IIIARKED +v 19,W

INPUT 22oG'1w I I 1 ,c,.,10N •• RlO I c33 011 C34 + c1s +

V I I I .001WD IN4007 4,7WD IMFO ..... 220 ,.

RJI 011 I I I I TO .. LL PINS " I IUIRKED ov u,z ••PUT I _J I

I NO Cl'TI Oii 15 I w ,---1------ I

29'X -· t---------,------µ IIOAllli....,-

10:L )---} ·• I I e,K _ _J IMttlHT O L

11 M )--- ~ .Y.. DENOTES COMPONENTS NOlE. i ' • Sl'ARE DELETED ON OOT;ED LINES ILL~RATE

21,Y )--- 1c,-1c• - TRI-STIITE STROBED HEX BUFFER/INVERTER UN0857ZZ-1011 INTERNAL CHIP c CTIONS +v (MOTOROLII MCU502CL OR EQUIVALENT)PIN 11- +v, l'IN I - ov ALL RESISTORS t/ WATT . ,ooK4>

22,z )---- 1cs-1c1 - I INPUT NANO 8 .. TE(ACI' C040H8F OR EQUIV .. LENT)l'IN ··- +v, l'IN UNLESS OTHERWISE ~l'EctFIEO, lCl - QUl'D EXCLUSIVE OR GATE(MOTOROLI' MCl4507CL) l'IN 14- +v PIN 7

11CI-OCII - OPTICAL COUPLER(CL"I REX CL 1-10 OR EQUIV .. LENT) '

Figure 6-3. Transmitter-Opto PCB N058722-1001 Schematic Diagram

6202A, P• 6-7 /8

~

, I

0451626-5901, Rev. 1

CONNECTOR "A"

IT:>~ I I

. I I I I I I I I I I

7 LINE 2

VI VISOZA8

vz VISOZA8

C2 I .033 IED

Cl .033 IED

Rl2 47 OHM 112 W

I XMT

RLY I

LEO 3 XMT

~---W lie! +12V

XMT DATA 21 -I I I I I I 1, I I --.. COIMlN MOOE

•• I I I ~ COIMIN MOOE FEED

~ ~

XMT J f +12V

RLY I

DI

IN4003

LED 2 CllNNECT

I I I I I I I I I

~---"W (1el +12V

Al: ::::-,.._RED. TO SEND RI. 1 r 20 _;, 'VI,,._. -·--HI-·

I I I I I I I I I I I I TP4

I ~R-IN

I I I I ·~ l

TP5

Rl4

IOK

n3 IW

R9 IOII.

C3 * 0,4 J .5 11'0 I N4003

aNIECT

' C=:J f •12V RLY 4

D3

IN'4003

......._

+SY

Rl6 511(

M

CONNECTOR •A•

R 1+1 .----1------------i 4

R 1-1 '-------------6-----------l 5

LED I loll

~ +12Y

\\

loll

CJ T +12V

RLY 2

02 -Mo--

IN4003

.... c: RLY 3

+SY

~·sv

II

UNION SWITCH & SIGNAL m CONNECTOR ''8"

