EDI 242E User manual

THIS MANUAL CONTAINS TECHNICAL INFORMATION FOR THE MODEL 242E SERIES
ENHANCED DC ISOLATOR.
SERIAL NUMBER:
PCB Issue B, 010-0242-001
1101XXXXX and up
REVISION: JANUARY 2011
pn 888-0242-003
Model 242E
Enhanced DC Isolator Unit
Operations Manual

THE MODEL 242E SERIES ENHANCED DC ISOLATOR IS DESIGNED AND
MANUFACTURED IN THE USA BY
EBERLE DESIGN INC.
PHOENIX, ARIZONA.
EDI IS CERTIFIED TO ISO 9001:2008 QUALITY SYSTEMS STANDARDS.
INFORMATION CONTAINED HEREIN IS PROPRIETARY TECHNICAL INFORMATION
OF EBERLE DESIGN INC. PUBLICATION, REPRODUCTION OR USE IN WHOLE OR
PART IS NOT PERMITTED EXCEPT UNDER TERMS AGREED UPON IN WRITING.
U.S. PATENT NO. 7,855,893
8COPYRIGHT 2011 EDI.

Table of Contents
Section 1 General....................................................................................................................1
1.1 Description....................................................................................................................1
1.2 Enhanced Features......................................................................................................1
1.3 General Characteristics ...............................................................................................1
1.4 Installation and Adjustments........................................................................................1
1.4.1 Output Polarity....................................................................................................1
1.4.2 Output Minimum Pulse Width ............................................................................2
1.4.3 Input Pulse Filtering............................................................................................2
1.5 Output (OUT) and Fault (FLT) Indicators....................................................................2
1.6 Theory of Operation.....................................................................................................2
1.6.1 System Description ............................................................................................2
1.6.2 Input Circuit.........................................................................................................3
1.6.3 MCU Circuit ........................................................................................................3
1.6.4 Output Circuit......................................................................................................3
1.6.5 Display and Switch Circuit .................................................................................3
1.6.6 Power Supply Circuit..........................................................................................3
1.7 Maintenance.................................................................................................................4
1.7.1 Trouble Analysis.................................................................................................4
1.7.2 Trouble Shooting Sequence ..............................................................................4
Section 2 Specifications ........................................................................................................5
2.1 Mechanical ...................................................................................................................5
2.2 Environmental ..............................................................................................................5
2.3 Electrical.......................................................................................................................5
2.4 Timing...........................................................................................................................5
2.5 Connections .................................................................................................................5
Section 3 Parts List and Schematic .....................................................................................6

Model 242E
Operations Manual
Eberle Design Inc. Page 1
Section 1
General
1.1 DESCRIPTION
The Eberle Design Model 242E is a dual channel DC Isolator unit designed to meet
Caltrans specifications TSCES 1989, and TEES August 2002 Chapter 1. The isolator unit
occupies one position of a 170 standard input file. The isolator unit card incorporates a
double-sided 44 pin edge connector for the connection of power, input, and output signals.
Each channel has individual front panel controls for testing the operational mode, and high
intensity front panel LEDs which are used to indicate the output state and a fault condition
on the output. Outputs are optically-isolated solid-state transistors.
1.2 ENHANCED FEATURES
The Model 242E builds on the standard DC Isolator capabilities by adding:
Additional Fault Output indicators to alert a technician to problems with the Model
242E outputs or associated Controller Unit inputs. This simplifies diagnosing problems
due to output or input circuit problems or wiring errors.
Three separate Input Pulse filter settings per channel provide a mechanism to screen
out transient input pulses that may be the result of noise conditions or signal bounce.
In some cases additional filtering can be used to ensure critical signals such as Flash
Sense are not improperly processed by the Controller Unit due to transient noise
injected into the cabinet wiring system, for example.
The polarity of the output signal can also be inverted individually for each channel.
1.3 GENERAL CHARACTERISTICS
Each channel of the Model 242E provides input hysterisis and digital filtering to qualify the
input signal. An input signal must meet the minimum pulse requirements specified in
section 1.8.5 in order to produce a valid True output.
Both the input and output circuits have been designed for maximum protection from
electrical transients. The inputs have been designed to withstand the discharge of a 10 uF
capacitor charged to +/- 1000 Vdc directly across the input pins, and a discharge of a 10 uF
capacitor charged to +/- 2000 Vdc applied through a source impedance of 5 ohms across
the input pins or to Equipment Ground. The outputs are protected by a transient clamp
diode.
The Model 242E handle assembly is made of GE LexanTM Type 121, which is a super
durable polycarbonate resin. The design of this assembly strengthens and protects the
whole PCB assembly much better than conventional metal face plates.
1.4 INSTALLATION AND ADJUSTMENTS
Installation of the unit consists of plugging into the appropriate slot of the Input File and
connecting the assigned inputs to the proper cabinet terminals. The edge connector is
keyed to prevent incorrect installation.
Following power-up, a front panel LED test will illuminate all indicators for two seconds.
1.4.1 OUTPUT POLARITY
If desired, the output polarity for Channel 1 and Channel 2 can each be inverted by setting
the DIP switches SW1.1 and SW1.4 marked “Polarity” to the ON position. The polarity may
also be inverted by installing optional jumpers SEL1 and SEL2 respectively.

