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Technical ManualTechnical Manual

ASTC-12 CabinetTraffic Control Cabinet

ASTC-12 Cabinet

Technical Manual

p/n: MN078150, Revision 2

81-1257 ASTC-12 Cab ine t Techn ica l Manua l Assemb ly MN078150 ASTC-12 Cab ine t Techn ica l Manua l Con ten t (Rev 2 ) 99 -525 ASTC-12 Cab ine t Techn ica l Manua l Cover A r t

© Copyright 2009 Peek Traffic Corporation. All rights reserved.

A reasonable attempt has been made to ensure the accuracy of the material in this manual. It is supplied, however, without warranty or representation of any kind. Peek Traffic Corporation assumes no responsibility and shall have no liability of any kind arising from the use of this publication or the material contained herein. Peek Traffic Corporation reserves the right to add, delete and/or change the material at any time. This manual may not be copied without permission from Peek Corporation. Trademarks ASTC 3000-PC-CBD, IQ ATC, IQ Link and IQ Central are trademarks of Peek Traffic Corporation. Windows is a registered trademark of Microsoft Corporation in the United States and other countries.

Table Of Contents ASTC-12 Cabinet Technical Manual

U.S. T raf f ic Corporat ion Page 3

Table Of Contents 1. REVISIONS...................................................................................................................................... 5

2. GLOSSARY...................................................................................................................................... 6

3. GENERAL DESCRIPTION ........................................................................................................... 7

3.1 INTRODUCTION ............................................................................................................................ 7 3.2 ENVIRONMENTAL REQUIREMENTS............................................................................................... 8 3.3 CABINET THEORY OF OPERATION ................................................................................................ 8

3.3.1 Normal (AUTO) Mode ........................................................................................................ 8 3.3.2 Flash Mode ......................................................................................................................... 8 3.3.3 OFF Mode........................................................................................................................... 9

3.4 MANHATTAN OPERATION ............................................................................................................ 9 3.5 DCI OPERATION .......................................................................................................................... 9 3.6 MANUAL OPERATION................................................................................................................. 10

4. CABINET DESCRIPTION........................................................................................................... 11

4.1 HEADER PANEL ASSEMBLY ....................................................................................................... 11 4.2 POWER DISTRIBUTION ASSEMBLY ............................................................................................. 11 4.3 INPUT FILE ASSEMBLY............................................................................................................... 15 4.4 RACK ASSEMBLY....................................................................................................................... 18

4.4.1 Output Section................................................................................................................... 18 4.4.2 Monitor Section................................................................................................................. 19

4.5 MISCELLANEOUS EQUIPMENT.................................................................................................... 20 4.5.1 Cabinet Address Card....................................................................................................... 20 4.5.2 Port-1 Harness.................................................................................................................. 22 4.5.3 P20 Red Monitor Cable .................................................................................................... 23

5. INSTALLATION........................................................................................................................... 25

5.1 PROCEDURE ............................................................................................................................... 25 5.2 EXPANSION CABINET INSTALLATION......................................................................................... 26 5.3 ADJUSTMENTS ........................................................................................................................... 26

6. CABINET MAINTENANCE........................................................................................................ 27

6.1 PREVENTIVE MAINTENANCE...................................................................................................... 27 6.2 TROUBLESHOOTING ................................................................................................................... 27

7. BILL OF MATERIALS ................................................................................................................ 29

7.1 ASTC-12 NYC CABINET STANDARD ........................................................................................ 29 7.2 ASTC-12 RACK ASSEMBLY....................................................................................................... 29 7.3 HEADER PANEL ASSEMBLY ....................................................................................................... 30 7.4 POWER DISTRIBUTION ASSEMBLY ............................................................................................. 31 7.5 RACK ASSEMBLY....................................................................................................................... 34 7.6 BACKPANEL ............................................................................................................................... 35 7.7 INPUT FILE ASSEMBLY............................................................................................................... 36 7.8 CABINET ADDRESS CARD .......................................................................................................... 36 7.9 ASTC PORT #1 TRANSIENT PROTECTION/TERMINATOR ............................................................ 37

ASTC-12 Cabinet Technical Manual Table Of Contents

Page 4 U.S. T raf f ic Corporat ion

8. ASTC-12 CABINET DRAWINGS............................................................................................... 39

8.1 ASTC-12 CABINET SHELL DIMENSIONS.................................................................................... 39 8.2 ASTC-12 CABINET SHELL DOOR DIMENSIONS.......................................................................... 40 8.3 ASTC-12 CABINET LAYOUT...................................................................................................... 41 8.4 ASTC-12 WIRING DIAGRAM – CABINET ................................................................................... 42 8.5 ASTC-12 WIRING DIAGRAM – INPUT FILE ................................................................................ 43 8.6 ASTC-12 WIRING DIAGRAM – PDA SCHEMATIC ...................................................................... 44 8.7 ASTC-12 HEADER ASSEMBLY .................................................................................................. 45 8.8 ASTC-12 RACK ASSEMBLY....................................................................................................... 46 8.9 ASTC-12 BACKPANEL............................................................................................................... 47 8.10 ASTC-12 CABINET MOTHERBOARD SCHEMATIC ...................................................................... 48 8.11 ASTC-12 CABINET MOTHERBOARD SCHEMATIC (COMPONENT SIDE) ...................................... 49 8.12 ASTC-12 CABINET MOTHERBOARD SCHEMATIC (SOLDER SIDE) .............................................. 50 8.13 ASTC-12 INPUT FILE ASSEMBLY .............................................................................................. 51 8.14 ASTC-12 INPUT FILE – PCB LAYOUT ....................................................................................... 52 8.15 ASTC-12 INPUT FILE – PCB SCHEMATIC.................................................................................. 53 8.16 ASTC-12 PDA ASSEMBLY........................................................................................................ 54 8.17 ASTC-12 PDA WIRING DIAGRAM ............................................................................................ 55 8.18 CABINET ADDRESS CARD ASSEMBLY & SCHEMATIC................................................................. 56 8.19 ASTC-12 PORT 1 CABLE HARNESS ASSEMBLY ......................................................................... 57 8.20 ASTC-12 BIU TERMINATION BOARD ASSEMBLY ..................................................................... 58 8.21 NEW YORK CITY ASTC-12 RCU KIT........................................................................................ 59 8.22 ASTC-12 CABINET HARNESSES ................................................................................................ 60

LIST OF TABLES

TABLE 1. PDA CONNECTOR PIN ASSIGNMENT.......................................................................................... 13 TABLE 2. CIRCUIT BREAKER TO LOADSWITCH ASSIGNMENT .................................................................... 14 TABLE 3. INPUT FILE POSITION ASSIGNMENTS.......................................................................................... 15 TABLE 4. BIU #1 & BIU #2 PIN ASSIGNMENTS ........................................................................................ 16 TABLE 5. INTERCONNECT CABLE ASSIGNMENT ........................................................................................ 17 TABLE 6. PDA#1 HARNESS PIN ASSIGNMENTS......................................................................................... 18 TABLE 7. CMU CHANNELS MONITORED................................................................................................... 20 TABLE 8. HEX TO BINARY CONVERSION USING ODD PARITY ................................................................... 21 TABLE 9. PORT 1 HARNESS PIN ASSIGNMENTS ......................................................................................... 23 TABLE 10. RED INTERFACE CONNECTOR PIN ASSIGNMENTS .................................................................... 24

Revisions ASTC-12 Cabinet Technical Manual


1. Revisions Rev By Date Reason A P Vu 3/24/2003 Draft Release. B P Vu 4/18/2003 Revised drawing BOM & added Port #1 Harness

details. C P Vu 6/1/2003 Added CAC, Port #1 Protection Terminator details

and detailed BOM section. D P Vu 7/14/2003 Version control reconciliation E P Vu 8/26/2005 Customer comments F P Vu 2/13/2006 Per 11/1/2005 teleconference

ASTC-12 Cabinet Technical Manual Glossary


2. Glossary A Ampere, amp

AC Alternating Current

ADC Analog-To-Digital Converter

BIU Bus Interface Unit

CFM Cubic feet per minute

DC Direct Current

FTR Flash Transfer Relay

Hz Hertz

kA Kiloamp, kiloampere

LED Light Emitting Diode

LSB Least Significant Bit

MC Mercury Contactor

MCB Main Circuit Breaker

μ micro

μs microsecond

mA milliamps

mm millimeter

ms millisecond

MSB Most Significant Bit

ns nanosecond

PC Personal Computer

PCB Printed Circuit Board

PDA Power Distribution Assembly

VRMS Volts Root Mean Square

VPP Volts Peak-to-Peak

W Watt

General Description ASTC-12 Cabinet Technical Manual


3. General Description 3.1 Introduction This manual presents the instructions and diagrams necessary to install, operate, and maintain the Model ASTC-12 cabinet. It also presents the theory of operation of the cabinet. Schematics, parts lists, and assembly drawings are given as an aid for quick troubleshooting and repair of malfunctions.

