MST-700 Multi Switch Tester - Athens Technical Specialists Inc.
Contents
1. gt SETUP TR HELP FL Figure 8 Main Menu 7 From the Main menu press the NEXT button until the display pointer points to TEST LS if you are testing a Load Switch or TEST FL if you are testing a Flasher To begin the test press the ENTER button MAIN MENU LS SETUP TR HELP FL Figure 9 Main Menu with TEST LS selected Page 11 of 20 MST 700 User s Manual Rev 1 0 Getting Started 8 If you have set SAVE DATA to YES in the Setup parameters you will see the following ENTER DEVICE ID screen as shown in Figure 12 You must enter a valid device ID The ID may be any combination of numbers or letters The minimum length is 1 character and the maximum length is 16 characters Press the CHANGE button to change the character indicated by the flashing cursor Press the NEXT button to move the cursor to the next character Press ENTER when complete ENTER DEVICE ID Figure 10 Enter Device ID screen 9 If you have set SAVE DATA to YES in the Setup parameters you will see the following SELECT MANUFACTURER screen as shown in Figure 13 Press the CHANGE button to scroll through the different manufacturers Press the ENTER button when you have selected the correct manufacturer Note If the correct manufacturer is not on the list you may select OTHER SELECT MANUFACTURER gt EDI Figure 11 Select Manufacturer screen 10 The test will now proceed and the pass fail results will be displayed o2. 24 AM Figure 7 Date Time setup screen Page 10 of 20 Press the CHANGE button to adjust the FULL LOAD test time in increments of 1 minute Set this value to NONE if you do not want to run this test Press NEXT when finished Press the CHANGE button to toggle the SAVE DATA setting to YES or NO Press NEXT when finished Press the CHANGE button to toggle the HALT ON FAIL setting to YES or NO Press NEXT when finished Press the NEXT button to move the display cursor to each position Press the CHANGE button to adjust each value Press ENTER when finished You will now be returned to the MAIN MENU MST 700 User s Manual Rev 1 0 Getting Started This section provides step by step instructions for running a test on a Load Switch Transfer Relay and Flasher However to avoid possible electric shock burns or fire read all information contained in this_ manual before attempting to use the Tester Testing a Load Switch or Flasher Perform all of the safety checks described in the Safety Information section Turn the power switch to the OFF position Insert a Load Switch or Flasher into the appropriately marked socket Turn the power switch to the ON position The Tester will perform some internal system checks and then display the Main Menu as shown in Figure 10 6 If you have not already adjusted the Setup parameters refer to the Tester Setup Parameters section ARON MAIN MENU LS
3. ambient air temperature MST 700 User s Manual Rev 1 0 Service and Calibration The MST 700 Tester has no user serviceable parts Under no circumstances should the user attempt to open the Tester enclosure If the Tester appears to be malfunctioning contact ATSI to make arrangements for repair See the Limited Warranty section of this manual for details ATSI strongly recommends that each Tester be calibrated yearly A yearly calibration will verify that your Tester is operating within the original manufacturers specifications and provide you with a detailed calibration report for documentation Please visit www atsi tester com for the latest pricing of calibration services and extended maintenance plans Page 19 of 20 MST 700 User s Manual Rev 1 0 Limited Warranty and Return Merchandise The MST 700 Product distributed by Athens Technical Specialists Inc ATSI is warranted to the original purchaser Purchaser to be free of defects in materials and workmanship for a period of one year from the purchase date stated on the invoice Within this period in the event of a defect malfunction or other failure of the product while in the custody of the Purchaser ATSI will remedy the defect or cause of failure without charge to the Purchaser The Purchaser s sole remedy is restoration of product operation ATSI accepts no liability for incidental or related expenses Under no circumstances will ATSI s liability exceed the purchase pric