I / •SY

I ibzf D6f •1cs 1c1 330° 1N751 T JO T .OJ TP2 I ~4W 11'0 ll'D

>-----<~-+---.---... ----t-----1----+------.... ----~+12v

I I I I I I

D5 IN4003

+ C4 10 11'0

C6 .01 11'0 TPI

~~~~t--~_._~--~~--~--~-----~~--+~~--,

CONNECTOR "A"

XMTIT. I RLY I I

I

L------i2

L-------t3 I I I I

... JT RLY 3 I

I

-------110

'-----------i9 I

TP3 CONNECTOR "A" I I I

REC DATA ">--..... --...... -------ll9

CONNECT~

9

Rl7

IM 7

NOTE: I RI L6' 7, I 8, 19L20 J 21 SHOWN ON ASSEMBLY, ARE "Zt.RO OHM" Rt.SI S !ORS, < MOULDED JUMPERS I AND ARE ~OT REPRESENTED ON SCHEMA Tl C. :

RLY 4 I I I

------....113

~---------ll2

Figure 6-4. FRC Parallel Interface PCB N451441-6801 Schematic Diagram

6202A, p. 6-9/10

CONNECTOR "A"

I I

V2 Vl50LAIOA

COIMJN MODE

B BAT

C6 .001 II'

N BAT

D451626-6201, Rev. 1

RIO 33 OHM ~w

cs .001 II'

Rl3 IOK

TP2

TPI

03

RLYI ''R"

R4

50 OHM SW

R5

25 OHM SW

ov

RII IK IW

R3 Cl

33if:M RLY2

.001 II'

C3

.001 II'

"XMT" LEDi

~\

+12V

RLY3 +

:J I +12V

XMT

DI ........ IN4003

"M" LED2

~----'llv-------1-""..-----•12V

R8

IOK

RLY2

I---<>----- +I 2V

IN4003

+J_c7 1.5 II' °" IN4003

RI 33 OHM ~w

C2 .001 II'

ov

RLY3 11XMT"

•5V

Rl6 SIK

R'J 33 OHM ~w

C4 .001 II'

Rl4

IM

VI V150LAIOA

1-

CONNECTOR "A"

+5V

CONNECTOR "B" I I I I


..-----------9-----+----o----------•SV

Rl7 330 OHM

1& •i.c10 lN751 TIOII'

c, .01 II'

TP4

+12V +12V

D5 1 IN40~3

ca .01 II'

CII 10 II'

TP5

2::>--<P---+---,--+-----0----__.-----+-----..-----<1,----~0V DC COINON

''REC" LED3

6 R~ (1.i) I •5V > IK \\

TP3

CONNECTOR "A"

Figurl: 6-5. FRC Serial Interface PCB N451441-7001 Schematic Diagram

6202A, p. 6-11/12

D451315-5701, Rev. 7

~ PINS

I ,2

.. ,B

,,1 F,H

?. AMP ON • ISOZ. . S.AMP ON-\501 e.-~ LI

>-~~~-·sw•r-~~~ ... 11-~.-~--<1'""°"~~~~~~.....,

1, 20V TO J2V DC

ll'fl'UT R .. 'MiE Oii ·130\

Fl

IN•OOJ 02

"Ir INPUT IU.MG,E FOR ·'1301. .. ,UO\I ~V TO l&IIOC.

,o, TA"NSZOfll8 f.5K lt ..

'"'" C!!.+ .,

- uoow "T sov

Ctt_+

~UMF .. T

200V

f I I O+ I

INl'UT

INNIT

INPUT

1'$1 +sv Dc

CONV£RTER

1'82. +12v DC

CONVERTER

OUTPUT

UNION SWITCH & SIGNAL EB

~ ~.

I I PINS l'IN8

Tl'I ,------------------------------------------------~11,T

O I ,•sv Dc , +sy pc >"•'T _ p . T,U

Tl'2 .------------------------------------------~zz,z I ' ,ov ,, ov DC )21,22 9 f , Y,Z

Tl'1if-+0 I , I ,•rivDc I' +uvoc )"•20 - - ·~ ,-------------------------------------------------j ,,,v

OUTl'UT

l'SJ. ·IIV DC

CONVERTER

' OUTPUT O N/C

-<? I Tl'4.. ·I 2V DC ) 1,10 ' '·UV DC ' K,L

,---------------------------------------------~-.·

Figure 6-6. Power supply Converter PCB N451441-3303 Schematic Diagram

6202A, p. 6-13/14

..

September. 1985 A-09/85-250-2777-1 ID0038F. 0043F

PRINTED IN USA

SERVICE MANUAL 6202A Appendix B

FCE-500

Auxiliary Equipment Parts List

and

Application Guide



B.l L-10 RELAY, SHELF AND RACK MOUNTING (See Figure B-1)

. Item Qty Description US&S Part No • Remarks

L-10 Relay

1 1 L-10 Relay N234555 1 L-10 Relay N234555-001 -Alternate option:

Arranged for plug con-nection.

2 1 Guide Pin -Part of N234555-001: Prevents reverse inser-tion of plug connector. ..

Shelf Mounting

3 2 Mounting Hole -use U2 screw or bolt for mounting.

Rack Mounting

4 2 Mounting Hole -Use 1/4• screw or bolt for mounting.

Plug Connector

5 1 Plug Connector N228747

6202A, p. B-2


FRONT VIEW SIDE VIEW

Figure B-1. L-10 Relay Mounting

6202A, p. B-3


B.2 DN-11 RELAY, SHELF AND RACK MOUNTING (See Figure B-2)

Item Qty Description US&S Part No. Remarks

DN-11 Relay

1 1 DN-11 Relay N262767 -Option: Slow release relay with 1500 ohm coi and shock absorber Nl72589.

1 DN-11 Relay N309382 -Option: Norma 1 action relay with 2000 ohm coi and shock absorber Nl72589.

Shelf Mounting

6 4 Mounting Hole -Use UO screw or bolt for mounting.

Rack Mounting

2 2 Mounting Bracket Ml99781 3 1 Mounting Hardware N338692 -For mounting bracket to

shock absorber.

4 2 Mounting Hole -use 1/4• screw or bolt for mounting.

Plug Connector

5 1 Plug Connector Nl08879

6202A, p. B-4

SIDE VIEW

FRONT

UNION SWITCH & SIGNAL EE

TOP VIEW

1--- 3-1/2" --ti

FRONT

TOP VIEW OF RELAY

----------------·-·- ... -· -- ·-·

Figure B-2. DN-11 Relay Mounting

6202A, p. B-5


B.3 DN-22 RELAY, SHELF AND RACK MOUNTING (See Figure B-3)


DN-22 Relay

1 1 DN-22 Relay N234820 -Option: Slow release relay with 1500 ohm coil and shock absorber Nl85129.

1 DN-22 Relay N316906 -Option: Norma 1 action relay with 2000 ohm coiJ and shock absorber Nl85129.

Shelf Mounting

2 4 Mounting Hole -use ilO screw or bolt for mounting.

Rack Mounting

3 2 Mounting Bracket Ml99781 4 1 Mounting Hardware N338692 -For mounting bracket to

shock absorber.

5 2 Mounting Hole -Use 1/4• screw or bolt for mounting.

Plug Connector

6 1 Plug Connector N222405 -With front connector N222100, right side connector N222181 and left side connector N222182.

