D PDF

1:2 Redundant System Controller
Operation and Maintenance Manual

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Drawing Number 14576, Revision D, May 15, 2012
ECR 11334 MSI
This manual applies to the
Model RSC-1200.
Supports Firmware Version 2.2x
EXPORT CONTROL WARNING The disclosure of this document or its contents to non-U.S. persons, or the
transmission of its contents outside the United States must be in compliance with U.S. Export Laws and Regulations.
The bearer of this document is under obligation to know the applicable restrictions for the dissemination of its contents
that relate to U.S. Export Laws and Regulations or any other U.S. government approvals.
Proprietary Notice
Information contained in this manual is provided in order to enable users to install, operate and maintain their
equipment. All such information, including but not limited to design concepts, block diagrams, schematics, parts lists,
assembly drawings, wire lists, theory of operation, and other explanations is the exclusive property of General
Dynamics SATCOM Technologies except for the rights expressly granted by contract. The contents of this manual and
any subsequent volumes which may become a part thereof may not be copied, reproduced or duplicated by any
means, whether photographically, manually, or by optical scanning, without express written permission of General
Dynamics SATCOM Technologies.
Copyright 2012 by General Dynamics SATCOM Technologies, Inc. All rights reserved.
60 Decibel Road, Suite 200 State College, PA 16801 USA

Phone: (814) 238-2700 FAX: (814) 238-6589
www.gdsatcom.com
DMAN-14576 Rev. D
Table of Contents
Section 1
General Information ......................................................... 1-1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
How to Use This Manual ........................................................1-1

Safety Information .................................................................1-1
General Introduction..............................................................1-2
Purpose of Equipment ............................................................1-2
Equipment and Accessories Supplied .....................................1-2
Options Available ...................................................................1-3
Specifications.........................................................................1-4
Section 2
Installation....................................................................... 2-1
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.4
2.4.1
2.4.2
2.5
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
2.5.7
2.6
2.6.1
2.6.2
2.7
2.7.1
2.7.2
2.7.3
Section 3
3.1
3.2
Inspection..............................................................................2-1
Mechanical Installation ..........................................................2-1
Indoor Controller ..............................................................2-1
Switching Assembly ..........................................................2-2
Interconnecting Control Cable ...........................................2-3
CE Compliance ......................................................................2-3
Use of Shielded Cables ......................................................2-4
Grounding the Controller ..................................................2-4
Controller Interfaces ..............................................................2-4
J1, J2 Line Inputs.............................................................2-5
J3 Control Cable Interface.................................................2-6
J4 External Alarm Inputs..................................................2-6
J5 RCP Link......................................................................2-8
J6 Loop ............................................................................2-9
J7 Serial I/O.....................................................................2-9
J8 Parallel I/O ................................................................2-15
Switching Assembly Interfaces .............................................2-17
Plate Assembly Interfaces
(LNA/LNB Systems) ........................................................2-17
Switching Assembly Interfaces
(SSPA and Other Systems) ..............................................2-17
Controller Configuration.......................................................2-18
From the Front Panel ......................................................2-18
Using Serial I/O..............................................................2-19
Detailed Descriptions ......................................................2-19
Operation ......................................................................... 3-1

Description of Controls and Indicators ...................................3-1
Table of Contents i
DMAN-14576 Rev. D
3.2.1
3.2.2
3.3
3.4
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.5.7
3.5.8
3.5.9
3.6
3.6.1
3.6.2
3.7
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
3.8
3.9
3.10
Section 4

