SERVICE MANUAL 6193

CTC INTERLOCKING FAILOVER

ODD/EVEN 5-MINUTE TIMER
N451564-0701

' ,.

August, 1983
WP1462A, Dskt 0223A UNION SWITCH & SIGNAL DIVISION
A-08/83-10-2540-1 AMERICAN STANDARD INC./ SWISSVALE, PA 15218

llNTED IN USA
 UNION SWITCH & SIGNAL b:j
CONTENTS.

Section

I INTRODUCTION 1
1.1 GENERAL 1
1. 2 COMPONENTS 2
1. 2.1 Panel 2
1. 2.2 PCB's 2
1.2.2.1 Microprocessor Timer (N451605-3901) 2
1.2.2.2 Conditional Power Supply (N451605-4001) 3/4
1.2.2.3 Power Filter (N451605-5601) 3/4
1.3 SPECIFICATIONS 3/4
1.3.1 Physical/Mechanical 3/4
1. 3. 2 Electrical/Electronic 3/4
1.3.3 Miscellaneous 3/4

II FUNCTIONAL DESCRIPTION 5
2.1 GENERAL 5
2.2 MICROPROCESSOR TIMER PCB 6
2.2.1 Microprocessor and Peripherals 6
2.2.2 PCB Inputs and Outputs (PIA to Weidmuller Plugs) 6
2.2.3 LED Indications 11/12
2.3 CONDilIONAL POWER SUPPLY PCB 11/12
2.3.1 General 11/12
2.3.2 Circuit Operation 15/16

III INSTALLATION 17/18

3.1 PANEL MOUNTING 17/18
3.2 POWER APPLICATION 17/18
3.3 MISCELLANEOUS CONNECTIONS 17/18
3.4 SYBTEM CUT-IN 17/18

IV TROUBLESHOOTING AND MAINTENANCE 19

4.1 GENERAL 19.
4.2 SYSTEMATIC TROUBLESHOOTING 20
4.2.1 Complete Assembly (System Test) 20
4.2.1.1 Test Procedure Comments 20
4.2.1.2 Recommended Test Equipment 21
4.2.1.3 Test Set-Up 21
4. 2.1.4 Procedure 21
4.2.2 Microprocessor Timer PCB 23
4.2.2.1 Test Procedure Comments 23
4.2.2.2 Recommended Test Equipment 23
4.2.2.3 Test Set Up 24
4.2.2.4 Procedure 24
4.2.3 Conditional Power Supply PCB 29
4.2.3.1 Test Procedure Comments 29
4.2.3.2 Recommended Test Equipment 29
4.2.3.3 Test Set-Up 30
4.2.3.4 Procedures 31

v CPS PCB, RESISTOR R2 (TBD) kEPLACEMENT 35/36

5.1 GENERAL 35/36
5.2 PROCEDURE 35/36

l.
\.lJ UNION SWITCH & SIGNAL

CONTENTS (Cont'd)

Section

Appendix A PARTS LIST

A.l MICROPROCESSOR TIMER PCB N451605-3901 A2
A.2 CPS PCB N451605-4001 A4
A.3 POWER FILTER PCB N451605-5601 A6

ILLUSTRATIONS

Figure

l 5-Minute Odd/Even Timer Application Block Diagram 1

2 5-Minute Odd/Even Timer Functional Block Diagram 7/8

3 Microprocessor Timer PCB Schematic Diagram 9/10

4 Conditional Power Supply and Power Filter PCB Schematic 13/14

Diagrams

5 CPS PCB Test Set-Up 31

6 CPS PCB 12V Test Waveform No. 1 33/34

7 CPS PCB 12 V Test Waveform No. 2 33/34

8 CPS PCB 12V Test Waveform No. 3 33/34
Al Microprocessor Timer PCB Component Layout A3

A2 CPS PCB Component Layout A5

A3 Power Filter PCB Component Layout A6

l.l.
 UNION SWITCH & SIGNAL ffi
SECTION I
INTRODUCTION

1.1 GENERAL

The Odd/Even 5-Minute Timer automatically switches a CTC-supervised field

station to local routing should the station fail to receive office
instructions. The device enables field personnel to assume manual c9ntrol of
the signal apparatus in the affected territory, and is intended to maintain
traffic movement through blocks which would otherwise be placed in a
restricted condition.

The Odd/Even 5-Minute Timer receives and processes two signals from the office
data code unit, one of which is designated an odd bit and the other an even
bit. The office is programmed to transmit one signal, then the alternate, in
fiev minute intervals on a continuous basis. If either signal is not received
by the Timer after five minutes and a two minute allowance period (seven
minutes total), a fail relay is deenergized. The fail relay, in turn, places
the station in local routing.

The Odd/Even 5-Minute Timer may be integrated with any CTC office/field data
system which is capable of transmitting the appropriate signals in five minute
intervals. A separate unit is provided for each field station. The unit
operates from a 12 Vdc (nom.) batsery power supply. Figure 1-1 shows the
general application of the Timer.

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6193, p. 1
W UNION SWITCH & SIGNAL

1.2 COMPONENTS

1.2.1 Panel

The Odd/Even 5-Minute Timer consists of a sheet metal enclosure designed for
mounting in a standard 19 inch equipment rack. The back panel supports three
printed circuit boards (Microprocessor Timer, Conditional Power Supply and
Power Filter) which, in turn, contain all unit electronics and wiring
terminals. Weidmuller connectors are used for board-to-board and external
wiring.

1.2.2 PCB's

1.2.2.1 Microprocessor Timer (N451605-3901)

The Microprocessor Timer PCB contains all processing logic for the Odd/Even
5-Minute Timer. Its general functions include processing of the special
monitor bits from the office, output of various failover signals and output of
a 500 Hz check signal to the Conditional Power Supply PCB. The principal
components on this board include:

Mic roproces so r

The board contains one 6802 Microprocessor IC as the principal controlling

chip. It is an NMOS device which contains 128 bytes of built-in random access
memory (RAM) and operates on 5 Vdc. Its operations are sequenced by a 4.0 MHz
crystal, XTAL 1.

EPROM
The board contains one 2716 Erasable Programmable Read-Only Memory (EPROM) IC,
which carries the resident operating program for the unit. It has a capacity
of 2K bytes of data.

PTM
One 6840 Programmable Timer Module is provided on the board to sequence
various operations between the microprocessor and its peripherals.

PIA

One 6821 Peripheral Interface Adapter (PIA) IC is used on the board to

interface and condition all external signals with the microprocessor logic.

Power Supply Converter IC

The Microrprocessor Timer PCB contains a 12 Vdc (nom.) to 5 Vdc power supply
converter IC which develops operating power for on-board components from the
external supply. The 5 Vdc output is also connected to the Conditional Power
Supply PCB.

LED's

The board contains seven Light Emitting Diodes which indicate the status of
various interfaced signals, and the operating condition of board itself.

