SPECIAL SPECIFICATION 6717 Local Control Unit

Transcription

1 1995 Metric CSJ , Etc. SPECIAL SPECIFICATION 6717 Local Control Unit 1. Description. This item shall govern for the furnishing and installation of local control units in designated field locations and equipment cabinets as shown on the plans and as detailed in the special specifications. 2. Materials. All materials furnished, assembled, fabricated or installed under this item shall be new, corrosion resistant, and in strict accordance with the details shown on the plans and in the specifications. (1) General Requirements. (a) The LCU system must operate over a temperature range from minus 34 C to 74 C (30 F to 165 F). (b) The LCU system shall be configured with five optically isolated input and three optically isolated output printed circuit boards as described in paragraphs 2.(4)(e) and 2.(4)(f) respectively. (c) Any variations from the specifications will require the prior approval of the project Engineer. (2) Enclosure. (a) Mechanical. The enclosure shall be of rigid metallic construction, enclosed on all sides, environmentally sealed, and connected to the 120 V AC earth ground terminal. The exterior finish shall be durable and corrosion resistant. All exterior labeling shall be permanently applied to the enclosure. The front panel of the enclosure shall be secured by a full width hinge at the bottom and by captive screws or other rugged metallic latching mechanism at the top. The bottom hinge shall allow the front panel to rotate through 180 degrees to allow the printed circuit boards to be accessed using a bus extender card of standard std bus dimensions. Each enclosure shall contain a permanently affixed label identifying the manufacturer and containing a manufacturer's unique serial number. The enclosure shall provide an unused area measuring at least 25 mm by 76 mm (1" x 3") at the top center on the outer face of the front panel for a department applied identifying label

2 The enclosure shall be of adequate dimension to contain the power supply, the printed circuit boards and their connecting cables, and other wiring necessary on the front panel, but shall not exceed 355 mm (14") in depth, 355 mm (14") in width, and 200 mm (8") in height. The bottom of the enclosure shall be fitted with antiskid rubber feet or strips. (b) Electrical. The enclosure shall contain a non-switching power supply to provide regulated DC power for the computer system. The power supply shall consist of a removable module, accessible from a removable or hinged rear panel, or from the right front of the enclosure. If installed from the front of the enclosure, the power supply shall not interfere with access to the installed printed circuit boards and shall be shielded to prevent inadvertent contact with any potentially damaging power sources. During normal operations, it must be entirely contained within the system enclosure. The power supply must meet the following minimum electrical specifications: 1. Nominal 120 V 60 Hz AC operation, capable of operating from 95 to 135 Vrms AC and from 57 to 63 Hz. 2. Outputs: At +05 V: At +12 V: At -12 V: 3.0 A 0.5 A 0.5 A 3. Line regulation: At 5 V: Less than +/- 0.5% for +/- 10% line change At +/- 12 V: Less than +/- 1.0% for +/- 10% line change 4. Load regulation: At 5 V: Less than +/- 0.5% for +/- 50% load change At +/- 12 V: Less than +/- 1.0% for +/- 50% load change. 5. Output ripple: At 5 V: Less than 10 mv peak-to-peak At +/- 12 V: Less than 50 mv peak-to-peak 6. Current limiting overload and short circuit protection on all outputs. 7. Capable of delivering full rated output from minus 34 C to plus 74 C (30 F to165 F). If derating is required, the outputs in 2. must be increased to obtain the specified ratings over the full temperature range. 8. Documentation shall include manufacturer's schematics, parts list, and specifications indicating compliance with the above requirements