6202A, p. B-6

FRONT SIDE

-11-1/S"f-

l ~ """----7-5/8"--1\~

SIDE VIEW ©


,...__ 3-13/16" --f . V§) @ [¢i].--©

©

LEFT

FRONT TOP VIEW

14----4-1/4"--....

r 4"--.i

FRONT

TOP VIEW OF RELAY

Figure B-3. DN-22 Relay Mounting

6202A, p. B-7.


B.4 PN-150/250 RELAY, SHELF MOUNTING (See Figure B-4)

Ite1t Qty Description US&S Part No. Remarks

PN-150/250 Relay

PN-lSOBE Relay N322513-003 -Normal acting with 2000 ohms coil.

PN-lSOBE Relay N322521-002 -Normal acting with 2000 ohms coil.

PN-250BE Relay N322550-706 -Normal acting with 2000 ohms coil.

PN-250BES Relay N322550-707 -Normal acting with 2000 ohms coil.

Relay Bracket

1 1 Single PN-150 Bracket N373826 -With terminal block.

Single PN-150 Bracket N373904 -Without terminal block.

2 1 Double PN-150 Bracket N373828 -With terminal block. or Single PN-250 Bracket

Double PN-150 Bracket N373914 -Without terminal block. or Single PN-250 Bracket

Base

3 As Reg. PN-150 Base N451376-0301 -Base only. As Reg. PN-150 Base N451376-0302 -Base with hardware.

4 As Reg. PN-250 Base N438689 -Base only, latch facing right.

As Reg. PN-250 Base N438689-001 -Base with hardware, latch facing right.

As Reg. PN-250 Base N438689-002 -Base only, latch facing left.

As Reg. PN-250 Base N438689-003 -Base with hardware, latch facing left.

Contact Springs (Reference only)

5 As Reg. AWG U4/U6 J680195-0001 -Mounting.base shipped with full complement

As Reg. AWG UO/U2 J680195-0002 As Req. AWG US/122 J680195

Crimping Tool (Reference Only)

6 AWG U4/U6 J397139 AWG UO/U2 J397138 AWG US/120 J397188

6202A, p. B-8

'if ! I


0 C A g, 1g

g2 2g G-~--+1 i + + +: I+ + + I

L-t:.-=!: --~

0

F E D C B A

0

1gggggg1 sgggggga gggggggg ,ogggggg,o 11gggggg,, 12gggggg,2

F E D C B A

0 0

.. F'igure B-4. PN-150/250 Relay Shelf Mounting

6202A, p. B-9


B.5 PN-150/250 RELAY, RACK MOUNTING (See Figure B-5)


Universal Equipment Rack

l l 31• Universal Equipment R344876 Rack

2 l 20• Universal Equipment R37ll 74 Rack

Mounting Bar

" 3 l Relay Bracket X341594-001 -For 31• rack. Bar M381334 -Ref. only. Bolt, s/16•-ua x 1-114• J046089 -Ref. only. Nut, 5/16•-ua J048195 -Ref. only. Clamp M381298 -Ref. only. Washer, 3/a• J047052 -Ref. only.

4 l Relay Bracket X341564-001 -For 21• rack. Bar M381333 -Ref. only. Bolt, 5/16•-ua x 1-1/4• J046089 -Ref. only. Nut, s/16•-na J048195 -Ref. only. Clamp M381298 -Ref. only. Washer, 3/a• J047052 -Ref. only.

Base

5 As Req. PN-150 Base N451376-0301 -Base only. As Req. PN-150 Base N451376-0302 -Base with hardware.

6 As Req. PN-250 Base N438689 -Base only, latch facing right.

As Req. PN-250 Base N438689-001 -Base with hardware, latch facing right.

As Req. PN-250 Base N438689-002 -Base only, latch facing left.

As Req. PN-250 Base N438689-003 -Base with hardware, latch facing left.

Contact Springs (Reference only)

7 As Req. AWG tl4/U6 J680195-0001 -Mounting base shipped with full complement

As Req. AWG UO/U2 J680195-0002 As Req. AWG U8/t22 J680195

Crimping Tool (Reference only)

8 AWG U4/U6 J397139 AWG UO/U2 J397138 AWG U6/t20 J397188

6202A, p. B-10

"

II) SUPPORT BARS

3 4

\ 1 2

I J 6

8


0

+ +: I

+ + I

L~.-=! __ + i

1Qgg1 eggge gggge 1ogggo 11ggg1

~2

0

F E D C B A 1gggggg1 sggggggs 9gggggg9 10gggggg,o 11gggggg,, 12gggggg,2

F E D C B A

0 0

5

Figure B-5. PN-150/250 Relay Rack Mounting

6202A, p. B-11


B.6 CAPACITOR/RESISTOR UNIT, SHELF OR RACK MOUNTING (See Figure B-6)

• Item Qty Description US&S Part No. Remarks

capacitor/Resistor Unit

1 1 Capacitor/Resistor Unit N266187

Shelf or Rack Mounting

'' 2 5 Mounting hole -use 1/4• screw or bolt

for mounting.

SIOEVIEW I

Figure B-6. Capacitor/Resistor Unit Mounting

6202A, p. B-12

I

'

UNION SWITCH & SIGNAL ffi B.7 CODE LINE LIGHTNING ARRESTER (See Figure B-7)


Code Line Lightning Arrester (USG-A)

1 3 Code line lightning N451522-0201 arrester USG-A

Mounting

2 2 Mounting block N451522-0303 -Mounting block comes with hardware required to mount USG-A arresters

3 2 Mounting holes -use 1/4• screw or bolt for mounting.

Figure B-7. Code Line Lightning Arrester Mounting

6202A, p. B-13


B.8 CODE LINE FILTER, SHELF OR RACK MOUNTING (See Figure B-8)

Item Qty Description

Code Line Filter

1 1 Code line filter

Code line filter

Code line filter

Shelf or Rack Mounting

2 4 Mounting hole

------10-1/8"--------SIOE VIEW

US&S Part No. Remarks

N237446 -Option: Code line filter without de blocking capacitor and without carrier blocking reactor.

N235113 -Option: Code line filter with de blocking and without carrier blocking reactor.

N235112 -Option: Code line filter ~ de blocking capacitor and with carrier blocking reactor.

-Use 1/4• screw or bolt for mounting.

TOP VIEW

·r-------- - - --------. I

1 0000000' I I

., 00000 I ® rij\ I 00000\.:V 'm · O I 00000 ®00000®

0000000: I - --- --- -·- -- -- -- -- --.J·

T :.