6193, p. 2
 UNION SWITCH & SIGNAL ffi
1. 2. 2. 2 Conditional Power Supply (N451605-4001)

The Conditional Power Supply (CPS) PCB energizes the external failover relay
when system and unit internal operating conditions are satisfactory, and
cancels power when conditions are not met. Principle circuits include a tuned
LC circuit, transistor-oscillator stage and transformer/rectifier. A single
LED indicates the presence of the required 12 volt output.

1.2.2.3 Power Filter (N451605-5601)

The Power Filter PCB is used to interface battery power and fail monitor
signals into the Microprocessor PCB, and failover signals from the that PCB.
It contains a transformer and capacitors to filter out ac ripple from 10 Hz to
l KHz.

1.3 SPECIFICATIONS

1.3.1 Physical/Mechanical

Overall Dimensions: L = 19 in., W = 10.5 in., H = 4.5 in.

Access: Removable front cover

Mounting: Standard 19" rack

External Connections: 12-plug Weidmuller terminal strip

(Power Filter PCB)

Temperature Environment: -400 to +700 C

1.3.2 Electrical/Electronic

Power Supply Input: 10 to 16 Vdc (12 Vdc nominal.),@ 1.0

amps

Inputs (Odd/Even Signals): Relay Contact

Coil Energize Output (Failover): 12 Vdc, less than 100 milliampheres

Logic Families (Microprocessor PCB): 6800 series Microprocessor and

peripherals, Intel EPROM and CMOS

1.3.3 Miscellaneous

Maintenance Aids: Removable PCB' s

LED's
Test Points
Software diagnostics
500 Hz output (from Microprocessor PCB)

6193, p. 3/4
'

..,
 UNION SWITCH & SIGNAL ffi
SECTION II
FUNCTIONAL DESCRIPTION

2.1 GENERAL (See Figure 2)

The Odd/Even 5-Minute Timer is designed to control two vital external relays.
The Timer keeps the Failover Relay energized so long as two dedicated office
code bits are alternately received in five-minute intervals. The Status Relay
is energized when the even bit is received, and deenergized when the odd bit
is received. Separate relay contacts are used to input these bits (in the
US&S DDL-601B application, relay-output PCB contacts provide these inputs).
The loss of these bits can be interpreted as a code system connnunication
failure which has also affected control and indication bits.

At system start or after a system reset, the office code unit will transmit a
bit over one of the two lines to the Timer, typically at one of the five
minute marks during the hour. One line is designated even and the other odd.
When the first bit is received, the Timer will store the type of bit (odd or
even) in memory and begin a five minute counter. At the same time, the status
output energizes the Status Relay (if the first bit is even), and the failover
output energizes the Failover Relay. The next bit received from the office is
expected to arrive over the alternate bit line exactly five minutes after
receipt of the previous bit. If this bit arrives on time, the Timer will
deenergize the Status Relay (if this bit is odd)> reset its counter to O
minutes, store the new bit and count through five minutes.

The above routine is repeated so long as a bit is received over the correct
(alternate) line at the correct time, unless and until there is an
interruption. The Failover Relay remains constantly energized.

If no bit arrives at the end of the five minute period, the Timer will insert
a two minute buffer period in which a late bit may arrive without causing a
failover command.

If no bit arrives at the end of the two minuter buffer period, the Timer will
deenergize the Failover Relay and lock the latest position of the Status
Relay, which indicates the last properly received bit from the office. The
same will occur if a bit is received within the alotted time, but over the
wrong line.

The Failover Relay is energized by the Timer's Conditional Power Supply PCB
which, in turn, provides power for the relay on the condition that a 500 Hz
check signal is received from the Microprocessor PCB. The Microprocessor PCB
generates the check signal so long as (a) the correct office odd/even bits are
received at the correct time, (b) operating power (external and internal) for
the Timer is at proper levels and (c) the Microprocessor PCB passes its own,
periodic internal diagnostics.

6193, P• 5
~ UNION SWITCH & SIGNAL

2.2 MICROPROCESSOR TIMER PCB (See Figure 3)

2.2.1 Microprocessor and Peripherals (Except PIA External I/0)

Housekeeping communications between 6800 series components on the

Microprocessor Timer PCB take place on 14 address lines (AO - AlO, Al2, Al4,
AlS), eight data lines (DO - D7) and five control lines (E, R/W, VMA, IRQ,
RESET). A peripheral device (EPROM, PTM, PIA) will have data read from it or
written into it by the microprocessor chip (IC3). The microprocessor selects
a peripheral for data communication using the address lines. Address line AlS
is used to create chip-enable (CE) signals for the peripherals. IC2 inverts
this line to the PTM and PIA. Eight-bit data is carried over the data lines,
which are common to the microprocessor and all peripherals.

The five applied microprocessor control lines are as follows:

VMA (Valid Memory Address) - This signal is used to indicate the presence of
valid address data on the address bus. It is applied to IC2, in conjunction
with line AlS, to generate the chip-enable signal for the PIA and PTM.

! - This is a clocked output from the microprocessor which sequences

operations between the microprocessor and the peripherals.

R/W (Read/Write) - This ou~put informs the peripherals if the microprocessor

is in a reari (data in) or write (data out) state.

IRQ (Interrupt Request) - This is an input to the microprocessor which is

applied by the PTM or PIA and is used to flag a change of operation.

RESET - This line inputs the reset signal from pushbutton switch SWl, or at
power turn-on, and causes a general reset of the microprocessor and the
peripherals. (Two gates of IC2 are used to debounce the SWl signal so that
the microprocessor does not receive an erratic reset input).

2.2.2 PCB Inputs and Outputs (PIA to Weidmuller Plugs)

The PI.A uses 15 pin-outs for interfacing PCB-external signals (odd/even

inputs, failover, status etc.) with the microprocessor. Optical-coupler !C's
are installed in all PI.A lines to electrically isolate low-level signals from
possible voltage transients in the external-signal area of the board (all
circuits between the PIA outputs and the Weidmuller plugs).

The PIA output circuits incorporate a cross-check circuit which allows the
microprocessor to verify the output. For example, in the circuit connected to
PA3 and PB2 (Microprocessor Timer PCB operation monitor), the PB2 line
controls the switching of transistor Qll, coupler IC17, and transistors
Ql2/Ql3, which should provide a pulse at Weidmuller plug J3 every two
seconds. The pulses are indicated by LED 7 (flashes every two seconds). The
pulses are sent back to the PIA (pin PA3) through coupler IC18. The
microprocessor is then able to check the operation of two couplers and three
transistors on the PCB by comparing the PB2 output with the PA3 input. Output
circuits are represented by optical couplers IC8, 9. 10, 11, 17 and 18. The
function of each of the output circuits is described by the attendant LED;
refer to section 2.2.3.

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6193, P• 7/8
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Figur~ 3. Microprocessor Timer PCB Schematic Diagram

-6193, P• 9/10
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 UNION SWITCH & SIGNAL w·
PIA line Pli7 carries the 500 Hz, Conditional Power Supply PCB check signal
from the Microprocessor circuit. The check signal operates on a 50% duty
cycle and is the product of a 300 microsecond diagnostics interrupt routine
performed by the microprocessor. During the routine, the microprocessor
performs various checks on its peripherals and external inputs and outputs.
If any component or line fails the diagonostics, the microprocessor does not
return the PCB to routine operation and the system goes into the fail
condition.

