MICROSENSE TRAFFIC CONTROLLER HANDBOOK, …MICROSENSE TRAFFIC CONTROLLER HANDBOOK, INSTALLATION AND MAINTENANCE MANUAL . Doc No. 40-9001-008 Iss 11 MTC Handbook, Installation and Maintenance

Doc No. 40-9001-008 Iss 11 MTC Handbook, Installation and Maintenance Manual

File 9001008iss11 Microsense Systems Limited 2000 Page 1 of 44

MICROSENSE TRAFFIC CONTROLLER

HANDBOOK, INSTALLATION AND MAINTENANCE MANUAL


Page 2 of 44 Microsense Systems Limited 2000 File 9001008iss11

LEFT INTENTIONALLY BLANK



MICROSENSE SYSTEMS LIMITED

PRODUCT: Microsense Traffic Controller, (MTC)

DOCUMENT TITLE: Handbook, Installation and Maintenance Manual

DOCUMENT NUMBER: 40-9001-008 DATE: 15/06/00

PREPARED BY: D. Christer FILE: HABA2171.DOC

FUNCTION: Hardware Engineer HELD: Engineering

DOCUMENT ISSUE HISTORY

ISSUE DATE CHANGE/ECN NUMBER

02 03 04 05 06 07 08 09 10 11

15/01/92 06/01/92 06/01/92 09/11/92 09/03/93 25/05/94 01/05/95 14/12/95 29/05/96 15/06/00

ECN 90281 ECN 91393 ECN 91394 Document restructured. ECN 92507 ECN 93587 ECN 94735 ECN 94795 ECN 95922 ECN 94779 & 96948 ECN 00244

COPYRIGHT MICROSENSE SYSTEMS LIMITED The copyright in this document is vested in Microsense Systems Limited. It may not be reproduced in whole or in part in any form without the prior consent of Microsense Systems Limited, and then only on condition that this notice is included in any reproduction. Unless otherwise expressly stated, neither this document nor any information contained in it shall be deemed to form part of a binding offer or contract on the part of Microsense Systems Limited. Microsense Systems Limited reserves the right to alter without notice any information in this document in pursuit of its policy of continued product improvement and enhancement.



HEALTH AND SAFETY WARNING

This equipment is connected to Mains Voltage. The mains power supply MUST be isolated before any connections are made/removed or maintenance work commenced.

This equipment MUST only be connected to the specified incoming mains power supply. Persons permitted to use and/or work on this equipment must be appropriately qualified and trained. The contents of

this handbook and all other relevant documents, safety notes, labels, etc MUST be observed.

This equipment MUST NOT be used or modified in any other way other than that for which it is intended. Any such use or modification will invalidate any warranty and may invalidate Department of Transport Approvals. Note that the size and weight of the outercase is such that 2 persons will normally be required to lift it safely.

CE MARKING

Where this equipment carries a CE Marking, the marking applies to EU Council EMC Directive 89/336/EEC (as amended by Article 9.4 of the Telecommunications Terminal Equipment Directive and Council Directive 92/31/EEC) when the equipment is installed and used as described in this Handbook.



TABLE OF CONTENTS

1. INTRODUCTION 8

1.1 Abbreviations and Terms 8

1.2 Electrical Installation Practice 8

2. PRODUCT DESCRIPTION 8

3. SPECIFICATIONS 9

3.1 Mains Supplies 9

3.2 Internal Power Supplies 9

3.3 Fusing 10

3.4 Mechanical 11

3.4.1 Access and Mounting Arrangements 11

3.4.1.1 Root 11

3.4.1.2 Front Door 11

3.4.1.3 Manual Panel 11

3.4.1.4 Electricity Board Supply 11

3.4.1.5 Telephone Line Termination 11

3.4.1.6 Hazardous Voltages 12

3.4.1.7 Removal of Electronic Equipment 12

3.4.2 Equipment Practice 12

3.5 Environmental 12

3.6 Inputs 13

3.6.1 General Purpose Inputs 13

3.6.2 Solar Cell 13

3.6.3 Engineer's Terminal 13

3.6.4 Lamp Monitoring Toroids 13

3.7 Outputs 13

3.7.1 Lamp Drives 13

3.7.2 General Purpose Outputs 13

3.7.3 DFM Lamp 13

4. HARDWARE FACILITIES 14

4.1 General 14

4.2 Allowable Combinations of Facilities 15

4.3 Hardware Module Descriptions 15

4.3.1 CPU Module 15

4.3.1.1 CPU Board 15

4.3.1.2 Input/Output Interface Board 16

4.3.1.3 Integral Lamp Monitor (ILM) Board 17

4.3.1.4 Diagnostic LEDs 17

4.3.2 LSC Module 18

4.3.2.1 Interconnection with CPU Module 18

4.3.2.2 Green State Sensing 18

4.3.2.3 Lamp Switching 18

4.3.3 Power Module 18

4.3.3.1 Dimming 19



4.3.4 Manual Panel 19

4.3.5 Low Voltage Termination Panels 19

4.3.6 E.L.V Wait Lamp Facility 19

5. INSTALLATION 21

5.1 Wiring Practice 21

5.2 Installing the Root 21

5.3 Outercase Installation 21

5.4 Electricity Board Supply 21

5.5 Termination of Signal Cables 22

5.6 Cable Insulation and Continuity Tests 22

5.6.1 Insulation Tests 22

5.6.2 Conductor Continuity Tests 22

5.6.3 Earth Continuity Test 22

5.6.4 Aspect Loads 23

5.6.5 Earth Bonding 23

5.7 Connecting the Intersection Cables 23

5.7.1 Solar Switch 23

5.7.2 Regulatory Signs 23

5.7.3 Auxiliary Mains Supply 23

5.7.4 Mains Detector Supply 23

5.7.5 Phase Lamp Drives 23

5.7.6 Low Voltage Connections 24

5.7.7 Low Voltage Detector Supply 24

5.8 Installation of Electronic Modules 24

5.8.1 Power Module 24

5.8.2 CPU Module 25

5.8.3 LSC Module 25

5.8.4 Manual Panel 26

5.9 Switching the Controller On 26

5.10 Sealing the Base 27

6. MAINTENANCE 28

6.1 General 28

6.1.1 Replaceable Items under First Line Maintenance 28

6.2 Replacement of First Line Maintainable Items 28

6.3 Fault Finding 28

6.3.1 Quick Reference Fault Finding Table 29

6.4 Spares 32

6.4.1 Fuses 32

6.4.2 Modules 33

6.4.3 Sundry Spares 33



Figure 4.1(a) - Equipment Layout 34

Figure 4.1(b) - Equipment Layout 35

Figure 4.1(c) - Equipment Layout 36

Figure 4.1(d) - Equipment Layout 37

Figure 5.2 - Installing the Root 38

Figure 5.3 - Outercase Installation 39

Figure 5.7(b) - Top Mains Voltage Termination Panel 41

Figure 5.7(c) - Bottom Low Voltage Termination Panel 42

Figure 5.7(d) - Top Low Voltage Termination Panel 43

Figure 6.0 - ELV Transformer Mounting Plate 44



1. INTRODUCTION

This document is intended to help the user install and maintain the Microsense Traffic Controller, (MTC). Installation is straightforward and setting up has been designed to be easily and quickly achieved. Using an Engineer's Terminal, the extensive software monitoring and fault logging facilities of the controller allow faulty equipment to be quickly pin-pointed. For further details refer to the MTC Handset Command Manual, (doc no. 40-9001-030).