3 The enclosure shall contain a STD bus backplane with a minimum of 12 slots, complete with solder tail printed circuit board card edge connectors and upper and lower card guides. Connectors and guides shall be mounted on approximately 19 mm (0.75") centers. Jumper wires or wire wrapping shall not be used on the backplane. The rear panel of the enclosure shall contain a simplex 120 V AC, 15 A AC receptacle, fused but unswitched, to provide power to an external modem. (3) Front Panel Mounted Components. The front panel of the enclosure shall contain the following switches, connectors, and indicators: (a) Reset Switch. An externally accessible momentary pushbutton switch, with a minimum 10 mm (0.375") diameter pushbutton, rated for a minimum of 50,000 cycles. The front panel shall be labeled "RESET" near this switch. (b) Power Switch. An externally accessible, illuminated rocker switch, rated for a minimum of 50,000 cycles. Illumination shall be provided by a 120 V neon lamp. The switch contacts shall be rated for at least 1 A at 120 V AC. The front panel shall be labeled "Power" near this connector. (c) Fuse Holder. An externally accessible fuse holder for standard 6 mm x 32 mm (0.25" x 1.25") 3AG fuses, including an appropriately sized fuse. The fuse shall be capable of being replaced from the front of the enclosure without the use of any tools. The front panel shall be marked with the fuse current rating near the fuse holder. (d) Ports. Two DB25 female receptacles. These connectors provide the transition between two external RS-232 cables and internal ribbon cables connecting to the two serial ports on the CPU printed circuit board and to the watchdog timer board. Both connectors shall be secured to the front panel by a Fastener Specialties FSD-3 or equivalent mounting bracket and 4-40 threaded jacksockets. The front panel shall be labeled "Communications Port" and "Diagnostic Port" near these connectors. These ports shall be provided with polyethylene dust caps. (e) Power Connector. An AMP nine pin circular connector, wall mounted, with AMP or functionally equivalent pin contacts. This connector shall be secured to the front panel by a Fastener Specialties FSU-16 or equivalent nut ring and 4-40 threaded screws. This connector provides the external power sources as indicated below: Pin 1: 120 V AC Pin 2: 120 V AC common Pin 3: 120 V AC earth ground Pin 7: Plus 24 V DC Pin 8: Plus 24 V Dc ground The front panel shall be labeled "Power" near this connector

4 (f) I/O Connectors. Four AMP or equivalent 57 pin circular connectors with rectangular panel mount flange, using AMP or functionally equivalent socket type contacts. These connectors shall be secured to the front panel by a Fastener Specialties FSS2-25 or equivalent nut ring and 6-32 threaded screws. These connectors provide the interface between the field control points and the optically isolated inputs and outputs. These connectors must mate with external cables which use AMP connectors and AMP pin type contacts. These connectors shall be labeled from left to right, as seen from the front, as "I/O- 1", "I/O-2", "I/O-3", and "I/O-4" near each connector. These connectors shall have dust caps tethered to each connector. The connectors shall be mounted so that pins 1 through 25 are on the left side of the enclosure and pins 34 through 57 are on the right side. Pins 54, 55, 56, and 57 are used for keying purposes only. On the connector labeled I/O-1, socket terminal 54 shall contain an AMP or equivalent keying plug. On the connector labeled I/O-2, socket terminal 55 shall contain a keying plug. On the connector labeled I/O-3, socket terminal 56 shall contain a keying plug. On the connector labeled I/O-4, socket terminal 57 shall contain a keying plug. On each connector, pin 52 shall be connected to the external 24 V DC source internally through the "Power" connector (pin 7). Pin 53 on each connector shall be connected internally to the external 24 V DC ground through the "Power" connector (pin 8). (g) Toggle Switch. An externally accessible SPDT toggle switch capable of switching 2 A at 24 V DC. The front panel shall be labeled "On-line Enable" near this switch. This switch shall be mounted and connected so that the up position provides continuity in the circuit and the down position breaks continuity. (h) On-line LED. An externally visible red T1-3/4 LED operating from the 24 V DC external power source. The front panel shall be labeled "On-line Status" near the LED. (i) Thumbwheel. An externally accessible hexadecimal thumbwheel switch with positions labeled 0 through 15. The switch shall include endplates and a protective dust shield. The switch shall be connected so that the CPU reads the binary equivalent of the value indicated on the dial. The front panel shall be labeled "Channel Address" near this connector. (j) Voltage LED's. Three externally visible T1-3/4 LEDs with appropriate current limiting resistors to indicate the status of the DC power supply outputs. These LEDs shall be labeled "5V", "+ 12V", and "- 12V" near each LED. (k) Terminal Blocks. Three sets of eight position terminal blocks or jumpers for terminating the optically isolated input and output printed circuit boards, mounted on a circuit board attached to the inner face of the front panel. Discrete wiring intended to be terminated on screw clamp terminals shall be tinned on an appropriate length of bare wire. Additional connections may also be made on this circuit board. Refer to the interior front panel schematic shown on the plans for the following discussion on these terminations