2.2.3 LED Indications

Table 1 lists the seven Microprocessor Timer PCB LED's and their functions.
Refer to Appendix A, Parts List, for the component locations of the LED's.

Table 1. Microprocessor Timer PCB LED's

LED NO. FUNCTION BEHAVIOR

1 Fail mode status Lights steadily when unit LS

operating, goes dark upon
failover (Fail Relay deener-
gized)

2 Status of odd/even bits On when even bit is received

and processed, off for odd bit

3 Spare

4 Voltage state of even bit Lights when even.bit line goes

line high

5 Spare

6 Voltage state of odd bit Lights when odd bit line goes
line high

7 Mic roproces so r Timer PCB Flashes once every two seconds

operational status

2.3 CONDITIONAL POWER SUPPLY PCB (See Figure 4)

2.3.1 General

The basic function of the Conditional Power Supply PCB is to generate 12 Vdc@
3.5 amps (max.); this power is used to keep the Failover Relay energized when
operating conditions are satisfactory. The 500 Hz check signal received from
the Microprocessor Timer PCB is amplified by a tuned LC circuit and rectified
to control a transistor oscillator stage. The oscillator is used to drive a
push-pull transistor pair, developing an ac signal which is transformer
coupled and rectified to produce the desired output. Three conditions must be
satisfied for the CPS PCB to provide the 12 volt output:

6193, P• 11/12
 UNION SWITCH & SIGNAL w

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Figure 4. Conditional Power; Supply and Power Filter PCB Schematic Diagrams
I
6193, P• 13/14
 UNION SWITCH & SIGNAL ffi
1. The PCB must receive 12 Vdc directly from the battery which
powers the Timer.

2. The PCB must receive 5 Vdc from the Microprocessor Timer PCB
(5 volt regulator).

3. The PCB must receive the 500 Hz (50% duty cycle) check signal from the
Microprocessor PCB.

2.3.2 Circuit Operation

A 500 Hz, 5 Vdc logic square wave is applied to Rl, which causes Ql to switch
off and on. This causes current to flow through R2 and the primary of Tl. An
ac voltage is developed across Tl, and coupled across the tuned circuit of C2
and the secondary of Tl. The circuit is tuned to a resonant frequency of 500
Hz. R2 is adjusted for approximately 10.5 VPP at TPl. Q2 is an emitter-
follower used for current gain. The 500Hz is then half-wave rectified to a
negative de voltage at TP2. D4 serves as a voltage level detector to power
the Colpitts oscillator, which consists of C5-C8 and R7-Rll. The oscillator
produces 4 VPP (approx.) at 2.5 Khz at TP3. The signal is then amplified
(current) by Q4 and the voltage amplified by Q5. The signal at TP4 then
drives a push-pull transistor pair, Q6 and Q7. This develops a rough square
wave of 9 VPP (approx.) at TP5. That voltage is transformer-coupled by T3 to
drive power transistors Q8 and Q9. A 22 VPP square wave (approx.) is present
at both TP6 and TP7. That signal is then transformer-coupled by T4 and
full-wave rectified by D7 to produce 10 Vdc (approx.) at 2.5 amps load current.

6193, p. 15/16
 UNION SWITCH & SIGNAL w
SECTION III
INSTALLATION

3.1 PANEL MOUNTING

The Odd/Even 5-Minute Timer unit is designed for mounting 1.n a standard 19
inch equipment rack, typically next to the field code unit which supplys the
special system monitor bits. Placement of the panel should take into account
minimizing of cabling length to the code unit and relays, and accessibility
for periodic maintenance. Avoid installing the unit near areas of excessive
heat. If necessary, supply the unit with its own source of ventilation.

3. 2 POWER APPLICATION

The Odd/Even 5-Minute Timer requires one 12 Vdc, 1.0 amp battery (range: 10 to
16 Vdc) for operating power. The power input lines should be equipped with
lightning arresters and secondary surge suppressors to prevent possible
component damage. US&S recommends the USSP-11 secondary surge suppressor
(N451552-0503), which is intended to provide both forms of protection. The
Bl2 line is connected to Weidmuller plug J6 on the Power Filter PCB, Nl2 to
plug J5.

3.3 MISCELLANEOUS CONNECTIONS

Figure 2 shows the termination of the signal w1.r1.ng to the Odd/Even 5-Minute
Timer. Make certain that relay wiring is correctly terminated according to
heel, front and back contacts. At least 1/4 inch of insulation should be
removed from the wiring to be connected to the Weidmuller plugs; the conductor
does not have to be. "tinned".

3.4 SYSTEM CUT-IN

Once the office/field code system is operational, the Odd/Even 5-Minute Timer
may be turned on at any time. Power turn-on automatically causes a reset
action on the Microprocessor Timer PCB. The single LED on the CPS PCB will
light, and microprocessor LED 7 will change to the standard two second flash
rate. The CPS PCB should also emit a faint, high-pitched tone from its
transformer core. The first bit received will cause the Failover Relay to
energize. If the bit is odd, microprocessor LED 1 should remain off. If the
bit is even, LED 1 should light.

6193, P• 17/18
 UNION SWITCH & SIGNAL ~
SECTION IV
TROUBLESHOOTING AND MAINTENANCE

4.1 GENERAL

The troubleshooting procedures given in this section should only be performed

by properly qualified and equipped personnel. If the Odd/Even 5-Minute Timer
is not repairable in the field, it should be returned to US&S for repair or
replacement through the district sales representive or:

Union Switch & Signal Division

American Standard Inc.
1789 S. Braddock Avenue
Swissvale, PA 15218
Attn: RMR Section

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

Prior to performing detailed PCB troubleshooting, the unit should be given a

thorough visual and hands-on inspection for any outward defects which may be
causing or contributing to a problem. This includes loose or broken wires in
the Weidmuller plugs, damaged, loose or missing PCB components, and damage to
PCli tracking and circuit board material.

Attention should also be given to possible system problems which may give the
appearance of a problem with the Timer itself. For example, the local code
unit may be receiving the proper bit instructions from the office, but is
failing to output those bits to the Timer.

The Odd/Even 5-Minute Timer will deenergize the Failover relay if an

operational problem occurs with the unit, as well as when odd/even monitor
bits are not received properly. If the Failover Relay is deenergized and the
code system is known to be communicating properly, the following checks should
be made:

a. Check battery power. If battery output falls below specification, the

CPS PCB will automatically cancel its 12 volt output to the Failover
Relay.

b. Check the continuity of the fuse on the Power Filter PCB, using an
ohmmeter. If broken, replace (power off) and turn power back on. The
Microprocessor Timer PCB should go to self diagnostics and normal
operation (refer to section 3.4) since power-up causes a microprocessor
reset. If the diagnostics phase does not occur (LED 7 dark), there may
be a continuity problem with the Power Filter PCB. If diagnostics do
occur, but normal operation is not restored, there may be a fault in the
Microprocessor Timer PCB.

