OPERATION AND SERVICE MANUAL - Lincast International Pty Ltd
Contents
1. C M GEN FAIL or S GEN FAIL Indicates that the generator was charging the battery but is now not charging the battery The system will be running on batteries and the traffic flow will not be affected This alarm may be inhibited by pressing 700 YELLOW TIME This is to allow the motor to be turned off for refuelling or maintenance Possible Causes Motor run out of fuel Generator not working Broken wires or poor connection to battery NOTE The generator output should be approx 13 8v When the generator stops the battery voltage drops to approx 12v The controller detects the change between 13v and 12 9v and brings up the Generator Fail alarm You may notice that it can take up to 2 minute for the alarm to occur after the generator stops This is due to the fact that the battery voltage drops from the charging voltage to 12v quite slowly the time taken depending on the load and condition of the battery D M LINK FAIL or S LINK FAIL Indicates that the radio communication between the master and slave is faulty How far you can receive a signal depends on 1 Frequency Lower the frequency the further the transmission 2 Power output Higher the power the further the transmission 3 Aerial Better the aerial the further the transmission 4 Ground plane Larger the ground plane the further the transmission Ground is the metal area at the base of the aerial Some aerials are design2. YELLOW TIME Open Security Key in the amount of time in minutes the generator is to run Clear 630 YELLOW TIME Memorise the time 615 YELLOW TIME Close Security To view Enter 903 YELLOW TIME Page 11 CS 200 Operation and Service Manual Page 12 MAINTENANCE LOG The CS 200 has an inbuilt logging system which can be helpful for field maintenance but is intended mainly for base maintenance Access is from the keypad by entering a special code to select the required information To prevent the System Unreliable alarm being invoked during setup or testing a Fault Free period of 3 minutes has to expire before faults are counted for this alarm To clear System Log To select System Log Codes M DEAD VOLT M LOW VOLT M GEN FAIL M LINK FAIL M RED FAIL M YELLOW FAIL M GREEN FAIL M SENSOR FAIL M LANTERN FAIL M REMOTE FAIL M FATAL ERROR S DEAD VOLT S LOW VOLT S GEN FAIL S LINK FAIL S RED FAIL S YELLOW FAIL S GREEN FAIL S SENSOR FAIL S LANTERN FAIL S REMOTE FAIL S FATAL ERROR UNRELIABLE Enter 999 YELLOW TIME Enter 900 YELLOW TIME Description Master battery below 10v Master battery below 11v Master generator stopped during normal operation Master not receiving Slave Master red globe failure Master yellow globe failure Master green globe failure Master vehicle sensor not connected Master lanterns not connected or inverter failure Master remote lantern failure Ma
3. Max AUX lamp drive current Temperature Dimensions Weight Generator fail voltage level Generator start voltage Low voltage level Fatal voltage level Operational Specifications 1 way operation 2 way operation Manual return 2 way operation Auto return Time entry Mode selection Min and Max times Distance apart Max Lantern Visual Range Alarms Fault response time Faulty Unit Other Unit Low voltage Communications Audible alarm ON time Transmitter Power output RF Freq 1 RF Freq 2 Deviation Modulation Data format llv 18v 1A Tx on lights off 6A 5A 15 Deg to 60 Deg C Width 275mm Depth 270mm Height 100mm Master 4 2Kg Slave 3 4Kg 13v 11 5V 11V Unit goes to Flash Yellow 10V Unit turns off User inhibit if req Not allowed in NSW Keypad Keypad Preset as requested Radio 1000m LOS Cable 50m 100m lt Isec lt 2 sec lt 10sec lt Ssec 5min 1 watt 151 4MHz 151 575MHz must obtain permission 3 0KHZ FM FSK V23 Standard MUST obtain permission from the ACMA government agency in your state to use RF Freq 2 CS 200 Operation and Service Manual Page 5 OPERATIONAL FEATURES 1 way operation Flash YELLOW Manual Auto Time mode Normal Vehicle actuated mode 2 way operation Manual return Auto return Not allowed in NSW 5 Cable Manual Controller can be operated up to 100m from the master unit Radio Manua