The Model ASTC-12 cabinet is designed to house an ASTC Controller Unit and utilizes standard plug-in modules capable of operating twelve Model 200 loadswitches in any combination of Vehicles, Pedestrian, or Overlap movements.

The ASTC-12 cabinet is comprised of the following assemblies:

• Cabinet Rack Assembly

• Power Distribution Assembly

• Input File Assembly

• Header Panel Assembly

Cabinets accept the following plug-in modules:

• (1) Model ASTC Controller Unit

• (1) 2010ASP-NYC Monitor Unit

• (2) Bus Interface Unit

• (1) Cabinet Address Card

• (12) Model 200 Loadswitch

• (1) Model 204 Flasher Unit

• (6) Model 430 Heavy Duty Relay (Flash Transfer)

• (1) DC Interconnect Adapter Module

• Model 222NY Two Channel Loop Detector Sensor Unit (10 maximum)

• Model 224NY Four Channel Loop Detector Sensor Unit (5 maximum)

• Model 242 Two Channel DC Isolator

ASTC-12 Cabinet Technical Manual General Description


3.2 Environmental Requirements • Temperature Range: .–35° to +165° F (–37° to +74° C)

• Relative Humidity: .....5% to 95% relative

• Power: .......................90 to 135 VAC, 60 Hz

• Weight: ......................125 lbs

• Size: ..........................15" L x 19" W x 35" H

• Mounting: ..................Side of Pole

• Wiring: .......................MIL-W 16878D, Type B or better

3.3 Cabinet Theory of Operation The main AC power enters the ASTC-12 Cabinet through field terminal block AC+ LI located on the field termination section of the rack assembly. The AC– and equipment ground inputs are terminated on their respective busses. The AC+ input is wired to the main and equipment circuit breakers located in the Power Distribution Assembly (PDA).

The ASTC-12 Cabinet has three modes of operation: AUTO, FLASH, and OFF. The mode of operation selected depends on the settings of two switches on the Rack assembly in the Cabinet. The ON/OFF switch, when placed in the OFF position, causes the cabinet to be in the OFF mode, no matter what condition the other switch is in. The AUTO/FLASH switch, in the AUTO position, allows normal operation. When placed in the FLASH position, the cabinet enters a FLASH mode. A third switch, the door switch, operates in conjunction with the Model 2010ASP-NYC Conflict Monitor. If the Conflict Monitor is removed and the Cabinet door is closed, the cabinet will switch to the FLASH mode.

3.3.1 Normal (AUTO) Mode

In the NORMAL mode, the traffic lights are controlled by the loadswitches, which in turn are under the control of the Bus Interface Unit via SDLC communication with the ASTC Controller’s program control.

The 120 VAC is distributed as follows: The current flows through the Main circuit breaker CB1, through the closed contacts of the mercury contactor MC1, through the four signal bus circuit breakers (CB-A, CB-B, CB-C, and CB-D), through the loadswitches (L1 – L12) in the output section of the Rack Assembly, and out the terminal blocks (FT1, FT2, and FT3) to the traffic lights. If the Molex jumper block is selected for Red Flash, the current to the red light circuits flows through the closed contacts of the normally open flash transfer relays (closed due to the application of 120 VAC to the coils of the relay) before going to the field terminals. The mercury contactor (MC) is normally open and closes when its coil is energized. The coil is energized when the cabinet is in the normal (AUTO) mode of operation and de-energized when any of the switches are in the FLASH, OFF or closed position, or when the monitor unit detects a malfunction.

3.3.2 Flash Mode

In FLASH operation, 120 VAC is removed from the coil of the MC. The MC opens, removing the 120 volts from the loadswitches, and thus the lights. At the same time, the voltage applied

General Description ASTC-12 Cabinet Technical Manual


to the coil of the flash transfer relays is removed, causing the relays to de-energize. This results in the relay contacts closing, completing the current path from the flasher unit through the rack assembly. The flash transfer relays now switch the pulsating current from the flasher unit directly to the red lights, bypassing the loadswitches. If the cabinet is configured for yellow flashing, then the yellow lights are connected to the flasher.

The intersection will also transfer to the FLASH mode if the Conflict Monitor detects a malfunction. These include the following basic monitor functions:

1. Conflicting green or yellow indications 2. Absence of +24 VDC to the monitor unit 3. Absence of a watchdog timing pulse

NOTE: Refer to the 2010ASP-NYC Conflict Monitor Manual for a full list of monitor functions that will initiate the transfer to FLASH mode.

3.3.3 OFF Mode

All traffic lights are completely de-energized in the OFF mode.

In this mode, 120 VAC is applied to the Flash Transfer Relay, which prevents the flasher from connecting to the red light circuits. With the Signal switch in the OFF position, current is prevented from passing through the coil of MC1, thus removing power from the loadswitches. As a result, all traffic lights remain dark.

3.4 Manhattan Operation The ASTC Controller operating in the ASTC-12 cabinet supports the Manhattan Communica-tions Protocols for communication with New York City’s Vehicular Traffic Control System (VTCS). The interconnect uses a Remote Communications Unit (RCU) operating with a revised RCU firmware. All functionality of previous versions of the RCU is now incorporated into the ASTC Controller firmware. The sole function of the revised RCU is to convert RF signals to serial data for processing by the ASTC Controller.

A Manhattan deployment requires the following equipment:

• Remote Communication Unit (with revised firmware)

• RCU power plug

• RCU communication harness connecting to ASTC Controller

• VIDT

• (2) RCU coaxial cable (transmit and receive)

3.5 DCI Operation The Outer Boroughs employ a traffic system that uses a ±100 VDC pulsing method for communication between the VTCS and existing traffic intersection controllers. To allow the ASTC Controller to operate within this system, a DC Interconnect (DCI) Module is used. The DCI module provides an interface between the existing New York City VTCS and the ASTC

ASTC-12 Cabinet Technical Manual General Description


Controller. The purpose of the DCI is to convert the ±100 VDC pulses to the logic levels required to interface with the ASTC Controller via the cabinet’s BIU.

The equipment required for a DCI Deployment is as follows:

• DCI Module

• Demarcation termination block

• Telephone cable wiring

3.6 Manual Operation The ASTC-12 cabinet provides a Manual Mode of operation that allows an operator to control the ASTC Controller by means of a hand-operated switch. This will allow the operator to manually control the progression of the controller through its programmed intervals.

This is done using Manual Police Cord that has a pushbutton switch on one end and a Phono Plug on the other. Upon the insertion of the phono plug into the cabinet’s Manual Control Jack, the Manual Control Enable signal is applied to the controller. This causes the ASTC Controller to stop timing in all intervals except the vehicle change and clearance intervals. When the pushbutton is pressed, the controller steps to the next clearance interval. Normal operation resumes upon the removal of the phono plug.

Cabinet Description ASTC-12 Cabinet Technical Manual


4. Cabinet Description The ASTC-12 cabinet consists of four basic assemblies: Header Panel Assembly, Power Distribution Assembly (PDA), Input File Assembly, and Rack Assembly.

4.1 Header Panel Assembly Each ASTC-12 cabinet is equipped with a Header Panel Assembly located at the top of the cabinet. The assembly contains a thermostatically controlled fan, a thermal alarm sensor with an indicator, and a controller power outlet receptacle. This assembly is connected to the cabinet via the PDA#3 harness, which mates with the PDA#3 connector on the PDA.

The electric fan has an air moving capacity of 100 cfm. The fan vents air out between the top of the cabinet and the cabinet front door. The front door is provided with louvered vents and a removable air filter. The fan is thermostatically controlled and manually adjustable to operate at any temperature between 90º – 150º F (33º – 65° C) with a differential of not more than 43º F (6° C) between automatic turn on and turn off. The fan unit power is provided by the PDA and routed through a circuit breaker on the PDA. A ¼ A fuse protects the cabinet fan circuit.

Also provided on this assembly is a fixed temperature sensor which provides a Thermal Alarm closure contact. This sensor will provide an alarm signal to the Bus Interface Unit (BIU) when the cabinet’s internal temperature reaches 150º ± 5° F (35º C). A visual indicator for the thermal alarm condition is also provided.

A controller duplex receptacle outlet is provided to supply Filter AC+ for use by the controller. A 10A fuse in the PDA protects this receptacle.