The troubleshooting program for the 5 Minute Odd/Even Timer is divided into
three parts. The first part consists of a general system test. Jumpers are
appliea to the Power Filter PCB plugs to simulate various code system inputs;
basic voltage checks are also performed. The second part of the program
consists of a thorough checkout of the Microprocessor Timer PCB. This

6193, P• 19
w UNION SWITCH & SIGNAL

procedure is applied when the system test results indicate a local problem
with the Microprocessor Timer PCB. The third part of the program consists of
a thorough checkout of the CPS PCB and, like the Microprocessor Timer PCB
program, is conducted on the basis of the initial system test results.

4.2 SYSTEMATIC TROUBLESHOOTING

4.2.1 Complete Assembly (System Test)

4.2.1.1 Test Procedure Comments

If any step in the section 4.2.1.4 procedure is not executed· properly, the
maintainer must restart the procedure at step 1. The purpose of each step or
steps is as follows:

Step No. Purpose

2 Check output of 5 volt regulator on Microprocessor Timer PCB.

3 Verify microprocessor operation by injecting a reset.

4 Check 12 volt input to Microprocessor Timer PCB from CPS PCB.

5 Simulate an odd bit input.

6 Simulate termination of the odd bit input.

7 Simulate an even bit input.

8 Simulate termination of the even bit input.

9 Input the odd bit again, but leave on to verify that micropro-
cessor sets fail mode when the even bit fails to arrive.

10 Terminate this odd bit input.

11 Input the even bit again, but leave on for seven minutes to
verify that microprocessor sets fail mode when the odd bit
fails to arrive.

12 Terminate this even bit input.

13 Simulate another odd bit input.

14 Terminate the odd input bit and inject a reset. The inicropro-
should show normal operation (LED 7 flashes), even though the
fail mode output has been deenergized (LED 1 off).

15 Simulate another even bit input. Leave on for seven minutes to

verify that microprocessor stays in fail mode.

16 Verify that Fail Relay output is deenergized following step 15.

6193, P• 20
 UNION SWITCH & SIGNAL t:t:J
17 Verify that Status Relay Output is deenergized following step 15.

18 Simulate another odd bit input to verify energizing of Status

Kelay output.

19 Check that Fail Relay output is also energized as a result of the

new odd bit input.

21 Check that Status Relay output is deenergized as a result of the

latest even bit input.

20. Simulate another even bit input to verify energizing of the Fail
Relay output.

4.2.1.2 Recommended Test Equipment

Device Specifications

Power Supply (Qty= 1, recommended Oto 15 Vdc, 4 amp

model: VIZ #WP706)

Multimeter (Qty= 1, recommended Voltmeter: 0 to 20 volts

model: Simpson 260) Ohmeter: continuity capability

Frequency Counter (Qty= 1, recom- Frequency reading: 500 Hz,+/- 1 Hz

mended model: H.P. 5300)

Stop Watch (Qty= 1) Capable of measuring 7 min., +/- 1 min.

Load Resistors (Qty= 2) 50 ohm, 2 W

4.2.1.3 Test Set-Up

Turn off power and remove panel front cover.

4.2.l.4 Procedure

Operation Verification

1. Turn unit power on. 1.

2. Connect voltmeter"+" lead to 2. Voltmeter should show +5.0 Vdc,

Weidmuller plug Jl5 on the +/- 0.5 Vdc.
Microprocessor Timer PCB; con-
nect the"-" lead to Jl2.

3. Press pushbutton. SWl on the 3. LED 7 should light for 2 seconds,

Microprocessor Timer PCB. go dark for 2 seconds, etc.

4. Connect voltmeter "+" lead to 4. Voltmeter should show +12.0 Vdc,

Weidmuller plug Jl on the +/- 1.0 Vdc.
Microprocessor Timer PCB.

6193, P• 21
~ UNION SWITCH & SIGNAL

Operation Verification

5. Connect a Jumper wire between 5. LED's land 4 on the Micropro-

Wei<lmuller plugs TB1-J2 and cessor Timer PCB should light.
JlO on the Power Filter PCB.

6. Pull J2 end of jumper. 6. LED 1 should remain lit.

LED 4 should go dark.

7. Reconnect jumper to plug J4 on 7,. LED 1 should remain lit. LED's 6

the Power Filter PCB; other end and 2 should light.
remains on JlO.

8. Pull J4 end of jumper. 8. LED's land 2 should remain lit.

LED 6 should go dark.

9. Reconnect jumper to plug J2. 9. LED 1 should remain lit. LED 2

Trip stopwatch when jumper is should go dark. LED 1 should go
is closed. dark 7 minutes,+/- 2 sec. after
the jumper is closed.

10. Pull J2 end of jumper. 10. LED 4 should go dark.

11. Reconnect jumper to plug J4; 11. LED's l, 2 and 6 should light. LED
other end remains in JlO. 4 should go dark. LED l should go
Trip stopwatch when jumper is dark 7 minutes, +/- 2 sec. after
closed. the jumper is closed.

12. Pull J4 end of Jumper. 12. LED 6 should go dark and LED l
should remain dark. LED 2 should
remain lit.

13. Reconnect jumper to plug J2. 13. LED's land 4 should light. LED's
2 and 6 should go dark.

14. Pull J2 end of Jumper, press 14. LED 7 should turn on for two
pushbutton SWl for a moment, seconds, go dark for two seconds,
then release. etc. LED's l, 2 and 6 should
go dark.

15. Reconnect jumper to plug J4. 15. LED's 1, 2 and 6 should light.
Trip stopwatch when jumper is LED l should go dark 7 minutes,
closed. +/- 2 sec. after the jumper is
closed.

16. Connect two load resistors (50 16. LED l should be off.
ohm, 2 W each) from J7 and J8 on
the Power Filter PCB to Jl on
the processor PCB.

17. Connect voltmeter"+" lead to 17. Voltmeter should read O.O Vdc, +/-
plug Jl on the Microprocessor 0.5 Vdc. LED l should remain dark.
Timer PCB, and the "-" lead to
plug J7 on the Power Filter PCB.

6193, p. 22
 UNION SWITCH & SIGNAL ffi
Operation Verification

18. Move voltmeter"-" lead to plug 17. Voltmeter should read 11.0 Vdc, +/-
J8 on the Power Filter PCB. LO Vdc.

19. Connect a jumper between plugs 19. Voltmeter should show 0.0 Vdc,
J2 and JlO on the Power Filter +/- 0.5 Vdc.
PCB.

20. Move voltmeter"-" lead back to 20. Same as step 18.

plug J7 on the Power Filter PCB.

· 21. Move J2 end of jumper (step 18) 21. Same as step 18.
to plug J4.

:t.2. Move voltmeter "-" lead to plug 22. Same as step 18.
J8 on the Power Filter PCB.

23. Turn off power and remove all 23.

test equipment.