This document is not intended to give any details of controller facilities, for this information refer to the MTC Facilities Manual, (doc no. 40-9001-009). 1.1 Abbreviations and Terms CPU - Central Processing Unit DFM - Detector Fault Monitoring Dtp - Department of Transport FT - Fixed Time IEE - Institute of Electrical Engineers LMU - Lamp Monitoring Unit LSC - Lamp Switch Card MOVA - Microprocessor Optimised Vehicle Actuation MTC - Microsense Traffic Controller OC - Open Circuit OMU - Outstation Monitoring Unit OTU - Outstation Transmission Unit PROM - Programmable Read Only Memory RAM - Random Access Memory RTC - Real Time Clock SC - Short Circuit SDE/SAE - Speed Discrimination/Speed Assessment ZXO - Zero Voltage Cross-Over 1.2 Electrical Installation Practice

The installation of this equipment must conform to the requirements of the IEE Regulations and the Electricity at Work Regulations, (1989). Deviations from these requirements could not only be unsafe, but could lead to incorrect or sub-standard operation.

2. PRODUCT DESCRIPTION The MTC comes in a single door outercase and complies with the latest DTp specification TR0141, 'Microprocessor Based Traffic Signal Controller for Isolated, Linked and Urban Traffic Control Installations'. The controller equipment consists of a number of modules which are mounted to the sides and rear of the outercase interior. An optional swing-out frame is available for mounting of ancillary equipment such as OMU, OTU, detector rack, etc. All access to the controller is via a single front door. Manual facilities are available behind the Manual Panel access flap, situated on the front door of the outercase. See section 3.4.1 for more details.



3. SPECIFICATIONS 3.1 Mains Supplies Voltage:- 220 or 240 volts +15% -20% (48-52Hz).

Current:- 13 amps total controller load at 240 volts when a 10 amp, (small) Dimming Transformer is fitted.

20 amps total controller load at 240 volts when a 20 amp, (medium) Dimming Transformer is fitted.

30 amps total controller load at 240 volts when a 30 amp, (large) Dimming Transformer is fitted.

The controller will work normally when the mains is interrupted for up to 50 mS. 3.2 Internal Power Supplies

The power supplies listed below are available for use by ancillary equipment, which may be within or external to the outercase.

Auxiliary AC supply:- 18 volts AC +/-3% @ 75 VA isolated from mains voltages, nominal Mains supply, when a 10 amp, (small) Dimming transformer is fitted.

or 18 volts AC +/-3% @ 75 VA isolated from mains voltages, nominal Mains supply, when a 20

amp, (medium) Dimming transformer is fitted.

or 18 volts AC +/-3% @ 100 VA isolated from mains voltages, nominal Mains supply, when a 30 amp, (large) Dimming transformer is fitted.

Detector Supply:- 24V DC +/-3% fused at 4A. Mounted on the I/O termination pcb, this is derived from the 18

volts AC supply, and is used to power the detector circuits. Auxiliary Mains:- As section 3.1 above, but at 5 amp maximum.

The auxiliary mains is connected to a switch, which breaks the live and neutral, and a fuse which is mounted on the power panel.

Note: the fuse is only on the live feed.

Maintenance Socket:- As section 3.1 above, but at 13 amps maximum. The socket includes an RCCB to BS4293 which will trip at earth fault currents of 30 mA and within 30 ms, isolating the live and neutral lines.



3.3 Fusing The following fusing is provided. Note that where a current value appears in brackets () this is referring to a particular size of Power Module, (i.e. 10A, 20A or 30A), (see also section 4.3.3 ). ITEM PROTECTION LOCATION Cabinet Switch:- RCCB, CONN Unit and Detector Mains Supply 15A, CARTRIDGE Elec. Board Supply Panel Cabinet Switch:- Contr. Supply, (10A) 15A, CARTRIDGE Elec. Board Supply Panel Contr. Supply, (20A) 20A, CARTRIDGE Elec. Board Supply Panel Contr. Supply, (30A) 30A, CARTRIDGE Elec. Board Supply Panel Controller Switch 13A, 1" Power Module, (10A) Controller Switch 20A, CARTRIDGE Power Module, (20A) Controller Switch 30A, CARTRIDGE Power Module, (30A) CONN Unit 5A, 1" Power Module Detector Supply, (mains) 5A, 20mm A.S. Power Module F6 Detector Supply, (low voltage) 5A, 20mm A.S. Power Module F7 Regulatory Signs minimum 5A, 20mm A.S. Power Module F8 Solar Cell 100mA, 20mm Q.B. Power Module F9 Bright/Dim Sense 100mA, 20mm Q.B. Power Module F10 Controller PSU Mains I/P 1.25A, 20 mm A.S. Power Module F3 24 V Logic Supply 1.25A, 20 mm A.S. Power Module F2 12 V Logic Supply 4A, 20 mm Q.B. Power Module F1 LSC Module Mains Supply 15A, 1.25" HRC Q.B. Power Module F4 (10A) LSC Module Mains Supply 2 x 15A, 1.25" HRC Q.B. Power Module F4/F5 (20A) LSC Module Mains Supply 2 x 20A, 1.25" HRC Q.B. Power Module F4/F5 (30A) LSC Triac Drivers 2 x 7 A, 1.25" HRC Q.B. LSC CPU 12 V Logic Supply 3.15A, 20mm A.S. CPU Board F1 CPU 24 V Logic Supply 1A, 20mm A.S. CPU Board F2 CPU 0 V Logic Protection 100 mA, 20mm Q.B. CPU Board F3 0V external 100mA, 20mm Q.B. Low voltage termination pcb Detector Supply 4A,20mm Q.B. Low voltage termination pcb FM Lamp driver protection 250mA 20mm Manual Panel PCB (Iss 4 onwards PCB, Filament Bulb option only)

WARNING : THE CORRECT FUSE TYPE AND VALUE MUST BE USED. USE OF INCORRECT FUSES MAY

CAUSE PERMANENT DAMAGE TO THE CONTROLLER OR COMPROMISE ITS SAFETY. SUCH DAMAGE IS

NOT COVERED BY WARRANTY.



3.4 Mechanical Outercase dimensions:- height - 1211 mm width - 733 mm depth - 544 mm Root dimensions:- height - 370 mm width - 723 mm depth - 509 mm Material:- Outercase - 3 mm aluminium coated to BS381C NO. 693. Root - Hot dip galvanised mild steel. Weight total:- 115 Kg, (for a 32 phase controller) 3.4.1 Access and Mounting Arrangements The general arrangement is such that, with the exception of the transformer and mounting plate, all equipment is directly fixed to the Outercase and the Outercase in turn is fixed directly to the Root. 3.4.1.1 Root The Root is manufactured in one piece and must be concreted into the ground. When installed, approximately 50mm of the root should protrude above ground level, (see also section 5.2). 3.4.1.2 Front Door There is one main door at the front of the outercase, whereby access to the hardware and cable terminations can be gained. The front door also provides access to the Electricity Board supply termination and also the telephone line termination, (if required). The main door is secured top and bottom by compression locks, (standard GEC type 'T' key) and in the centre by an S18 lock. As there is only one main outercase door and the Manual Panel access is on this door, the controller can easily be mounted against a wall or in an alcove. 3.4.1.3 Manual Panel There is a small access door on the front door of the outercase. The Manual facilities are located behind this door, which is secured by a standard Type 900 lock. It is not possible to gain access to any other equipment from behind this door. 3.4.1.4 Electricity Board Supply Access to the Electricity Board supply panel can be gained by opening the main outercase door and also the large equipment swing frame, (if fitted). A wooden panel is secured to the bottom, rear of the outercase interior for termination of the Electricity Board supply. 3.4.1.5 Telephone Line Termination As an option it is possible to terminate an armoured, 4 wire Telephone cable to a secondary jack socket located within the outercase, on a termination panel.