4.2 Power Distribution Assembly The PDA functions as the entry point for AC power to the cabinet and contains main and secondary circuit breakers, cabinet transient and voltage surge protection, clean power filtering, and a +24 VDC power supply. The major components of the PDA includes the following:

• (1) One-pole, 30 A 120 VAC Main Circuit Breaker

• (1) One-pole 15 A 120 VAC Equipment Circuit Breaker

• (4) One-pole 15 A 120 VAC Signal Bus Circuit Breaker w/ Auxiliary Switch

• (1) Duplex NEMA 5-15R Ground Fault Interrupt Equipment Receptacle

• (5) Fuses o DC Power Supply AC Fuse (1A) o DC Power Supply Output Fuse (2A) o Flasher Unit Power (15A) o Controller Unit (10A) o 12 VAC (1/4 A)

• (1) DC Power Supply Indicator (AC+, +24VDC)

ASTC-12 Cabinet Technical Manual Cabinet Description


• (1) DC Power Supply Test Points (+24VDC, Lgc Gnd)

• (1) 12 VAC LED Indicator

• (1) 60 Amperes Mercury Contactor, 120 VAC

• (1) Surge Arrestor

The PDA is of a modular design and can be removed for troubleshooting purposes. The PDA mounts to the lower right section of the cabinet rack assembly and is fastened using two quarter-turn wing-nut fasteners. It has a side cover that may be opened during operation, but caution must be exercised since high voltage AC power is present inside the assembly. If any question exists regarding safety, it is best to remove power from the cabinet before opening the panel.

Interconnections to the rack assembly are made via connectors PDA1, PDA2, and PDA3 with the following pin assignment (see Table 1):



Pin PDA1 Function PDA2 Function PDA3 Function

1 Signal CB1 CM Fail (Door Sw) AC+ (Filtered)

2 Signal CB3 CM Fail (Fr PDA) AC- (Filtered)

3 Signal CB4 CM Fail (To PDA) Chs Gnd

4 CM Interlock Equipment CB

5 Signal CB2 Cabinet Alarm

6 12 VAC

7 Chs Gnd

8 AC– AC–

9 Flasher AC+ AC+

10 Signal CB4

11 Signal CB1 MC Coil Door Switch (Intlk)

12 Lgc Gnd Door Switch (Intlk)

13 +24 VDC Door Mon/Therm Sensor

14 Signal CB3 Lgc Gnd

15 Signal CB2 +24 VDC

Table 1. PDA Connector Pin Assignment

As its name implies, the PDA is responsible for the distribution of power within the cabinet. Input power enters on the quick connect connector and feeds a 30 A Main Circuit Breaker (MCB). The MCB supplies power to the controller receptacles, flasher fuse, +24 VDC power supply, and the mercury contactor (MC). The MC is a normally open switch rated at 60 A.

The PDA utilizes a cabinet Surge Arrestor to protect the cabinet from catastrophic electrical surges and high frequency noise. In addition, the Arrestor employs a Series Hybrid Inductor circuitry, which provides additional filtering. The Arrestor has the following ratings:

• Peak Current 30,000 A (@ 8 x 20µs waveform)

• Clamp Voltage 250V @ 30kA

• Response Time <5 ns

• Surge Life 25 occurrences @ 10kA (8 x 20μs)

• Filtering Line and Neutral to Ground

The Mercury Contactor provides power to four 15 A signal circuit breakers. These signal circuit breakers are wired to the Rack Assembly and feed the loadswitches as follows:

Circuit Breaker Loadswitch

CB1 Loadswitch 1, 2



CB2 Loadswitch 3, 4

CB3 Loadswitch 5, 6, 11, 12

CB4 Loadswitch 7, 8, 9, 10

Table 2. Circuit Breaker to Loadswitch Assignment

These four single-pole, signal circuit breakers are equipped with an auxiliary switch feature and have a medium trip delay characteristic. The normally closed contact of the auxiliary circuit is wired in series with the cabinet flash system so that any tripped breaker shall cause the cabinet to transfer to the flash mode. The breaker’s auxiliary switch circuit is closed when the breaker is in the on position.

An Equipment Circuit Breaker rated for 15 A with a short trip delay characteristics provides power to the GFI equipment receptacle and the cabinet fan. The GFI equipment receptacle with a ground fault circuit interrupter as defined in the Nation Electrical Code is provided on the front panel. Circuit interruption will occur on 6 mA of ground fault current and will not occur with less than 4 mA of ground fault current.

The Flasher fuse is rated at 15 A and feed the Flasher units in the Rack Assembly to provide two alternating signal drives rated at a maximum of 15 A each.

A +24 VDC power supply is included in the PDA. The power supply module provides the +24 VDC needed for the operation of most of the cabinet control components. The unit is of a ferro-resonant design having no active components and conforms to the following requirements:

• Line Regulation: 2 percent from 90 to 135 VAC at 60 Hz, plus an additional 1.6 percent for each additional one percent frequency change.

• Load Regulation: 5 percent from 0.5 to 2.0 A with a maximum temperature rise of 86º F (30° C) above ambient.

• Design Voltage: +24 ± 0.5 VDC at full load.

• Full Load Current: 1.75 A

• Ripple Noise: 2 VPP and 500 mVRMS at full load

• Line Voltage: 90 to 135 VAC

• Minimum Voltage: +23 VDC

Power is derived from the filter portion of the cabinet arrestor and is applied through F1 (1A) to the primary side of the transformer. AC tuning capacitor (6 μF 660 VAC) is self-regulating and prevents variations in input voltage from affecting the output level of the power supply. The transformer drives a high capacity diode bridge rectifier along with one large 23,000 μF, 50 VDC filter capacitor, providing low ripple voltage at full-load (1.75 A) current. A parallel 1KΩ 1 W load resistors prevents any residual charge on the filter cap in the event of an open circuit after the power is removed. Fuse F2 (2.0-Ampere slow blow) is used to protect against accidental overloading. Test points for the +24 VDC and DC ground are available on the PDA front panel.



Also provided in the PDA is an unregulated 12 VAC power supply. The 12 VAC is provided for use by the BIU for isolation of Pedestrian and Preempt inputs. Power is applied through F5 (0.25 A) to the primary side of the 12 VAC transformer. The developed 12 VAC is protected from overloading by a 0.25 A resettable fuse. An LED indicator for the presence of this voltage is provided on the front panel. This LED is wired in series with a Zener diode preventing it from illuminating when the voltage is below 7 VAC.

4.3 Input File Assembly The Input File Assembly supports two Bus Interface Units (BIUs), any combination of two- and four-channel devices, and a DC Interconnect module. The types of input devices that can be inserted into the Input Files are two- and four-channel detectors (loop or magnetic), AC and/or DC isolators, and preemption modules. The input devices provide the BIU with information such as vehicle presence, AC and DC isolation, and DC interconnect signals. Position assignments for the cabinet equipment are shown in Table 3:

Slot Equipment Type

1, 2 Bus Interface Units

3 – 11 2/4 Channel Detector/Isolator Units

12 2-Channel Detector/Isolator Unit, DC Interconnect

Table 3. Input File Position Assignments

The first two slot connectors mate with a BIU via 64-pin DIN connectors. The slots are hardwired to force the BIUs to operate as address #3 in Slot 1 and address #4 in Slot 2.

The BIU is responsible for generating all discrete Input/Output signal utilized in the cabinet. It provides interface and control between the ASTC Controller and cabinet via SDLC communication.