4.2.2 Microprocessor Timer PCB

4.2.2.l Test Procedure Comments

The Microprocessor Timer PCB test procedure is broken into five sections. The
first section (steps 1 to 9) is a general input voltage continuity test. The
second section (steps 10 to 32) is a general output voltage continuity and
feedback test. The third section (Step 33) provides a general continuity
check between critii;:al test points and Weidmuller plugs. The fourth section
(steps 34 to 43) applies to the microprocessor chip and the generation of the
500 Hz check signal. The fifth section (steps 44 to 59) is an input/output
functional test similar in format to the system test (refer to section
4.2.1.1). If the procedure in this last section is not executed properly, the
maintainer must resturn to the first step (44).

4.2.2.2 Recommended Test Equipment

Device Specifications

Power Supply (Qty= 2, recommended Oto 15 Vdc, 5 amp

model: vri fwP706)

Multimeter (Qty= 2, recommended Voltmeter: 0 to 20 volts

model: Simpson 260) Ohmeter: continuity capability

Frequency Counter (Qty= 1, recom- Frequency reading: 500 Hz,+/- l Hz

mended model: H.P. 5300)

6193, p. 23
m
UNION SWITCH & SIGNAL

Device Specifications --~

··t:
,-

Oscilloscope (Qty= 1, recommended Frequency range:

model: Tektronix 453
Time base:

Dual channel inputs with chopped or

alternate operation

ac or de coupling

External sweep mode

Accuracy:

Veritcal amp. sensitivity:

Stop Watch (Qty= 1) Capable of measuring 7 min., +/- 1 sec.

Load Resistors (Qty= 1 each) 50 ohm, 2 W, lK ohm, 1/4 W

4.2.2.3 Test Set Up

a. Remove IC's 3, 4, 5 and 6 from the PCB.

b. Disconnect all chassis wires from the Weidmuller plugs.

c. Turn on and adjust power supply #1 to +12 Vdc (+/- 0.5 Vdc), then turn
supply off.
ci. Turn on and adjust power supply #2 to +12 Vdc (+/- 0.5 Vdc), then turn
supply off.

e. Connect positive of power supply #1 to Weidmuller plugs Jl4 and Jl on the

PCB. Clasp screw may be useri for contact; make certain chassis wires
remain in plugs.

f. Connect negative of power supply #1 to plug Jl3.

g. Connect positive of power supply #2 to Jl.

h. Connect negative of power supply #2 to J2.

1. Turn on both power supplies.

4.2.2.4 Proceriure

Operation Verification

1. Connect"-" lead of voltmeter #1 1. Voltmeter #1 should show +4.0 Vdc,

to TP12 and "+" lead to IC6 +/- 0.5 Vdc.
socket, pin 40.

6193, p. 2-24
 UNION SWITCH & SIGNAL b'::J
Operation Verification

2. Attach a jumper wire between 2. LED 3 should light steadily and

Weidmuller plugs J2 and J8. voltmeter #1 should show O.O Vdc,
+/- 0.5 Vdc.

3. Move voltmeter 1H "+" lead to 3. Voltmeter #1 should show +4.0 Vdc,

pin 18 of IC6 socket. +/- 0.5 Vdc.

4. Move jumper end in plug J8 to 4. LED 5 should light steadily and

J9; other end remains in J2. voltmeter #1 should show O.O Vdc,
+/- 0.5 Vdc.

5. Move voltmeter #1 "+" lead to 5. Voltmeter #1 should show +5.0 Vdc,

pin 8 of IC6 socket. +/- 0.5 Vdc.

6. Move Jumper end in plug J9 to 6. LED 4 should light steadily and

J6; other end remains in J2. voltmeter #1 should show O.O Vdc,
+/- 0.5 Vdc.

7. Move voltmeter #1 "+" lead to 7. Voltmeter #1 should show +4.0 Vdc,

pin 9 of IC6 socket. +/- 0.5 Vdc.

8. Move jumper end in plug J6 to 8. LED 6 should light steaaily and

J7; other end remains in J2. voltmeter #1 should show 0.0 Vdc,
+/- 0.5 Vdc.

9. Remove jumper wire from Weid- 9.

muller plugs J7 and J2.
10. Connect jumper. between pin 13 of 10. LED 1 should be off. Other LED's
IC6 socket (TP4) and TP12. may be on.

11. Move voltmeter #1 "-" lead to 11. Voltmeter #1 should show 5.0 Vdc,
TP12 and "+" lead to pin 6 of IC6 +/- 0.5 Vdc.
socket (TP5).

12. Connect 50 ohm resistor between 12.

between Weidmuller plugs Jl and
J4.

13. Connect voltmeter #2 "+" lead to 13. Voltmeter #2 should show O.O Vdc,
plug Jl and 11 - 11 lead to J4. +/- 0.5 Vdc.

14. Remove jumper between in TP4 14.

and TP12.

15. Connect lK ohm resistor between 15. LED 1 should light steadily.
TP4 and TPll. Voltmeter #1 should show O.O Vdc,
+/- 0.0 Vdc. Voltmeter #2 should
show +12.0 Vdc, +/- 1.0 Vdc.

16. Connect jumper between TP6 and 16. LED 2 should be off. Other LED's
TP12. may be on.

6193, p. 25
w UNION SWITCH & SIGNAL

Operation Verification

17. Move voltmeter 1/:l "+" lead from 17. Voltmeter #1 should show 5.0 Vdc,
TP5 to TP7. +/- 0.5 Vdc.

18. Move 50 ohm load jumper end in 18.

plug J4 to JS; other end remains
in Jl.
11
19. Move voltmeter #2 -
11
lead from 19. Voltmeter 1F2 should show 0.0 Vdc,
plug J4 to JS. +/- 0.5 Vdc.

20. Remove jumper between TP6 and 20.

TP12.

21. Move lK ohm jumper end on TP4 to 21. LED :/J:2 should light steadily.
TP6; other end remains on TPll. Voltmeter :/J:l should show O.O Vdc,
+/- 0.5 Vdc. Voltmeter #2 should
show +12.0 Vdc, +/- 1.0 Vdc.

22. Connect jumper between TP8 and 22. LED 7 should be dark. Other LED's
may be on.

23. Move voltmeter #1 "+" lead from 23. Voltmeter #1 should show 5.0 Vdc,
TP7 to TP9. +/- 0.5 Vdc.

24. Move 50 ohm jumper end from plug 24.

JS to J3; other end remains 1n
Jl.
25. Move voltmeter 1F2 "-" lead from 25. Voltmeter :/J:2 should show O.O Vdc,
plug JS to plug J3. +/- 0.5 Vdc.

26. Remove jumper between TP8 and 26.

TP12.

27. Move lK ohm Jumper end from TP6 27. LED 7 should light steadily.
to TP8; other end remains on Voltmeter :/J:l should show 0.0 Vdc,
TPll. +/- 0.5 Vdc. Voltmeter :/J:2 should
show +12.0 Vdc, +/- 1.0 Vdc.