4. meter reset 647 CH 1 648 CH 2 500 Aux LightOFF Notin NSW 501 Aux Light ON Page 13 CS 200 Operation and Service Manual Page 14 CS 200 Trouble Shooting If you hear an alarm 1 A M DEAD VOLTS or S DEAD VOLTS Look around the site and notice A What type of day B Any big trucks near units C How far apart are the units D Are the units E Was there anyone transmitting nearby F Are the controllers in direct sunlight G Are the aerials connected H Has the slave been turned on properly Turn alarm off by pressing clear Press 902 YELLOW TIME and record Press 900 YELLOW TIME and record log Hot Temp Cold Wet Yes No n line of site Over a hill Around a treed corner Around a hill What frequency Yes No Yes No Yes Software version Serial number 3 i9 Si Indicates that the battery is below 10v and the system will turn itself off Possible Causes System running too long on batteries Battery terminals making poor connection B M LOW VOLTS or S LOW VOLTS Indicates that the battery is below 11v and the system will automatically go to FLASH YELLOW Possible Causes System running too long on batteries Batteries in poor condition Generator not charging battery Battery terminals making poor connection Page 14 CS 200 Operation and Service Manual Page 15
5. select this mode press the MANUAL mode button on the Master unit The system is now under the control of the manual controller Pressing the STOP button will terminate the running phase which will go to RED Both phases will stay on RED until a MASTER GREEN or SLAVE GREEN button is pressed Note that the pre set RED TIMES cannot be overridden While the Master is green pressing the SLAVE GREEN button will have no effect and vice versa c AUTO Time mode This mode is used to control a single lane of traffic where preset timers are used to regulate stop and go times Times are entered on the keypad and assigned to the appropriate timers All times are displayed on the LCD and automatically stored in memory when the system is turned off This alleviates the need to re enter the times every time the system is turned on Before entering this mode RED and GREEN times must be determined and entered into the Master unit To set use the keypad at the Master unit to enter the time then press the required TIME SETTING key eg Master Red Time Once the times have been entered press the AUTO mode button If the system is in FLASH YELLOW when the AUTO button is pressed then both phases will go to RED and traffic will be controlled in accordance with the preset times If the system is in NORMAL mode when the AUTO button is pressed then the present cycle will be allowed to finish before the AUTO mode takes control Page 7 C
6. CS 200 PORTABLE TRAFFIC LIGHT CONTROLLER Software 1 05 OPERATION AND SERVICE MANUAL CS 200 Operation and Service Manual Page 2 Manufactured by LINCAST INTERNATIONAL PTY LTD 2 3 Sir Laurence Drive Seaford Victoria 3198 PH 03 9776 4442 FAX 03 9776 4443 12 Doc 04 Page 2 CS 200 Operation and Service Manual Page 3 TABLE OF CONTENTS CS 200 TRAFFIC LIGHT CONTROLLER SPECIFICATIONS FEATURES OF THE CS 200 CONTROLLER FRONT PANEL INDICATORS MODES OF OPERATION 1 One Way Traffic Control a Flash Yellow b Manual 1 Manual Control Mode c Auto Fixed Time Mode d Normal Vehicle actuated Mode Two way Traffic Control a Manual 2 Manual return b Manual 3 Auto return c Selection d Software Security e Hardware Security OPERATIONAL FEATURES 1 Lantern Inhibit 2 Time displays 3 Min and Max times 4 No of signal lanterns 5 Green Running period 6 Max Reversion 7 State of signal indicators 8 Generator Audible Alarm 9 Auxiliary Lamp 10 Transmitter ON facility 11 Hour meter 12 RF Channel Selection 13 Generator Running Time MAINTENANCE LOG Clear Log System Log System Min and Max Time Software Version and Serial number Summary of Programming Codes CS 200 TROUBLE SHOOTING Page 3 CS 200 Operation and Service Manual Page 4 CS 200 SPECIFICATIONS Electrical Power supply voltage Current consumption 13 8v Max lamp drive current
7. OTE 3 Check at least once a year that frequencies and licences are still valid 2 Two way traffic control a Manual 2 Manual Return This mode of operation is used where traffic is flowing in both directions and road plant requires to cross or have access to the carriage way The CS 200 when in this mode is under the control of either the CABLED MANUAL CONTROLLER or a PORTABLE RADIO MANUAL CONTROLLER optional which can be used from a truck tractor or around the work site Both the Master and Slave show GREEN allowing traffic flow in both directions When the Master unit receives a STOP command both the Master and Slave go to RED This condition will remain until the Master unit receives a GO command where upon the Master and Slave go back to GREEN b Manual 3 Auto return Not allowed in NSW This mode of operation is used where traffic is flowing in both directions and road plant or other vehicles are leaving a work area and find it difficult to enter a busy carriage way The CS 200 when in this mode would have the CABLED MANUAL CONTROLLER or PORTABLE RADIO MANUAL CONTROLLER optional positioned so the driver of the vehicle wishing to enter the carriage way can operate the STOP button Both the Master and Slave show GREEN allowing traffic flow in both directions When the driver presses the STOP button both the Master and Slave go to RED After a preset time set by the Master Red time the Master and Slave go back to G
