Control Industries RC 1T5A Betriebsanleitung

RECEIVER

CONTROLLER

MODEL RC 1T5A

(S/N 10000 and Above)

CONFORMS TO FAA - L - 854

FIELD SERVICE INSTRUCTIONS

Rev-1

THIS DOCUMENT EMBODIES A PROPRIETARY

DESIGN ORIGINATED BY CONTROL INDUSTRIES,

INC., AND SHALL NOT BE DISCLOSED, USED, OR

DUPLICATED FOR PROCUREMENT OR

MANUFACTURING PURPOSES, UNLESS

SPECIFICALLY AUTHORIZED BY CONTROL

INDUSTRIES, INC.

Control Industries Inc.

614 Central Ave.

Findlay, Ohio 45840

TEL 419-800-0011

FAX 419-500-9015

HANDBOOK OF OPERATING AND MAINTENANCE

INSTRUCTIONS

RECEIVER CONTROLLER RC-1T5A

1.0 GENERAL:

The model RC-1T5A controller has been specifically designed to provide remote control of

airport lighting systems which require three separate control functions. This control system will

allow the approaching pilot to select high, medium or low levels of runway light intensity at his

discretion. The RC-1T5A is enclosed in a weather-proof water-tight housing and is conservatively

designed for continuous outdoor unattended operation.

The design and construction are compliant with FAA specification L-854.

The RC-1T5A receiver controller complies with FCC rules and regulations Part 15.

2.0 ELECTRICAL:

The receiver is an integrated-circuit design. The sensitivity is adjustable from 1 microvolt

to 30 microvolts as desired by the user, permitting a control range of 1 to 20 miles. Receivers are

shipped normally adjusted to a sensitivity of 10 microvolts. The unit is designed to operate from

120 volt ±20% 50-60 HZ single phase power.

3.0 THEORY OF OPERATION:

The system is activated upon receiving a series of pulses of R.F. energy where each

succeeding pulse follows the preceding pulse by not more than one second. Upon receipt of the

third pulse K1 closes, at the fifth pulse, K2 closes, and upon receipt of the seventh pulse, K3 closes.

NOTE: At any time in the sequence the pilot has the option of sending three, five or seven pulses

to command the intensity level to his requirements. The system will remain at the intensity level of

the last command received. The internal timer will continue to operate for 15 minutes after which it

will cause the system to revert to the original "off" condition. The timer is reset by the receipt of

any command at any time, reinitiating the 15 minute "run" cycle. Operating time may be selected in

15-minute intervals up to 1 hour by setting switches on the Receiver Board.

The receiver-controller is composed of three circuit cards which include the Interface/Power

Supply board, Relay Board, and Receiver/Decoder Board. The following describes the theory of

operation for each of the receiver-controller basic elements.

During system test, the 15-minute timing cycle may be terminated by pressing the ‘Reset’

switch on the base assembly.

Reference: Functional Diagram Figure A.

FIG A

Functional Diagram

FIG B

INTERCONNECTING WIRING DIAGRAM

(with Lightning Suppression Components)

3.1 RADIO FREQUENCY/DECODER CARD (C.I. PART #11-0255)

The radio receiver is a superheterodyne design operating at a nominal R.F. frequency within the VHF band of

118 to 136 MHz. An IF frequency of 10.7 MHz is utilized with the bandwidth controlled by a 6-pole crystal lattice filter.

This filter establishes nominal -60 db rejection at adjacent channel frequencies of ±25 KHz or more. It also establishes

an on-frequency bandwidth of nominally ±9 KHz at the -6.0 db points. A communications type integrated circuit provides

the IF gain, AM detection, RSSI and audio output. The audio output is buffered and delivered to a service jack for

maintenance and test purposes. A red LED indicator is included on the receiver card to visibly show the state of the

receiver logic. A microprocessor IC is programmed to count the RF pulses and send the command to turn on the

appropriate relays. The Timer function is programmed into the microprocessor and can be adjusted in 15-minute

intervals up to 1 hour by adjusting the dip switch settings. The microprocessor monitors a temperature IC and activates

a relay to power a chassis mounted resistor to provide heat in freezing conditions.

FIG C

RECEIVER CARD 11-0255

3.2 RELAY CARD (C.I. PART # 11-0195):

The output relays, K-1, K-2, K-3, and K-4 and their associated components, resistors R-2, R-4, R-6,R-8; indicator

LED’s D-2, D-4, D-6, D-8; diodes D-1, D-3, D-5, D-7; resistors R-1, R-3, R-5, R-7 and capacitors C-1, C-2, C-3, and

C-4 are contained on their own printed circuit card, P/N 11-0195. The relays and timer function are controlled by the

microprocessor on the receiver/decoder card 11-0255.

Diodes D-1, D-3, D-5, and D-7 are connected inversely across the relay coils to suppress the inductive transient

when the relays are turned off.