The signal assignments of the BIUs when used in these slots are shown in Table 4:



BIU #1 BIU #2

Row SIDE A SIDE B Row SIDE A SIDE B 1 +24 VDC +24 VDC 1 +24 VDC +24 VDC

2 Cabinet Add Select #1 Cabinet Add Select #2 2 Loadswitch 1 Red Loadswitch 1 Yellow

3 Cabinet Add Select #3 Cabinet Add Select #4 3 Loadswitch 1 Green Loadswitch 2 Red

4 Watchdog Disable Red Monitor 4 Loadswitch 2 Yellow Loadswitch 2 Green

5 Detector Reset #1 Detector Reset #2 5 Loadswitch 3 Red Loadswitch 3 Yellow

6 Detector Reset #3 Detector Reset #4 6 Loadswitch 3 Green Loadswitch 4 Red

7 Detector Reset #5 Detector Reset #6 7 Loadswitch 4 Yellow Loadswitch 4 Green

8 Detector Reset #7 Detector Reset #8 8 Loadswitch 5 Red Loadswitch 5 Yellow

9 Detector Reset #9 Detector Reset #10 9 Loadswitch 5 Green Loadswitch 6 Red

10 Detector #1 Input Detector #2 Input 10 Loadswitch 6 Yellow Loadswitch 6 Green

11 Detector #3 Input Detector #4 Input 11 Loadswitch 7 Red Loadswitch 7 Yellow

12 Detector #5 Input Detector #6 Input 12 Loadswitch 7 Green Loadswitch 8 Red



15 Detector #11 Input Detector #12 Input 15 Loadswitch 9 Green Loadswitch 10 Red



18 Det #17 In/DCI TX+ Det #18 In/DCI TX– 18 Loadswitch 11 Green Loadswitch 12 Red

19 Det #19 In/DCI RX+ Det #20 In/DCI RX– 19 Loadswitch 12 Yellow Loadswitch 12 Yellow

20 Cabinet Add Bit #1 Cabinet Add Bit #2 20 N/A N/A

21 Cabinet Add Bit #3 Cabinet Add Bit #4 21 N/A N/A

22 Stop Time Cabinet Add Parity 22 N/A N/A

23 Manual Enable Interval Advance 23 N/A N/A

24 Ext Minimum Recall Flash Sense 24 N/A N/A

25 Cabinet Alarm Pedestrian Call #1 25 N/A Pedestrian Call #3

26 Pedestrian Call #2 Preempt Call #1 26 Pedestrian Call #4 Preempt Call #3

27 Preempt Call #2 12 VAC 27 Preempt Call #4 12 VAC

28 BIU Address Bit 0 BIU Address Bit 1 (Gnd) 28 BIU Address Bit 0 (Gnd) BIU Address Bit 1 (Gnd)

29 BIU Address Bit 2 BIU Address Bit 3 29 BIU Address Bit 2 BIU Address Bit 3

30 Reserved Reserved 30 Reserved Reserved

31 Chassis Ground Reserved 31 Chassis Ground Reserved

32 Logic Ground Logic Ground 32 Logic Ground Logic Ground

Table 4. BIU #1 & BIU #2 Pin Assignments

Slot #3 to Slot #12 is a 22-pin dual-readout edge connector whose numbered side is connected to the respective lettered side. These slots are wired to accommodate both 2- and 4-channel devices. All appropriate signals are connected to these connectors to operate both DC and AC components.



Pins F and W on each connector connect to the proper BIU inputs on the motherboard. Output emitters, Pins H and X, are connected to logic ground.

NOTE: For DC Interconnect operation, insert the DCI Unit in Slot #12 and leave Slot #11 empty.

Interconnections between the Input File Assembly and the Rack Assembly are made via IDC connectors/headers on the rear of the Assembly. The connector cables are not cross-wired; they are straight 1-to-1 connected. The connector’s function assignments are shown in Table 5:

Pin C1 C2 C3 C4 C5 1 Loadswitch 1 Red Loadswitch 9 Green Ch.1 LP+ Ch.14 LP+ AC+

2 Loadswitch 1 Yellow Loadswitch 10 Red CH.1 LP– Ch.14 LP– AC–

3 Loadswitch 1 Green Loadswitch 10 Yellow Ch.2 LP+ Ch.15 LP+ CHS GND

4 Loadswitch 2 Red Loadswitch 10 Green Ch.2 LP– Ch.15 LP– 12 VAC

5 Loadswitch 2 Yellow Loadswitch 11 Red Ch.3 LP+ Ch.16 LP+ 24 VDC

6 Loadswitch 2 Green Loadswitch 11 Yellow Ch.3 LP– Ch.16 LP– LGC GND

7 Loadswitch 3 Red Loadswitch 11 Green Ch.4 LP+ Ch.17 LP+

8 Loadswitch 3 Yellow Loadswitch 12 Red Ch.4 LP– Ch.17 LP–

9 Loadswitch 3 Green Loadswitch 12 Yellow Ch.5 LP+ Ch.18 LP+

10 Loadswitch 4 Red Loadswitch 12 Green Ch.5 LP– Ch.18 LP–

11 Loadswitch 4 Yellow Cabinet Add Select #1 Ch.6 LP+ Ch.19 LP+

12 Loadswitch 4 Green Cabinet Add Select #2 Ch.6 LP– Ch.19 LP–

13 Loadswitch 5 Red Cabinet Add Select #3 Ch.7 LP+ Ch.20 LP+

14 Loadswitch 5 Yellow Cabinet Add Select #4 Ch.7 LP– Ch.20 LP–

15 Loadswitch 5 Green Cabinet Add Parity Ch.8 LP+ Not Used

16 Loadswitch 6 Red Cabinet Add Bit #1 Ch.8 LP– Not Used

17 Loadswitch 6 Yellow Cabinet Add Bit #2 Ch.9 LP+ Not Used

18 Loadswitch 6 Green Cabinet Add Bit #3 Ch.9 LP– Not Used

19 Loadswitch 7 Red Cabinet Add Bit #4 Ch.10 LP+ Ped Det #1

20 Loadswitch 7 Yellow Stop Time Ch.10 LP– Ped Det #2

21 Loadswitch 7 Green Ext Minimum Recall Ch.11 LP+ Ped Det #3

22 Loadswitch 8 Red Manual Enable Ch.11 LP– Ped Det #4

23 Loadswitch 8 Yellow Interval Advance Ch.12 LP+ Preempt #1

24 Loadswitch 8 Green Cabinet Alarm Ch.12 LP– Preempt #2

25 Loadswitch 9 Red Watchdog Ch.13 LP+ Preempt #3

26 Loadswitch 9 Yellow Disable Red Monitor Ch.13 LP– Preempt #4

27 Flash Sense

28 Not Used

29 Not Used

30 Not Used

31 Not Used

32 Not Used

33 Not Used

34

Pins Not Present

Not Used

Pins Not Present Pins Not Present

Pins Not Present

Table 5. Interconnect Cable Assignment



4.4 Rack Assembly The Rack Assembly combines the Input File, Output File, and field output panel into a single self-standing rack unit. This rack unit houses the Detector Cards, Load Switches, Flashers, Field Transfer Relays (FTRs), Conflict Monitor, etc. For ease of maintenance, the rack assembly is removable.

The rack assembly utilizes a PCB motherboard to reduce cabinet wiring. All necessary connectors for standard traffic equipment are mounted and interconnected on the mother-board. The rack assembly is provided with marker strips to identify the items in the rack. The marker strips can be easily written on using a pencil or ballpoint pen. The strips are located immediately below the item’s rack opening.

To aid in the discussion the rack assembly is described in two sections: output section and monitoring section.

4.4.1 Output Section The Output section is capable of housing 12 Model 200 loadswitches, a Model 204 flasher unit, six Model 430 heavy duty relays (FTRs), and 12 flash programming plugs. Together these components provides output load switching to intersection traffic signals.

DC trigger inputs for the Model 200 Loadswitch and +24 VDC are available on the backplane motherboard. These connector sockets are wired for the necessary power, input and output signals required to switch 120 VAC on and off to the intersection signal heads. All loadswitch outputs are terminated at field terminal blocks FT1, FT2, and FT3.

The red and yellow signal circuits of the loadswitches are available on a Molex-type receptacle which mates with a Molex-type plug to allow flash programming. A plug connector with programming jumpers is furnished for each circuit to allow red and yellow flash programming. Plug pins are crimped and soldered.

AC+ supply for the 12 loadswitches enters on PDA#1 Harness from the PDA and is distributed as shown in Table 6. Each of these power inputs for the loadswitches is connected through circuit breakers in the PDA. Each breaker is rated at 15 A.

Harness Pin Loadswitch 1 1 2 5, 6 3 7, 8 5 3

10 9,10 11 2 14 11, 12 15 4

Table 6. PDA#1 Harness Pin Assignments

Power for the Flasher Unit is available on PDA#1 Harness Pin 9. The Flasher Unit outputs go to the FTRs.



When the BIU issues a logic-ground-true loadswitch drive signal, the signal is routed to the individual loadswitch input. For example, loadswitch 1 Red receives a logic ground signal at Pin 6. Since the +24 VDC is supplied to Pin 9, current will flow in the loadswitch input circuit, specifically, the light emitting diode of an optical isolator. This turns on the output device causing current to flow from Pin 3 of the loadswitch to Pin 13 of the flash program block receptacle. Jumpers on the mating block then route the red signal through the flash transfer relay, and route the yellow signal directly to the field terminal. In the case of Red Flash programming, the program block ties Pin 13 to Pin 7 which connects to the normally open contact of FTR1, Pin 7. Therefore, the signal is routed through the relay common Pin 5, back through the program block to FT1 Position 1. In the de-energized state of FTR1 (FLASH mode), FT1-1B is connected through the program block and to the flasher output. Since the yellow signal is not required to flash in this instance, the program block routes this loadswitch signal directly to the output terminal block FT1. Note that the yellow and green signals are dark during flash operation due to the loss of AC+ on pin 1 of the loadswitch. The green signal does not flash; therefore, loadswitch 1 green connects directly to the output terminal block FT1 Position 3, bypassing the program block.