5 One set of eight terminal blocks or jumpers shall be connected to the 24 V DC source from the "Power" connector at a suitable point. This row shall be labeled "Input Common" near the connector strip. It provides a common connection point for the input optocoupler LED anodes. A second set of eight terminal blocks or jumpers shall be connected to the anode of one of eight corresponding blocking diodes (1N4004) and to the cathode of the front panel "On-line Status" LED indicator. The cathodes of these blocking diodes shall be connected to the individual terminals of the terminal blocks of this row. This row shall be labeled "Output Common". It provides a conducting path for the "On-line Status" LED through any relay whose contacts are closed to the "On- LINE Enable" switch and 24 V DC ground. A third set of eight terminal blocks or jumpers shall be connected to the switching contact of the front panel "ON-LINE ENABLE" toggle switch. This row shall be labeled "RELAY COMMON". It provides a common connection point for the output relays so that the "ON-LINE ENABLE" switch establishes or breaks the continuity of the output ground return. (l) Ribbon Cable Headers. The front panel circuit board shall perform the transition between the circular connectors and each of the two required 50 pin headers for each circular connector. The headers shall be fully shrouded with a center slot for a polarization tab, and shall be configurable to allow either an optically isolated input or output printed circuit board to be connected to each header. Pin 50 of each ribbon cable connecting header shall be connected directly to the switching contact of the "On-line Enable Switch" at a suitable point. Pin 48 of each ribbon cable connecting header shall be configurable to be connected to either the 24 V DC supply or to the cathode of one of the blocking diodes. These configuration options shall be labeled "Input Common" and "Output Common" respectively. (4) STD Bus Printed Circuit Boards. (a) General. The LCU shall contain a CPU, a watchdog timer, five optically isolated input, and three optically isolated output printed circuit boards as a basic system configuration. A memory expansion board may be required at a later time. All printed circuit boards and components must be rated for operation from minus 34 C to plus 74 C (30 F to 165 F). No point to point wiring or wire wrapping shall be used. All header connectors shall have contacts on 2.5 mm (0.1") centers. Backplane slot assignments and I/O board base port addresses are as follows, with slot 1 being the leftmost slot when viewed from the front:

6 Slot Port Circuit Board 1 CPU 2 Watchdog timer 3 Memory expansion 4 00H Optically isolated input 5 04H Optically isolated input 6 08H Optically isolated input 7 0CH Optically isolated input 8 10H Optically isolated input 9 40H Optically isolated output 10 44H Optically isolated output 11 48H Optically isolated output 12 Reserved for system expansion (b) CPU Board. The CPU printed circuit board shall meet the following minimum specifications: 1. The CPU board shall be compatible with the Z80 STD bus. 2. The CPU board shall contain a Z80 microprocessor, a Z80 DART or SIO/0 and a Z80 CTC, operating at 6 MHz. 3. The CPU board shall contain four 28 pin sockets for 24 or 28 pin static RAM, EPROM, or EEPROM memory devices. Each socket shall have an associated set of jumper blocks for proper selection of signals for standard JEDEC 2K, 4K, 8K, and 16K static RAM, EPROM, or EEPROM memory devices. One socket shall be configured for and shall contain a 2764 or equivalent EPROM device which responds to addresses from 0 to 8K. A second socket shall be configured for and shall contain a 6264 or equivalent static RAM device which responds to addresses from 8K to 16K. The third and fourth sockets shall be configured for and shall contain 2864 or equivalent EEPROM devices responding to address from 16K to 24K and from 24K and 32K respectively. The EEPROM shall provide a page mode write access feature with a page size of at least 16 bytes, and shall complete a byte write cycle in 10 msec or less. All memory devices shall operate with no wait states. 4. The CPU board shall contain two RS-232C compatible serial ports, each individually configurable as DTE or DCE. Each serial port shall terminate in a 14 pin, dual row, fully shrouded header with center slot for the mating connector's polarization tab. Pins on the connector shall mate with the RS- 232C TXD, RXD, RTS, CTS, DSR, and DTR signals. Each signal shall be switched between plus or minus 12 volts. The serial port connected to the A channel of the Z80 DART or SIO/0 shall be configured as DTE. The second serial port shall be configured as DCE. 5. The CPU board shall contain an 8 bit parallel I/O port terminated near the front edge of the CPU board by a 37 pin dual row header. Pin descriptions for the header are given in the following table:

7 Pin Signal Pin Signal 1 STROBE 2 GND 3 OUT0 4 GND 5 OUT1 6 GND 7 OUT2 8 GND 9 OUT3 10 GND 11 OUT4 12 GND 13 OUT5 14 GND 15 OUT6 16 GND 17 OUT7 18 GND 19 IN0 20 GND 21 IN1 22 GND 23 IN2 24 GND 25 IN IN4 29 IN CTC T2 T.O. 32 IN6 33 GND 34 IN7 35 CTC T3 CLK/TRG 36 CTC T2 CLK/TRG 37 5 V 6. Channel 0 of the CTC shall be used to generate the clock signal for DART channela. Channel 1 of the CTC shall be used to generate the clock signal for DART channel B. The Zero Count output of channel 2 and the trigger input for both channels 2 and 3 of the CTC shall be connected to pins 31, 35, and 36, respectively, of the above header. 7. All configuration options shall be accomplished by installation of shorting blocks on 16 square millimeter (0.025 in 2 ) Posts. 8. The following CPU board I/O port assignments are required:

8 I/O Port Address Function 78H DART channel A data 79H DART channel A command 7AH DART channel B data 7BH DART channel B command 7CH CTC timer 0 7DH CTC timer 1 7EH CTC timer 2 7FH CTC timer 3 FEH 8 bit parallel I/O port FFH Reserved for MEMEX, IOEXP control (c) Timer Board. The watchdog timer printed circuit board shall meet the following minimum requirements: 1. The watchdog timer board shall be compatible with the Z80 STD bus and the CPU board in 2.(4)(b). 2. The watchdog timer board shall generate a reset signal in the event an error condition is detected or upon detecting the end of a minimum duration "break" condition (receive data line in SPACE condition) on an RS-232C interface. The minimum break duration shall be nominally 0.5 seconds, and accurate to within 20% over the design temperature range. 3. The error condition reset signal shall be a valid pushbutton reset (PBRESET*) signal on the STD bus backplane. The break condition reset signal shall be jumper selectable as a valid PBRESET* signal or a non-maskable interrupt (NMI) on the STD bus backplane. 4. Two error conditions shall be detected: (1) if a user specified address is not accessed at least once per second, and (2) if a user specified address is ever accessed. The nominal one second interval shall be maintained between 0.8 and 2 seconds over the design temperature range. Both addresses shall be fully decoded in the Z80 memory address space and shall be selectable by appropriately setting DIP switches. The occurrence of either error condition shall result in the active reset signal. 5. The watchdog timer board shall provide a 14 pin, dual row, fully shrouded header for connecting to the RS-232C interface cable. Signal connections to this header shall be compatible with those on the CPU board in 2.(4)(b)4. Only TXD and RXD are required, selectable by a DTE/DCE jumper block. (d) Memory Board. No memory expansion printed circuit board is specified at this time. (e) Input Board. The optically isolated input printed circuit board shall meet the following minimum specifications:

9 1. The input board shall be compatible with the Z80 STD bus and the CPU board in 2.(4)(b). 2. The input board shall contain 24 optically isolated inputs, each capable of sensing 0 and 24 V input signals. 3. The input board ports shall be I/O mapped with fully decoded addressing. The base address shall be user selectable on any 4 byte boundary in the Z80 I/O address space. 4. The input board shall provide a 50 pin, dual row, shrouded header to connect to the input signals. The connector shall be the same type as that on the output board. The header shall have a center slot to accommodate a polarization tab on the mating connector. The optocoupler LED anodes shall be connected through an appropriate current limiting resistor and with a back EMF diode to the even numbered pins (2,4..., 48) on the header. The optocoupler LED cathodes shall be connected to the odd numbered pins (1,3,...47) on the header. The even numbered pins shall also be connected together. Pins 49 and 50 are not used, and shall not be connected to the other pins. (f) Output Board. The optically isolated output with relay printed circuit board shall meet the following minimum specifications: 1. The output board shall be compatible with the Z80 STD bus and the CPU board in Section 2.(4)(b). 2. The output board shall contain 24 optically isolated outputs, each capable of switching between 0 and 24 V DC. 3. The output board shall contain a nonlatching relay with normally open contacts, capable of switching 1.0 A at 24 V DC. 4. The output board ports shall be I/O mapped with fully decoded addressing. The base address shall be user selectable on any 4 byte boundary in the Z80 I/O address space. The relay shall be controlled through bit 0 of the fourth port in this four byte address block. The relay contacts shall close in response to a set bit 0 output to the port, and open in response to either a clear bit 0 output to the port, to a system reset, or to a power failure. 5. The output board shall provide a 50 pin, dual row, shrouded header to connect to the output signals. The connector shall be the same type as that on the input board. The header shall have a center slot to accommodate a polarization tab on the mating connector. The optocoupler phototransistor collectors shall be connected to the odd numbered pins (1,3,...,47) on the header. The optocoupler phototransistor emitters shall be connected to the even numbered pins (2,4,...,48) on the header. The even numbered pins shall also be connected together. Pins 48 and 50 shall be connected to the opposing relay contacts, with the relay contact on pin 48 also being connected to the emitters on the even numbered pins of the header