Resistors R-2, R-4, R-6, R-8 and LED indicators D-3, D-4, D-6, D-8 show when the relays have been activated. The

LEDs will be visible when the printed circuit board cover is in place.

Resistors R-1, R-3, R-5, R-7 and capacitors C-1 thru C-4 form arc suppression networks to reduce transient noise

when the relays deactivate the load relays. This arc suppression also increases relay life.

In case the load relays have very high coil impedance, keeping the loads energized after K-1, K-2 or K-3 are shut off,

the arc suppression networks may be disabled by removing capacitors C-1, C-2 and C-3.

K-4 is the heater control relay and has a green LED to indicate when the heater resistor is powered and heating.

Fig D

Plug-in Relay Assembly 11-0195

4.0 TROUBLE ANALYSIS:

A malfunction chart including several possible failure modes is supplied to assist the technician in analyzing the

probable cause. The receiver-controller is warrantied for one year from date of purchase. Failures not caused by

improper installation or abnormal treatment will be corrected by the manufacturer free of charge within the warranty

period.

4.1 TROUBLE ANALYSIS CHART:

The following tabulations will provide guidance for recognizing possible trouble and correction.

MALFUNCTION POSSIBLE CAUSE TEST AND REMEDY

AC voltage present but no DC Open 1.0 A. Fuse Test & Replace

LED indication Bad AC Switch Test & Replace

Defect in power supply. Return receiver to

electronic board, power manufacturer for service.

transformer or series

regulator transistors

DC OK, no LED Defect in receiver card Replace card, retest. Send

indication, no audio part number 11-0255 defective card to manufacturer

for repair or replacement

if in warranty.

DC OK Open 5A SLO BLO Fuse Test & Replace fuse with same

Relay closures normal type only

No output voltage any

control line

Failure to reset Timer indicator Defective Receiver/Decoder card, Use replacement card and retest.

after 5 seconds number 11-0255 Return defective card to manufacturer for

repair or replacement if in warranty.

Fails to turn off after 15 minutes Defective Receiver/Decoder Card, Use replacement card and retest.

Part number 11-0255 Return defective card to manufacturer for

repair or replacement if in warranty.

DC O.K., Defective Relay K-1, K-2, or K-3, Replace Relay Card P/N

output indicator LED's Normal whichever circuit is defective 11-0195 and retest.

5.0 MAINTENANCE:

The Model RC-1T5A is designed to require a minimum of maintenance under all ranges of service conditions. There

are no moving parts except the output contactor relays. With proper installation, no abuse or tampering, the unit should

deliver at least 10,000 hours of trouble-free operation.

5.1 MAINTENANCE CONCEPT:

The unit may be maintained readily by technician level personnel. The printed circuit boards are not readily

repairable in the field. Return defective printed circuit boards to Control Industries for repair / replacement by

the manufacturer. A stock of one each substitute cards should be retained to verify a suspected defective card by

simple substitution procedures. All other elements of the receiver-controller may readily be checked utilizing normal

electrical test procedures involving no special testing equipment other than a standard volt-ohmmeter. A standard

headset may be used to monitor the receiver at the audio jack.

5.2 OPERATING CHECKOUT:

The service technician may determine proper operation of the receiver-controller by completing the following

checklist:

(1) Check the presence of primary line voltage as measured between input terminals marked 115VAC and

neutral.

(2) Press AC power switch and observe Green DC power indicating LED inside the controller housing.

Illumination of this DC indicator implies proper power supply operation.

(3) Depress red test button three consecutive times within five seconds. This result is closure of Relay K-1 and

the illumination of the red LED indicator adjacent to relay K-1 on the Relay Card.

(4) After elapse of 5 seconds the timer indicator should extinguish.

(5) Depress red test button five times within five seconds. This should result in closure of Relay K-2 and the

illumination of the red LED indicator adjacent to relay K-2. Relay K-1 will remain closed.

(6) After elapse of 5 seconds the timer indicator should again extinguish.

(7) Depress red test button seven times within five seconds. This should result in closure of relay K-3 and the

illumination of the red LED indicator adjacent to relay K-3. Relays K-1 and K-2 will remain closed.

(8) Depress white reset button and confirm all relays and light go out.

(9) Place a short across Remote Disable terminals. Verify light next to terminals lights. Verify that when test

button is pressed three, five, or seven times no relays close. Remove short.

(10) Place the Decoder Disable switch in the on position. Verify light next to switch lights. Press red test button

seven times within 5 Seconds. Wait for the timer light to go out. Press the red test button three, five and

seven times to verify that the output does not change. Wait 15 minutes for the timer to disable the relays.

Press red test button three, five, or seven times to verify ability to reactivate after timeout.

The above procedures accomplish a complete operating check of all elements and functions of the Receiver-

Controller RC-1T5A.