If Yellow Flash is required, the Red Flash program block is removed from its receptacle and replaced with the yellow flash program block. In this configuration the red signal circuit is routed directly to its field terminal block, and the yellow signal is routed through the FTR contact to the output field terminal block.

A third type of program block is available for PED operation. Since FLASH operation is not required for PED phases, this program block routes loadswitch outputs directly to the field terminal blocks.

4.4.2 Monitor Section A Model 2010ASP-NYC Conflict Monitor is connected to the motherboard through a rigidly supported printed circuit board edge connector. The connector has two rows of 28/56 independent double readout bifurcated contacts on 0.156 inch centers. All signals necessary for monitor operation are brought to this connector via PCB traces on the motherboard backplane.

It is possible to remove the monitor unit without causing the intersection to go into FLASH operation, but only while the cabinet door is open. The cabinet contains a conspicuous warning against operation with the monitor unit removed.

Power is connected to Pin FF (AC+) and Pin 21 (AC–) of the signal monitor edge connector. Additional signals brought into the monitor are those wired to monitor the appropriate field outputs. These are the yellow and green/walk indications for purposes of conflict monitoring. The Conflict Monitor monitors the loadswitches on its respective channel inputs, e.g. Loadswitch #1 on Channel #1, etc. (see Table 7). In addition, signals such as WDT (Watch Dog Timer signal), +24 VDC monitor, DC stop timing output, DC ground, and external reset are signals that are involved with signal monitor activity and hence are connected to the edge connector.

Loadswitch CMU Channel Loadswitch CMU Channel

LS1 Ch. 1 LS7 Ch. 7



LS2 Ch. 2 LS8 Ch. 8

LS3 Ch. 3 LS9 Ch. 9

LS4 Ch. 4 LS10 Ch. 10

LS5 Ch. 5 LS11 Ch. 11

LS6 Ch. 6 LS12 Ch. 12

Table 7. CMU Channels Monitored

A 20-conductor cable for monitoring the red outputs of all signal loadswitches is provided and attached to the rack assembly. The cable is routed from the front of the Rack Assembly and plugged into the connector on the front of the Conflict Monitor.

A mechanical jumper is provided to facilitate normal operation when a loadswitch position is unused. The mechanical jumper must be inserted into the unused loadswitch connector to short pins one and three. This will provide an AC+ signal to that channel’s red input to prevent the Conflict Monitor from registering a Red-Fail condition when that position is unused.

Red monitor disable control is provided on the backplane motherboard through the red monitor (RM) control relay. The normally closed contacts provide 115 VAC to the red monitor select line on the monitor cable. When a logic ground signal is applied from pin B4 of the BIU connector, the RM relay energizes and opens the contacts, removing the 115 VAC from the Red enable pin 20 of the red monitor cable. The relay power is derived from the cabinet +24 VDC cabinet supply.

A flash sense relay is mounted on the front of the rack assembly. The flash sense relay determines the status of the current mode of operation of the cabinet. The relay is de-energized when the cabinet is in FLASH and thereby switches logic ground to the flash sense pin B24 of the BIU connector.

4.5 Miscellaneous Equipment

4.5.1 Cabinet Address Card A Cabinet Address Card (CAC) is used to assign a unique 16-bit address to each cabinet. The CAC module is a plug-in type circuit board with an edge card type connector on one end and a panel and extractor handle on the other end. The board dimensions are 4.5” high by 6.9” deep with a panel dimension of 4.5” high by 2.24” wide. This module contains a matrix of 20 diodes that can be configured to create a four-digit hexadecimal cabinet address. In addition, the front panel holds the test switches for the Stop Time and Min Recall functions. The CAC is fastened to the rack in order to prevent the card from being casually removed.

The CAC is configured by removing diodes per Table 8. The transmission of the cabinet address utilizes an odd-parity communication technique; therefore a parity bit must be accounted for. Table 8 shows Hexadecimal to Binary conversion using odd parity:



Hex Binary Parity Bit Needed? Result

0 0000 Y 10000 1 0001 N 00001 2 0010 N 00010 3 0011 Y 10011 4 0100 N 00100 5 0101 Y 10101 6 0110 Y 10110 7 0111 N 00111 8 1000 N 01000 9 1001 Y 11001 A 1010 Y 11010 B 1011 N 01011 C 1100 Y 11100 D 1101 N 01101 E 1110 N 01110 F 1111 Y 11111

Table 8. Hex to Binary Conversion Using Odd Parity

Odd parity requires that a 4-bit binary number have an odd number of 1s. If a binary number has an even number of 1s (or none at all), a parity bit is added before the MSB to make the number of 1s be odd.

The binary numbers are decoded this way: PB/MSB/b/b/LSB, where PB=parity bit, M=MSB of the 4-bit number, b=less significant bit, and L=LSB of the 4-bit number. A parity bit is only added if the number of binary 1s in a 4-bit number is even (or zero).

For example, 0, represented in binary as 0000, has no 1s (see Table 8). Therefore a parity bit is added. One, represented in binary as 0001, has an odd number of 1s, so no parity bit is needed. The same is true for 2. However, 3, represented in binary as 0011, has an even number of 1s, so a parity bit is added to make an odd number of 1s, hence 10011.

The formats for the different addressing schemes for New York City are as follows:

For Manhattan Coaxial Cable connected controllers: 00.x.CCCCC.AAAAAAAA

00 indicates that this controller is connected to the Manhattan Cable RF System. x is unused for this group CCCCC – is the Manhattan channel number (1-32) AAAAAAAA – forms a unique 8 bit address (1-240)



*Note that the channel number and address create a unique cabinet number (7680 possible).

For Outer Boroughs (100 VDC Interconnect) connected controllers: 01.LLLLLL.LLLLLLLL

01 indicates that this is an outer boroughs cabinet connected via DC control. As a result, it will expect the HOL, ADV, FADV, RESYN signals to be computed from the signals at the BIU inputs and will drive the BIU functions to transmit the CHECK and MSG functions. L…L forms a unique 14-bit cabinet address (16,384) which is used for database validation purposes. This type of communications connection does not support data exchange.

For NTCIP connected controllers: 1.PP.AAAAAAA.NNNNNN

1 indicates that this cabinet will use its serial data Port to communicate with the central computer using the NTCIP protocol. The NTCIP protocol conforms to NEMA TS2-1998, Section 3.3.6 for Actuated Type 1 (A1N Level 2) and Pretimed Type 1 (P1N Level 2) controllers. PP bits are used to identify the type of communications to be supported. This allows for a maximum of 4 configurations with 8192 controllers using each configuration. For TOPICS IV ‘00’ denotes 9600 bits-per-second serial communications. The other three settings (‘01’, ‘10’, ‘11’) are yet to be determined. A...A is concatenated with the NTCIP address to form a unique cabinet address for this communications configuration (8192) N…N bits are used for the NTCIP 6 bit (short) address as required in NEMA TS3.3-1996 Section 3.3.3.1 Figure 3-3.

4.5.2 Port-1 Harness

The ASTC-12 cabinet is equipped with a communication harness to interconnect the controller’s Port 1 signals to the BIU and to the transient protection/expansion assembly. Each harness provides a twisted pairs for the TX Data, TX Clock, RX Data, and RX Clock Signals. The harness’s connector is a 15-pin D subminiature type and has spring latches to ensure proper mating.



PIN FUNCTION

1 Rx Data+

2

3 Rx Clock+

4

5 Tx Data+

6

7 Tx Clock+

8

9 Rx Data–

10

11 Rx Clock–

12

13 Tx Data–

14

15 Tx Clock–

Table 9. Port 1 Harness Pin Assignments

4.5.3 P20 Red Monitor Cable

The P20 Red Monitor Cable is a 20-position ribbon cable with two Insulation Displacement Connectors on each ends for mating with a 2010ASP-NYC front panel connector. The cable routes the Field wire Red signals to the associated Conflict Monitor channel’s red signal inputs. In addition to the Red Signal inputs, there is a Red Enable input that activates the plus features of the monitor (refer to 2010ASP-NYC Manual). Table 10 shows the Red Interface cable pin assignments:

PIN FUNCTION PIN FUNCTION

1 Channel 15 Red 11 Channel 9 Red



4 Chassis Ground 14 Channel 6 Red


6 Special Function 2 16 Channel 4 Red


8 Special Function 1 18 Channel 2 Red



PIN FUNCTION PIN FUNCTION


10 Channel 11 Red 20 Red Enable

Table 10. Red Interface Connector Pin Assignments

Installation ASTC-12 Cabinet Technical Manual


5. Installation 5.1 Procedure

1. To place the cabinet into operation, check that all circuit breakers in the power distribution panel are off. Connect the input power to the field terminal block and the appropriate buss bar. The connections are black (AC+) to AC+ LI, green to the Equipment Ground buss bar, and white (AC–) to the neutral buss bar.