10 (5) Wiring and Cable Assemblies. (a) Internal. All internal wiring shall be of such length and secured in such a manner as to permit the hinged front panel to rotate through 180 degrees. With the front panel in this position, none of this wiring shall interfere with the insertion and removal of the STD bus printed circuit boards, nor shall it interfere with the use of an STD bus extender card with any of the system printed circuit boards. All ribbon cable connectors shall include strain reliefs. Discrete wire assemblies shall be bundled with sheathing or other suitable material. All joints and connections not contained in a connector assembly shall be insulated through the use of heat shrinkable tubing or other suitable material. Plastic connectors not mating to a printed circuit board connector shall use an integral latching mechanism to prevent inadvertent disconnection. All discrete wiring other than for AC power shall use 22 AWG stranded wire unless dictated by a particular connector requirement. (b) External 120/24 V Power Connector. Pin assignments for this connector are listed in part 2.(3)(e). The 120 V AC wiring shall be 18 AWG stranded wire for the 120 V source, common, and ground. The 120 V AC input shall be connected from the power connector, through the fuse, to the power switch and then the power supply and also from the fuse to the rear simplex receptacle, bypassing the switch. The 120 V AC common wiring shall have white insulation. The 120 V AC ground wiring shall have green insulation. The 120 V AC source wiring shall have black insulation. The 24 V DC input from the "Power" connector shall be connected through a suitable current limiting resistor to the front panel "On-line Status" LED indicator anode, to the terminal strip row labeled "Input Common", and to pin 52 of each 57 pin circular I/O connector. The 24 V DC ground from the "Power" connector shall be connected to the nonswitching terminal of the front panel "On-line Enable" switch, and to pin 53 of each 57 pin circular I/O connector. The 24 V DC wiring shall have blue insulation. (c) Internal Backplane Cable. This cable assembly provides appropriate signals from the STD bus backplane to the front panel circuit board or components mounted on the front panel. Ribbon cable or discrete wiring may be used. Securely attach the cable assembly to the STD bus backplane, either through a latching connector or by soldering. The cable shall be detachable, either at the front panel circuit board or through a latching, in-line connector inserted into the cable at a point past the front edge of the STD bus printed circuit boards to be installed in the enclosure. The following signals from the STD bus backplane are required:

11 Signal STD Bus Pin Insulation Color Use 5 volt 1, 2 White 5 volt LED indicator +12 volt 55 Red +12 volt LED indicator -12 volt 56 Red -12 volt LED indicator Ground 3, 4 Black Common return and active pushbutton reset PBRESET * 48 Blue Pushbutton reset switch (d) Serial I/O Cables. Two 14 conductor ribbon cables shall be used to connect the front panel mounted DB25 connectors to the two serial ports on the CPU printed circuit board and to the watchdog timer printed circuit board. Each cable is terminated on one end by the front panel DB25 connector and on the other end by a 14 pin female transition connector with polarization tab. The cable attached to the DB25 connector labelled "Communications Port" shall have an additional 14 pin female transition connector so that the cable may be connected to both the CPU board and the watchdog timer board. The ribbon cable shall have a pin one indicator stripe and shall be configured so that pin one on each termination is connected through this conductor. (e) Optically Isolated I/O Cables. A set of eight 50 conductor cable assemblies shall be provided to connect the optically isolated input and output boards to the front panel external connectors. Terminate each cable on each end with a polarized transition connector mating with the printed circuit board header. Table 2 lists the pin connections for these cables. The two 50-pin headers attached to connector "I/O-X" are referred to as connectors "I/O-Xa" and "I/O-Xb", where X is taken to be 1, 2, 3 or 4. Each ribbon cable shall have a pin 1 indicator stripe and shall be configured so that pin 1 on each termination is connected through this conductor. Pin one of the 50 pin header, which would normally be connected to pin one of the 57 pin circular connector referred to as "I/O-1", is instead connected to the cathode of the front panel "On-line Status" LED indicator. Pin 52 on each circular I/O connector shall be connected to the 24 V DC source from the "Power" connector. Pin 53 on each circular I/O connector shall be connected to the 24 V DC ground on the "Power" connector. Table 1. LCU Optically Isolated I/O Cables (X=2,3,4) Connector Pin Connector Pin Connector Pin Connector Pin I/O-1a 1 On-line - I/O-Xa 1 I/O-X 1 LED I/O-1a 3 I/O-1 2 I/O-Xa 3 I/O-X 2 I/O-1a 5 I/O-1 3 I/O-Xa 5 I/O-X