4. e Verify that there is approximately a 0 5 inch gap between the bottom of the Tester front panel and the surface on which it is resting The tester should be resting on 4 feet located on the bottom e Verify that there is nothing on top of the tester e Plug in the Tester to a three pronged grounded 120 Vrms AC outlet Use only the power cord provided with the Tester Do not use an extension cord Turn the Tester power switch to the ON position e Visually verify that both Tester cooling fans are operating e Verify that no obstructions are covering the ventilation holes on either side of the Tester Page 4 of 20 MST 700 User s Manual Rev 1 0 Safety Information Do not place anything on top of the enclosure t 0 gr Air gap Hard Surface Make sure air gap is unobstructed Figure 1 Tester placement Cooling fans in rear Top of Tester 6 10 t Figure 2 Minimum clearance distances The Tester is equipped with an internal temperature measurement sensor and if necessary will not allow a new test to begin if the Tester temperature is too high Also if necessary the Tester will go through a cool down cycle at the end of a test Do not shut off power to the tester during the cool down cycle If power is lost before the Tester has completed the cool down cycle the enclosure surfaces may be hot Page 5 of 20 MST 700 User s Manual Rev 1 0 Safety Information
5. MST 700 Multi Switch Tester For Load Switch Flasher and Transfer Relay NI y User s Manual Revision 1 0 Contacting ATSI ATSI 8157 US Route 50 Athens OH 45701 740 592 2874 Fax 740 594 2875 www atsi tester com Email for purchasing information sales atsi tester com Email for service service atsi tester com Table of Contents Explanation of Symbols Terms and Abbreviations ccccccccceeecseeeeeeeeeees 2 3 Safety Information esses sie ins sonetin naa ant wien veden 4 6 Introduction se sccacsicicecoudesnurdteneSeeedasaedtscdevsetensatancneeee mash EAA KANANIE TAEAE NAKAI dene ecees 7 Operator Interface and Pushbutton Descriptions cccccccccseceeeeeeeeeeeeeees 8 Tester Setup Parameters rannnnnnnnnnrnnnnrnnnnnnrrnnnrnnrnnnrrnnnrnrsrnnsrnnrsnesrnnrsnessnnnn 9 10 Getting Started uvaner eneretten KAKEAN Eae E Sakaio 11 13 Test Deser p iON S a a a a a a a e innta Aea A a aE Taaa Ei 14 17 Electrical and Mechanical Specifications cccccccscccceccececeeeeeeeeeeeeaeeeeeeees 18 Service nd Calibration sy csiensscesdste ess cine easels eeeticiieese dnne 19 Limited Warranty and Return Merchandise cccceeeeeeeeeeeeeeeeeeeeeeeeeenanaes 20 Page 1 of 20 MST 700 User s Manual Rev 1 0 Explanation of Symbols Terms and Abbreviations Graphical Symbols The following symbols are used on the MST 700 enclosure and in this manual Anytime one of these symbols is encoun
6. The RED IN voltage is set to 1 5 VDC 3 The RED IN current is measured 4 If the RED IN current is 20 mA or less the test status is PASS If the RED IN current is greater than 20mA the test status is FAIL The Input On Threshold Input Off Threshold and Maximum Input Current tests are repeated for the YEL and GRN channels Page 15 of 20 MST 700 User s Manual Rev 1 0 Test Descriptions Flasher Tests Flasher Connector Pin Assignment Pin Name Description 7 OUTPUT 1 Load circuit 1 8 OUTPUT 2 Load circuit 2 9 EGND Earth ground 10 NEUT AC neutral 11 AC LINE 120 Vrms nominal power for Flasher and output circuits 12 NC No connection Data Collection 1 A 1200 Ohm load is applied to OUTPUT 1 and OUTPUT 2 2 AC line voltage is applied to the AC LINE pin 3 Voltage and current data is collected for OUTPUT 1 and OUTPUT 2 for 10 seconds Flashes Per Minute Test The FPM rate for OUTPUT 1 and OUTPUT 2 is calculated from the data collected If the FPM rate is between 50 and 60 the test status is PASS If the FPM rate is less than 50 or greater than 60 the test status is FAIL On Period Test The on period for OUTPUT 1 and OUTPUT 2 is calculated If the on period is between 45 and 55 the test status is PASS If the on period is less than 45 or greater than 55 the test status is FAIL Same State Overlap Test The maximum amount of time that OUTPUT 1 and OUTPUT 2 are in the same state i e both on or both off is ca
7. The Tester is designed to test ONLY Load Switches Flashers and Transfer Relays that are designed in accordance with NEMA TS1 TS 2 or Caltrans Traffic Signal Control Equipment Specifications If you are not sure if a device meets this criteria do not attempt to test it Do not attempt to insert any other type of device or object into the test sockets Always turn the Tester power switch to the OFF position before inserting or removing a device Page 6 of 20 MST 700 User s Manual Rev 1 0 Introduction MST 700 Multi Switch Tester The MST 700 is an automated tester designed to test Load Switches Flashers and Transfer Relays that are used in traffic signal installations conforming with NEMA or Caltrans Specifications Operator Interface The operator interface consists of a 4 line by 20 character vacuum fluorescent display and 3 pushbuttons All test setup parameters are entered via this interface The results of each test are shown on the display See the Operator Interface and Pushbutton Descriptions section of this manual for detailed instructions Test Report A pass fail report may be generated for the Load Switch and the Flasher Reports may be stored on an optional SD memory card The memory card may be read by any computer equipped with a card reader Tested Parameters The following parameters are tested for each device See the Test Descriptions section of this manual for a detailed test descriptions Load Swi