8. R or FATAL ERROR Indicates 1 The computer inside the controller is faulty 2 Two or more lamps are on at the same time CHECK Lantern connector wiring Lantern wiring Swap the controllers eg Put the master controller in the slave trailer and vice versa Does the fault stay with the CONTROLLER Yes No I Unreliable Occurs when there has been 5 errors in the last 20 minutes Indicates that the transmission path is not reliable and should be attended to Page 16
9. REEN Page 8 CS 200 Operation and Service Manual Page 9 c Selection To select a two way mode the system is required to be in a FLASH YELLOW and a special sequence of keystrokes must then be performed The sequence is as follows MANUAL 2 022 MANUAL MANUAL 3 033 MANUAL When changing to MANUAL 2 or 3 mode the lanterns at both ends will go to GREEN The system is then under manual control only To go back to MANUAL One way operation turn the Master off and on d Software Security The Two way mode can be inhibited by the use of special codes therefore preventing their use at a work site To enable Enter 614 YELLOW TIME Security key open 642 YELLOW TIME Manual 2 enable 644 YELLOW TIME Manual 3 enable 615 YELLOW TIME Security key close To inhibit Enter 614 YELLOW TIME Security key open 643 YELLOW TIME Manual 2 inhibit 645 YELLOW TIME Manual 3 inhibit 615 YELLOW TIME Security key close Trying to select MANUAL 2 or 3 when it has been inhibited will result in FUNCTION DISABLED being displayed on the LCD e Hardware Security A key lock is provided on the back of the MASTER controller to disable the TWO WAY modes and will override all software options Page 9 CS 200 Operation and Service Manual Page 10 OPERATIONAL FEATURES 1 Lantern Inhibit The CS 200 may be placed into a condition where the system functions normally with the exception that th
10. S 200 Operation and Service Manual Page 8 d NORMAL Vehicle actuated mode This mode is used to control a single lane of traffic where vehicle detectors are used in conjunction with preset timers When a moving vehicle is detected a demand is stored displayed on the LCD and used to control traffic flow Before entering this mode RED and GREEN times must be determined and entered into the Master unit To set use the keypad at the Master unit to enter the time then press the required TIME SETTING key eg Master Red Time Once the times have been entered press the NORMAL mode button The system automatically registers an artificial demand for each phase for the first cycle and then allows the control of traffic in accordance with the detected vehicle flow and the times that have been preset If the vehicle detector is not connected an alarm will occur and the system will not select this mode NOTE 1 The type of vehicle sensor used will detect movement only It is therefore possible for a vehicle to be waiting and not have been detected If this is deemed to be a problem the sensor can be modified to produce a pulse every 2 5 minutes Contact supplier for details NOTE 2 Systems are supplied with detectors operating on a frequency of 10 525Ghz which do not require an individual licence Systems may be supplied ON REQUEST with detectors operating on a frequency of 10 587Ghz but these units will require an individual licence N
11. e lanterns remain blacked out The system must be in FLASH YELLOW before this mode can be selected and will return to FLASH YELLOW when lanterns are enabled again The main use of this mode is in the setup and testing of the system while the units are positioned on the side of the carriageway To select or de select this mode select FLASH YELLOW when press Enter 800 YELLOW TIME Lanterns OFF 801 YELLOW TIME Lanterns ON Time displays The system is supplied with all times displayed in seconds but they may be displayed in minutes and seconds if required The procedure to change displays is as follows Enter 614 YELLOW TIME Security open 640 YELLOW TIME Minutes and seconds 641 YELLOW TIME Seconds 615 YELLOW TIME Security close Min and Max Times Minimum and maximum times are factory set to RTA specifications No of signal lanterns A separate connector is provided on the side of the CS 200 in both the Master and Slave to provide auxiliary drives to a second controller called a CS 200R This controller must provide its own power for the lamps GREEN Running Period when in NORMAL mode When a vehicle actuates a detector the demand is processed and that phase will go to GREEN as soon as possible depending on the state of the opposite phase and the preset RED time After the MIN GREEN TIME has expired on the running phase the GREEN aspect is extended by a vehicle while it is actuating the detector and for a