28. Connect jumper between TP3 and 28. Some LED's may be on.
TP12.

29. Move voltmeter fF2 11 - 11 lead from 29. Voltmeter :/J:2 should show +11.5 Vdc,
plug J3 to JlO. Remove 50 ohm +/- 1.0 Vdc.
load.

30. Remove Jumper between TP3 and 30.

TP12.

31. Move lK ohm jumper end from TP8 31. Voltmeter #2 should show 0.0 Vdc,
to TP3.; other end remains on +/- 0.5 Vdc.
TPll.

6193, P• 26
 UNION SWITCH & SIGNAL ffi
Operation Verification

32. Remove all jumpers. 32.

33. Turn off power supplies #1 and 2. 33.

34. Check continuity between the 34. No short circuits should be

following sets of points: observed.

a. TP's 4, 6, 8
b. TP's 5, 7, 9
c. Plugs 6, 7, 8, 9
d. Plugs 3, 4, 5
e. Plugs 9, 10
f. Plugs 1, 2, 12, 14, -15

35. Reinstall IC's in sockets IC3, 35.

4, 5 and 6.

36. Set oscilloscope controls as 36.

follows:
Voltage: 2V/div.
Horiz.: 0.2 sec./div.
Trigger: Auto, +de

37. Connect oscilloscope ground on 37.

TP12 and probe on TPl.

38. Turn on #1 and #2 power 38 Oscilloscope should show +5.0 Vdc,

supplies. +/- 0.5 Vdc approximately 2 seconds
after the power supplies are turned
on.

39. Press pushbutton SWl for a 39. Scope should show a 500 msec.
moment, then release. square wave,+/- 250 msec.
Negative pulse should be at O.O
Vdc, +/- 0.5 Vdc.

40. Move scope probe to the follow- 40. Scope should show +5.0 Vdc, +/- 0.5
pins on the microprocessor chip Vdc at all pins.
( IC3): 2, 3, 6, 8, 35, 36

41. Move scope probe to TP2. 41. Scope should show a 1.0 MHz,
+/- O.l MHz square wave.

42. Move scope probe to plug Jll. 42. Scope should show a 500 Hz,+/- 20
Hz square wave, 3.7 VPP (min.)

43. Disconnect oscilloscope ground. 43.

44. Connect voltmeter (tfal or #2) "+" 44. Voltmeter should show +5.0 Vdc,
lead to TPll and "-" lead to +/- 0.5 Vdc.
TP12.

6193, P• 27
EE) UNION SWITCH & SIGNAL

Operation Verification "~

~_;

45. Connect voltmeter "+"lead to Jl 45. Voltmeter should show +12.0 Vdc,
and "-" lead to J2. +/- 1.0 Vdc.

46. Press pushbutton SWl for a 46. LED 7 should light for approx. 2
moment, then release. sec., go dark for 2 sec., light
again etc. indefinetly after SWl
is released.

47. Connect a jumper wire between 47. LED's 1 and 4 should light
plugs J6 and JlO. steadily.

48. Pull J6 end of jumper. 48. LED 1 should remain lit. LED 4
should go dark.

49. Reconnect jumper to J7. 49. LED 1 should remain lit. LED 2
and LED 6 should light.

50. Pull J7 end of jumper. 50. LED's 1 and 2 should remain lit.
LED 6 should go dark.

51. Keconnect jumper to J6. Trip 51. LED 1 should remain lit. LED 4
stopwatch when the jumper is should light when the jumper
closed. is closed. LED 2 should go dark.
LED 1 should go dark 7 minutes,
+/- 2 sec. after the jumper is
closed.
52. Pull J7 end of jumper. 52. LED 4 should go dark.

53. Reconnect jumper to J6. 53. LED 4 should li 6ht and LED's 1 and
should remain dark.

54. Move jumper from J6 to J7. Trip 54. LED's 1, 2 and 6 should light. LED
stopwatch when jumper is closed. 4 should go dark. LED 1 should go
dark 7 minutes,+/- 2 sec. after
the jumper is closed.

55. Pull J7 end of jumper. 55. LED 6 should go dark and LED 1
should remain dark. LED 2 should
remain on.

56. Reconnect Jumper to J7. 56. LED 6 should light and LED 1 should
remain dark. LED 2 should remain
on.

57. Move Jumper from J7 to J6. 57. LED's 1 and 4 should light, LED's
2 and 6 should go dark.

6193, p. 28
 . UNION SWITCH & SIGNAL tt:J
58. Remove jumper from J6, then 58. LED 1 should go dark. LED 7 should
press SWl for a moment. light for 2 seconds, go dark for 2
seconds, etc.

59. Reconnect jumper to J7. Trip 59. LED's 1, 2 and 6 should light.
stopwatch when jumper is closed. LED l should go dark 7 minutes,
+/- 2 sec. after the jumper is
closed.

60. Turn off both power supplies, 60.

disconnect all test hardware
and reconnect chassis wiring to
the Weidmuller plugs. Check
termination of wires via label
inside panel cover.

4.2.3 Conditional Power Supply PCB

4.2.3.1 Test Procedure Conunents

The test procedure for the CPS board is divided into two parts, including
testing of the tuned LC circuit and oscillator stage, and the circuits which
provide power supply output. These procedures are in priority order. A
signal generator is used to simulate the 500 Hz CPU PCB check signal.

Resistor R2 is factory-selected according to the tuning characteristics of the

particular board. This resistor does not have the same values for all CPS
PCB's. If tests show it to be the only faulty component on the board, it may
be replaced with a resistor having the same value. If any other components
require replacement, however, R2 must be selected using a decade resistor box
to insure that receiver tuning characteristics are properly maintained. Go to
Section V for the selection procedure.

4.2.3.2 Recommended Test Equipment

Device Specifications

Oscilloscope (Recommended models: Freq. range: DC to 30 MHz

Tektronix 545, 7603, 515)
Time base: .03 usec. to 12 sec./div.

Time base accuracy: 1%

Dual channel, alternate operation

AC or DC coupling

External sweep mode

Voltage accuracy: +/-3%

Sensitivity: Q.05V/div.

6193, P• 29
m
UNION SWITCH & SIGNAL

Test Equipment (Cont'd)

Device Specifications

Divider Probes, 10:l

(Reconnnended model: Tektronix P6006)

Power Supply Voltage range: 0 to 18 vdc

(Qty. = 2, reconnnended models:
HP 6200B, Harrison Labs 855B)
Current range: 4 amps (min.)

Ripple at any given output within above

range: 10 millivolts, peak-to-peak

Audio Oscillator (Reconnnended models: Freq. range: 10 Hz to 10 KHz

Wavetek 112, 134)
Output amplitude: 10 VPP or 0.5 volts
peak.

Frequency accuracy: 2%

Output impedance: SO ohms

Gated output availability

Power Resistor SO watts, 5%, 4 ohms

Card connector 44-contact dual sided,

US&S J709146-0162

4.2.3.3 Test Set-Up

1. Set up test instruments and components according to Figure S.

2. Turn on 5 and 12 volt power supplies and adjust to nominal voltages, then
turn off supplies.

3. Turn on signal generator and adjust for a Oto +S volts 500 Hz

square-wave. Hook oscilloscope to generator to develop pulse. A period
of 2 milliseconds(+/- 0.1 ms) will produce the 500 Hz signal (freq.=
1/period). Turn off generator when adjustment is complete.