l Figure B-8. Code Line Filter Mounting

6202A, p. B-14

\

UNION SWITCH & SIGNAL El3 B.9 P-4 TYPE RELAY, SHELF MOUNTING (See Figure B-9)

Iten: Qty Description US&S Part No. Re:nark s

P-4 Type Relay

1 1 P-4 Relay with 1900 N216112 Without plug connector coil

2 2 Mounting hole Use il2 screw or bolt

3 1 Plug Connector Nl09134 .

2

2

Figure B-9. P-4 Type Relay

6202A, p. B-15

~

J

r

September, 1986 . A-09/88-260-2777-1 ID0038F, 0043F

PRINTED IN USA

SERVICE MANUAL 6202A Appendix A

Parts List

for

FCE-500 Field Code Emulator System



A.l CARD FILE ASSEMBLY (See Figure A-1)

Item

1 2 3 4 5 6

7 8 9

10 11 12 13 14 15 16 17 18 19

6202A, p. A-2

Description

Complete Unit, SOZA System Complete Unit, 504B or 504C System

Enclosure, Printed Circuit Board Angle, Right Hand Angle, Left Hand Angle, Mounting Plate, Filler Board, Terminal, 502A System

• n 504B or 504C System Angle, Mounting Back Screw, 10-32 x 5/8, Flat Head Washer, #10 Lock, Steel Nut, 10-32 Hex, Steel Screw, 10-32 x 3/4 Fil. Hd. Washer Foot, Card File Mounting Screw, 10-32 x 1/2 Panhead Fastener, Self-Clinch Terminal Strip Screw, 6-32 x 3/8, Fil. Hd. Washer, #6 Lock Nut, 6-32 Hex, Steel

US&S Part No.

N451583-1301 N451583-1401

N451583-0304 M451584-25 01 M451584-2502 M451584-1401 M451584-2503 N451583-1201 N451583-1101 M451584-1801 J052092 J047733 J048172 J052298 M044618 M451584-1901 J507267 J560865 J731399-0033 J052242 J047662 J048148

UNION SWITCH & SIGNAL m 16

I ~ -f + -t ~r:lt::H::Jot:rt:tane:r .. -,~, -" .. ~nl~lt~:l-t~r.".":s-~'-'~-:-.. ~-~~":-=~

1

9, 10,14

13

16, 17, 18, 19

2

Figure A-1. FCE-500 Card File Assembly

F451583-13, Rev. 0 (502A)

F451583-14, Rev. 0 (5048/C)

. I

6 9, 10, 11,12

_________________________________ ..,,.._

: :e ____ &-_0_ e---- e-0 -e:: . I

I

I

I

-~·~•~•••s•••••••••••••••••••• ~ :e e e e ~ G>: ~ .. ------------ ............................... - ..

4

6202A, p. A-3

83 UNION SWITCH & SIGNAL

A.2 CONTROLLER PCB N451441-4305 (See Figure A-2)

Item

I Cl IC2, 3 IC4, 5 IC6 IC7 IC8 IC9, 10, IC12, 13 IC14, 15

11

IC16, 17, 18, 19 IC20 IC21 IC22 IC23, 24 IC25 IC26 IC27 IC28 IC29 IC6, 26 IC4, 5 ICl, 2, 3 IC12, 13 IC28 XTAL l Cl, 2 C3, 4, 5, 6, C7 - 21, 26 C22 - 25 LEDl - 7 Dl - 5 D6 - 11 RLY l SWl, SW2, SW6, SW7, SW4, SW5 Rl R2 R3 - 9 RlO, 11 Rl2, 13, Rl4 - 17, Rl8 - 26 R33 R34 R35 R36 R37 RN2 - 6 RNl RN7

SW3 swa

27 28 - 31

TPl - 16 STATION ADDRESS STATION ADDRESS SW6, 7, 8 Ql

6202A, p. A-4

Description

MC6809 Microprocessor IC Peripheral Interface Adapter IC Programmable Timer Module IC Random Access Memory IC l of 8 Decoder IC Triple, 3-Input NAND Gate IC Octal Transparent Latch IC Bi-directional Interface Level Converter IC CMOS Noninverting Hex Buffer IC CMOS Inverting Hex Buffer IC Quad, Two-Input NAND Gate IC CMOS Triple Gate IC Retrig/reset. Monostable Multivibrator Dual, EIA Line Receiver IC Triple EIA Line Driver Programmable Read Only M~mory IC 4-Stage Parallel In/Out Shift Register IC Programmable Voltage Reference Optical Isolator 24-Pin Socket 28-Pin Socket 40-Pin Socket DIP IC Socket Insulator, Converter Crystal, 4.000 MHz Capacitor, 27 PF, 500 Vdc Capacitor, .01 MFD, 100 Vdc Capacitor, .1 MFD, 50 Vdc Capacitor, 10 MFD, 35 Vdc Light Emitting Diode 5082 Diode, 1N4003 Low Volt Transient Suppress. Diode, 1N5908 Relay SPDT Toggle Switches DIP Switch, a-Rocker Rotary Switch, Coded a-Position Resistor, 200K ohm, 1/4 W Resistor, 51 ohm, 1/4 W Resistor, lK ohm, 1/4 W Resistor, lM ohm, 1/4 W Resistor, 5.lK Ohm, 1/4 W Resistor, !OK ohm, 1/4 W Resistor, lOOK ohm, 1/4 W Resistor, 2.2K ohm. 1/4 W Resistor, 2K ohm, 1/4 W Resistor, 6.8 megohm. 1/4 W Resistor, 61.9K ohm, 1/8 W Resistor, 20.0K ohm, 1/8 W Resi~tor Network, 3.3K ohm Resistor Network, lOOK ohm Resistor Network, lOK ohm PCB Ejector w/Pin Test Point Pin Socket Strip Jumper Pin Cover, DIP Switch Transistor, 2N3906

US&S Part No.

J715029-0321 J715029-0246 J715029-0244 J715029-0335 J715029-0334 J715029-0333 J715029-0332 J715029-0337 J715029-0l30 J715029-014l J715029-0097 J715029-0264 J715029-0310 J715029-0259 J715029-0258 N451575-0616 J715029-0l82 J715029-0354 J715029-0l 74 J725840-0003 J725840-0002 J725840-0001 J725840-0014 J780033 J709242-0009 J706936 J709145-0166 J709145-0330 J706625 J726150-0062 J723555 J792736-0006 J726211 J725707-0l35 J725707-0211 J725707-0210 J735519-0227 J735407 J735031 J735300 J735301 J735053 J735137 J735237 J735048 J735519-0063 J735519-0242 J723794 J735519-0338 J735519-0513 J735519-0546 J560839 J703175 J703364 J713795 J776674 J731398-0034

UNION SWITCH & SIGNAL EEi

F451441-43, Rev. 6

MICROPROCESSOR CONTROLLER PCB. RL~ N451441-43 REV,

{B.

RN4

RN3

::L J SWT LJ

;:,

0 f 1 n.

.. .. ::L Ju

SW4 SW6

1 "l

L _J sws

RN2 .

n·

~ I

?

?

?

1 "l RN5 f L _J u

RESET s --, [

NORMAL L --' SWI

ON s --, [

OPERATJ0- --' SW2

MARK s --, [

SPACE L --' SW3 R27

{ }

f

~nl uu? I