12. ed to work without a ground plane 5 Receiver sensitivity Better sensitivity the further the transmission 6 Data or speech The transmission path for computer data must be far better than for speech NOTE If the transmission path is obstructed by earth or rocks then the system will be unreliable OBSERVE Is the Receive light on the SLAVE unit flashing Yes Helps us to know where to look No CHECK Aerials Aerial leads If possible do a VSWR measurement on aerials Does the system work if the generators are turned off Does the system work if the units are closer together E M RED FAIL of S RED FAIL also for yellow and green lamps Indicate that the red lamp or the wiring to the red globe is open circuit CHECK Lamp That the lamp socket is not corroded Wiring in lantern connector is ok Swap the controllers eg Put the master controller in the slave trailer and vice versa Does the fault stay with the CONTROLLER Yes No Page 15 CS 200 Operation and Service Manual Page 16 F M SENSOR FAIL of S SENSOR FAIL Indicates that the vehicle detector is not connected to the controller Will only occur in NORMAL mode CHECK All connectors are tight Wiring is ok NOTE The audible alarm is inhibited when you first select NORMAL mode G M LANTERN FAIL of S LANTERN FAIL Indicates that the lanterns are not connected to the controller H M FATAL ERRO
13. l Remote Controller is available as an option 5 Times displayed in seconds or minutes and seconds All times easily entered and stored automatically in computer memory EEPROM Demand indication for setting up vehicle detection Battery charge indication and generator fail detection Accurate battery voltage of both master and slave available on the main control panel Fault description displayed on Liquid Crystal Display S Radio or Cable interconnection Cable mode not available in NSW i Auxiliary lamp on the back of the target board Hour meter is available as an option Two RF frequencies are available as an option T Auto Generator Start control line Not available in NSW MAINTENANCE FACILITIES Inbuilt fault log Lanterns can be turned off for setup or maintenance x Easy motherboard replacement Readily available components are used Australian made for support and spare parts Page 5 CS 200 Operation and Service Manual Page 6 FRONT PANEL INDICATORS The indicators used are solid state Ultra Bright 5mm dia LED s mounted in black plated brass bezel All the indicators listed below are provided on both Master and Slave Power Indicators Charge Indicates that the generator is charging the battery Lantern Indicators These indicators show the condition of the lanterns for both the Master and Slave They have been arranged and coloured to represent each signal lantern Status I
14. ndicators Transmit Indicates that the unit is transmitting data Receive Indicates that the unit is receiving valid data Demand Indicates the actual demand received from the vehicle detector Used to test and adjust the vehicle detector Remote Indicates that the unit is receiving valid data from the Radio Manual Controller and is used to check the operation of this unit Radio Manual Controller is an option Page 6 CS 200 Operation and Service Manual Page 7 MODES OF OPERATION 1 One Way Lane Traffic Control a FLASH YELLOW There are three ways the system can enter this mode 1 When the Master or Slave is turned on this mode is automatically selected 2 If a fault condition is detected 3 Selected by pressing the FLASH mode button b Manual 1 A small handheld cabled controller is used to control all manual functions It is connected to the Master Control panel via a 50 meter 4 core cable which can be extended to 100 meters The manual controller has three buttons STOP MASTER GREEN SLAVE GREEN Indication of the state of the traffic lights is also provided This indication will flash if a button is operated while the system is in a MINIMUM TIME period or RED CLEARANCE TIME This is important due to the fact that the minimum green and red times cannot be overridden and some indication needs to be given to the operator that the system has received the command but is waiting for a minimum time To