2. Place the ASTC Controller onto the top shelf of the rack assembly. Plug the Controller power cord into the Controller receptacle in the header assembly. Connect the SDLC communication cable to the Controller’s Port 1 connector. The SDLC cable needs to be properly connected to the ASTC Controller, the Bus Interface Unit, and the Termination Protection Board. Ensure the connector clips on the communication cable properly latch onto the locking blocks.

3. Signal light connections are made to the terminal blocks FT1, FT2, and FT3. Refer to the cabinet diagram provided with and located in the cabinet for terminal block position assignments.

4. The Detector input connections are made directly to terminal blocks FT4, FT5, FT6, and FT7. In addition to the vehicle loop detector connections, ensure any necessary pedestrian inputs or preempt inputs are connected to the appropriate positions.

Note: The AC– buss bar can be used as the reference for the pedestrian and preempt inputs.

5. Disconnect the Red Interface cable from the Model 2010ASP Conflict Monitor and remove the unit from the rack assembly. Program the appropriate dipswitch settings (refer to 2010ASP/2010ASP-NYC Conflict Monitor Technical Manual MN078135 for dipswitch settings details). Reinsert the Conflict Monitor. Remove the programming card from the Conflict Monitor and program the conflicts to be ignored by removing the appropriate diodes as marked. Solder the jumpers for those channels where yellow light monitoring is to be inhibited. Reinsert the programming card into the Conflict Monitor.

6. Connect the communication system: a. If using the Manhattan RCU (MRCU), install it by placing it onto the top shelf next to

the ASTC Controller as shown in Section 8.3. Connect power cable (part number H80033) from P1 to the Cabinet Controller Receptacle on the cabinet header assembly. Attach two RCU Coax Cables (part number 2-00455-01) to the VIDT mounted on the front lower left of the ASTC-12 Cabinet. Attach an RCU Communi-cation Adapter and Cable (part number H80034.01) from the RCU RS-232 port to Port 2 on the ASTC Controller. Turn RCU ON switch on.

b. If using the Outer Boroughs DCI module, install it into the right-most slot of the top rack, above the loadswitches and below the ASTC Controller as shown in Section 8.3. Connect jumper wires between Field Input Terminal Block pins FT4-1 (Tip) and FT4-2 (Ring) to the appropriate Tip and Ring connectors on the Cabinet Demarcation Terminal Block.

ASTC-12 Cabinet Technical Manual Installation


7. The ASTC-12 Rack Assembly provides twelve flash programming jumper plugs for selecting Red or Yellow flash. Insert the red, yellow, or pedestrian Molex plugs, depending on the type of flashing desired.

8. Install all required Loadswitches per intersection configuration and verify that the indicators on the Loadswitch front panels behave in accordance with Controller programming. Install the mechanical red jumpers in all unused Loadswitch connectors between Pin #1 & Pin #3.

9. Turn on all circuit breakers. For normal three-color operation, check that the Signal AUTO/FLASH switch is in the AUTO position and that the Signal ON/OFF switch is in the ON position.

5.2 Expansion Cabinet Installation When installing an optional expansion cabinet, remove the termination header transient protection from the BIU Termination Board, mounted on the left side of the Cabinet (see Section 8.20). Plug a Port 1 Cable from the top plug of the BIU Termination Board, route the cable to the expansion cabinet and plug the other end into the bottom plug of the expansion cabinet’s BIU Termination Board.

5.3 Adjustments The only adjustment necessary is the thermostat switch for the cabinet fan located in the Header assembly at the top of the cabinet. Set the thermostat to the temperature desired.

Cabinet Maintenance ASTC-12 Cabinet Technical Manual


6. Cabinet Maintenance 6.1 Preventive Maintenance The ASTC-12 Cabinets are designed to require minimum maintenance; however, certain simple steps should be taken to insure proper operation, such as periodically checking the air filter and replacing it if necessary and checking wiring, terminals, and connectors for signs of breakage and wear and repairing or replacing if necessary. Housekeeping steps such as vacuuming dust and cleaning the interior of the cabinet are valuable steps in maintaining good air circulation.

It is recommended that the ASTC-12 cabinet be checked at 6 months after installation and at least annually thereafter. After the initial check, a regular interval for preventive maintenance may be established based on the condition. Some locations may need attention more often than others depending on the environment in which they were installed.

The following maintenance procedures should be performed on a regular basis:

• Replace air filters.

• Check operation of fan assembly for proper operation to ensure adequate ventilation.

• Lubricate lock and three point locking mechanism.

• Check all wiring connections for tightness, corrosion, damaged insulation, etc.

• Check all equipment connections for corrosion, contamination, and damage, making sure they are properly seated.

• Check all mounting hardware for proper tightness.

• Check the integrity of all PDA harness connections and equipment ground bars.

• Vacuum dust and clean cabinet interior

Systematic evaluation of the 2010ASP-NYC Monitor Unit is necessary in determining safe system operation. The monitor may be removed and fully tested, then reinstalled and observed for proper channel operation.

6.2 Troubleshooting Troubleshooting the ASTC-12 Cabinet should be performed in accordance with procedures in the ASTC Cabinet Troubleshooting Guide, MN078166.

ASTC-12 Cabinet Technical Manual Cabinet Maintenance


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Bill of Materials ASTC-12 Cabinet Technical Manual