Rear Panel ....................................................................... 3-1
Front Panel ...................................................................... 3-1
Power Up .............................................................................. 3-4
Calibrating Nominal Currents................................................ 3-5
Modes of Operation ............................................................... 3-6
Local Operation................................................................ 3-6
Remote Operation ............................................................ 3-6
Remote Disables Local Option .......................................... 3-7
Local Lockout................................................................... 3-7
Remote Panel Lockout ...................................................... 3-8
Auto Mode ....................................................................... 3-8
Auto Disables Manual Option........................................... 3-9
Manual Mode ................................................................... 3-9
Manually Moving Switches in Manual or Auto Modes .........3-10
Remote I/O Interfaces ..........................................................3-11
Serial I/O .......................................................................3-11
Parallel I/O .....................................................................3-11
Handling Faults ...................................................................3-13
Unit Faults .....................................................................3-13
Power Supply Faults .......................................................3-14
Controller Faults.............................................................3-14
Fault Display Mode .........................................................3-17
RCP (Remote Control Panel) Fault ...................................3-17
Emergency Power .................................................................3-18
Noise Diode (OPTION) ...........................................................3-18
Tracking Unit (OPTION)........................................................3-19
Theory of Operation ......................................................... 4-1
4.1
4.2
4.3
4.4
4.5
4.5.1
4.5.2
4.5.3
Section 5
General Introduction ............................................................. 4-1

System Level Description....................................................... 4-1
Switching Assembly Description ............................................ 4-2
Control Cable Description ..................................................... 4-2
Controller Description ........................................................... 4-3
Power Supplies ................................................................ 4-4
Front Panel Board ............................................................ 4-4
Firmware ......................................................................... 4-4
Maintenance .................................................................... 5-1
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.5
ii Table of Contents
General Introduction ............................................................. 5-1

Recommended Equipment..................................................... 5-1
Preventive Maintenance Procedures....................................... 5-1
Performance Checks.............................................................. 5-2
Check Power Supply Voltages........................................... 5-3
Checking Unit Nominal Currents...................................... 5-3
Performance Verification ....................................................... 5-3
DMAN-14576 Rev. D
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
5.5.9
5.5.10
5.5.11
5.5.12
5.6
5.6.1
5.6.2
5.6.3
Section 6
6.1
6.2
Section 7
7.1
7.2
7.3
7.4
Section 8
8.1

Power Supply Tests ...........................................................5-5
Unit Over-current Protection Tests ....................................5-5
Unit Current Monitor Tests ...............................................5-6
External Alarm Input Tests ...............................................5-7
Capacitor Charge Current Limiter Tests ............................5-7
Front Panel Tests ..............................................................5-8
Plate Assembly Tests.........................................................5-9
Parallel I/O Output Tests ................................................5-10
Parallel I/O Input Tests...................................................5-11
Serial I/O Tests ..............................................................5-12
RCP Link Port Tests ........................................................5-12
RF Tests .........................................................................5-12
Troubleshooting ...................................................................5-13
On-Line Repairs..............................................................5-14
Emergency Unit Power ....................................................5-15
Board Removal................................................................5-16
Drawings .......................................................................... 6-1

Drawing Index .......................................................................6-1
Warranty .......................................................................... 7-1

Technical Support..................................................................7-1
Warranty ...............................................................................7-1
Return Procedures .................................................................7-2
System Configuration....................................................... 8-1

Appendix A
Serial I/O Protocol ........................................................... A-1
Appendix B
Glossary ........................................................................... B-1
Appendix C
Fault Codes ...................................................................... C-1
Table of Contents iii
DMAN-14576 Rev. D
List of Illustrations
1-1
2-1
2-2
2-3
2-4
2-5
2-6
3-1
3-2
5-1
Model RSC-1200 1:2 Redundant System Controller ........................................ 1-3

Redundant System Controller Rear Panel Interfaces ....................................... 2-5
Daisy-Chained Controllers Using RS-485 Serial I/O ....................................... 2-9
A Typical RS-422 Bus................................................................................... 2-11
A Typical RS-485 (4-Wire) Bus...................................................................... 2-12
A Typical RS-485 (2-Wire) Bus...................................................................... 2-14
Binary Coded Decimal (BCD) Digit Code Chart ............................................. 2-28
Redundant System Controller Rear Panel ....................................................... 3-1
Redundant System Controller Front Panel ...................................................... 3-2
Emergency Unit Power ................................................................................. 5-15
List of Tables
1-1
2-1
2-2
2-3
2-4
4-1
5-1
6-1
6-2
List of Equipment and Accessories Normally Supplied .................................... 1-3