The telephone line termination has been designed and sited so as to prevent it becoming accidentally connected to any hazardous voltage, (see section 3.4.1.6). 3.4.1.6 Hazardous Voltages Any voltage greater than 25V AC RMS or 60V DC is covered in such a manner as to prevent accidental connection to the operator or the telephone line. Any cover, whose removal will expose a voltage of greater than 25V AC RMS or 60V DC is clearly labelled with a Hazardous Voltage warning. 3.4.1.7 Removal of Electronic Equipment By the disconnection of mountings and connectors, it is possible to remove all of the electronic equipment from the outercase, without disturbing the intersection cabling, (see also section 5.8). 3.4.2 Equipment Practice The electronic equipment within the controller outercase is divided into the following four top-level modules :- 1) CPU Module, (see section 4.3.1) 2) LSC Module, up to 4 off, (see section 4.3.2) 3) Power Module, (see section 4.3.3) 4) Manual Panel, (see section 4.3.4) The intersection cable terminations are made to panels secured to the rear of the outercase interior. These panels are connected to the electronic modules via cableforms. The cableforms are attached to the modules via PCB connectors, thereby allowing easy removal. This arrangement permits easy access for an installation/maintenance engineer. The termination blocks used for the intersection cables will accept four 1 mm square solid core wires per terminal. The controller has provision for detectors to be mounted either in a small 12" x 3U rack secured to the rear of the outercase interior or in a standard 19" x 3U rack fitted in the optional swing-out equipment frame. 3.5 Environmental The controller has been environmentally tested in excess of the requirements of the latest DTp Specification TR0141.



3.6 Inputs 3.6.1 General Purpose Inputs There are up to 64 inputs available (depending on software fitted) each with the following specification:- Open Circuit voltage - +24 volts +/- 20% Short Circuit current - < 10 mA Low input state - 250 Ohms max High input state - 100K Ohms min Maximum applied voltage - 75 volts (application of voltages greater than this will not damage any input circuits, other than the one in question). Inputs may be configured for either high or low as the active state. 3.6.2 Solar Cell Dim state - Mains voltage Bright state - Open circuit 3.6.3 Engineer's Terminal Connector - 25 way female 'D' type, (DCE) Transmission details - 1200 Baud, 7 data bits, (+ even parity), 1 start bit, 1 stop bit, full duplex RS 232 circuits - TX data (all at V24 levels) RX data DTR Supply - + 5 volts on pins 9 and 10, (at 250 mA max)

Minimum character set - A to Z 0 to 9 . + - = ? or ! or * / or : or ; 3.6.4 Lamp Monitoring Toroids The ILM Card has provision for 48 toroid inputs, which are connected by means of individual 2 pin connectors. The toroids are fitted over the looms between lamp switch cards and termination panels, or over the street cables themselves. The toroids can be installed on the cables with either polarity, the software automatically compensates for the phase of the measured signal. 3.7 Outputs 3.7.1 Lamp Drives Mains voltage at 4 amps max per drive, (Red, Amber/Wait Indicator and Green aspects). 3.7.2 General Purpose Outputs There are up to 32 relay isolated outputs available (depending on software fitted) for use each with the following specification:- Short Circuit impedance - 180 Ohms +/- 5% Short Circuit current - >/= 50 mA Open circuit impedance - >/= 100K Ohms Maximum applied voltage - 75 volts (application of voltages greater than this will not damage any output circuits, other than the one in question). 3.7.3 DFM Lamp 24V, 2.8W Miniature Edison Screw (MES), or high brightness LED.



4. HARDWARE FACILITIES 4.1 General The equipment, housing, power supplies, etc have been designed to accommodate a wide range of facilities. Refer to figures 4.1 (a), (b), (c) & (d) for equipment layout of the controller. The following list summarises all the hardware facilities of the MTC. Manual Panel - signals On/Off switch - lamps test button - DFM lamp - mode select switch, (normal, manual & FT) - part-time inhibit switch - stage select buttons and indicators, (7 + all red) - prohibited move selected indicator - awaiting selection indicator - higher priority mode running indicator - manual mode not available indicator - manual panel door switch CPU Card - handset connector - configuration data PROM

- battery backed config data RAM, (working timings) Note:- Battery Link (LK1) must be

- battery backed real time clock fitted and charged for at least 12hrs

- battery before battery will function. - CPU RESET button - fault log entry indicator - warning log entry indicator - watchdog indicators - processor running indicators - 32 general purpose buffered inputs Lamp Switch card - 4 red aspect phase drives - 4 amber aspect/wait indicator phase drives - 4 green aspect phase drives - green voltage sense circuits - lamp fuses I/O Interface Card - 32 general purpose buffered inputs - 32 relay isolated outputs - select power-down state of output, (OC or SC) - direct interface to Ferranti OTU available via low voltage termination pcb. Optional ILM Card - 48 channels of lamp monitoring inputs - select card address Power Supply Module - power supply for input and output circuits, (+24V) - logic power supply, (+12V) - controller mains switch - maintenance socket and RCCB - auxiliary equipment mains switch, (fused) - mains fusing



Mains Voltage Termination panels - solar cell input - aspect driver outputs - lamp returns - regulatory signs power - auxiliary mains supply, (after fused switch) - detector mains supply - bright/dim sense voltage Low Voltage Termination Panels - detector/push-button inputs - OTU interface - telephone line termination - 24V detector power supply Outercase - Electricity Board termination panel and cabinet switch - CET type cable termination bars - mains/dim transformer - manual panel access door - 12" x 3U rack, (for detectors, SDE/SAE, LMU, etc) Optional Swing-out Equipment Frame, (small or large) - 19" x 3U rack, (for detectors, SDE/SAE, LMU, etc) - OTU - OMU - MOVA unit 4.2 Allowable Combinations of Facilities The combinations of facilities and equipment that can be used together, both internally and externally, will increase in time as suppliers of ancillary equipment request the use of their equipment to be endorsed. Equipment that has been endorsed for use with the controller is as shown in the TAMP document, (doc No. 40-9001-010). 4.3 Hardware Module Descriptions 4.3.1 CPU Module The CPU Module consists of a metal casing containing the CPU Board and the I/O Interface Board, (if required). Each board has connectors along its edges which locate with apertures in the module casing to allow for connection of the cableforms which lead to the termination panels and other modules. The CPU module also has a number of diagnostic LEDs that indicate the status of the controller. 4.3.1.1 CPU Board This contains the Main Processor and the Secondary Processor. The two processors communicate with each other via a serial data bus. Wherever possible, I/O is handled by the Secondary Processor, freeing the Main Processor from low level tasks and allowing maximum provision for future software expansion. Each processor has its own hardware watchdog, both of which are interlocked to the signals on/off relays, ensuring that the signals are extinguished in the event of either watchdog failing. The Main Processor is an INTEL 80186 and is reserved to perform the 141 functions and any I/O essential to them, such as the Handset, Diagnostic LED drives and Watchdog. Configuration data, (junction details) is held in a PROM which is accessed by the Main Processor. Handset modifiable configuration data is downloaded to RAM, (handset RCP command) where it is accessed by the Main Processor. This RAM data is backed-up by a battery fitted to the CPU Board, which is capable of supporting the handset modifiable configuration data and the clock during a power failure. The Secondary Processor is an INTEL 8031 which performs the following functions:- - LSC control - Independent Green Conflict Monitoring, (conflicts, compliance and sense discrepancies) - Monitoring of 32 standard inputs



- Monitoring/Control of Manual Panel - Monitoring/Control of I/O Interface Board - Monitoring/Control of ILM Board The CPU board provides 32 general purpose inputs, (0-31) that can be used for inputs from the street, (e.g. detectors, push-buttons, etc). Inputs from ancillary equipment, supplied by Microsense Systems Ltd, that are within the controller outercase need not be isolated from the ancillary equipments power supply. Inputs from ancillary equipment that is external to the controller outercase must be via isolated relay contacts or solid state equivalent. For input specification see section 3.6.1. 4.3.1.2 Input/Output Interface Board Two types of I/O interface board are available identified by the number on the silkscreen of the pcb. On earlier controllers, this is 50-9003 On later controllers, this is 50-9334 The I/O cards differ in a number of respects, specifically the connector pin assignments, their compatibility with the various types of termination panel, and the functions of the plug-in links on the card.