12 Connector Pin Connector Pin Connector Pin Connector Pin I/O-1a 7 I/O-1 4 I/O-Xa 7 I/O-X 4 I/O-1a 9 I/O-1 5 I/O-Xa 9 I/O-X 5 I/O-1a 11 I/O-1 6 I/O-Xa 11 I/O-X 6 I/O-1a 13 I/O-1 7 I/O-Xa 13 I/O-X 7 I/O-1a 15 I/O-1 8 I/O-Xa 15 I/O-X 8 I/O-1a 17 I/O-1 9 I/O-Xa 17 I/O-X 9 I/O-1a 19 I/O-1 10 I/O-Xa 19 I/O-X 10 I/O-1a 21 I/O-1 11 I/O-Xa 21 I/O-X 11 I/O-1a 23 I/O-1 12 I/O-Xa 23 I/O-X 12 I/O-1a 25 I/O-1 13 I/O-Xa 25 I/O-X 13 I/O-1a 27 I/O-1 14 I/O-Xa 27 I/O-X 14 I/O-1a 29 I/O-1 15 I/O-Xa 29 I/O-X 15 I/O-1a 31 I/O-1 16 I/O-Xa 31 I/O-X 16 I/O-1a 33 I/O-1 17 I/O-Xa 33 I/O-X 17 I/O-1a 35 I/O-1 18 I/O-Xa 35 I/O-X 18 I/O-1a 37 I/O-1 19 I/O-Xa 37 I/O-X 19 I/O-1a 39 I/O-1 20 I/O-Xa 39 I/O-X 20 I/O-1a 41 I/O-1 21 I/O-Xa 41 I/O-X 21 I/O-1a 43 I/O-1 22 I/O-Xa 43 I/O-X 22 I/O-1a 45 I/O-1 23 I/O-Xa 45 I/O-X 23 I/O-1a 47 I/O-1 24 I/O-Xa 47 I/O-X 24 I/O-1a 48 Terminal - I/O-Xa 48 Terminal - I/O-1a 50 Terminal - I/O-Xa 50 Terminal - I/O-1b 1 I/O-1 26 I/O-Xb 1 I/O-X 26 I/O-1b 3 I/O-1 27 I/O-Xb 3 I/O-X 27 I/O-1b 5 I/O-1 28 I/O-Xb 5 I/O-X 28 I/O-1b 7 I/O-1 29 I/O-Xb 7 I/O-X 29 I/O-1b 9 I/O-1 30 I/O-Xb 9 I/O-X 30 I/O-1b 11 I/O-1 31 I/O-Xb 11 I/O-X 31 I/O-1b 13 I/O-1 32 I/O-Xb 13 I/O-X 32 I/O-1b 15 I/O-1 33 I/O-Xb 15 I/O-X 33 I/O-1b 17 I/O-1 34 I/O-Xb 17 I/O-X 34 I/O-1b 19 I/O-1 35 I/O-Xb 19 I/O-X 35 I/O-1b 21 I/O-1 36 I/O-Xb 21 I/O-X 36 I/O-1b 23 I/O-1 37 I/O-Xb 23 I/O-X 37 I/O-1b 25 I/O-1 38 I/O-Xb 25 I/O-X 38 I/O-1b 27 I/O-1 39 I/O-Xb 27 I/O-X 39 I/O-1b 29 I/O-1 40 I/O-Xb 29 I/O-X 40 I/O-1b 31 I/O-1 41 I/O-Xb 31 I/O-X 41 I/O-1b 33 I/O-1 42 I/O-Xb 33 I/O-X 42 I/O-1b 25 I/O-1 43 I/O-Xb 35 I/O-X 43 I/O-1b 37 I/O-1 44 I/O-Xb 37 I/O-X 44 I/O-1b 39 I/O-1 45 I/O-Xb 39 I/O-X 45 I/O-1b 41 I/O-1 46 I/O-Xb 41 I/O-X 46 I/O-1b 43 I/O-1 47 I/O-Xb 43 I/O-X 47 I/O-1b 45 I/O-1 48 I/O-Xb 45 I/O-X

13 Connector Pin Connector Pin Connector Pin Connector Pin I/O-1b 47 I/O-1 49 I/O-Xb 47 I/O-X 49 I/O-1b 48 Terminal - I/O-Xb 48 Terminal - I/O-1b 50 Terminal - I/O-Xb 50 Terminal - (f) On-line Enable Switch. This switch is intended to be used to manually disable the optically isolated outputs by breaking the continuity in the 24 V DC common ground return line for each of the installed output boards. The non-switching terminal should be connected to the 24 V DC ground input on the "Power" connector. The switching contact shall be connected to the terminal strip row labeled "Relay Common". These wires shall have blue insulation. (g) On-line Status LED Indicator. The on-line LED indicator anode shall be connected to the front panel 24 V DC input through a suitable current limiting resistor. The cathode shall be connected to the pin one input optocoupler LED anode on the optically isolated input printed circuit board mounted in slot 4 through the 50 pin connector referred to as "I/O-1a". The "On-line Status" LED cathode shall also be connected to the anodes of each of the blocking diodes on the terminal strip row labeled "Relay Common". (h) Hexadecimal Thumbwheel Switch. Connect the hexadecimal thumbwheel switch to the Parallel I/O port header on the CPU board using a 20 pin dual row connector. If discrete wiring is used, the cable assembly shall be sheathed. Pullup resistors shall be installed on the front panel circuit board. The following pin assignments are required. Hex Switch Connection 20 Pin Connector Parallel I/O Port Header Binary Digit Binary Digit Binary Digit Binary Digit (polarizing plug)