Fuse Ratings .................................................................................................. 2-6
J4, External Alarm Inputs .............................................................................. 2-7
J7, Serial I/O Connector .............................................................................. 2-10
J8, Parallel I/O Pinout ................................................................................. 2-16
AUTO Mode Truth Table ................................................................................. 4-5
Recommended Test Equipment....................................................................... 5-1
Drawing Types ............................................................................................... 6-1
Drawing Index................................................................................................ 6-2
iv Table of Contents
DMAN-14576 Rev. D
Section 1
1.1
General Information
How to Use This Manual

This manual contains information on how to install, operate and
maintain the Model RSC-1200 1:2 Redundant System Controller.
Information is organized according to section, with index tabs for
convenience. Within each section the pages, Figures and Tables
are numbered by section and by order of appearance within the
section.
To locate information quickly, refer to the table of contents. To
locate a figure or table, refer to the list of figures and list of tables,
which immediately follow the table of contents. To find a definition
of an unfamiliar word or acronym, refer to the glossary of
acronyms and terms at the end of the manual.
Safety information is summarized in the following section.
Warnings, cautions or notes appear prior to dangerous procedures
throughout the manual.
Section 7, Warranty, contains warranty information and return
procedures to be followed in the event that factory repair is
required. Please refer to this section for information on how to
contact the factory for service.
1.2
Safety Information
This equipment has been designed to minimize exposure of
personnel to hazards, and is a safety class I device (provided with
a protective earth terminal).
Before applying power, verify that the equipment has been set to
match the available line voltage and that the correct fuse is
installed.
An uninterruptable safety earth ground must be provided from the
main power source to the input wiring terminals through the
power cord set. The equipment is supplied with a three conductor
AC power cable, which must be connected to a grounded outlet or
be used with a three-wire to two-wire adapter with the green
grounding wire firmly connected to an electrical ground at the
power outlet.
WARNING
Failure to ground the equipment as described will cause a

potential shock hazard that could result in personal injury.
Servicing instructions are for use by service-trained personnel
only. To avoid dangerous electric shock, do not perform any
General Information 1-1
DMAN-14576 Rev. D

servicing unless qualified to do so. Do not replace components
with the power cable connected. Capacitors within the equipment
may still be charged even if the power cable has been
disconnected. Discharge before touching.
WARNING
Adjustments described in this manual are performed with power

applied while protective covers are removed. Always be careful not
to come into contact with dangerous voltages while performing
these procedures and never work alone.
For continued protection against fire hazard, replace the line
fuse(s) only with fuse(s) of the same current rating and type
(normal or slo-blo).
Do not operate this equipment in the presence of flammable gases
or fumes. Operation of any electrical equipment in such an
environment is dangerous and can cause explosions and/or fires.
1.3
General Introduction
This technical manual provides installation, operation and service
instructions for the 1:2 Redundant System Controller.
1.4
Purpose of Equipment
Down time must be minimized in todays complex systems. The
failure of a single on-line unit (amplifier or other device) can put a
system off the air. Designed to minimize down time, a 1:2 redundant
system has one standby unit and two main, or primary units. The
1:2 Redundant System Controller monitors the status of the units
and switches the standby unit on-line when a fault is detected in
either of the main units. The redundant units can be low noise
amplifiers or block converters (LNAs or LNBs), solid-state power
amplifiers (SSPAs), or other devices.
1.5
Equipment and Accessories Supplied

The 1:2 Redundant System Controller, illustrated in Figure 1-1,
consists of the items in Table 1-1.
1-2 General Information
DMAN-14576 Rev. D
FAULTS
1:2 REDUNDANT
SYSTEM CONTROLLER
CONTROLLER
PS 1
INPUTS
POL 1
OUTPUTS
UNIT 1
CAL
UNIT 3
POL 1
CAL
POL 2
CONTROLS
LOCAL
REMOTE
REMOTE PANEL LOCKOUT
PS 2
RSC-1200
POL 2
RCP
FAULT
RESET
PANEL
TEST
UNIT 2
OFFLINE
AUTO
MANUAL
SHIFT
CAL
OFFLINE
INC
FUNCTION
A BCDE FGH I J
SETTING
9876543210
DEC
CONTROLLER
LINE CORDS (2)
Figure 1-1. Model RSC-1200 1:2 Redundant System Controller