Model 242E
Operations Manual
Eberle Design Inc. Page 2
Polarity Switch
Input
Output
OFF
True
True
False
False
ON True False
False True
1.4.2 OUTPUT MINIMUM PULSE WIDTH
If desired, the output pulse width for both channels can be set to 100 milliseconds minimum
by installing jumper SEL3.
1.4.3 INPUT PULSE FILTERING
Each channel can be individually configured to modify the default input pulse width
specifications described in section 1.8.5.
Polarity
Switch
Filter B
Switch
Filter A
Switch
Input
Open

Closed
Input
Closed

Open
Minimum Input
Pulse Width
Accept
OFF
OFF
OFF
10 ms
10 ms
10 ms
OFF
OFF
ON
100 ms
10ms
100 ms
OFF
ON
OFF
100 ms
100 ms
100 ms
OFF
ON
ON
200 ms
10 ms
200 ms
ON
OFF
OFF
10 ms
10 ms
10 ms
ON OFF ON 10 ms 100ms 10 ms
ON
ON
OFF
100 ms
100 ms
100 ms
ON
ON
ON
10 ms
200 ms
10 ms
1.5 OUTPUT (OUT) AND FAULT (FLT) INDICATORS
Each channel provides an OUT and FLT indicator. The OUT indicator illuminates when the
input meets the Pulse Width Accept specifications of 1.8.5 (or as modified by the Filtering
settings of 1.4.2). This state is intended to produce the True (low) state to the controller
unit.
If a cabinet fault or isolator output failure causes the true electrical state of the output to
differ from the intended state, the FLT indicator will illuminate. This may be caused by a
failure of the Model 242E output circuit, a wiring malfunction in the cabinet, or an input
circuit malfunction in the controller unit.
1.6 THEORY OF OPERATION
Reference designators shown are for Channel 1. Designators for channel 2 are shown in
brackets [ ].
1.6.1 SYSTEM DESCRIPTION
The sensor circuitry can be broken down into seven major blocks. Each “Input Circuit” block
contains the electrical transient devices and the input biasing circuit. Although the Model
242E has two DC inputs, a single digital processing section is used to process both inputs.
The microcontroller unit “MCU” Block provides the input voltage threshold and input pulse
width filtering function on both channel 1 and channel 2 DC input circuits.

Model 242E
Operations Manual
Eberle Design Inc. Page 3
The MCU then controls the OUTPUT and DISPLAY blocks appropriately. If jumper SEL3 is
installed a valid input pulse will generate an output pulse of 100 milliseconds minimum.
The microcontroller also reads the state of the TEST switches on the front panel. If the
TEST switch is in the ON (locked) or MOM (momentary) position it will force the output to
the asserted (True) state regardless of the input circuit state. The TEST switches are
processed through the MCU for pulse width input and output requirements.
Valid output calls are made via optically isolated solid state transistors. Output calls are
indicated on the front panel by means of high intensity LEDs labeled “OUT”.
The Model 242E operating voltage is generated by a high efficiency off-line switching
power supply. The VDD supply for the microcontroller and display elements results from a
post regulated 5 Vdc.
1.6.2 INPUT CIRCUIT
Resistors R5, R7, R11, and R12 [R6, R8, R13, and R17] provide the input bias and voltage
scaling circuit. The resulting voltage at U8.8 [U8.9] is then processed by the microcontroller
U8. Metal Oxide Varistor RV4 [RV5] provides input electrical transient protection.
1.6.3 MCU CIRCUIT
The microcontroller U8 processes the input voltages to perform the voltage threshold and
pulse width filtering functions. All signal processing is performed in the digital domain and
controlled by firmware embedded in the microcontroller. This unit does not rely on analog
delay, pulse, or comparator circuits for processing the input signals.
1.6.4 OUTPUT CIRCUIT
The output driver Q2 [Q1] is isolated from both the AC Mains and the internal GND
reference of the Model 242E by opto-couplers U6 [U2]. CR1 [CR2] provides electrical
transient protection for the output driver Q2 [Q1].
The actual electrical state of the output circuit is monitored by the MCU via opto-coupler U7
[U3]. This output state is used to generate the FLT indicator status on DS1.4 [DS2.4].
1.6.5 DISPLAY AND SWITCH CIRCUIT
The OUT LED indicator DS1.3 [DS2.3] for the channel output is driven directly from the
microcontroller U8. The input TEST switch SW4 [SW5] is read by the microcontroller U8
using strobe U8.19 [U8.18].
1.6.6 POWER SUPPLY CIRCUIT
The main power supply is a fully isolated switching design. MOV RV7 provides electrical
transient protection. The AC Mains voltage is rectified and charges C3 to a nominal 170
Vdc. Controller U1 drives transformer T1 at approximately 144 KHz to produce an isolated
DC voltage at C15, C16, and C17. Inductor L1 and C14 filter the high frequency switching