14 3. Documentation Requirements. Five (5) complete sets of operation and maintenance manuals shall be provided. The manuals shall include the following: - Complete and accurate schematic diagrams - Complete installation procedures - Complete performance specifications (functional, electrical, mechanical, and environmental) on the unit - Complete parts list including names of vendors for parts not identified by universal part numbers such as JEDEC, RETMA, or EIA. - Pictorial of components layout on circuit board - Complete maintenance and trouble-shooting procedures. - Complete stage-by-stage explanation of circuit theory and operation. 4. Testing Requirements. (1) General. It is the policy of the Department to require performance testing of all materials and equipment not previously tested and approved. If technical data is not considered adequate for approval, samples may be requested for test by the Engineer. The contract period will not be extended for time lost or delays caused by testing prior to final Department approval of any items. For LCU designs not previously approved, the Contractor shall furnish one or more sample LCUs for Design Approval Testing, as directed by the Engineer. In addition, all LCUs delivered under this contract may, at the direction of the Engineer, be subjected to Operational Testing. Final inspection and acceptance of the LCUs shall be made following the successful completion of the Operational Test. (2) Design Approval Test. Design Approval Tests shall be conducted on one or more sample LCU s as directed by the Engineer. The Engineer shall be notified a minimum of 25 working days in advance of the delivery of the sample LCUs. With the Engineer's approval, all testing will be done at the manufacturer's facility. The Department will complete the Design Approval Test within 10 working days after the scheduled delivery date. The Design Approval Test shall consist of a Functional Test, as described in section 4.(4), and an Environmental Test, as described in section 4.(5), on one or more of the sample LCUs. (3) Operational Test. An Operational Test shall be performed on each delivered LCU. The Contractor shall provide the Engineer 25 working days advance notice of the delivery date of a lot of LCUs. The Department will complete Operational Testing of the delivered lot of LCUs within 10 working days of the specified delivery date. Operational Testing shall consist of a Functional Test on each delivered LCU and an Environmental Test on one or more randomly selected LCUs, as directed by the Engineer

15 Those LCUs failing any part of the Operational test shall be rejected, and the remaining LCUs shall be accepted. Rejected LCUs may be repaired at the contractor's facility and resubmitted for Operational Testing as a separate lot. If any modifications to the design are necessary, the same modifications shall be applied to any LCUs previously accepted under this contract. The contract period shall not be extended as a result of delays in completing the Operational Test. (4) Functional Test. The Functional Test described below shall be used to verify that the LCU operates in accordance with the provisions of this Specification. (a) Examination of Equipment. The LCU shall be examined carefully to verify that the materials, design, markings, and workmanship comply with the requirements of this Specification. (b) Application of Power. Prior to the application of power, continuity and resistance measurements shall be performed on the LCU. The LCU power switch shall be in the ON position. Continuity shall be demonstrated between the 120 V AC power, common, and ground terminals on the power connector and the corresponding terminals on the rear simplex outlet, between the 120 V ground terminal on the power connector and the chassis, and between the corresponding 24 V DC power and ground terminals on the power connector and each of the four I/O connectors. The resistance between the 120 V ground terminal on the power connector and the 120 V and 24 V power and common terminals on the power connector and each I/O connector shall be at least 10 Megohms. With the power switch in the OFF position, the LCU shall be connected to a 120 V AC source and a 24 V DC power supply. The AC and DC power indicators on the LCU front panel shall remain unlit. With the power switch in the ON position, all power indicators shall be brightly lit. (c) Functional Test Program. With power removed, a Functional Test program shall be installed in the CPU board memory socket responding to address 0. After connecting any necessary test fixtures, the Functional Test program shall be executed to perform the tests described in this section. If the Functional Test program identifies no discrepancies between the LCU under test and these Specifications, the LCU shall be deemed to have passed the Functional Test. Otherwise, the LCU has failed the Functional Test. The functional test program shall demonstrate the proper operation of the LCU in the following areas. Additional tests may be required at the direction of the Engineer: 1. Monitoring and control of the RTS, CTS, DTR, and DSR modem control signals on both DART channels, including continuity and proper connection of the cables between the CPU board and the front panel connectors. 2. Proper operation of the DART transmitter and receiver circuitry, including continuity and proper connection of the interconnecting cables