7. Bill of Materials 7.1 ASTC-12 NYC Cabinet Standard

Component Description Manufacturer Manufacturer’s Part Number

001736 RELAY, 120VAC, 20A@120VAS, DPDT, POWER, FTR MAGNECRAFT 136-6273A1

080681 BAG, 10.0X13.0, PLASTIC, ZIPLOK, W/EYELETS, ASTC CONTROLLER

AVL PER DESCRIPTION

2-00070-01 CABINET, ASTC-12, ALUM, EVERGREEN, DT#9 LK USTC 2-00070-01

A80122 INSTALL KIT, ASTC, NYC USTC A80122

ASTC-CAC CABINET ADDRESS CARD, ASTC USTC ASTC-CAC

7.2 ASTC-12 Rack Assembly


001087 WASHER, LOCK, INT, #10, SS AVL PER DESCRIPTION

070008 WASHER, FLAT, #10, 0.215ID X 0.5OD X 0.4T, SS AVL PER DESCRIPTION

072640 CABLE TIE, 7.4, 30LB BLK, POLYPROPYLENE PANDUIT PLTS2S-M100

072641 CABLE TIE, 4, 11LB BLK, POLYPROPYLENE PANDUIT PLT1M-M100

104833 PCB ASSY, INTER CABINET RS-485 TRANSIENT PRTCTN USTC 104833

28021123-003 CONN ASSY, FLASH PLUG PRED, NEMA & 170 USTC 28021123-001

28021123-007 CONN ASSY, FLASH PLUG RED FLASH, 170 USTC 28021123-007

28021123-008 CONN ASSY, FLASH PLUG YELLOW, FLASH, 170 USTC 28021123-008

28026068-001 STANDOFF, #6 X 3/8LG, 1/4, RND, AL LYNTRON AL6341-06-0.375-0

28026219-010 PLUG, KEY FLASH ASSY, USTC 28026219-010

ASTC-12 Cabinet Technical Manual Bill of Materials



INSULATED, BEAU SOCKET

4202-2 SCREW, 10-32 X 0.5, BINDING SLOT HEAD, SS AVL PER DESCRIPTION

A80040.01 ASTC-12 HEADER ASSY USTC A80040.01

A80041 ASTC-12 RACK ASSY USTC A80041

A80043 ASTC-12 PDA ASSY USTC A80043

A80044 ASTC-12 INPUT FILE USTC A80044

A80047 PORT #1 TERM HEADER ASSY USTC A80047

H80035.01 HARNESS, INTRCNT J2 USTC H80035.01

H80035 HARNESS, INTRCNT J1 USTC H80035

W0071-309 WIRE, 6 AWG, WHT, PVC NYL JKT, 33/27, 600V, 105C AVL PER DESCRIPTION

7.3 Header Panel Assembly P/N: A80040.01


BELDEN 83336 072674 CABLE 18AWG 3 COND

THERMAX EXE1819/3STJ

080637 COVER, HEADER PANEL USTC 501071

000815 DIODE 1N4001 RECTIFIER AVL 1N4001

AIRFLOW IT12038115BH E0024 FAN CABINET STD

SUNON SP101A1123HBT

AIR FLOW EC-0446-2 28027004-001 FAN CORD PS 290

PAPST LZ120

ROTRON 476042

AIR FLOW 8170 E0026 FAN GUARD

SUNON B-5

ABY218 FAN PLATE USTC ABY218

LTLFUSE 313.250 000396 FUSE 0.25A 250V SLOW

BUSSMAN MDL-1/4

000329 FUSE HLDR 1/4X1-1/4 01EA LTLFUSE 342 012

80565 GROMMET RUBBER INSUL HH SMITH 2175

080514 HEADER PANEL PLATE USTC 500913




072790 INDICATOR RED LENS 24V IDI/CHIC 2191L1-24V

008145 NUT 1/4-20 HEX S/STL AVL PER DESCRIPTION

N300-116 NUT KEPS 6-32 S/STL AVL PER DESCRIPTION

G02023 NUT KEPS 8-32 S/STL AVL PER DESCRIPTION

000680 RECEPTACLE DUPLEX OUTLET LEVITON CR15-I

000346 SCRW 10-32x1/2 P/HD PHIL AVL PER DESCRIPTION


16762946-320 STNDOFF 1/4 HEX 6-32x AVL PER DESCRIPTION

001829 SWITCH P/B SPST N/C PNL CUTLER H 8411K8

002388 TERM BLOCK 4P 20A 300V BEAU 73104

BUD TS-15 001681 THERMOSTAT FAN CONTROL

THERM-O AFF116 STYLE 47016

072676 THERMOSTAT, DISC SELCO CA-150

000533 WIRE PVC NY 18 AWG BLK AVL MIL-W-16878D BN

000537 WIRE PVC NY 18 AWG GRN AVL MIL-W-16878/17 BN

000532 WIRE PVC NY 18 AWG WHT AVL MIL-W-16878/17 BN

070614 WIRE PVC NY 18AWG RED AVL PER DESCRIPTION

28023185-500 WIRE PVC NY 18AWG WHT/RD AVL PER DESCRIPTION

000271 WSHR #6 FLAT S/STL AVL PER DESCRIPTION

000355 WSHR #6 LK INT TOOTH AVL PER DESCRIPTION


001089 WSHR #8 LK INT TOOTH S/S AVL PER DESCRIPTION

7.4 Power Distribution Assembly P/N: A80043


072553 1/4-TURN FASTENER #82 SOUTHCO 82-32-201-20 072765 1/4-TURN FASTENER #82 SOUTHCO 82-12-320-20 070990 ARRESTOR, CABINET ARRIS DOT-19S 080577 ASTC-12 PDA COVER USTC 500986 16774481-008 BANANA JACK (RED) NEWARK 39F1574 16774481-009 BANANA JACK,(BLACK) EF JOHNS 108-0903-001




104668 BOM-PCB ASTC PDA USTC 104668 H0155 BUSHING, SNAP HEYCO .875 HEYCO 2126 BLK SB875-11 080638 BUSS BAR 4 POS CB USTC 501114 072641 CABLE TIE 4" 11LB BLK PANDUIT PLT1M-M100 072640 CABLE TIE 7.4" 30LB BLK PANDUIT PLTS2S-M100 072545 CAP 23000μF 50VDC CDE DCMC233U050BA2B 072881 CAP 6μF 660VAC 3" MALLORY 32KE6606A BRK0066 CAPACITOR BRACKET GE 128A2244ACP21 BRK0065 CAPACITOR BRACKET 2"D MALLORY VR8 070202 CIRCUIT BREAKER 15A SP CARLINSW CA1-B0-22-615-121C CB0024 CIRCUIT BREAKER 15A SP CARLINSW CA1-B2-24-615-121C 070657 CIRCUIT BREAKER 30A SP CARLINSW CA1-B0-22-630-121C

MAGNCRFT WM60A-120A 28023057-002 CONTACTOR 60A 1 POLE

MDI SP-1130-120A D200-76 DIODE BRIDGE RECTIFIER G.I. GBPC25-02 28023125-002 DIODE LED RED HP HLMP3301

BUSSMAN MDL-1/4 000396 FUSE 0.25A 250V SLO-BLO

LTLFUSE 313.250 BUSSMANN MDL-1

000394 FUSE 1.0A 250V SLO-BLO LTLFUSE 313 001 BUSSMANN MDL-2

000330 FUSE 2.0A 250V SLO-BLO LTLFUSE 313 002

16750231-001 FUSE 10A 250V MDA BUSSSMAN MDA-10 22474 FUSE 15A 250V MDA SLO-BLO BUSSMANN MDA-15

LTLFUSE 342 012 000329 FUSE HLDR 1/4X1-1/4 01EA

BUSS HTB-42I 072790 INDICATOR RED LENS 24V IDI/CHIC 2191L1-24V

LTLFUSE 970-670A-03WCN DSP0014 INDICATOR, NEON-INCAN

CHI MIN 2110A2 000338 LATCH SLIDE SOUTHCO A3-40-625-12 070252 LED HOLDER T1-3/4 BLK VCC CLP125BLK 008225 NUT KEPS 10-32 S/STL AVL PER DESCRIPTION N300-116 NUT KEPS 6-32 S/STL AVL PER DESCRIPTION G02023 NUT KEPS 8-32 S/STL AVL PER DESCRIPTION 080562 PDA CHASSIS ASTC-12 USTC 500985




080563 PDA CONN BRACKET USTC 500970 080589 PDA CONN HOLDER USTC 501004 080559 PDA FRONT PANEL ASTC-12 USTC 500947 002080 RC NTWK 0.1μF 100 OHM PAK 104M06QC100

HUBBELL GF5252I EAGLE GF15V 002081 RECEPT 15A 125V GFI

LEVITON 65991 99000045-063 RES 1K 1W 5% AVL PER DESCRIPTION 070441 RETAINING RING FOR LED AVL PER DESCRIPTION MFG0028 RUBBER CAP FOR 1/4" NUT STOCKCAP SC.500X1"L 701-89 MS51957-27 SCRW 6-32x5/16 P/HD PHIL AVL PER DESCRIPTION 000353 SCRW 6-32x5/8 P/HD PHIL AVL PER DESCRIPTION H0700-806 SCRW 8-32x3/8 P/HD SLT AVL PER DESCRIPTION 001790 TBG H/SHRINK FP 1/4 BLK ALPHA FIT 221-1/4 BLACK 070941 TERM CONTACT, #10/12, 75A ANDERSON 5915

PANDUIT DPF14-250F1B-3K 4808 TERM FASTON 0.250 x 0.032

AMP 3-520408-2 LOOSE 070880 TERM HOUSING, BLACK, LK ANDERSON 75LOKBLK

HOLLINGS XR5109N-T – TAPE 070072 TERM RING #10 12/10 INS

PANDUIT PN10-10R-2K HOLLINGS XR1903SN-T – TAPE PANDUIT PN14-10R-3K 070062 TERM RING #10 16-14 INS

T&B RB873M HOLLINGS XR1891SN-T – TAPE PANDUIT PN18-10R-3K 070071 TERM RING #10 22/18 INS

T&B RA873M HOLLINGS XR1857SNT MOLEX AA-821-06 PANDUIT PN18-6R-3K

16760846-016 TERM RING #6 22/18 INS

T&B RA853M AMP 52930-3 HOLLINGS XBS20532SN-T PANDUIT PN18-8SLF-3K

070069 TERM SSPD #8 22/18 INS

T&B RA2243M 072785 TRANSFORMER 120/24VAC PAC TRAN 072785 071266 WIRE PVC NY 20 AWG BLUE AVL PER DESCRIPTION




071267 WIRE PVC NY 20 AWG WHT/ AVL PER DESCRIPTION 000551 WIRE THHN 10AWG GRN AVL PER DESCRIPTION 000550 WIRE THHN 10AWG WHT AVL PER DESCRIPTION 000271 WSHR #6 FLAT S/STL AVL PER DESCRIPTION 000355 WSHR #6 LK INT TOOTH AVL PER DESCRIPTION 000273 WSHR #6 SPLIT LK S/STL AVL PER DESCRIPTION