Model 242E
Operations Manual
Eberle Design Inc. Page 4
noise. The resulting voltage at VCC is regulated to 19.0 +/- 1 Vdc. The opto-coupler U4 and
reference U5 provide the closed loop feedback to the power supply controller U1 for
regulation. Regulator VR1 regulates VCC down to 5.0 Vdc for the microcontroller U8.
1.7 MAINTENANCE
The Model 242E requires no adjustments or preventive maintenance.
1.7.1 TROUBLE ANALYSIS
The following list should be used to trouble-shoot the Model 242E installation. If the Model
242E unit itself is suspect, see Section 1.7.2 for a complete internal testing sequence.
a. Neither channel responds to DC inputs
a. Power supply fault
The Model 242E requires a 115 Vac nominal supply. The unit will operate at
voltages as low as 80 Vac, however, an AC Mains voltage below this may result
in the unit entering a reset state. In this case, the unit will appear to be non-
functional.
b. Channel does not detect all inputs
a. Input voltage or pulse width does not meet the requirements of section 1.8.4 or
1.8.5.
Verify that the DC input voltage level is less than the DC Inputs True
specification. Verify that the DC input pulse width is greater than the Input Pulse
Width Accept specification.
1.7.2 TROUBLE SHOOTING SEQUENCE
Apply 115 Vac nominal mains power to AC+ pin J1-N referenced to AC- pin J1-M. Connect
a jumper circuit to the DC inputs J1-D [J1-J] and J1-E [J1-K] to simulate the closure of the
input contacts. The following signal measurements are referenced to test point “GND”.
NOTE: internal test point “GND” is isolated from AC-. Care should be exercised in probing
internal test points.
a. Input Bias Power Supply
Voltage at test point V_UNF should be 19 ±1 Vdc.
Possible component faults are: controller U1, diodes CR10 and CR14,
transformer T1, inductor L1, or opto-coupler U4.
b. Regulated Power Supply
Voltage at test point VDD should be 5 ±0.2 Vdc.
Possible component faults are: voltage regulator VR1.
c. Microcontroller
Waveform at pin 5 of P1 (or U8.18) should be a 2.5 us high to low pulse every 1
millisecond.
Possible components at fault are: microcontroller U8.
d. Output Circuit
Output signals are processed by the microcontroller U8 and appear at U8.6
[U8.5] and on the display LEDs but are not appearing at the output pins.
Possible components at fault are: opto-coupler U6 [U2], output transistor Q2
[Q1].

Model 242E
Operations Manual
Eberle Design Inc. Page 5
Section 2
Specifications
2.1 MECHANICAL
Height...............................................................................................................4.50 inches
Width .................................................................................................................1.2 inches
Depth (excluding handle) ..............................................................................6.875 inches
2.2 ENVIRONMENTAL
Storage Temperature Range ...................................................................... -45 to +85 oC
Operating Temperature Range................................................................... -34 to +74 oC
Humidity Range (non-condensing) .......................................................0 to 95% Relative
2.3 ELECTRICAL
AC Supply Voltage Minimum ..................................................................................80 Vac
AC Supply Voltage Maximum ...............................................................................135 Vac
AC Supply Power Maximum ...............................................................................2.5 Watts
DC Inputs
True (low)...........................................................................................less than 8 Vdc
False (high).................................................................................greater than 12 Vdc
Optically Isolated Solid State Outputs
True (low, 50 mA)...........................................................................less than 1.5 Vdc
False (high).................................................................................greater than 16 Vdc
Maximum Leakage Current (high)......................................................less than 1 uA
Maximum Current.............................................................................................50 mA
Collector Voltage Maximum............................................................................50 Vdc
2.4 TIMING
Input Pulse Width Reject (Filter A & B Off)................................................less than 5 ms
Input Pulse Width Accept (Filter A & B Off)........................................greater than 25 ms
Input Pulse Width Accept (Filter A & B Off)..................................................typical 10 ms
2.5 CONNECTIONS
Edge Connector mates with connector type Cinch 50-44A-30
PIN
FUNCTION
D
Input CH 1
E
Input CH 1 Common
F
CH 1 Output Collector
H
CH 1 Output Emitter
J Input CH 2
K
Input CH 2 Common
L Equipment Ground
M
AC -
N
AC +
W
CH 2 Output Collector
X
CH 2 Output Emitter