.J '-'U •

!CT

JC26

lC6

[Cl I

lCIO

lC9

!CS

IC4

lC19 lC20

1 I 1 [ J <I

? .e20} ~2 } .A

ICI

1 J

:E~I 0 a:

J

1 "-~ lOT ] "'n { J.:;fd2 { }

J 06 [ ]

09 [ ] 1 -n

uU

J

... "'n cu

1

J

? RIB

?

Rl6 L,J

J

TP6Q { } []C6

!Cl8 R•9 co;n

1 ~ J, J

TP7 lC25

0 !Cl 4

~ ? 1

J

rPeOj29} IC23

JC24

1

J

ICIS

TPI 4

J O

0 ... - -N - N a:t

Q 0:: 0 0:: 0

0 ..r F=l'", F=l,..., F=l N a:

[ J L,J L.J L,J L.J L,J L.J C26

"' N u

J {a:} "'

;;:O 1 ... ,-;-

RI 7 { }

1

J

J uu lC21

? 1

1 J

lC3

n.., uc

1

zv,~ l~~cr> ... N-J

OVI O lC27 R28 ...... ~a: ctQ ~o { } .,, ...

RI 3 : : { }

• -,._r-

RN7 RNI [ ]C7 . n . n· --.....,--

n"' tc16 Uu

N

u

J '-- _, u u Q TP13

'-----'

TPS O l 1\

[Jes . --.....,--1

R31 { } ,uo { }

• -,._r-

!Cl 3

1 IC! 7

J '-- _, Rl2 { } R26 { }

1 .,. R25 { }

~ ~ TP3 ~ + u O u nnnT~4 J

"' ... ..,

r

l

x

TPt ___j

o~ lC2 ~ ::i ::i LJ ,.., ..., 1=v=i_

UUU LJ LJ t;:J" L,Jo Yo

0 + TP2

Figure A-2. Controller PCB N451441-4303 Component Layout

(i202A, p. A-5


A.3 CONTROL DELIVERY PCB N451441-3601 (See Figure A-3)


RYl - 16 Relay, Mercury Wetted J72615 3-0070 !Cl, 4, 9, 14 Hex Buffer Inverter J715029-0141 IC2, 3, 7, 8 Quad Latch J715029-0149 IC5, 10, 13 Resistor Network, lOOK Ohms J735519-0254 IC6 Triple, 3-Input NAND Gate J715029-0104 ICU Quad Exclusive OR Gate J715029-0121 IC12 Dual, 4-Input NAND Gate J715029-0ll5 Rl, 2, 3 Resistor, 2K ohm, 1/4 W J735048 R4 Resistor, 390 ohm, 1/2 W J720763 Cl capacitor, • 01 mFd, 100 Vdc J709145-0166 C2 Capacitor, 10 mFd. 20 Vdc J706373 C3 - 34 Capacitor, .001 mFd, 3000 Vdc J709145-0359 Dl - 20 Diode, 1N4003 J723555 Ql Transistor, 2N4234 J731327 LEDl, 2 Light Emitting Diode J72615 0-006 2 TPl - 27 Test Point Pin J703175 Ql Transistor Mounting Pad J792072

6202A, P. A-6

F451441-36

C20 = C22 = C24 = C26 = C28 = C30 = C32= C34 = C1 9 _ C21 - C23 - C25 - C27 _ C29 - C31 - C33 -

a: Ill > ... _, :!:

er >_, a:

~ -Ill O -Ill O -Ill O -Ill ! -Ill :; -Ill ! -Ill g -Ill .. Ot .. 0 ...... N .. .., ...... .,, .. • -0

.. N N N N N N O N O .. In 'lo I'- e0at O ON ffl O In lO ~

_.., __ ...... NNNN .. NNN 0.-0. 0. .. 0. 0. 0. 0. 0. 0. 0. N 0. 0. ... I!: ... ... I!: ... ... ... .... .... .... .... I!: .... .... I!: .. -0. .... ]

CJ TP10

TP9

TP8

TPT

TP8

TP!5

TP4

TP3

TPZ

j I J 1 1 IC4 IC9 IC14

N 0 Ill ..J

CJ .. en 0111 111111 ..JII:

Q Q ,c

TP1

I ] I 1 • 1C3 • JC8

I 1 I J • 1C2 • 1C7

j 1 ] IC6

I ] • ICS

CONTROL DELIVERY UN451 441 -3601 REV.

] • lC13

I J • 1C12

f 1C11

1

• IC10


Figure A-3. Control Delivery PCB N451441-3601 Component Layout

6202A, p. A-7


A.4 TRANSMITTER-OPTO PCB N085722-1001 (See Figure A-4)


OCl - 16 Optical Isolator IC J715029-0174 ICl - 4 Strobed Hex Inverter/Buffer IC J715029-0192 IC5, IC6 8-Input NAND Gate IC J715029-0151 IC7 Quad Exclusive OR Gate IC J715029-0121 Rl - 32 Resistor, 220 Ohm, 1 W J721155 R33 - 48 Resistor, 150K Ohm, 1/4 W J735040 R49 - 64 Resistor, 22K Ohm, 1/4 W J735093 R65 - 77 Resistor, 2.2K Ohm, 1/4 W J735237 R78 - 88, 66 - 76 Resistor, lOOK Ohm, 1/4 W J735137 Cl - 16 capacitor, .1 mFd, 200 Vdc J706827 C17 - 32, 35 Capacitor, 1 mFd, 35 Vdc J706387 C33 Capacitor, .001 mFd, 500 Vdc J706242 C34 Capacitor, 4.7 mFd, 35 Vdc J706422 Dl - 17 Diode, 1N4007 J723912 D18 - 33 Diode, 1N5368B J726150-0045 D34 - 49 Diode, 1N5305 J726150-0103 LED 1,2 Light Emitting Diode J72615 0-006 2 TPl to TP38 Test Point Pin J703175

6202A, p. A-8

UNION SWITCH & SIGNAL m F085722-0004, Rev. 10

:;: "'r-' C::J c .

tll -tt-;

__ ;:; __ I __ ~--~~0 .l~:" :;. ~

UN085722-1001 0£ ~~o~==::J I\::: TRANSMITTER OPTO INTERFACE v ..

(5 ] + :: ;!;

I .. : ft ::::i c f u.u ..

Figure A-4. Transmitter-Opto PCB N085722 Component Layout

6202A, p. A-9


A.5 FRC PARALLEL INTERFACE PCB N451441-6801 (See Figure A-5)


RLYl, 2 Relay, Mercury-Wetted Contact J726153-0106 RLY3, 4 Relay, Mercury-Wetted Contact J726153-0070 !Cl Optical-Coupler IC J715029-0174 IC2 Hex, Buffer/Inverter IC J715029-0141 Ql, 2 Transistor 2N6387 J731398-0065 Rl, 6, 7, 15, 18 - 21 •zero-ohm• Resistor (Jumper) J582510 R2, 3, 4 Resistor, 2K Ohms, 1/4 W J735048 R5 Resistor, lK Ohm, 1/4 W J735031 RS, 9, 14 Resistor, lOK Ohm, 1/4 W J735053 RlO, 11 Resistor, 5. lK Ohm, 1/4 W J735301 Rl2 Resistor, 47 Ohm, 1/2 W J721189 Rl3 Resistor, lK Ohm, 1 W J720851 Rl6 Resistor, 5 lK Ohms, 1/4 W J735067 Rl7 Resistor, 1 Megohm, 1/4 W J735300 R22 Resistor, 330 Ohm, 1/4 W J735060 Cl, 2 capacitor, .033 mFd, 400 Vdc J709145-0172 C3 Capacitor, 1.5 mFd, 35 Vdc J706421 C4, 5 capacitor, 10 mFd, 29 Vdc J706373 C6, 7 Capacitor, .01 mFd, 100 Vdc J709145-0166 LEDl - 4 Light Emitting Diode, Red J726150-0062 Dl - 5 Diode 1N4003 J723555 D6 Diode 1N751A J723747 Vl, 2 Metal Oxide Varistor J735544 TPl- 5 Test Point Pin J703175

6202A, p. A-10

UNION SWITCH & SIGNAL ffi F451441-68, Rev. 1

RL Y I RLY 2

Cl C2

DI -a: }- 02 -a: }-LEO I -c }- -c }-