16 3. Proper operation of the CTC as a timing generator and timer, including compatibility with external, independently timed equipment. 4. Proper operation of the watchdog timer board reset functions, including measurements of the pertinent intervals. 5. Proper operation of the hexadecimal switch. 6. Proper operation of the on-line enable switch, the on-line status LED, and the output board relays. 7. Proper operation of the reset switch. 8. Proper operation of the optically isolated input and output circuit boards, including continuity and proper connection of the associated cables between the boards and the front panel connectors. (5) Environmental Test. The Environmental Test described below shall be used to verify that the LCU operates in accordance with the provisions of this Specification under specified extremes of temperature, humidity, and voltage. (a) Environmental Test Setup. An Environmental Test monitoring program shall be installed in each LCU to be tested. Each LCU shall be placed in an environmental chamber capable of meeting the specified environmental conditions. On each LCU the on-line enable switch shall be in the UP position and the power switch shall be in the OFF position. Each LCU shall be connected to an AC power source and power shall be applied. Connect each LCU by appropriate cables to a 24 V DC power supply and a computer system external to the environmental chamber. The computer system shall be used to provide a printed record of significant events occurring during the test. The optically isolated outputs attached to connector I/O-4 shall be connected to the optically isolated inputs attached to connector I/O-2 through fixtures attached to the external I/O connectors. (b) Environmental Test Procedure. The following tests shall be performed in the order indicated. In all cases, the rate of change of temperature shall not exceed 17 C per hour. 1. Low Temperature, Low Voltage Test. With power applied to each LCU under test, the environmental chamber door closed, and humidity controls off, the AC input voltage to all LCUs shall be adjusted to 95 V AC. The external computer system shall be used to cause each LCU to report its operational status. The status report shall be logged with the time, temperature and voltage, and any errors that are detected. The environmental chamber temperature shall be reduced to -34 C (30 F). The LCU operational status shall be logged near the midpoint of this temperature transition and at the completion of the transition. Power shall then be removed from the LCUs for a period of five (5) hours. Power shall then be restored and the operational status for each LCU shall again be logged

17 2. Low Temperature, High Voltage Test. With the humidity controls off and the temperature at -34 C (30 F), the AC input voltage to the LCUs shall be increased to 135 V AC and the operational status of each LCU shall be logged. The LCUs shall continue to operate for a period of at least 1 hour, after which time the operational status of each LCU shall again be logged. 3. High Temperature, High Voltage Test. With the humidity controls set not to exceed 95% relative humidity and the input voltage at 135 V AC, the environmental chamber temperature shall be increased to 43 C (109 F). With the humidity controls adjusted to maintain constant absolute humidity at 43 C (109 F) wet bulb, the environmental chamber temperature shall be increased to 74 C (165 F) and 18% relative humidity. The operational status of each LCU shall be logged at the approximate midpoint of each of these transitions. The LCUs shall continue to operate for a period of at least 15 hours and the operational status of each LCU shall be logged at least every three hours. 4. High Temperature, Low Voltage Test. With the environmental chamber at 74 C (165 F) and 18% relative humidity, the input voltage shall be reduced to 95 V AC and the operational status of each LCU shall be logged. 5. Completion of Environmental Test. The LCU input voltage shall be adjusted to 120 V AC. The environmental chamber humidity controls shall be turned off and the temperature reduced to room temperature. When the temperature has stabilized, the LCUs shall continue to operate for 1 hour. The operational status of each LCU shall be logged at the approximate midpoint of this temperature transition and at the conclusion of the final one hour interval. If, at the conclusion of the environmental test, the status log indicates that no errors were detected, the LCUs shall be deemed to have passed the Environmental Test. (c) Environmental Test Monitoring Program. An Environmental Test monitoring program shall be installed in each LCU to be tested. The Environmental Test monitoring program shall perform the same functions as the Functional Test program but without any requirements for manual manipulation of the LCUs under test. Additional tests may be required at the direction of the Engineer. 5. Measurement. This Item will be measured as each unit furnished, installed, made fully operational and tested in accordance with this Special Specification. 6. Payment. The work performed and materials furnished in accordance with this Item and measured as provided under "Measurement", will be paid for at the unit price bid for "Local Control Unit". This price shall be full compensation for all equipment described under this Item, all cables and connectors, all documentation and testing and for furnishing all labor, materials, training and equipment necessary to complete the work