Earlier type I/O Cards (Number 50-9003, Small metal cased relays) The 50-9001 I/O interface board has been manufactured in three different variants: 1) 8 relay isolated outputs and 8 inputs 2) 16 relay isolated outputs and 16 inputs 3) 24 relay isolated outputs and 24 inputs. These inputs and outputs can be used for an OTU interface and can be connected directly to a Ferranti OTU using ribbon cables. The same PCB is used for both variants, with components fitted as required. For input specification see section 3.6.1 and for output specification see section 3.7.2. Normally open and normally closed contacts are available from each relay and either may be selected by use of the plug in links on the I/O card. The options available are as follows :- Position A - power-down state = SC Position B - power-down state = OC Normally open and normally closed contacts are available from each relay and either may be selected by use of the plug in links LK0 - LK23 on the I/O card. Links 0 - 23 correspond to outputs 0 - 23 respectively. Link 24 allows Input 16 to be connected to the TXCNF bit on certain OTU’s (when connected directly to the I/O card by means of ribbon cables) If this function is required then link 24 should be set to the ‘A’ position , otherwise it should be set to the ‘B’ position. Links 25- 28 allow outputs 16 and 17 to be connected to the DCR1 and DCR2 bits on certain OTUs(when connected directly to the I/O card by means of ribbon cables). If this function is required, the links should be set to the ‘B’ position, otherwise they should be set to the ‘A’ position.



Later type I/O Cards (Number 50-9334, Large plastic cased relays) The 50-9334 I/O interface board is available in two different variants as follows :- 1) 16 relay isolated outputs,(0-15) 2) 32 inputs, (32-63) and 32 relay isolated outputs, (0-31) These inputs and outputs can be used for an OTU interface and can be connected to a Ferranti OTU using ribbon cables via the low voltage termination pcb. The same PCB is used for both variants, with components fitted as required. For input specification see section 3.6.1 and for output specification see section 3.7.2 . Normally open and normally closed contacts are available from each relay and either may be selected by use of the plug in links LK0 - LK31 on the I/O card. Links 0 - 31 correspond to outputs 0 - 31 respectively. The options available are as follows :- Position A - power-down state = OC Position B - power-down state = SC Link 32 selects the software address of the I/O card, and should be left in the factory set position (furthest from the heatsink) unless specifically advised otherwise. Note that incorrect operation of the I/O card will result if this link is set to the wrong position. 4.3.1.3 Integral Lamp Monitor (ILM) Board This optional board provides inputs for 48 channels of lamp monitoring. The toroid leads must be connected sequentially starting at PL1. The board connects to the CPU card at connector P19, daisy chaining from the connector to the IO card (if present). The toroids will normally be installed around the looms between LSCs and terminal blocks, the exception is when a phase drive is to be split between monitoring channels. For such split phase monitoring it will be necessary to install the toroids around the lamp drive cabling. The ILM card is provided with two links, situated next to the CPU ribbon connector (PL8), these links define the address of the card. Four combinations of link sets are possible but the normal setting is with both links in the position remote from connector (PL8). Issue 7 main processor (C2409001 010 to 017) and issue 3 secondary processor (C5129001007) or later software is required to make use of the ILM facility. 4.3.1.4 Diagnostic LEDs A number of diagnostic LEDs exist to indicate controller status. These LEDs can only be seen from inside the outercase when the CPU module is closed. A description of each LED follows:- Watchdog Failure LEDs

A watchdog failure LED exists for each processor. When either watchdog fails then the associated Watchdog Failure LED will be lit and the signals will be extinguished. When a watchdog has occurred the CPU RESET button must be pressed to get the software running again.

Processor Running LEDs

A separate Running LED exists for each processor. Under normal operation this LED pulses slowly at a rate of 0.5Hz. Should the LED become permanently ON or OFF then its associated processor is inoperative. During initialisation the LED for the Secondary Processor flashes at the faster rate of 2.5Hz until it receives configuration data from the Main Processor.



Fault Log Entry LED

Under normal operation this LED will be extinguished. Should the LED become illuminated, this indicates that there is an entry in the controller's Fault Log, (this will also switch the signals off). This LED is controlled by the Main Processor.

Warning Log Entry LED

Under normal operation this LED will be extinguished. Should the LED become illuminated, this indicates that there is an entry in the controller's Warning Log. This LED is controlled by the Main Processor.

4.3.2 LSC Module The LSC Module consists of a metal casing containing one or two LSCs, each of which is capable of controlling four phases, (i.e. 12 aspect drives). Each LSC has a mimic display of the triac drive states on LEDs which are visible through apertures in the side of the module casing. 4.3.2.1 Interconnection with CPU Module Each LSC is connected to the CPU Module via two separate cables; the common data bus cable and the personality cable. The common data bus cable carries the signals common to all LSCs and comprises of 12 data lines, (1 per aspect drive), DC power and ground. This is a ribbon cable with daisy chained IDC connectors at appropriate points, to connect to all LSCs in the controller. The personality cable carries the signals specific to each LSC and comprises a latch enable line, 8 green sense signals and a ground. The CPU Module has 8 separate connectors for the personality cables of all possible LSCs in an MTC. The LSC inputs are pulled low internally, such that all triacs will remain in the off state, should the data bus cable become disconnected. 4.3.2.2 Green State Sensing The green sense signals generated on the LSC are routed back to the CPU board via the personality cable. These signals are used by both processors in performing Green Conflict Monitoring. The green sensors detect the presence of a voltage above a threshold level, which lies between the limits of 24V - 48V RMS. The sensors detect the presence of full-wave AC, half cycles of either polarity, or DC of either polarity. The signals represent a lamp on state by a low voltage, (logic '0' level). The green sense inputs on the CPU board have been designed, such that all greens appear to be on if the personality cable becomes disconnected, (thereby forcing the CPU to extinguish all of the lamps, due to a green non-compliance fault, a green conflict fault or both). 4.3.2.3 Lamp Switching Triacs are used to switch the mains to the lamps. The triacs are turned on at the positive-going ZXO of the mains. The triacs are turned off at zero current. The timing for this is derived from the Secondary Processor. Each triac is capable of switching 4 amps continuously at the nominal mains voltage. However each LSC has an overall current switching capacity of 12 amps. 4.3.3 Power Module The Power Module contains the signal relays, bright/dim relay, fusing and ancillary supplies for detectors, OTU/OMU, etc. It also provides two unregulated DC supplies, one of which powers the logic and a separate supply for relays and ancillary equipment. Power Modules are available in 10A, 20A and 30A ratings, depending upon the loading of the installation. The ZXO generator and Solar Switch conditioning are located on the Power Module, so that the CPU Module is free of mains voltages. The Power Module's components are contained in a metal case which is secured to the rear of the outercase interior.



4.3.3.1 Dimming Provision has been made for a Photo Electric cell, (solar switch) to be connected to the controller, such that the intensity of the signals, (aspects and wait indicators) can be controlled to a bright or dim state. Dimming is performed by use of an auto-transformer. Three different sizes of auto-transformer are available for different controller loadings, 10 amps (small), 20 amps (medium) and 30 amps (large). The Dimming transformer has input tappings for 220V or 240V operation, with output tappings to provide the following dimming voltages:- - 120 volts +/- 5 Volts - 140 volts +/- 5 Volts - 160 volts +/- 5 Volts A relay is provided to switch the signals between the bright and dim states. The relay is capable of handling or switching the maximum load expected on the controller, (30 amps). 4.3.4 Manual Panel This panel is mounted on the outercase door behind an access flap and provides facilities for mode selection and manual stage control. The Manual panel is connected to the CPU board via a 34-way ribbon cable. 4.3.5 Low Voltage Termination Panels

General purpose inputs and outputs are routed from the CPU card and I/O card to the low voltage termination panels

on the inner left hand side of the controller cabinet. Inputs 0 - 31 are handled by the CPU card, all other inputs and

outputs (if fitted) are handled by the I/O card.