RLY 3 RLY 4 c~ RI R6

-c }-11 J! !

II R2 0 0 LEO 2 c~ -c }- -{ } Rl3 r CONNECT R3 -c }- Rl4

LEO 3

[ ~ C3 Q TP3 c~ -c }-XIIT R4 ..... -c :0-LEO 4 R7 I 11

04 a,

c~ z"' -(RS}- 02 01

y -a: }- ~:,:

REC r-i r-i 03 -c "'"' }- .,. , .. -RIS .......

? 1 _.., ,,..-

l.__l ..... ..... l.__l ....

J ... ... yy ' ICI

... g; L "' ..... :? ..... 1

..... ..... RIS J y y RIO RII

y y .... "' IC2 ii ii .....

Rl9 y

..... 1!20

y

> u.J 0::

u.J u-<x:O w... co 0:: <.D u..l I ...._ -::z: """" -= ... ... u Lt,

a:

0:: """" R21 "' .. w... ::z: u .., ..... -c }-

+ri, ri,+"' .... ® 0 0 .....,

m ii: ~ t; ~ RR

_J 6 ... ,..,,..,LJ LJ....., y O L.J L.J

Figure A-5. FRC Parallel Interface PCB Component Layout

6202A, p. A-11


A.6 FRC SERIAL INTERFACE PCB N451441-7001 (See Figure A-6)

Item

RLYl RLY2, 3 IC! IC2 Ql Rl, 2, 3, 9, 10 R4 R5 R6, 7 RS, 13 Rll Rl2 Rl4 Rl5 Rl6 Rl7 VI, 2 DI, 2, 4, 5 D3 D6 LED! - 3 SWl Cl - 6 C7 cs, 9 ClO, 11 TPl- 5 Ql Ql QI

6202A, p. A-12

Description

Relay, Mercury-Wetted Relay, Mercury-Wetted Contact Hex, Buffer/Inverter IC Optical-Coupler IC Transistor 2N63S7

33 ohms, 1/2 w 50 ohms, 5 w

25 ohms, 5 w 2K Ohms, 1/4 W !OK Ohm, 1/4 W lK Ohm, 1 W 5 • lK Ohm, 1/ 4 W 1 Megohm, 1/ 4 W lK Ohm, 1/4 W 51K Ohms, 1/4 W 330 Ohm, 1/4 W

Resistor, Resistor, Resistor, Resistor, Resistor, Resistor, Resistor, Resistor, Resistor, Resistor, Resistor, Varistor Diode 1N4003 Diode 1N4007 Diode 1N751A Light Emitting Diode, Red Switch, Toggle Capacitor, .001 mFd, 500 Vdc Capacitor, 1.5 mFd, 35 Vdc Capacitor, .01 mFd, 100 Vdc capacitor, 10 mFd, 20 Vdc Test Point Pin Screw, 16-32 x 5/16 Nut, 16-32 Hex Washer, 16 Lock

US&S Part No.

J726153-0123 J726153-0070 J715029-0141 J715029-0174 J73139S-0065 J721247 J072332 J576792 J735048 J735053 J720851 J735301 J735300 J735031 J735067 J735060 J735541 J723555 J723912 J723747 J726150-0062 J725707-0038 J70299S J706421 J709145-0166 J706373 J703175 J525030 J048148 J047713

UNION SWITCH & SIGNAL ffi F451441-70

r RI R2 n { } { } [ ] C2 ,-1.., [ J

R3 VI

Cl [ J [ } [ ] C3 '-r' LJ I C4

q9

RU3j I RLY2 I I RLYI I XMT lot R ,...L, nn

·~ ..,.....

LJ LJ RIO cs Y2

C6 n

TP2 0

n n 01 02 RI I LJ -<I: J- -<I: J- -0:: ]- [ J 03

-c J- -c ]-R6 TP3 0 R7

LJ LJ 1112 -{ J-

0 Rl3 -{ J-R4 RS TPI

I

[ J N ,c

QI

r1i r1i n 1114 -c J-

y l;:I RB 04 v ? IC2 l ?o 1

XIII' O J J c :;J LEDi +c1 0 0 ICI

lot c :;J LE02 Rl6

REC -c J- 1115 -{ J-

C:;J LED3

.... oi u ... ... a: .... .... z + + :§ - "' "' Ao t,= ~";'" ii 0 0

a:-........ .,, .... ... "' ,.,., R Fl u u

u~> u u

:!:1:~ [] [ l y y y L,J L,J

L ®

_f ~ ot ...

Figure A-6. FRC serial Interface PCB Component Layout

6202A, p. A-13

UN10N SWITCH & SIGNAL

A.7 POWER SUPPLY CONVERTER PCB N451441-3303 (See Figure A-7)

Item Descriotion US&S Part No.

RI Resistor, 510 Ohm, 1/4 w J735159 R2, 3 Resistor, l.2K Ohm, 1/4 W J735042 Cl capacitor, 2000 mFd, 50 Vdc J709145-0350 C2 Capacitor, 0.47 mFd, 200 Vdc J706152 D2 Diode, 1N4003 J723555 Dl Transient Voltage Suppressor 37.1 J792736-0002 LED I, 2, 3 Light Emitting Diode J726150-0062 PSI 5 Vdc output Power Supply Converter J709557-0004 PS2, 3 12 Vdc Output Power Supply Converter J709557-0005 Fl Fuse Clip J576794 Fl Fuse, 5 amp, 32 Vdc J710040 SW! Switch Mounting Bracket M451563-1401 SWl Switch ON/OFF Plate J718014 SW! SPST Toggle Switch J725707-0051

6202A, p. A-14

"

F451441-33, Rev 7

r ......

::;

\

::: + .. _ ..

rl .J,3

, LJn -. .... >

LJ ........ --.... > z 0.., u.., u..:. =· • o-.... "' • u z

.....J = =

8 m

~ I ::

[ J .. .. CJI L[.] L

;:;

... .. I

... .. ..

L ·I

:: + .. .. ...

L I

_J

:; + ;;; ...


: I

n~·[b LJ= .. - .. --· c •• .. :::

_) Figure A-6. Power Supply Converter PCB N451441-3303 Component Layout

6202A, p. A-15


A.8 FCE STORAGE UNIT AND CABLE ASSEMBLY (See Figure A-8)

Item

!A 18 2 3 4 5 6 7 8 9

10 11 12 13 14 15

16

17 18 19 20 21 22 23 24 25 26 27 28 29

Description

Cable, 19-Conductor, 20 Ga., Shielded (502A) Cable, 19-Conductor, 20 Ga., Shielded (5048/C) Wire, 20 Ga. PVC Housing. Connector Contact Plug, Keying Spacer Bracket, Strain Relief Spring, Latch Screw, 4-40 x 7/8 Panhead, Stainless St!. Washer,44 Lock Nut, 4-40 Hex, Steel Tie, Cable Label (Indication) Label (Control) Storage Unit (Complete), 502A System

• • • 5048 or 504C System *Board, Terminal, 502A System

• • 5048 or 504C System *Plate, Top *Screw, 10-32 x 3/4 Fil. Head *Washer *Washer, flO Lock, Steel *Nut, 10-32 Hex, Steel *Name Plate *Screw, 8-32 x 1/2, Panhead *Washer, f8 Pl. Fl. Steel *Washer, f8 Lock *Nut, 8-32 Hex, Steel *Clip, Cable *Foot, Mounting *Screw, 10-32 x 1/2, Panhead

*Components that make up item 15

6202A, p. A-16

US&S Part No.

A045829 A045831 A045663 J713797 J709248 J718271 M45!393-0202 M451187-6601 J680!90-001 J507297-0114 J047765 J480006 J703387 M45!559-5602 M451559-5603 N451584-2601 N451584-2602 N438950 Nl73234 M45!584-2401 J052298 M044618 J047733 J048172 M451108-5202 J050968 J047745 J047681 J048166 J700651 M451584-1902 J507267