Table 1-1
Quantity
List of Equipment and Accessories Normally Supplied

Description
Indoor Redundant System Controller
Line Cord, USA

When the 1:2 Redundant System Controller is supplied as part of
a redundant system, other equipment, such as an LNA or LNB
plate assembly, or redundant SSPA switching assembly, and an
interface cable are also normally supplied. Refer to Section 8 of this
manual, System Configuration, for system-specific information,
such as outline drawings, schematic diagrams, assembly
drawings, bills of material, test data sheets, and product
specifications.
1.6
Options Available
The following options are available for redundant systems using
the Redundant System Controller. Some are only available at time
of order; others can be field installed. Contact the factory for more
information.
Chassis slides for rack-mount units
Control cableup to 300 m (1000 ft) length, Ku-band systems;
or up to 150 m (500 ft), L-, C- and X-band systems
Control cable for direct burial service; lengths as above
Remote control panel
Upgrade to Dual 1:1 configuration
Transmit reject filters (LNA/LNB systems)
System offline input and/or output test ports
General Information 1-3
DMAN-14576 Rev. D
Input and/or output directional couplers

Noise sources
Tracking unit support
Refer to Section 8, System Configuration, for the exact

configuration of your system and the options installed.
1.7
Specifications
Refer to the specification sheet included in Section 8, System
Configuration, for performance specifications of the Redundant
System and Controller.
1-4 General Information
DMAN-14576 Rev. D
Section 2
2.1
Installation
To install the Redundant System Controller, use the information
contained in this section.
2.2
Inspect the equipment before installation. See Inspection,

Section 2.2.
To install the equipment, see Mechanical Installation
procedures in Section 2.3.
For electromagnetic compatibility requirements, see CE
Compliance, Section 2.4.
To connect to the controller, see Controller Interfaces, Section
2.5.
To connect to a switching assembly, see Switching Assembly
Interfaces, Section 2.6.
To configure various features and options prior to operation,
see Configuration, Section 2.7.
Inspection
Inspect the shipping container for damage. If it or its cushioning
material is damaged, keep it until the contents of the shipment
have been checked for completeness and the system has been
checked electrically and mechanically.
Check that all items in the list of Equipment and Accessories,
Table 1-1, were received with the shipment. Also check the
packing list in the shipping container for a list of additional items
that may have been ordered.
If the Redundant System Controller has been damaged in
shipment, file a claim with the carrier. Keep all packaging
materials for the carrier's inspection. If the contents are
incomplete or there is evidence of improper packaging, notify
General Dynamics immediately.
2.3
Mechanical Installation
Install the system in three parts: indoor controller, switching
assembly, and interconnecting control cable.
2.3.1
Indoor Controller
The Redundant System Controller is designed to be mounted into
a standard 19-inch EIA equipment rack. The controller requires
Installation 2-1
DMAN-14576 Rev. D

2U (3.5 inches) of vertical rack space, and is 17.5 inches (445 mm)
deep. Choose a location in the rack that will provide adequate
ventilation and allow cooling air to circulate through the
perforated top and bottom covers at the rear of the chassis.
The equipment should be mounted on rack slides or support rails
should be used at the rear of the chassis to support the weight of
the controller.
CAUTION
Do not try to support the controller by its front panel. Always use
rack slides or support rails. The front panel is not designed to
support the weight of the chassis.
After choosing an appropriate location in the rack, mount the
movable section of the rack slides or the fixed support rails to the
rack.
Attach the controller to the slides and slide it into the rack as far
as it will go. If using support rails, slide the controller onto the
rails and push it fully into the rack.
Attach the front panel to the rack using pan head 10-32 screws
and flatwashers.
2.3.2
Switching Assembly
2.3.2.1
Outdoor Plate Assembly (LNA/LNB Systems)

Install the outdoor plate assembly in a convenient spot near the
feed of the dish. Refer to the outline drawing in Section 8, System
Configuration, for mounting details of the plate assembly. Loosen
the mounting screws for the waveguide switch support brackets
and adjust the parts for alignment with the waveguide input ports.
Do not expose the outdoor plate assembly to direct rainfall or
snowfall. The assembly is moisture resistant but not waterproof.
Use an appropriate gasket and mating flange at waveguide flange
joints for a weatherproof seal. For longest life of the motorized
waveguide switch, the waveguide system should be pressurized
and filled with dry air or gas. Long term exposure to moisture can
cause rust and eventual degradation of the mechanism.
2.3.2.2
Other Systems (SSPA Systems, etc.)