There are two different issues of I/O card (see section 4.3.1.2) which interface to different styles of termination panel.

The new style I/O cards interface to PCB termination panels by means of ribbon cables. The connector formats are not

compatible with the old I/O card. Hence new I/O cards can only be used with PCB termination panels. It is not possible

to retro-fit a new I/O card into a controller using the old type of termination panel.

Likewise it is not possible to interface a PCB termination panel to an I/O card of the old type.

The new termination panel incorporates a power supply of the same rating as the BPPSU, hence no power supply is

normally required in the detector rack.

The new termination panel incorporates 2 additional connectors which translate the pin-out into a format compatible

with the Siemens OTU, allowing direct connection to be made via ribbon cables.

This was previously achieved by connection of the old I/O card directly to the OTU via ribbon cables since the pin-outs

were compatible. The recently introduced PCB termination panel allows for connection of OTU equipment by means of ribbon cables. When connected in this manner, the 16 OTU reply bits will be routed to CPU inputs 0 - 15, and the TXCNF bit of the OTU will be routed to CPU input 16. If input 16 is used for other purposes (typically a detector input) this can lead to problems since the OTU bit will conflict with it. Should this problem occur, it can be overcome in the field by cutting link LK3 on the termination panel PCB. This effectively isolates the connection between the OTU and I/P 16, but still allows it to be accessed via the terminals on the termination panel. Due to the fact that TXCNF is rarely if ever used, later builds of the PCB Termination panel omit LK3. This link should only be reinstated if TXCNF is explicitely required. Link 3 is located between the 2 off 40 way headers PL1 and PL3. It is the third link from the top counting downwards from C4. The PCB low voltage termination panel incorporates 16 links designated LKA - LKP. These links provide the facility to select whether the relay outputs are isolated or commoned When the links are made, the ouputs will be connected to a common return. LKA - LKP correspond to outputs 0 - 15 respectively for the top low voltage termination panel and to outputs 16 - 31 respectively for the bottom low voltage termination panel.. The links would normally be made when an OTU is connected to the termination panel via ribbon cables. If the links are not made, then each output will be connected to an isolated pair of terminals on the termination panel and will have no electrical connection with any other output. 4.3.6 E.L.V Wait Lamp Facility



The transformers required for driving E.L.V. wait lamps can be accommodated in the Microsense Traffic Controller by means of a plate fitted to the inner left hand side of the cabinet. This allows the following combinations of transformers to be accommodated :-

1 x 80W Transformer

2 x 80W Transformer

3 x 80W Transformer

1 x 160W Transformer




1 x 80W and 1 x 160W Transformers

1 x 80W and 1 x 400W Transformers

1 x 160W and 1 x 400W Transformers Figure 6.0 shows details of the plate and transformer fitting.



5. INSTALLATION 5.1 Wiring Practice Wiring of the installation should be carried out in accordance with the IEE Wiring Regulations for Electrical Installations. It is recommended that ELV circuits such as pedestrian push-buttons are not included in the same multicore cable as aspect drive conductors, (i.e. LV circuits). 5.2 Installing the Root The root should be concreted into the ground prior to the outercase being installed. All of the MTC's equipment is fixed to the outercase which in turn is fixed to the root. The transformer is fitted to the root but is easlily removable, hence installation of the root may be carried out with or without the transformer in place. On flat ground the root should be concreted into the ground such that approximately 50mm of it protrudes above the pavement level, (see figure 5.2). Space must be left inside the root for the cables to be pulled into the controller. It is essential that the root is installed flat and level. A spirit level, (placed across both diagonals) should be used to check this. On a sloping surface the root should normally be concreted in with a minimum of 30mm protruding above the pavement level. Where this cannot be achieved the surface should be levelled around the root to ensure that approximately 50mm of the root protrudes above the pavement level. 5.3 Outercase Installation Installation of the outercase is the same whether the electronic modules have been removed or not. First ensure that the top surface of the root is clean and free of debris. Apply a bead of sealing compound (see below), 4 to 5mm thick to the top face of the root and 10 to 15mm in from the outer edge. Ensure that additional sealant is applied around the studs, approximately 10mm from the studs. Ensure that the lower face of the outercase is clean and free of debris. Lower the outercase onto the fixing studs, taking care that the case is lowered vertically so that the sealant is evenly spread as the weight of the cabinet is lowered.

NOTE THAT THE SIZE AND WEIGHT OF THE OUTERCASE IS SUCH THAT 2 PERSONS WILL NORMALLY BE

REQUIRED TO DO THIS SAFELY. Now secure the outercase to the root using the original fixings, (M10 washer and nylock nut - 4 positions, as shown in figure 5.3).

Note : Polyurethane sealant is advised for use on the cabinet base joint, grey colour is to be preferred.

A suitable type is “Hylomar Polyurethane Sealant”, available from : W.M Canning Ltd. Microsense Stock Code :ROOTSEAL Marston Bentley Division Cale Lane Wigan WN2 1JR

It should be noted that ordinary mastic or bathroom sealants are not recommended due to the relatively short life in use of most of these products. 5.4 Electricity Board Supply Anytime after the outercase has been installed, (see section 5.3) the mains supply from the Electricity Board can be terminated. The supply is terminated on the wooden board, secured to the bottom, rear of the outercase interior. The Electricity Board supply earth must be connected into the earth bar on the wooden board. The tails from the main cabinet switch, (also mounted on the wooden board) may now be terminated to the Electricity Board supply.

N.B. ENSURE THAT BOTH THE CABINET AND POWER MODULE MAINS SWITCHES ARE IN THE 'OFF'

POSITION BEFORE THE TAILS ARE CONNECTED. CONNECTION OF THE SUPPLY SHOULD ONLY BE

CARRIED OUT BY THE LOCAL ELECTRICITY BOARD OR ITS AGENTS.



A 32 amp, (minimum) fuse from the Electricity Board is recommended. 5.5 Termination of Signal Cables Cables should be pulled through the root to a length of approximately 2 metres and such that the armouring can be secured to one of the CET termination bars. The armouring is terminated using a CET gland fixed to the CET bar. The outer sheathing should be trimmed back such that when the cable is passed through the CET gland it is just below the gland. The armouring is then trimmed to approximately 30mm and folded back on the outside of the gland. The armouring should then be secured in place using a jubilee clip or hose clip. N.B. The individual conductors will be connected to the various Termination Panels of the MTC.

WARNING : DO NOT MAKE ANY ELECTRICAL CONNECTIONS UNTIL THE INSULATION TESTS DESCRIBED

IN SECTION 5.6 HAVE BEEN COMPLETED SATISFACTORILY. 5.6 Cable Insulation and Continuity Tests The tests included here do not strictly form part of the MTC installation procedures and have been included as a guide only. Refer to the appropriate authorities for complete specifications covering such tests in your area.

WARNING : THE MAINS, (OR ANY OTHER VOLTAGE) TO ANY OF THE CABLES MUST BE DISCONNECTED

BEFORE ANY OF THE TESTS DESCRIBED BELOW ARE UNDERTAKEN. All loads, (e.g. signal transformers) must be disconnected from the cable at the 'neutral' side before commencing with these tests. 5.6.1 Insulation Tests The insulation resistance measured should be greater than 2 Megohms at 1000 Volts. The tests to be performed are:- - conductor to conductor - conductor to cabinet earth - conductor to cable armouring, if the armouring has not been connected to the cabinet earth 5.6.2 Conductor Continuity Tests This test is performed by connecting each conductor in turn to the 'neutral' conductor at the far end and then measuring the resistance. The resistance should be in agreement with that expected when considering the cross-sectional area of the cable and its length. 5.6.3 Earth Continuity Test This test is performed by connecting an approved test set and cannot be adequately undertaken by using an ordinary multimeter. The test is usually performed by applying mains voltage to earth for a short time.