5 ,,./4

I~ LL m-= ~

' FRONT OF CONN, BLOCK ~ TYPICAL "-._CONTACTS "A" 8 "I"

FOR "JA" OR "JS" AT THIS END

CONNECTOR "JA"

WIRING DIAGRAM <504BIC>

!~: 5 . 6 7

CONNECTOR "JB"

FRONT OF BLOCK

A B c D E F

50 WIRING DIAGRAM <502A>

He.-! "'D"''I

"TS" 1ils·,1·o wHT I

18

49 WIBK/GN

tt~~~=::: 11 -e12

Ltjj~iG~E::::; : ~ 19

1-1.~~~-- ~ 0

W..iµ@'7<;;~--. 20 W..!!.!~~~-23 L-IHl-':*;.-':,;;---.,,. I 5 1-4+.:*:;'*-- 22 1-1.~,W.:;fu-:~ 21

W4!~-',;l-;,-} SPARES

SHIELD

~·Je ..

!~ c D E F H

2

"TS 11

7,8,'3.~~ OR I O 0------1

lA

E"TB~

0 II 12 13 14 15 25

24

SHIELD

3

/8

TO TERMINAL STRIP "TS" ON FCE-500 UNIT <FOR REF ONLY>

SEE WIRING DIAGRAM ~

~ ...I al

.... ::c ~

0

I ~

l s

15

STORAGE UNIT UNDERSIDE VIEW

' "TB"

10

l/' •

0

t'HT

0

21

UNION SWITCH & SIGNAL m 15

STORAGE. UN I T UNDERSIDE VIEW

2 "TB"

22

30 •

0

WHT

,2 SPARE WIRE I ~

UN

END WIRE

.3

I 12

~ND OF BRACKET

9---t 3--~ ? 6-1 0

1

1LJ 1-

.I 8

10 •+

n--f

5048 504C

UN

502A

F451458-54, Rev. 1, F4f1458-55, Rev. 1 and D451584-26, Rev. O

·------··--'--- 23, 24, 25, 26, 27

18, 19, 20, 21

~ -.ti- -. ~ -~------------· -~---------------· ---------------r-, I I I I I I

M -~ T: I

I I I I I I I I I I I ,-··

:V' 20, 21, 29 : I I

I I

ml- @. T: I·

: 22 ! : I \_ ' I I

,fff'\ I 1 I

-@- -;w \ ! -<ID: -@-. .

28

17

16,"--~, I I I I I I I I I I I I I I

1· I ~

f,r.--1 I I I I, .it,l,f--lt.' •• __ _; ___ _

FCE Storage Unit, Cable Assembly and Wiring Diagram

6202A, p. A-17/18

FCE-500

SERVICE MANUAL 6202A ADDENDUM 1

Field Code Emulator

This addendum updates service manual SM-6202A, which was printed in September, 1985. No replacement pages are included in the addendum. The following corrections may be marked in the manual:

2-9

2-11/12 and

2-13/14

2-23

2-25/26 to

2-31/32

October. 1987 ID0038F,0043F A-10/87-75-2777-AD1

PRINTED IN USA

sec./Fig.

Sec. 2.2.1.1

Figures 2-2 and 2-3

section 2.2.2.1

Figures 2-6 to 2-9

Revision

Scratch out the following system part numbers (no longer available):

N451583-0923 N451583-0924 N451583-0925

Same as above.

Scratch out the following system part numbers (no longer available):

N451583-0926 N451583-0927 N451583-0928

N451583-0929 N451583-0930

Same as above.

UNION SWITCH & SIGNAL AMERICAN STANDARD INC.IPITISBURGH, PA 15237

COPYRIGHT 1987, usas DIVISION OF AMERICAN STANDARD INC.

SPECIAL APPENDIX

SERVICE MANUALS 6199 6202 6203A 6200 6202A 63008 6201 6203 6300C

Operation, Installation and Maintenance

WIDE RANGE POWER SUPPLY CONVERTER PCB N451441-7601

for

DDL-601 A and DDL-601 B/X

Field Code Units

SAM-II

Stand Alone Monitor

FCE-500 Field Code Emulator

GENISYS

Non-Vital logic Emulator

EVENlTRAK

Digital Event Recorder - Monitor Unit

NOTE: Attach a copy of this appendix to each of the service manuals listed above.

February, 1988 100161F A-02/88-300·2853·1

PRINTED IN USA

UNION SWITCH & SIGNAL AMERICAN STANDARD INC./PITISBURGH, PA 15237

COPYRIGHT 1988. usas DIVISION OF AMERICAN STANDARD INC.

1.1 GENERAL

SECTION I DESCRIPTION

The Wide Range DC/DC Power Supply Converter PCB N451441-7601 is designed as a direct replacement for the N451441-3301, -3302 and -3303 Power supply converter PCBs used in the DDL-601A, DDL-6018, SAM-II, FCE-500, GENISYS and EVENTTRAK systems. It input accepts de voltage in the range of 9.5 to 35 Vdc, and outputs +5, +12 and -12 Vdc to power internal circuits on these systems.

The -7601 board is installed in the same cardfile slot as the N451441-3301, -3302 and -3303 boards. No changes in •a• connector keying plugs are necessary. The board is compatible with existing power input connector/cable assemblies.

1.2 DESIGN

Electronic components of the -7601 board include a single de/de power converter module, a choke, two capacitors, a diode, a transient voltage suppressor (see Figure 1) and four LEDs with current-limiting resistors. The converter module generates regulated +5 and .:!:,12 Vdc outputs from the unregulated 9.5 to 35 Vdc input. This module can be switched on and off externally, and is capable of adjusting its output according changes in the load on the 5 Vdc output (refer to section 1.3). Choke Ll and capacitors Cl/C2 form an LC filter for battery noise on the converter module input. Diode Dl provides reverse polarity protection, while voltage spikes are limited by MOV surge suppressor 02. LED4 indicates the presence of the 9.5 to 35 Vdc input to the converter module, while LEDs 1, 2 and 3 monitor the +5 Vdc, +12 Vdc and -12 Vdc outputs, respectively.

1.3 REMOTE ON/OFF AND REMOTE SENSE

Two functions are incorporated in the Wide Range Power Supply Converter PCB that were not available on the -3301, -3302 and -3303 boards·. These are remote on/off control and a remote sense capability.