Model 242E
Operations Manual
Eberle Design Inc. Page 6
Section 3
Parts List and Schematic
|-----------------------------------------------------------------------------------------------------------------------|
|Item|EDI Part Number|Qty|Description |Reference |Manufacturer |
|----+---------------+---+-------------------------------------------------+-------------------+------------------------|
|1 | |1 |(NO COMPONENT) |J1 | |
|2 | |6 |(NO COMPONENT) |GND HV+ HV- VCC VDD| |
|3 | |2 |(NO COMPONENT) |SEL4-5 | |
|4 | |1 |(NO COMPONENT) |E3 | |
|5 | |2 | |M1-2 | |
|6 | |1 |PIC Programming Port |P1 | |
|7 |215-5610-S |4 |Resistor, 560 OHMS, 1/2W, 5%, 2010 surf. mnt. |R5-8 | |
|8 |220-5600-S |2 |RESISTOR,1W,56 Ohm,5%,2512 SMD |R3-4 |PANASONIC |
|9 |251-1052-S |3 |RESISTOR, 1/8W, 10.5K, 1%, 1206 surface mount |R11 R13 R30 | |
|10 |251-1211-S |1 |RESISTOR, 1/8W, 1.21K, 1%, 1206 surface mount |R26 | |
|11 |251-1961-S |3 |RESISTOR, 1/8W, 1.96K, 1%, 1206 surface mount |R12 R17 R31 | |
|12 |251-8061-S |1 |RESISTOR, 1/8W, 8.06K, 1%, 1206 surface mount |R25 | |
|13 |255-0000-S |2 | |E4 E6 | |
|14 |255-0000-S |3 |RESISTOR, 1/8W, 0 OHMS, 5%, 1206 surface mount |E2 E7 E9 | |
|15 |255-1020-S |3 |RESISTOR, 1/8W, 1K, 5%, 1206 surface mount |R21 R24 R32 | |
|16 |255-1030-S |2 |RESISTOR, 1/8W, 10K, 5%, 1206 surface mount |R14-15 | |
|17 |255-1040-S |2 |RESISTOR, 1/8W, 100K, 5%, 1206 surface mount |R22 R33 | |
|18 |255-2700-S |2 |RESISTOR, 1/8W, 27 Ohm, 5%, 1206 surface mount |R10 R28 | |
|19 |255-4310-S |1 |RESISTOR, 1/8W, 430 Ohm, 5%, 1206 surface mount |R27 | |
|20 |255-4720-S |4 |RESISTOR, 1/8W, 4.7K, 5%, 1206 surface mount |R1-2 R9 R29 | |
|21 |255-4730-S |2 |RESISTOR, 1/8W, 47K, 5%, 1206 surface mount |R19-20 | |
|22 |255-5110-S |2 |RESISTOR, 1/8W, 510 Ohm, 5%, 1206 surface mount |R16 R18 | |
|23 |255-6210-S |4 |RESISTOR, 1/8W, 620 Ohm, 5%, 1206 surface mount |R34-37 | |
|24 |300-1070-035S |1 |CAPACITOR, ELECTROLYTIC, 100uF, 35V, 20%, SMT,6.3|C7 | |
| | | |x 8 | | |
|25 |300-3360-250R |1 |CAPACITOR, ELECT, 33uF, 250WV, 20 %, RDL |C3 |ILLINOIS 336CKR250M |
|26 |300-3370-035S |1 |CAPACITOR, ELECTROLYTIC, 330uF, 35V, LOW ESR, |C14 |ILLINOIS 227AXZ016M |
| | | |20%, SMT | | |
|27 |300-3370-035S |2 |CAPACITOR, ELECTROLYTIC, 330uF, 35V, LOW ESR, |C16-17 |NICHICON UPL1V221MPH |
| | | |20%, SMT | | |
|28 |310-1060-006S |1 |CAPACITOR, TANTALUM, 10UF, 6.3V, 20%, 1206 CHIP |C18 |PANASONIC ECSTOJY106R |
|29 |320-1020-050S |2 |CAPACITOR, CER.MULT, 0.001uF, 50V, 10%, 1206 CHIP|C10 C13 | |