8. age the connector The RS 232 port is provided for connection to a PC for future firmware upgrades and is not needed for normal Tester operation AES www atsi tester com OFF MAIN MENU TEST LS gt SETUP EST TR HELP EST FL GE RS 232 ENTER NEXT TFT SD CARD GOGG OIO Figure 3 Operator Interface Pushbutton Functions Button Function NEXT Advances the screen pointer gt or cursor B to the next item CHANGE Changes any adjustable parameter pointed to by the screen pointer or flashing cursor ENTER Executes the function pointed to by the screen pointer or saves the parameter that was adjusted with the CHANGE button Page 8 of 20 MST 700 User s Manual Rev 1 0 Tester Setup Parameters The following parameters must be set before you begin running tests Once set the Tester stores the parameters in memory and they do net need to be set again unless a change is required Full Load Time Range NONE or 1 30 minutes The Full Load test is an optional test that may be ran at the beginning of a Load Switch test This test will apply the nominally rated full load 10 Amps at 120 Vrms to each Load Switch output one at a time For example if the time is set to 15 minutes the load will be applied to the red output for 20 seconds then the yellow output for 20 seconds and then the green output for 20 seconds This cycle will repeat for 15 minutes If you do not wish to
9. e for items claimed to be defective This Limited Warranty does not extend to any Product that has been damaged or rendered defective as a result of accident misuse abuse modification of the product or service by anyone other than ATSI EXCEPT AS EXPRESSLY SET FORTH IN THIS WARRANTY ATSI MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICUALR PURPOSE ATSI EXPRESSLY DISCLAIMS ALL WARRANTIES NOT STATED IN THIS LIMITED WARRANTY ANY IMPLIED WARRANTIES THAT MAY BE IMPOSED BY LAW ARE LIMITED TO THE TERMS OF THIS EXPRESS LIMITED WARRANTY Warranty Repair What you must do to return the Product for repairs covered under the Limited Warranty Request a Return Merchandise Form by phone fax or email from the ATSI Service Department or complete the form at www atsi tester com Return the Product along with the completed form with prepaid postage to ATSI 8157 US Route 50 Athens OH 45701 740 592 2874 740 594 2875 Fax service atsi tester com Note To protect your Product against in transit damage or loss it is recommended that all shipments be insured Page 20 of 20 MST 700 User s Manual Rev 1 0
10. ety Information IMPORTANT SAFETY INFORMATION READ BEFORE ATTEMPTING TO USE THE MST 700 The MST 700 Tester should only be used by qualified and authorized traffic signal technicians who are familiar with generally accepted electrical safety practices as well as local and national safety codes To avoid possible electric shock burns or fire read all information contained in this manual before attempting to use the Tester Do not use the Tester around explosive gas vapor or dust Do not use the Tester in a wet environment Do not use the Tester outdoors e Do not use the Tester in an area where the ambient air temperature is greater than 80 F Do not attempt to open any part of the Tester enclosure Do not place anything on top of the Tester Do not block the air ventilation openings on the sides or bottom of the Tester Do not block the cooling fans located in the rear of the Tester The Tester must dissipate large amounts of power heat during certain tests It is therefore extremely_ important to verify that both cooling fans are operating and all ventilation openings are free from_ obstructions before attempting to run any tests Before starting any tests do all of the following also see Figure 1 and Figure 2 e Place the Tester on a solid surface e Leave at least 10 inches of clearance in the front and rear of the Tester Leave at least 6 inches of clearance on each side of the Tester