The remote on/off control allows the board to be turned on and off from a remote location (power on/off switch by-passed). This is accomplished by switching or connecting the •control• line to the input voltage return line or pins(-). For remote switching, the on-board power on-off switch must be left in the ON position. When not used, the •control• line should be left open.

The •sense• lines enable the power converted module to compensate for voltage changes caused by line resistance or loads on the 5 Vdc output. This is accomplished with external connections between the •sense+• line and 5 Vdc and between the •sense-• line and the COM at the destination point. When a voltage drop occurs, the •sense• line level is monitored by the converter module and the 5 volt output is automatically adjusted to the correct output voltage level. For the DDL-601A/BX, SAM-II, FCE-500, GENISYS and EVENTTRAK systems, no external connections are required to utilize the remote sense capability. These connections are already exist on the cardfile motherboard.

p. 1

selected specifications of the -7601 board are as follows:

Fuse: 7.5 amp, 32 V Choke: 1 mH, 10 amps, 0.038 ohms Power Input: 9.5 to 35.0 Vdc@ 50 w, 5% ripple

Sink to 10 mA Remote On/Off control: Outputs: +5 Vdc@ 3 amps,+ 1%

+12 Vdc@ 1 amp,+ 2% -12 Vdc@ 1 amp,+ 2%

SECTION II MAINTENANCE

If the Wide Range Power supply Converter PCB is not supplying proper operating voltage for the system, first check the front edge LEDs. LED 4 indicates· if the board is receiving external input power. LEDs 1 through 3 indicate whether the power converter module is supplying output voltages. If all of these LEDs are dark, check the input level at TPS (+) and TP6 (-). In addition, check the input fuse. If these checks do not reveal a problem, the entire board should be replaced. Do not attempt to replace or repair the converter module.

To verify output voltage levels, attach a digital voltmeter common to TP2 and •+• probe in sucession to TPl (+SV), TP3 (+12V) and TP4 (-12V) See Figures 1 and 2 for test point locations. The voltmeter should show the output values listed in the Section I specifications. If any of these values are out of tolerance, the board should be replaced.

The Wide Range Power supply converter PCB may be tested in TS-203 test set. Use the same procedures as those for the earlier N451441-3301, -3302 and -3303 boards. Auxiliary test equipment, test point numbering and values are the same as those for the earlier boards.

CAUTION

DO NOT INSTALL OR REMOVE THE WIDE RANGE POWER SUPPLY CONVERTER PCB FROM THE TS-203 WITH TEST SET POWER ON, OTHERWISE COMPONENT DAMAGE MAY RESULT.

p. 2

~

~ ~

' ii!

ri[;~ t + !

(

f ~ +,~

§(:

~(: -(~ : !?

I i l I l I I I I I I

~ +

I!:

h~

-= ...

£

~ i

;;: I ..:

'( r J~i---,--------1

Eg:J, l :1 ·

~ ~

' ~ i!

~~ g ~ l g I;!~ : ~

+

~

:l §

• J

·r ::c .. - ; ! ~ !

i I g

-zt.::u- I §

.~ ~ ·-

10 a.- o·

t3 ··-. I 13

r I!:

• ii: I

[~~~' ~~~~~:JI Figure 1. Schematic Diagram

"' ti . t• et ~ 0 c .. z .,

ii : : .. " ... , . • I : 3 .. 0 ,. .. •• ... .... ... t • 1 ., • 1 v s . •• ~. ... ~. I l $$ •• ... ,r

~h t~N 2

SECTION III ORDERING AND PARTS LIST

(See Figure 2)

New systems such as the EVENTTRAK Monitor, FCE-500 Field Code Emulator and GENSISY Non-Vital Logic Emulator are shipped with Wide Range Power supply Converter PCB N451441-7601. When ordering replacements for the earlier N451441-3301, -3302 or -3303 power supply converter PCBs, specify the N451441-7601 PCB in all cases. None of the earlier boards will be supplied as replacements, howvever US&S will continue to provide repair service on these boards.

The component parts list for the -7601 board is as follows:

Item

PS! SWl Fl Fl Ll TPl-7 Cl C2 Dl LEDl-4 02 Rl R2, 3 R4

Description

DC/DC Converter Module Toggle switch, SPOT Fuse, 7.5 amp, 32 v Fuse Clip Choke, 1 mHy, 10 A Test point turret Capacitor, 2300 mFd, 50 Vdc capacitor, .47 mFd, Diode, 1N4003, 200 Vdc Light Emitting Diode Transient voltage suppressor, 35-42 Vdc Resistor, 330 ohms, 1/4 w Resistor, lK ohms, 1/4 w Resistor, I.SK ohms, 1/4 w

p. 4

US&S Part No.

J709557-0007 J725707-0135 J710083 J576794 J709538 J731396 J709145-0350 J706152 J723555 J713344 J792736-0002 J735060 J735031 J735139

LI c ... ___ .,.

SKI

ON _f -,

[ OH L _j

R4 { }

[ J c :J LE04 INPUT

F'I RI

{ }

00 [ J 02

IT } 01 )C

C:J [ J LEDi •5V TPI

0

- J )C

C2 )C

><

•5V + T~5o INPUT T~6o

.. Cl ;I

TPT

0 CONTROL

.... .... z W•

~~ u, V'I-

R2 { } "'"" ........

"'"' C:J

... ... LED? +12V

TP3

0 +12V l

>C

>C

PSI

TP4 ,..

-12v )C

R30 { } .... C:J LE03

.. -12v TP2

0 ..

COM .. ..

c N I ....

.. >C a:,

"' DClDC POWER SUPPLY .,. N451441-7601 REV

>C ,.

Figure 2. component Layout

P• 5

6202A SERVICE MANUAL FCE-500 - Global Product Support

Documents