Model 242E
Operations Manual
Eberle Design Inc. Page 7
|30 |320-1030-100S |2 |CAPACITOR, CER.MULT, 0.01uF, 100V, 10%, 1206 CHIP|C8-9 | |
|31 |320-1040-050S |5 |CAPACITOR, CER.MULT, 0.1uF, 50V, 10%, 1206 CHIP |C1-2 C15 C19-20 | |
|32 |325-1010-500R |1 |CAPACITOR, CER.DISC, 100pF, 500V, 10%, RDL |C12 |PANASONIC |
|33 |325-4700-500R |1 |CAPACITOR, CER.DISC, 47pF, 500V, 10%, RDL |C11 |PANASONIC |
|34 |335-1040-630R |2 |CAPACITOR, 0.1UF, 630V, 10%, METALIZED FILM, 15mm|C5-6 | |
|35 |410-0053-S |2 |DIODE, TRANS. SUPR., SMA5.0A, 5V,SMA |CR9 CR11 |MOTOROLA |
|36 |410-0140-S |1 |DIODE, SCHOTTKY, MBRS140T3, 40V,1A, SMB |CR14 |ON SEMI |
|37 |410-0160-S |1 |DIODE, ULTRAFAST, MURA160T3, 600V,1A, SMA |CR10 |ON SEMI |
|38 |410-1526-S |1 |TRANSORB, SMCJ26A, 26V, 1500W |CR13 |DIODES, INC. |
|39 |410-4005-S |8 |DIODE, S1K, 800 PIV, 1A |CR3-8 CR21-22 | |
|40 |410-4148-S |8 |DIODE, 1N4148WS, SMT SOD323 |CR15-20 CR23-24 |DIODES INC. |
|41 |410-4755-S |2 |DIODE, ZENER, CMZ5941B, 1.0W, 5%, 43V,SMA |CR1-2 | |
|42 |420-2811-S |5 |OPTOCOUPLER, PS2801-1, 4 PIN SOP |U2-4 U6-7 |NEC PS2801-1 |
|43 |425-0318 |2 |DISPLAY, LED MODULE, DUAL, RA, HIGH BRIGHTNESS |DS1-2 | |
|44 |430-0006-S |2 |TRANSISTOR, MMBTA06LT1, NPN, 80V, 500 mA,SOT-23 |Q1-2 | |
|45 |440-0030 |2 |REGULATOR, METAL OXIDE VARISTOR |RV4-5 | |
|46 |440-0150 |1 |REGULATOR, METAL OXIDE VARISTOR, S14K150 |RV7 | |
|47 |440-0431-S |1 |REGULATOR, TL431AID, VOLTAGE REF., 1%, SO8 |U5 |MOTOROLA |
|48 |440-1051-S |1 |REGULATOR, SWITCHING, OFFLINE |U1 |ON SEMI NCP1051ST136T3|
|49 |440-7805-S |1 |MC7805BD2T, 5V REG., 1A, D2PAK |VR1 |MOTOROLA |
|50 |485-0687-S |1 |PIC16F687-I/SS, PROC, 20PIN SSOP |U8 |MICROCHIP PIC16F687-I/SS|
|51 |520-0102-P |1 |Connector, Header, 2 Pin, Samtec |SEL3 | |
|52 |610-0078-S |2 |SWITCH, SPDT, ON-OFF-MOM, TOGGLE, SMT |SW4-5 |APEM TL38WS84065 |
|53 |630-0060 |1 |SWITCH, DIP-SWITCH, 6 POS |SW1 |C&K |
|54 |780-0060 |1 | |CVR1 | |
|55 |800-0140 |1 |TRANSFORMER, PCMT, OFFLINE,2.5W |T1 |TRANSTEK MAGNETICS |
| | | | | |TMP60543CT |
|56 |850-0047-S |1 |INDUCTOR, 4.7uH, SMT 1210 |L1 | |
|-----------------------------------------------------------------------------------------------------------------------|

Model 242E
Operations Manual
Eberle Design Inc. Page 8

Model 242E
Operations Manual
Eberle Design Inc. Page 9

Model 242E
Operations Manual
Eberle Design Inc. Page 10