5.6.4 Aspect Loads This test is performed when the cables are terminated at the aspects. A DC measurement is taken to ensure that there are no short circuits of lamp transformers, etc. A test to earth is also recommended at this point. 5.6.5 Earth Bonding To comply with the IEE regulations all metalwork, (e.g. outercase, electronic module cases, poles, etc) must be bonded to the earth continuity conductor. The resistance of all such bonds should be checked in a similar manner to that described in section 5.6.3. 5.7 Connecting the Intersection Cables When terminating cables care must be taken to ensure that no stray wire strands are left exposed. 5.7.1 Solar Switch

WARNING : FAILURE TO OBSERVE SECTION 5.6.4 COULD RESULT IN DAMAGE TO THE CONTROLLER OR

CABLING. The solar switch connections are located on terminal block TB33 which is on the bottom mains voltage termination panel, (see figure 5.7(a) ). 5.7.2 Regulatory Signs


CABLING. The mains power for regulatory signs is located on terminal block TB33 which is on the bottom mains voltage termination panel, (see figure 5.7(a) ).

Note:- To maximise the number of regulatory signs that can be driven by the controller, a capacitor is required across

the supply at each sign for power factor correction. (Page reg. signs require 6f capacitor and Siemans/GEC reg. signs

require 4f capacitor) 5.7.3 Auxiliary Mains Supply


CABLING. This is the mains output from the fused switch on the power module, which is used to power auxiliary equipment, (e.g. OTU, OMU, etc). The connections for this supply are located on terminal block TB33 which is on the bottom mains voltage termination panel, (see figure 5.7(a) ). 5.7.4 Mains Detector Supply


CABLING. The mains detector supply is located on terminal block TB33 which is on the bottom mains voltage termination panel, (see figure 5.7(a) ). This provides a 240 volts AC supply for powering detectors. 5.7.5 Phase Lamp Drives


CABLING. The connections for the phase lamp drives are located on both of the mains voltage termination panels, (see figures 5.7(a) & (b) ). Phases start at the bottom of the outercase to make cabling easier and also to make future expansion easier. The lamp returns, (common 0 volts) are located on terminal blocks TB35, TB37 & TB39 which are on the bottom mains voltage termination panel. There are up to 36 lamp return terminals available, depending upon the size of power module fitted. Lamp outputs are located on terminal blocks TB26, TB28, TB30, TB32, TB34, TB36, TB38 & TB40.



5.7.6 Low Voltage Connections This covers detector inputs, push-button inputs, OTU interface and general purpose outputs. The connections for these inputs and outputs are located on the low voltage termination PCBs, (see figures 5.7(c)). For specific low voltage connection details refer to the Microsense Works Specification, or MTC Build Specification.

NOTE : INPUTS FED FROM EXTERNAL EQUIPMENT MUST BE FROM ISOLATED RELAY CONTACTS THAT

ARE NOT GROUNDED ON EITHER SIDE. 5.7.7 Low Voltage Detector Supply The low voltage detector supply is located on terminal blocks 9 and 10, pins 1 and 2, of the low voltage termination pcb. This provides a 24V DC supply for powering detector cards.

NOTE : THIS SUPPLY MUST NOT BE GROUNDED. 5.8 Installation of Electronic Modules If the electronic modules were removed earlier for ease of installation then the following section details how to re-fit them. 5.8.1 Power Module Place the power module over its fixing studs on the rear of the outercase interior and secure with the original fixings, (M6 washer and nylock nut - 4 positions). The cables in and out of the power module should now be plugged back in. The connectors should all be hanging free in the proximity of their associated sockets. The power module cables breakdown into the following, with their socket locations in brackets () :- - Mains Input, (bottom) - Low Voltage detector supply, (middle left hand side) - Power to CPU Module, (top left hand side) - Signals to CPU Module, (top left hand side) - Bright/Dim Transformer, (right hand side) - Lamp Returns, (right hand side) - General Mains supplies, (right hand side) - LSC Module Mains supplies, (right top) Note:- All of these connectors are different so there is no danger of plugging any of them into the wrong socket.



5.8.2 CPU Module With the CPU module open, place it over the fixing studs on the rear of the outercase interior and secure it with the original fixings, (M6 washer and nylock nut - 4 positions). The cables in and out of the CPU module should now be plugged back in. The connectors should all be hanging free in the proximity of their associated sockets. Firstly the cables that are connected inside the CPU module should be plugged back in. These cables are as follows, with their socket locations in brackets () :- - LSC 8 Personality, (P13) - LSC 7 Personality, (P12) - LSC 6 Personality, (P11) - LSC 5 Personality, (P10) - LSC 4 Personality, (P9) - LSC 3 Personality, (P8) - LSC 2 Personality, (P7) - LSC 1 Personality, (P6) - LSC Data Bus, (P21) If an ILM board is included, the twisted pair leads from the Lamp Monitoring Toroids should be connected to the appropriate connectors on the board starting sequentially from PL1. The order off connecting each phase toroid will be found in the Junction Configuration forms. When the above cables have been re-connected the CPU module can be closed and the remaining cables can be plugged back in. These cables all plug into the left hand side of the module and their sockets are silk screened on the casing as follows :- - Power Module - Power, (P14) - Power Module - Signals, (P16) - Manual Panel, (P20) - General Inputs, (P18) - I/O Interface board, up to 3 cables, (P4, P3 & P2) It is important to confirm that the appropriate code EPROMs, configuration EPROM, and RAM are fitted to the CPU module to ensure correct operation. On a new installation, this will have been checked by Microsense during assembly. When replacing an existing CPU module this can be achieved by removing these devices from the old CPU and installing in the replacement. The devices which need to be transferred are listed below :- - IC 14 - Configuration EPROM - IC 13 - Main processor code EPROM - IC 15 & 16 - Main processor RAM - IC 31 - Secondary processor EPROM 5.8.3 LSC Module There may be up to 4 LSC modules which are all mounted on the right hand side of the outercase interior, starting from the bottom. Slide the back of the module under the retaining strip and locate the front over the fixing studs. Now secure the module with the original fixings, (M6 washer and nylock nut - 2 positions). The cables in and out of the LSC module should now be plugged back in. The connectors should all be hanging free in the proximity of their associated sockets. The cables breakdown into the following, with their socket locations in brackets () :- - Mains supply, 1 per LSC, (front) - Module case earth, (front) - Personality ribbon, (rear) - Data Bus ribbon, (middle) - Lamp Outputs, 2 per LSC, (rear) - see note below

NOTE : THE LAMP OUTPUT CABLES MUST BE CONNECTED THE RIGHT WAY UP, (I.E. CONNECTOR

MARKED 'U' IN THE UPPER SOCKET AND CONNECTOR MARKED 'L' IN THE LOWER SOCKET).



5.8.4 Manual Panel Place the manual panel into its housing. Ensure that the studs on the panel are protruding through the holes in the rear of the housing and then secure the panel with the original fixings, (M10 shakeproof washer and nut - 4 positions). Now secure the manual panel door micro-switch or reed switch using the original fixings (M2 screw, shakeproof washer and nut - 2 positions or M3 screw, spacer, plain washer and nut – 2 positions), ensuring that the switch makes contact when the door is closed. Finally plug the manual panel ribbon cable back in.