11. lculated If the maximum overlap time is greater than 17 ms the test status is FAIL If the maximum overlap time is 17 ms or less the test status is PASS Page 16 of 20 MST 700 User s Manual Rev 1 0 Test Descriptions Transfer Relay Tests Transfer Relay Connector Pin Assignment Pint Name Coil AC Coil Neut NC A NC B COMMA COMMB NO A NO B ONOOARWNDN Description 120 Vrms nominal power for relay coil AC neutral connection for relay coil Normally closed contact A Normally closed contact B Common for NC A and NO A Common for NC B and NO B Normally open contact A Normally open contact B The transfer relay test verifies proper functioning of the normally open and normally closed contacts The user may press the CHANGE button to toggle the Coil AC power on or off The state of the relay contacts is shown on the display If a contact fails to function properly FAIL is indicated next to the corresponding pin number Page 17 of 20 MST 700 User s Manual Rev 1 0 Electrical and Mechanical Specifications Electrical Operating Voltage Operating Current Cooling Data Storage Media Mechanical Enclosure Dimensions Weight Environment Operating Temperature Range Page 18 of 20 120 VAC 60Hz 12 Amps full load Fan Cooled SD memory card 64 MB SanDisk or equivalent 3U Rackmount Type 19 3 W x 20 5 D x 5 25 H 22 Ibs Indoor laboratory use only 32 F to 80 9 F
12. n the screen If you have set HALT ON FAIL to YES in the Setup parameters the test will pause on each failure and prompt you to press the NEXT button to continue If you have set HALT ON FAIL to NO the test will proceed without any further interaction required Page 12 of 20 MST 700 User s Manual Rev 1 0 Getting Started Testing a Transfer Relay Turn the power switch to the OFF position Turn the power switch to the ON position ARON Figure 10 Insert a Transfer Relay into the appropriately marked socket Perform all of the safety checks described in the Safety Information section The Tester will perform some internal system checks and then display the Main Menu as shown in 6 From the MAIN MENU press the NEXT button until the display pointer points to TEST TR as shown in Figure 14 LS TR FL MAIN MENU SETUP HELP Figure 12 Main Menu with TEST TR selected 7 Press the ENTER button to begin the test 8 Press the CHANGE button to toggle the power to the relay coil on or off as many times as you wish 9 The state of the relay contacts is shown on the display 10 Press the ENTER button to end the test Page 13 of 20 MST 700 User s Manual Rev 1 0 Test Descriptions Load Switch Tests Load Switch Connector Pin Assignment PIN Name Description AC Line 120 Vrms nominal power for output circuits 2 EGND Earth ground 3 RED OUT Red signal output 4 LGND Logic gro
13. or the amount of time that is set in the FULL LOAD setup screen See the Tester Setup Parameters section of this manual for details on setting the time Page 14 of 20 MST 700 User s Manual Rev 1 0 Test Descriptions Input On Threshold This test verifies that an input voltage of 5 5 VDC will turn the output on when the DC supply voltage is greater than 22 VDC 1 A 1200 Ohm load is applied to RED OUT 2 The DC supply voltage is set to greater than 22 VDC 3 The RED IN voltage is set to 5 5 VDC 4 The RED OUT rms current is measured 5 If RED OUT rms current is within the nominal range allowing for AC line fluctuation it is considered to be ON and the test status is PASS If RED OUT is not on the test status if FAIL Input Off Threshold This test verifies that an input voltage of 16 5 VDC will turn the output off when the DC supply voltage is less than 26 VDC 1 A 1200 Ohm load is applied to RED OUT 2 The DC supply voltage is set to less than 26 VDC 3 The RED IN voltage is set to 16 5 VDC 4 The RED OUT peak current is measured 5 If RED OUT peak current does not exceed 10 mA it is considered to be OFF and the test status is PASS If the RED OUT peak current is greater than 10 mA the test status is FAIL Maximum Input Current This test verifies that a Load Switch input circuit will not draw more than 20 mA when the DC supply is between 22 and 26 VDC 1 The DC supply voltage is set to less than 26 VDC 2
14. run this test set the value to NONE Save Data Yes or No If Save Data is set to Yes the results of a Load Switch or Flasher test will be saved to an SD memory card See the Operator Interface and Pushbutton Descriptions section of this manual for instructions on how to insert and remove the SD memory card If Save Data is set to No the test results will not be saved and will only be shown on the display Halt On Fail Yes or No If Halt On Fail is set to Yes a Load Switch or Flasher test will halt on any test failure The failure will be displayed on the screen until the NEXT button is pressed If Halt On Fail is set to No each failure will be displayed on the screen as it happens but the test will continue Set Clock The clock date and time must be set correctly in order to save reports The format for the date is MM DD YY The format for time is HH MM AM PM The following pages will guide you step by step through the Setup process Page 9 of 20 MST 700 User s Manual Rev 1 0 Tester Setup Parameters From the MAIN MENU press NEXT until the display pointer points to SETUP Press ENTER and the FULL LOAD setup screen will appear as shown in Figure 4 FULL LOAD 10 MINE Figure 4 Full Load test time setup screen NEX Teis SAVE DATA YESI Figure 5 Save Data setup screen HALT ON FAIL NONP Figure 6 Halt On Fail setup screen NEXT MM DD YY HH MM 05 30 06 9