5.3 DETAILED MAINTENANCE INSTRUCTIONS:

If during the performance of check out as specified in paragraph 4.1 improper operation is noted, the following

explanations and instruction procedures will simplify servicing the controller:

5.3.1 POWER SUPPLY:

It should first be determined that proper power 115V AC, 60 cycles is being applied to the input connector terminals

labeled 115V AC and Neutral (Figure K). This may be determined by use of a suitable volt-ohmmeter; Simpson Model

260 or equivalent.

The power supply Circuit is located on the main interface PCB and in not field serviceable. All power supply

electronics are located on this PCB except the power transformer (T-1) located on the main chassis as depicted in

Figure K. A green LED indicator is provided to indicate presence of 12 volts DC. This indicator is the lower-most of a

series of indicators located on the right-hand side of the PC board cover. This indicator glows green at all times when

the receiver is turned on and D.C. is present. The location of this D.C. power indicator is depicted in Figure K.

Indication of the presence of A.C. power as measured by an appropriate A.C. voltmeter and failure of the D.C.

indicator indicates a Main Interface PCB failure. The following steps should be accomplished in sequence. Verify

proper output voltage from Power Transformer.(T-1) The output voltage of the power transformer should be

approximately 16V AC. Remove the Receiver/Decoder, and Relay cards one at a time and observe the D.C.

indicator. This procedure removes and isolates any possible shorts in the relay or radio boards. Recheck for proper

D.C. indicator operation. If a failure remains, contact Control Industries Inc. to further troubleshoot and set up for

service.

5.3.2 RELAY BOARD

The relay printed circuit board part number 11-0195 controls the three control outputs and the temperature resistor.

Activated by a signal from the Receiver/Decoder board relays on the relay board close to provide voltage to the

control output pins. Relay K1 Controls the Control 1 output. Relay K2 controls the Control 2 Output. Relay K3 controls

the Control 3 output. Relay K4 controls the heater resistor. Control output relay activation can be monitored by the

red LED’s mounted on the top of the relay board sticking through the plastic board cover. The temperature relay can

be monitored by the green LED on top of the relay board also sticking through the plastic board cover.

This board is non field serviceable and must be replaced in the event of failure.

5.3.3. RECEIVER/DECODER:

The Receiver/Decoder Board is printed circuit board identified as C.I. part # 11-0255. The board compromises the

complete receiver, decoder, and timer functions for the unit.

An effective method of determining condition of the receiver board may be accomplished by listening to the audio at

the output jack identified in Figure K. A head set or suitable audio amplifier will reveal a slight pressure of noise which

gives a general indication if the receiver is operative or inoperative. Depressing the red test button should cause a

loud hum to occur in the headset and cause the timer and signal LED’s to light. The timer light will extinguish after 5

seconds the signal will extinguish are test button in released. Absence of either of these indications represents

probable receiver board failure.

The microprocessor on the receiver/decoder board controls the decoder, timer, disable functions, and temperature

as explained below.

5.3.3.1 DECODER FUNCTION:

The Microprocessor counts the inputted clicks within a 5 second period from the first click and activates the

corresponding relays to output to the proper control lines.

3 Clicks = 120vac out to Control Line 1

5 Clicks = 120vac out to Control Lines 1, and 2

7 Clicks = 120vac out to Control Lines 1, 2, and 3.

5.3.3.2 TIMER FUNCTION:

After the 5 second timer light goes out. The internal timer will start a 15-minute countdown. After 15 minutes the

board will reset and open and Control Lines that were activated. The timer will reset to 15 minutes if another

selection in made during the countdown period.

The Time out period come preset to 15 minutes but is adjustable in 15-minute periods up to 1 hour by adjusting dip

switch setting on the Receiver/Decoder board. See chart below.

15 Minutes

1 X

2 X

30 Minutes

X O

2 X

45 Minutes

1 X

X N

60 Minutes

X O

X N

5.3.3.3 DISABLE FUNCTIONS:

Remote Disable: A short across these two terminals indicated by a red led next to the terminal block. Will disable the

decoder of the microprocessor and out the unit in stand-bye mode. This is where you could attach a photo sensor or

external switch to disable the unit.

Decoder Disable Switch: With this switch in the on position as indicated by a red led next to the switch, the unit will

lock in on the last command given during the 5 second activation period. The unit will hold that command for the time

out period and will not accept another command until after the time out period has ended.

Example: If the timer is set to 15 minutes and the decoder receives 7 clicks in the 5 second period the unit will close

relays for Control 1, 2, and 3 and lock them on during the 15 minutes period.

5.3.3.4 TEMPERATURE FUNCTION:

The Microprocessor monitors a temperature IC mounted to the Receiver/Decoder PCB and activates a relay on the

relay board when the temperature drops below 40F. This powers a heater resistor on the bottom of the chassis to

prevent the unit from freezing. Temperature relay activation can be determined by the green LED on the relay board.

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