4. Remove PCB trom card file (power off) and attach to card connector.

6193, p. 30
 UNION SWITCH & SIGNAL w
........

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Figure 5. CPS PCB Test Set-Up

4.2.3.4 Procedures

A. Tuned LC Circuit and Oscillator

Operation Verification Possible Problem Area

1. Turn on 5 vdc power 1. 1.

supply and signal
generator.

2. Connect GND of 2. Scope should show 10.5 V 2. Tl, C2, R3, Q2

scope to JS and VPP (+/- 0.2 V) wave with
scope probe to period of 2 milli-
TPl. seconds(+/- 0.1 ms).

6195, P• 31
w UNION SWITCH & SIGNAL

Operation Verification Possible Problem Area

3. Move scope probe 3. Scope should show a 3. D2, D3, C3-C8

to TP3. 4.0 (+/- 0.5) VPP sine Q3, T2
wave having period of
0.4 mS, +/- 0.1 (i.e.
f = 2.5 Khz.)

B. Power Supply Output

1. Leave scope GND on 1. Scope should show 10.0 V 1. Q4-Q7

pins JS. Hook scope (approx) square wave
probe to TP4. having period of 0.4 ms,
+/- O.l ms (f = 2.5 Khz),
as shown in Figure 6.

Note: The wave may not

be a perfect square wave.
Overshoot is not an impor-
tant factor. Voltages in
Figure 6 are approxi-
mate, but should be near
10 volts.

2. Move scope probe 2. Scope should show a 2. Q6, Q7, C9, ClO, T3
to TPS. 9/0 - 10.0 V square wave
having a period of 0.4 ms
+/- O.l ms (f = 2.5 KHz)
as shown in Figure 7.
3. Move scope probe 3. Scope should show a 3. Q8, Q9, T4
to TP6. 21 - 24 VPP square wave
having a period of 0.4
ms,+/- O.l ms, as shown
in Figure 8.

4. Move scope probe to 4. Same wave should be 4. Same components as

TP7. developed as in step 3. step 3.

s. Hook scope GND on J3 s. Check for 10 Vdc +/- 1.0 s. LED 1, D7

and scope probe on Vdc. LED 1 should be on.
J4. Current on 12 Vdc supply
should be 3 amps. Ripple
on output should be no
more than +/- 1.0 Vdc.

6193, p. 32
 UNION SWITCH & SIGNAL w
VOLTAGE

11V
10V
9V ---

Figure 6. CPS PCB Output Test Waveform No. 1

VOLTAGE

4.5±.5
_____ r-:.4ms=l_
-:::! .2m5 __ _

3.5±.5

ov - - - - - - - - - - - - - - - -

-3.5±.5
- 4.5 ± .5 '----..&...------11:;.._------'---+- TIME

Figure 7. CPS PCB Output Test Waveform No. 2

VOLTAGE
•

22V
---
-1:~·~1 ____
~ --- ...........

ov

Figure 8. CPS PCB Output Test Waveform No. 3

6193, p. 33/34
 UNION SWITCH & SIGNAL w
SECTION V
CPS PCB, RESISTOR R2 (TBD) REPLACEMENT

5.1 GENERAL

When a component on the CPS PCB is replaced, a new resistor must be selected
and installed at R2 to insure that the LC circuit is properly tuned. The new
resistor may or may not have the same value as the existing R2 resistor. If
tests determine that R2 itself is faulty (no other faulty components), the
resistor may be replaced directly with a new component having the same value.
The following procedure requires the same test equipment and set-up as
indicated for the CPS PCB in sections 4.2.3.2 and 4.2.3.3, plus a decade
resistor box.

5. 2 PROCEDURE

Operation Verification

1. Connect 5 Vdc power supply and 1.

signal generator. Connect scope
GND probe to JS and probe to TPl.

2. Remove R2 from PCB (leave as much 2.

of the leads as possible) and
install decade resistor box (with.
clip leads). Adjust box to
lK ohm.

3. Turn on power supplies and 3.

instruments.

4. Adjust decade oox until desired 4. Scope should show 10.5 VPP, +/-
signal is obtained at TPl. 0.2 VPP, square wave with a period
of 2.0 +/- 0.1 ms (i.e. f = 500 Hz)

5. Turn off instruments. Determine 5.

the nearest standard value resis-
tor to that on the decade box and
solder resistor onto R2 leads.

6. Turn on instruments and recheck 6. Voltage should still be in the

voltage at TPL range of 10.5 +/- 0.2 VPP.

7. If TPl voltage is not satis- 7.

factory, repeat procedure to
verify that decade box is not in
error.

8. Turn off power supplies before 8.

removing equipment.

6193, P• 35/36
 SERVICE MANUAL 6193
Appendix A

PARTS LIST
For

CTC INTERLOCKING FAILOVER

ODD/EVEN 5-MINUTE TIMER
N451564-0701

August, 1983
WP1462A, Dskt 0223A UNION SWITCH & SIGNAL DIVISION
A-08i83-10-2540-l AMERICAN STANDARD INC./ SWISSVALE, PA 15218

PRINTED IN USA
tij UNION SWITCH & SIGNAL

A.l MICROPROCESSOR TIMER PCB N451605-3901 (See Figure AZ)

Item Description US&S Part No.