15. tch Tests Flasher Tests Transfer Relay Tests Inputs On Off Voltage thresholds Outputs Flashes per minute Outputs Continuity Inputs Max input current Outputs Percentage on time Outputs Max off state current Outputs Overlap time Outputs Max load current Outputs Min load current Page 7 of 20 MST 700 User s Manual Rev 1 0 Operator Interface and Pushbutton Descriptions The operator interface consists of a 4 line by 20 character vacuum fluorescent display three pushbuttons an RS 232 port an SD memory card slot and an ON OFF switch see Figure 3 All tester setup parameters and data are entered with the three pushbuttons labeled NEXT CHANGE and ENTER The SD memory card slot is provided so that test reports may be saved to an SD card if desired Once saved to an SD card the test reports may be read by a PC equipped with an SD card reader Saving reports to the SD card is optional and may be enabled or disabled using the SETUP screen See the Tester Setup Parameters section of this manual for details NOTE To insert the SD card into the slot gently push the card in as far as it will go and then remove pressure The card should make a clicking sound and then lock into place To remove the SD card gently push in on the card as far as it will go and then remove pressure The card should unlock and partially eject It is then free to be removed DO NOT PULL OUT ON THE CARD WHEN IT IS IN THE LOCKED POSITION Doing so will dam
16. tered the user should be aware of the condition described here next to each symbol Terms and Abbreviations Caution Risk of danger Read the Users Manual before operating the MST 700 Caution Hot Surface The following is a list of terms and abbreviations used throughout the text of this manual along with the definition Term or Abbreviation Definition Caltrans California Department of Transportation Flasher Solid state device used to flash traffic signal lamps by turning the power on and off at a predetermined rate FL Flasher see definition of Flasher FPM Flashes per minute Load Switch Solid state device used to switch the power to traffic signal lamps LS Load Switch see definition of Load Switch mA milliamperes thousandths of an amp ms milliseconds thousandths of a second NEMA National Electrical Manufacturers Association PC Personal computer Tester The ATSI MST 700 Multi Switch Tester Transfer Relay TR Page 2 of 20 An electro mechanical relay used in a traffic signal electrical cabinet Transfer Relay see definition of Transfer Relay MST 700 User s Manual Rev 1 0 Explanation of Symbols Terms and Abbreviations Term or Abbreviation Definition TS 1 Traffic Control Systems Standard published by NEMA see NEMA TS 2 Traffic Control Systems Standard published by NEMA see NEMA VDC Volts DC Vrms Volts RMS root mean squared Page 3 of 20 MST 700 User s Manual Rev 1 0 Saf
17. und return for DC supply 5 YEL OUT Yellow signal output 6 RED IN Red input 7 GRN OUT Green signal output 8 YEL IN Yellow input 9 DC SUPPLY DC supply for input circuits 10 GRN IN Green input 11 NEUT AC neutral 12 NC No connection Full Load Test 1 A 12 5 Ohm load is connected to RED OUT 2 The DC supply voltage is set to greater than 24 VDC 3 The RED IN voltage is set to 1 5 VDC for twenty seconds 4 The RED OUT rms current is measured 5 If RED OUT rms current is within the nominal range allowing for AC line fluctuation it is considered to be ON and the test status is PASS If RED OUT is not on the test status if FAIL 6 A 12 5 Ohm load is connected to YEL OUT 7 The DC supply voltage is set to greater than 24 VDC 8 The YEL IN voltage is set to 1 5 VDC for twenty seconds 9 The YEL OUT rms current is measured 10 If YEL OUT rms current is within the nominal range allowing for AC line fluctuation it is considered to be ON and the test status is PASS If YEL OUT is not on the test status if FAIL 11 A 12 5 Ohm load is connected to YEL OUT 12 The DC supply voltage is set to greater than 24 VDC 13 The YEL IN voltage is set to 1 5 VDC for twenty seconds 14 The YEL OUT rms current is measured 15 If YEL OUT rms current is within the nominal range allowing for AC line fluctuation it is considered to be ON and the test status is PASS If YEL OUT is not on the test status if FAIL Steps 1 15 are repeated f
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