NOTE: THE CONTROLLER SHOULD NOT BE POWERED WITH THE MANUAL PANEL RIBBON CABLE

DISCONNECTED. 5.9 Switching the Controller On

NOTE : THE BASE OF THE CONTROLLER SHOULD BE SEALED BEFORE THE CONTROLLER IS PUT INTO

OPERATION, (SEE SECTION 5.10). Ensure that all fuses are correctly fitted, (see section 3.3) and all modules are fitted with their associated cables connected. Also ensure that the correct Configuration PROM is fitted. (IC14). Place the signals on/off switch on the Manual panel in the OFF position. Now switch the controller ON at both of the mains circuit breakers, (one on the Electricity Board supply panel and one on the power module). Plug a handset into the connector on the CPU module and select the correct baud rate, (1200) if applicable. Now download the configuration's working timings into the controller's RAM using the handset RCP command, (note that the CPU RESET button will need to be pressed after the RCP). When the data has been successfully downloaded the Running LED for the secondary processor should start flashing at a rate of 0.5 Hz, (i.e. the same as the main processor). If at this point the fault log indicator comes on and an entry of 'RTC:FAULT' exists, then set-up the time of day and date using the handset TOD and CAL commands. When this has been done clear the fault log using either the FLF or RFL handset command. Note that the CPU RESET button may need to be pressed after this, if indicated on the handset display. Clear the Warning Log using either the RFL or WRN handset command and its indicator on the CPU module should be extinguished. Check that the Fault Log indicator is still extinguished. If either of these indicators are on then the

appropriate log should be viewed on the handset to find the problem, (handset commands FLF and WRN). DO NOT continue until the controller is running without any Fault Log entries. If faults do still exist then refer to section 6.3). Before switching the signals ON it is recommended that the aspect cabling is checked using the handset LMP command. This command is used to drive each aspect output, so that the cabling may be checked. If at any point during these tests the aspects fail to illuminate as expected, a multimeter should be used to check for the presence of mains voltage on the relevant output terminal(s). If this voltage is absent then switch off both the Controller and Cabinet switches and check the following fuses:- - LSC fuses - Controller Switch fuse - Power Module fuses F4 and F5 If any fuses are blown, this will normally be indicative of a short-circuit between an aspect cable(s) and either neutral or

earth. The tests of section 5.6.4 MUST be repeated and any short-circuits cleared before any of the fuses are replaced. Attention is drawn to section 3.3 and the warning therein.



When the aspect cabling is known to be correct the signals can be switched on via the manual panel signals on/off switch. Commissioning tests may now be performed on the junction as required by the appropriate Local Authority. Note that the above process, (except aspect cabling checks) will also need to be performed if the configuration PROM is replaced, otherwise the controller will be working with timings, etc from the old configuration. 5.10 Sealing the Base

NOTE : THE CONTROLLER SHOULD NOT BE LEFT FOR ANY LENGTH OF TIME WITH THE ELECTRONIC

MODULES INSTALLED AND THE BASE NOT SEALED. The base can be sealed anytime after the outercase has been installed, the Electricity Board supply terminated and the intersection cabling completed, (but the individual conductors not necessarily terminated) However it is recommended to leave sealing the base until the junction has been successfully commissioned. First remove the Bright/Dim transformer mounting plate using the

1/4 turn fasteners and unplug the loom (caution

should be execrised in removing the 20A and 30A transformer). Fill the inside of the root with sand up to the bitumen level indicator, (i.e. about 50mm below the top face of the root. The sealant should now be poured in over the sand.

Note that the sealant should NOT be allowed to reach the top face of the root, but should finish about 25mm below. The Bright/Dim transformer mounting plate can now be refitted. Ensure that there is a good seal around the edge of the case and around all base entry points, such as cable entry through the sealant.



6. MAINTENANCE 6.1 General It is possible for a third party to maintain the MTC to the first line level, corresponding to fault finding to module level. To maintain the quality and integrity of the product, faulty modules should be returned to Microsense, or their approved agents, for repair.

WARNING : USE OF COMPONENTS OTHER THAN THOSE PERMITTED, OR MODIFICATIONS OR

ENHANCEMENTS THAT HAVE NOT BEEN AUTHORISED BY MICROSENSE SYSTEMS LIMITED MAY

INVALIDATE THE TYPE APPROVAL OF THIS PRODUCT. 6.1.1 Replaceable Items under First Line Maintenance

WARNING : THE MAINS SUPPLY TO THE CONTROLLER SHOULD BE SWITCHED OFF AND ISOLATED

BEFORE ANY ITEMS ARE REPLACED. The modules that may be replaced at the first line maintenance level are as follows:- - CPU Module, (including I/O Interface Board and ILM Board, if used) - LSC Module - Power Module - Manual Panel (note Filament bulb or LED option) The other items that may be replaced at the first line level are:- - Bright/Dim Transformer - Fuses, (see section 3.3) - DFM Lamp, (24V, 2.8W Miniature Edison Screw, MES) – Filament bulb option only



NOT COVERED BY WARRANTY. 6.2 Replacement of First Line Maintainable Items Section 5.8 contains relevant information to enable replacement of first line maintainable items. 6.3 Fault Finding Fault finding techniques rely on module replacement principles. To assist in fault finding the CPU Module is fitted with Watchdog, Processor Running, Fault Log Entry and Warning Log Entry diagnostic LEDs, (see section 4.3.1.3). For fault finding purposes the controller may be operated with the mimic LEDs on the LSC Modules operating but without driving the signal heads. This is achieved by unplugging the LSC phase drive connectors from all fitted LSC Modules and unplugging the lamp return neutral connector from the power module. If the software is functioning, the Engineers Terminal, (handset) may be used to find faults that may be present, not only with the MTC, but with ancillary equipment, such as detectors. A comprehensive range of handset commands exist for this purpose. The table in section 6.3.1 provides quick reference fault finding information. A number of fault symptoms are listed together with likely causes and the action(s) required to rectify them.



6.3.1 Quick Reference Fault Finding Table

Some of the common problems experienced are listed, together with their likely causes in order of descending probability. This list is not intended to be comprehensive, but rather to allow the cause of common faults to be quickly located.

SYMPTOM LIKELY CAUSES ACTION

Main processor watchdog

Configuration PROM, (IC14) faulty/not fitted. Check/replace.

Main processor S/W PROM, (IC13) faulty/not fitted.

Check/replace.

Main processor RAM chips, (IC15/16) faulty /not fitted/incorrect size.

Check/replace.

Main processor, (IC12) faulty/not fitted. Check/replace.

Faulty CPU board. Replace CPU board.

Secondary processor watchdog

Secondary processor S/W PROM, (IC31) faulty/not fitted.

Check/replace.

Secondary processor RAM chip, (IC34) faulty/not fitted.

Check/replace.

Secondary processor, (IC26) faulty/not fitted.

Check/replace.

Faulty I/O card or cable I/O to CPU. Disconnect I/O card and retry.


No communication with handset

Configuration PROM, (IC14) faulty/not fitted. Check/replace.

Main processor S/W PROM, (IC13) faulty/not fitted.

Check/replace.

Main processor RAM chips, (IC15/16) faulty /not fitted/incorrect size.

Check/replace.

Main processor, (IC12) faulty/not fitted. Check/replace.


Relay fault (REL) Blown fuse - power module F4/F5. See Blown fuses below.

Faulty power module. Replace power module.

Faulty cable CPU to Power Module, (20-way)

Replace cable


Green conflict fault(GCF)

Short circuit on street. Disconnect LSC output plugs and re-test. Megger suspect street cables.

Loose neutral connection in controller or short circuit on street.

Disconnect LSC output plugs and re-test.

Configuration inconsistent with size of controller, (IC14).

Check/replace.

Faulty LSC. Replace LSC module.

Faulty cable LSC to CPU, (10-way). Check/replace.


Green conflict monitor (GCM)


Green sense discrepancy (GSC)


Faulty cable LSC to CPU (10 way). Replace cable.