15. period of 5sec following the termination of the vehicle detector output At the end of this extension period and if there have been no further actuations on the running phase in this time this phase will go to RED If a vehicle actuates a detector as it approaches a RED PHASE and the other phase is GREEN and being extended a demand is stored and the MAX GREEN TIMER of the running phase is started When this timer expires the controller will service the other phase Maximum Reversion when in NORMAL mode In the event of the GREEN period being terminated by the operation of the MAXIMUM GREEN TIMER a demand is stored for that phase and is acted upon as soon as traffic on the other phase permits State of signal Indicators On both Master and Slave coloured ultra bright LED s which represent the lanterns provide indication of which aspect is on Any faulty lamp will be indicated by an error display on the LCD eg MASTER RED GLOBE FAILURE Page 10 CS 200 Operation and Service Manual Page 11 8 Generator Audible Alarm The audible alarm for GENERATOR FAIL alarm can be inhibited while the generator is being serviced Enter 700 YELLOW TIME Generator Audible Alarm OFF 701 YELLOW TIME Generator Audible Alarm ON 9 Auxiliary Lamp The auxiliary lamp is positioned behind the target board and provides indication to the operator when that unit is showing RED To allow low power consumption at night the Auxiliary lamp may be
16. ster fatal error System dead or two globes on Slave battery below 10v Slave battery below 11v Slave generator stopped during normal operation Slave not receiving Master Slave red globe failure Slave yellow globe failure Slave green globe failure Slave vehicle sensor not connected Slave lanterns not connected or inverter failure Slave remote lantern failure Slave fatal error System dead or two globes on Five alarms have occurred in the last 20 minutes Page 12 CS 200 Operation and Service Manual Page 13 SYSTEM MIN AND MAX TIMES Enter 901 YELLOW TIME The LCD will display the MIN and MAX times that have been programmed into the system SOFTWARE VERSION AND SERIAL NO Enter 902 YELLOW TIME The LCD will display Model No Software Version Serial No Hour Meter GENERATOR RUN TIME Enter 903 YELLOW TIME The LCD will display The amount of time the generator will run CS 200 COMMAND TABLE SUMMARY 900 System log 901 System times 902 Software version 903 Generator Run Time 999 Clear log 800 Lanterns OFF 801 Lanterns ON 700 Generator Fail Audible Alarm OFF 701 Generator Fail Audible Alarm ON 600 Program Remote 609 Master Tx on 610 Slave Tx on 611 Remote Tx on 614 Security key open 615 Security key close 630 Set Generator Run Time 640 Minutes display 641 Seconds display 642 Manual 2 enable 643 Manual 2 inhibit 644 Manual 3 enable 645 Manual 3 inhibit 646 Hour
17. turned off and on as follows Enter 500 YELLOW TIME Aux lamp OFF Not in NSW 501 YELLOW TIME Aux lamp ON Not in NSW 10 Transmitter ON facility The transmitter can be forced to stay on for 15 seconds to allow the testing of its output as well as the condition of the aerial To initiate this facility Select FLASH YELLOW Enter 614 YELLOW TIME Open Security 600 YELLOW TIME Master Tx on 610 YELLOW TIME Slave Tx on 611 YELLOW TIME Remote Tx on 615 YELLOW TIME Close security 11 Hour Meter This facility is an option and may be purchased at any time To reset meter Enter 614 YELLOW TIME Open Security 646 YELLOW TIME Reset Meter 615 YELLOW TIME Close Security View 902 YELLOW TIME 12 RF Channel Selection This facility is an option and may be purchased at any time To change the RF channel Select FLASH YELLOW Enter 614 YELLOW TIME Open Security 647 YELLOW TIME Channel 1 648 YELLOW TIME Channel 2 615 YELLOW TIME Close Security Note 1 A licence needs to be purchased from the ACMA government agency in your state Note 2 Permission to use channel 2 needs to be obtained from the ACMA government in your state 13 Generator Run Time When the controller senses that the battery voltage is below 11 5 V for a period of approx 10 seconds a relay is operated to start the generator The relay is operated for a pre set time set by the operator To set Enter 614
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