7.5 Rack Assembly P/N: A80041


070935 1/4-TURN FASTENER #82 SOUTHCO 82-47-113-20

080538 ASTC ADDR FRONT PANEL USTC 500966

H80045 ASTC CAB SERVICE PLUG USTC H80045

080504 ASTC CM PANEL USTC 500888

A80042 ASTC-12 BACKPANEL ASSY USTC A80042

28022432-001 BUSS BAR, 13 POS COPPER ILSCO D167-12

A80045 CAB ADDR CAGE ASSY USTC A80045

072720 DUST COVER EDGE CONN SULLINS EXM22DSXH-S388

H80042 HARNESS, ASTC-12 PORT1 USTC H80042

H80040 HARNESS, INPUT RK PWR USTC H80040

H80036 HARNESS, LOOP INP USTC H80036

H80019.01 HARNESS, P20 ASTC 2FT USTC H80019.01

080583 LABEL CAB ID PLATE USTC 500994

072831 LABEL, ID, ASTC-12 RACK USTC 072831

080552 LEFT SIDE PANEL ASTC-12 USTC 500952

080560 LS SUPPORT BOTTOM PNL USTC 500948

080595 LS SUPPORT LWR TOP PNL USTC 501012

080561 LS SUPPORT TOP PANEL USTC 500968

080596 LS SUPPORT UPR TOP PNL USTC 501013

080584 MTG RAIL LEFT ASTC-12 USTC 500993

080585 MTG RAIL RIGHT ASTC-12 USTC 500992

080553 RIGHT SIDE PANEL ASTC-12 USTC 500953

001093 SCREW 4-40 X .25 FLAT AVL PER DESCRIPTION




MS51957-41 SCRW 8-32x1/4 P/HD PHIL AVL PER DESCRIPTION

072744 STNDOFF 10-32X3/4L AVL PER DESCRIPTION

080555 TOP SHELF ASTC-12 USTC 500951

000364 WASHER #8 INTERNAL/ AVL PER DESCRIPTION

7.6 Backpanel PN: A80042


080551 BACKPANEL ASTC-12 USTC 500955 H0162 BUSHING, SNAP HEYCO 0.75 HEYCO SB-750-10

MICRO-PL MPS-0156-28-DW-5HK 000920 CONN CARD EDGE 28/56 DIP

T&B A6D28DS29A2 072682 CONN HEADER 6 PIN W/LCK MOLEX 26-61-5060 070984 CONN PCB HDR 20P IDC FCI 53611-G20-6 070983 CONN PCB HDR 26P IDC AMP 102321-6 072683 CONN PCB HDR 34P IDC AMP 102321-8 000584 CONN POWER 15P PLUG MOLEX 03-09-2159 000585 CONN POWER 15P RECP MOLEX 03-09-1157 16779283-115 CONN POWER 15P RECP MOLEX 03-09-1154 000598 CONN TERM SOCKET PC MOLEX 02-09-1134 072901 CONNECTOR 12(P) RECP BEAU S6-5412 072903 CONNECTOR 6(P) RECP BEAU S6-5406 072902 CONNECTOR 8(P) RECP BEAU S6-5408 000816 DIODE 1N4004 RECTIFIER AVL 1N4004 104717D FAB-PCB ASTC 12-MAIN CAB ALMATRON FAB.COMPLETE 080603 LBL ENG SET OF 3 USTC 501023 002080 RC NTWK 0.1μF 100 OHM PAK 104M06QC100 K0030 RELAY PCB 5A @ 115VAC P&B R10-E1X2-115V

P & B T85N11D114-12 001392 RELAY POWER 0.5A @ 120V

TYCO 8-1393792-8 001779 RELAY RETAINER SPRING P&B 20C249 S100-221 RELAY SOCKET 2 POLE PCB P&B 27E128 001785 RES 510 OHM 1/2W 5% CF DIGI-KEY 510H-ND




MS51957-41 SCRW 8-32x1/4 P/HD PHIL AVL PER DESCRIPTION 072585 TERM BLOCK 12P 65A 600V MARATHON 1112S 4806-12 TERM BLOCK 12P 85A 600V MARATHON 1112 072619 TERM BLOCK 2P 65A 600V MARATHON 1102S 072642 TERM STRIP 12P 30A 100V BEAU 73212-A-50 001084 WSHR #8 FLAT S/STL AVL BY DESCRIPTION 009005 WSHR #8 LOCK EXT TOOTH AVL PER DESCRIPTION

7.7 Input File Assembly PN: A80044


SPC0077 938-125 LED SPACER BIVAR 938-125

070991 CONN DIN 64P RECEPTACLE 3M 7164-60B5TH

072629 CONN HEADER 6 PIN MOLEX 26-61-1060

072572 CONN PCB CARD EDGE 22P SULLINS EZM22DCWH-S11

072683 CONN PCB HDR 34P IDC AMP 102321-8

070300 CONN PCB HEADER 26 PIN FCI ELEC 53611-G26-4

104721C FAB-PCB ASTC-12 INPUT USTC 104721C

080558 INPUT FILE BOTTOM USTC 500946

080557 INPUT FILE TOP ASTC-12 USTC 500945

072833 LABEL,ID,ASTC-12 INPUT USTC 072833



7.8 Cabinet Address Card PN: ASTC-CAC


ASM 8100-3.000-440A-5 HND0025 A-1043-29 3 IN HANDLE

CAREY AL-1514-0440-29 PL 080515 ASTC ADDR FRONT PANEL USTC 500915 000257 DIODE 1N4148 SWITCHING DIODE INC 1N4148DITR-ND 104626B FAB-PCB ASTC CABINET USTC 104626B 000371 LABEL 1X.38 SILVER BRADY THT-3-428-10



001078 NUT HEX 4-40 STL/ZN AVL PER DESCRIPTION 000046 RES 10K 1/4W 5% CF PHILLIPS CR25-10K SRW0015 SCRW 4-40 x 1/2 BNDG HD AVL PER DESCRIPTION SRW0005 SCRW 4-40 x 1/4 BHMS SLTD AVL PER DESCRIPTION SRW0046 SET SCRW 4-40 x 1/2 SKT HD AVL PER DESCRIPTION DS-840 SPACER 1/4" x 1/4" x 3/4" ALARD CHEM FILM/GOLD SWH0126 SWITCH TOG SPDT TAIWAY 100-SP-1-T2B4B6Q-E WSR0015 WASHER #4 INTERNAL TOOTH AVL PER DESCRIPTION

7.9 ASTC PORT #1 TRANSIENT PROTECTION/TERMINATOR P/N: 104833


070294 CONN D-SUB 15P RECPT R/A AMP 747845-4

DIO0130 DIODE P6KE6.8CA ON SEMI P6KE6.8CA

104831B FAB-PCB INTER CABINET RS USTC 104831B

071063 INSULATOR THERMAL TO-220 THERMALY 43-77-8

072370 LATCHING BLOCK W/SLOT AMP 745286-2

072735 MOV 115V 30J 14MM EPCOS S14K115

070245 SCREW 4-40 x 0.38 FILLSTR ACCUTITE 0406MPL



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ASTC-12 Cabinet Drawings ASTC-12 Cabinet Technical Manual


8. ASTC-12 Cabinet Drawings 8.1 ASTC-12 Cabinet Shell Dimensions



8.2 ASTC-12 Cabinet Shell Door Dimensions



8.3 ASTC-12 Cabinet Layout



8.4 ASTC-12 Wiring Diagram – Cabinet



8.5 ASTC-12 Wiring Diagram – Input File



8.6 ASTC-12 Wiring Diagram – PDA Schematic



8.7 ASTC-12 Header Assembly



8.8 ASTC-12 Rack Assembly



8.9 ASTC-12 Backpanel



8.10 ASTC-12 Cabinet Motherboard Schematic



8.11 ASTC-12 Cabinet Motherboard Schematic (Component Side)



8.12 ASTC-12 Cabinet Motherboard Schematic (Solder Side)



8.13 ASTC-12 Input File Assembly



8.14 ASTC-12 Input File – PCB Layout



8.15 ASTC-12 Input File – PCB Schematic



8.16 ASTC-12 PDA Assembly



8.17 ASTC-12 PDA Wiring Diagram



8.18 Cabinet Address Card Assembly & Schematic



8.19 ASTC-12 Port 1 Cable Harness Assembly



8.20 ASTC-12 BIU Termination Board Assembly



8.21 New York City ASTC-12 RCU Kit



8.22 ASTC-12 Cabinet Harnesses

81-1257

Peek Traffic Corporation2906 Corporate WayPalmetto, FL 34221ph: (941) 845-1200in U.S.:fx:web: www.peektraffic.com

(800) 245-7660(941) 365-0837

astc-12 cabinet technical manual - ustraffic.net cabinet technical manual - rev 2… · astc-12...

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