Green non compliance

No mains power to LSC due to:- - Blown LSC fuse. - Blown power module fuse F4/F5. - Faulty power module or LSC or wiring between power module and LSC.

See Blown Fuses below. See Blown Fuses below. Check/replace.

Short circuit on street. Disconnect LSC output plugs and re-test.

Loose neutral connection in controller or on street.

Disconnect LSC output plugs and re-test.





Software faults (MSF or SSF)

Internal fault conditions. Note all relevant information and refer to Microsense.

RTC fault (RTC) Corrupt data due to flat battery or link not fitted on CPU.

Set date and time and allow time for battery to recharge.


RAM fault (RAM) CPU board battery flat or link not fitted. Restore Config Parameters (RCP)


PRM fault:M (PROM fault on main processor)

PROM (IC13) faulty/corrupt. Check/replace.

Bad contact with IC socket. Check/rectify.


PRM fault:S (PROM fault on secondary processor)

PROM (IC31) faulty/corrupt. Check/replace.

Bad contact with IC socket. Check/rectify.


CRM/CFG fault(PROM fault on configuration)

PROM (IC14) faulty / corrupt / incompatible. Check/replace.

Bad contact with IC socket Check/rectify.


No response from inputs (stuck short circuit)

CPU board fuse F2 blown. Find cause and replace fuse.

Power module fuse F2 blown. Find cause and replace fuse.

Fusible resistors blown on CPU board. Replace CPU board.


No response from inputs (stuck open circuit)

CPU board fuse F3 blown. Find cause and replace fuse.


Blown fuses:- - LSC fuses

Short circuit of aspect to neutral or earth. Disconnect LSC output plugs and re-test. Megger cables to find fault and then replace fuse.


- CPU board F1 (12V DC)









- CPU board F2 (24V DC)



- CPU board F3 (OV) Input 0V shorted to mains. Find cause and replace fuse.

- Power module F1 (12V DC)






- Power module F2(24V DC)



- Power module F3 (PSU live)

Faulty power module PCB. Replace power module.

- Power module F4/F5 (LSC live) F4 = phases A to P F5 = phases Q to F2

Short circuit of aspect to neutral or earth. Disconnect LSC output plugs and re-test. Megger cables to find fault and then replace fuse.


Faulty wiring from power module to LSC. Check wiring for shorts.

- Power module F6 (Det live)

Detector mains supply shorted to neutral or earth.

Check wiring and detectors.

- Power module F7(18V AC)

Detector 18V AC supply short circuited. Check wiring and detectors.

- Power module F8 (Reg signs)

Reg sign supply shorted to neutral or earth. Check wiring and reg signs.

- Power module F9 (Solar cell)

Solar cell supply shorted to neutral or earth. Check wiring and solar cell.

- Power module F10 (Bright/Dim sense)

Bright/Dim sense shorted to neutral or earth. Check wiring and LMU/OMU.

- Termination PCB F1 F2

Detector Supply shorted on detector rack Large external Fault current on COMMON

Check wiring and detectors Check external wiring



6.4 Spares 6.4.1 Fuses See also section 3.3. ITEM MICROSENSE PART NUMBER Cabinet Switch (15A, CARTRIDGE) FCART 15 Cabinet Switch (20A, CARTRIDGE) FCART 20 Cabinet Switch (30A, CARTRIDGE) FCART 30 Controller Switch (13A, 1") FN25 13000 Controller Switch (20A, CARTRIDGE) FCART 20 Controller Switch (30A, CARTRIDGE) FCART 30 CONN Unit (5A, 1") FN25 5000 F6-Mains Detector Supply (5A, 20mm A.S.) FS20 5000 F7-L.V. Detector Supply (5A, 20mm A.S.) FS20 5000 F8-Regulatory Signs (minimum 5A, 20mm A.S.) FS20 5000 F9-Solar Cell (100mA, 20mm Q.B.) FN20 100 F10-Bright/Dim Sense (100mA, 20mm Q.B.) FN20 100 F3-Controller PSU Mains I/P (1.25A, 20 mm A.S.) FS20 1250 F2-24 V Logic Supply (1.25A, 20 mm A.S.) FS20 1250 F1-12 V Logic Supply (4A, 20 mm Q.B.) FN20 4000 F4-LSC Module Mains Supply (15A, 1.25" HRC Q.B.) FRC32 15000 F4/F5-LSC Module Mains Supply (15A, 1.25" HRC Q.B.) FRC32 15000 F4/F5-LSC Module Mains Supply (20A, 1.25" HRC Q.B.) FRC32 20000 Triac Drivers (7 A, 1.25" H.R.C. Q.B.) FRC32 7000 CPU Board F1-12 V Logic Supply (3.15A, 20 mm A.S.) FS20 3150 CPU Board F2-24 V Logic Supply (1A, 20 mm A.S.) FS20 1000 CPU Board F3-0 V Logic Protection (100 mA, 20 mm) FN20 100 Low Voltage termination PCB F1 (100mA, 20mm) FN20 100 Low voltage termination PCB F2 (4A, 20mm) FN20 4000 Manual Panel FM Lamp driver protection (250mA 20mm) FN20 250 (Iss 4 onwards PCB, Filament Bulb option only)



NOT COVERED BY WARRANTY.



6.4.2 Modules ITEM MICROSENSE PART NUMBER Maxi Cabinet Complete *) MTCCAB Maxi Cabinet Main Door *) MTCDOOR Root MMAXI 9005081 Small Bright/Dim Transformer, (10A) LMA 1410 Medium Bright/Dim Transformer, (20A) LMA 3000 Large Bright/Dim Transformer, (30A) LMA 4500 Small Power Module, (10A) *) MTCPSU10 Medium Power Module, (20A) *) MTCPSU20 Large Power Module, (30A) *) MTCPSU30 CPU Module Case Assembly MCPU 9003050 CPU Card *) MTCCPU I/O Interface Card, (16 O/P) *) MTCIO16 I/O Interface Card, (32 I/P, 32 O/P) *) MTCIO32 4 phase LSC Module *) MTCLSC4 8 phase LSC Module *) MTCLSC8 Police, (Manual) Panel Module *) MTCPOLPAN Cabinet Mounted Detector Rack *) MTCDET12

General Purpose Termination panel *) GPTERM 6.4.3 Sundry Spares ITEM MICROSENSE PART NUMBER DFM Lamp MELI 242.8 This Handbook MTCHANDBOOK MTC Facilities Manual MTCFACILMAN

MTC Handset Command Manual MTCHSCMDMAN



Figure 4.1(a) - Equipment Layout



Figure 4.1(b) - Equipment Layout



Figure 4.1(c) - Equipment Layout



Figure 4.1(d) - Equipment Layout



Figure 5.2 - Installing the Root



Figure 5.3 - Outercase Installation

MASTIC APPLIED

TO TOPFACE



Figure 5.7(a) - Bottom Mains Voltage Termination Panel



Figure 5.7(b) - Top Mains Voltage Termination Panel



Figure 5.7(c) - Bottom Low Voltage Termination Panel



Figure 5.7(d) - Top Low Voltage Termination Panel



Figure 6.0 - ELV Transformer Mounting Plate

FIT CAPTIVENUT TO BAR

ELV TRANSFORMER MOUNTING PLATE : (FITTING OF 2 X 400W TRANSFORMERS SHOWN)

PLATEBOLTED

TO SIDEOF CASE

PLATESECURED WITH

1/4 TURN FASTENERS

TRANSFORMERSBOLTED TO

PLATEPRIORTO FITTING

Documents

MICROSENSE TRAFFIC CONTROLLER HANDBOOK, …MICROSENSE TRAFFIC CONTROLLER HANDBOOK, INSTALLATION AND MAINTENANCE MANUAL . Doc No. 40-9001-008 Iss 11 MTC Handbook, Installation and Maintenance