ICl Hex Buffer Inverter IC, CMOS J715029-0141

IC2 Quad 2-Input NAND Gate IC J715029-0185
IC3 Microprocessor IC J715029-0247
IC4 EPROM J715029-0285
IC5 Programmable Timer Module IC J715029-0244
IC6 Peripheral Inerface Adapter IC J715029-0246
IC7 5 Volt Regulator IC J715029-0324
IC8-18 Optical-Isolator IC J715029-0236
Dl,10,11,12,13 Diode, 1N4007 1000 Vdc J723912
02-9 Diode, 1N914A J726031
LED 1-7 Light Emitting Diode, MV5054-3 J726150-0121
Rl,17,28,31,34,37,40,44,55 Resistor, l Megohm, 1/4 W J735300
R2,3,8,19,42,47,57,60,61 Resistor, lOK Ohm, 1/4 W J735053
R4-7 Resistor, 3.3K Ohm, 1/4 W J735138
R9,20,43,59 Resistor, 470 Ohm, 1/4 W J735141
RlO, 21,48 Resistor, lOOK Ohm, 1/4 W J735137
Rll, 22,49 Resistor, 4.7K Ohm; 1/4 W J735034
Rl2,23,50 Resistor, 220 Ohm, l W J735519-0507
Rl3,18,24,29,46,51,56 Resistor, lK Ohm, 1/4 W J735031
Rl4, 25, 52 Resistor, 820 Ohm, 1/4 W J735246
Rl5,26,45,53 Resistor, 510 Ohm, 1/4 W J735159
R30,33,36,39 Resistor, 750 Ohm, 1/4 W J735056
R32,35,38,41 Resistor, lK Ohm, 1/2 W J720882
R58 Resistor, 2 Ohm, 5 W J723078
Cl,4-8,10,12,14 Capacitor, l Mfd., 50 Vdc J709145-0330
C2,3 Capacitor, 27 Pfd., 500 Vdc J706936
C9, 11, 13, 15 Capacitor, .Ol Mfd., 100 V J709145-0166
Cl6 Capacitor, 4.7 Mfd., 35 Vdc J706422
Cl7 Capacitor, 100 Mfd., 20 Vdc J709144-0099
Cl8 Capacitor, 1 Mfd., 35 Vdc J706387
Ll Choke, VKZ00/10-38 J709161
XTAL l Crystal, Quartz, 4.00 Mhz. J709242-0009
Ql,5,11 Transistor, 2N2222 J731256
Q2,6,12 Transistor, 2N3964 J731398-0050
Q3, 7, 13 Transistor, D44H2 J731398-0080
Q9 Transistor, 2N3117 J731398-0079
QlO Transistor, 2N4037 J731291
Vl-4 Varistor, Metal Oxide, 27 Vdc J735545
IC7 Heat Sink, Alum. J792469
IG4 IC Socket, 24-Pin J725840-0003
IC5 IC Socket, 28-Pin J725840-0002
IC3,6 IC Socket, 40-Pin J725840-0001
TPl-12 Test Point Lug J703175
SWl Pushbutton Switch, SPDT J725 707-0181
Jl Weidmuller Term. Block, 15-Plug J776709
QlO Transistor Mtg. Pad J792072
Ql,2,5,6,9,ll,l2 Transistor Mtg. Pad J792437

6193, P• A2
 ':r:I
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a1::11::1a c14 LJR4o
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ri ..--. •
('.)
R50 a:a: C15 a:Uo,ao C13LJ a:a: IC 1
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LED1 IC8 IC9
....._ •
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O
R25 IC10
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a: a: "' IC16
R1
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C2 C3 le :1
0
p O ri~n
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o ~ nn n
: • ....._ TPs uu
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uu c.:a
cs

ri 0
(l) U -"- e ..__, UN - " - e ..__, R4 5
p v1 R9 c
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0 llJ u uur An!"QTP4 n llJ
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:; ;;
06
DS R42 ~
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e
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...:J
1--' 010 RS C :I c c :a
L.:.. :I
I ; ;I R6
MICROPROCESSOR TIMER
.."°w N451605-3901 REV .
R61 R4a R3

.
't:I

e
~
QJ UNION SWITCH & SIGNAL

A.2 CPS PCB N451605-400l (See Figure A2)

Item Description US&S Part No.

Rl, 13 Resistor, 47K Ohm, 1/4 W J735035
R2,4,5,ll,16,17 Resistor, 47K Ohm, 1/4 W J735035
R3 Resistor, 39 Ohm, 1/4 W J735519-0462
R4, 5, 11, 16 Resistor, lK Ohm, l/4W J735031
R6 Value TBD
R7 Resistor, 510K Ohm, 1/4 W J735405
R8 Resistor, 180K Ohm, 1/4 W J735519-0359
R9 Resistor, 3K Ohm, 1/4 W J735052
RlO Resistor, 100 Ohm, l/4W J735050
Rl2 Resistor, lOK Ohm, l/4W J735053
R14 Resistor, 30K Ohm, l/4W J735068
Rl5 Resistor, 510 Ohm, l/4W J735159
Cl,8 Capacitor .l Mfd., 50 Vdc J709145-0330
C2 Capacitor, 0.47 Mfd., 100 Vdc J709145-0028
C3 Capacitor, 4.7 Mfd., 35 Vdc J706422
C4 Capacitor, 5 Mfd., 50 Vdc J709145-0482
cs Capacitor, 0.5 Mfd, 200 Vdc J702827
C6 Capacitor, .01 Mfd., 100 Vdc J709075
C7 Capacitor, .022 Mfd. 100 Vdc J706564
C9, 13 Capacitor, .0056 Mfd. 50 Vdc J709145-0504
Cl0,12 Capacitor, 47 Mfd. 16 Vdc J709145-0505
Cll Capacitor, 580 Mfd. 20 Vdc J709144-0074
Dl,2,3 Diode, 1N914 J726031
D4 Zener Diode, LVA462A J726150-0079
D5,6 Diode, 1N4003 200 Vdc J723555
D7 Bridge Rectifier J726030-0102
LED 1 Light Emitting Diode MV5054-3 J726150-0121
Ql,2,5 Transistor, 2N3117 J731398-0079
Q3,4 Transistor, 2N3964 J731398-0050
Q6 Transistor, 2N2270 J731186
Q7 Transistor, 2N2905 J731206
Q8,9 Transistor, 2N3055 J731263
Tl Inductor, Pot. Core N451030-5721
T2 Inductor, Pot. Core N451030-5708
T3 Inductor, Pot Core N451030-5709
T4 Transformer N451039-4601
Ll Inductor, Pot Core N451030-5710
TP Test Point Terminal J703175
Jl Weidmuller Terminal Block, 7-Plug J776708
Ql-5 Transistor Mtg. Pad J792437
Q6,7 Transistor Mtg. Pad J792072
Q8,9 Heat Sink J792469
TPl-7 Test Point Pin J703175

6193, P• A4
 UNION SWITCH & SIGNAL

_J
I
L _jlJL
- 0
n
_J
CONDITIONAL
POWER SUPPLY
N451605-400 1
REV.
_j.r •

F451605-40, Rev. 0

Figure AZ. CPS PCB Component Layout

6193, P• AS
t:t::f UNION SWITCH & SIGNAL

A.3 POWER FILTER PCB N451605-5601 (See Figure A3)

Item Description US&S Part No.

Dl Suppressor, Trans. Volt J792736-0002

D2 Diode, 1N4003 200 Vdc J723555
Cl Capacitor, 2300 Mfd., 50 Vdc J709145-0350
C2 Capacitor, 0.47 Mfd., 200 Vdc J706152
Ll Choke, 1 MH, 10 Amp J709538
Fuse 1 Fuse, 5 Amp, 32 Vdc J710040
Fuse l Fuse Clip J576794
TBl Weidmuller Terminal Block, 10-Plug J725715-0007
TB2 Weidmuller Terminal Block, 12-Plug J725 715-0008
TPl,2 Test Point Lug J703175

ISS-:-:i
r-.c= T81
==110
L1
TO SWITCH
•
OTP1 war: _
...a:~
ri D==D 8 ...J Ct
-co
u..,,
C2

LJ
FUSE 1

D2 c ll [] D1
EB 3::
a:
win
I

C1 oin
a....,.

c ~
z
TP20
L 1 LEAD L 1 LEAD
. .
L:J ..:J

D451605-56, Rev 1

Figure A3. Power Filter PCB Component Layout

6193, P• A6