Refer to the outline drawing in Section 8, System Configuration,
for mounting details of the switching assembly. For SSPA systems,
also refer to the accompanying equipment manuals for specific
installation instructions.
2-2 Installation
DMAN-14576 Rev. D

Use an appropriate gasket and mating flange at waveguide flange
joints for a weatherproof seal. For longest life of the motorized
waveguide switch, the waveguide system should be pressurized
and filled with dry air or gas. Long term exposure to moisture can
cause rust and eventual degradation of the mechanism.
2.3.3
Interconnecting Control Cable

The control cable assembly may be customer-supplied or ordered
from the factory. (A mating connector for a customer-supplied
cable is available separately.) In most installations, only one cable
is needed between the Redundant System Controller and the
switching assembly.
The factory supplied control cable assembly not only provides
power to the motorized waveguide switch and carries control and
status information between the controller and the switching
assembly, but also can provide 15 Vdc, 50600 mA power to the
units, (e.g., LNAs or LNBs). In systems that make use of this
feature, separate power connections to the outdoor plate assembly
are not required.
Two grades of factory-supplied cable are available: standard
service (standard), and direct burial (optional).
Standard service cable has an outer PVC jacket that is UV
stabilized and can be installed outdoors. However, it should
not lie in water, and should not be buried underground.
For more severe environments, order direct burial grade
cable. This type can be laid directly on the ground or even
buried underground.
If it is necessary to remove the connector from one end in order to
feed the cable through conduit, refer to the cable assembly
drawing, 10899 or 13032 in Section 6, Drawings, for wiring
information of the factory-supplied cable.
NOTE
2.4
On factory-supplied cables for LNA and LNB systems, the end that
connects to the controller has a short pigtail with a plastic 3-pin
connector attached. You may use this connector to supply
emergency 15 Vdc power to the units (e.g., LNAs or LNBs). See
Section 5.6.2 for more information.
CE Compliance
General Dynamics redundant LNA/LNB systems and SSPA
systems have been tested for compliance with CE regulations for
electromagnetic susceptibility and emissions. In order to achieve
proper emissions and susceptibility performance of the system,
certain installation conditions must be met.
Installation 2-3
DMAN-14576 Rev. D
NOTE
2.4.1

All cables connected to the controller should be kept as short as
possible, and located and oriented to avoid pickup or radiation of
electrical interference.
Use of Shielded Cables

With the exception of AC (mains) power cords, and the switching
assembly control cable, all cables connected to the Redundant
System Controller (RSC) and optional remote control panel (RCP)
must be of fully shielded construction.
Cable Shield Termination at Controller. The shield of each
cable must be connected to a metal connector housing at the
controller (RSC or RCP) end. The connector housing must be
securely screwed to the standoffs on the rear of the controller
chassis.
Cable Shield Termination at End Opposite Controller. The
opposite end of the cable should terminate inside a shielded
connector housing or enclosure, and the shield should be
securely connected to Protective Earth at that end of the cable.
2.4.2
Grounding the Controller

The controller must be securely connected to the buildings power
system ground or earth. The Protective Earth stud on the rear
panel of the controller must be connected to the equipment
mounting rack using a low-impedance copper braid, kept as short
as possible. The equipment mounting rack containing the
controller must be connected to the building or facilitys Protective
Earth using a low-impedance copper braid, kept as short as
possible. When the controller is in normal use (i.e. not being
serviced) the front panel must be securely clamped to the
equipment mounting rack using four screws.
2.5
Controller Interfaces
Major I/O groups for the Redundant System Controller are:
Line inputs, J1 and J2
Control cable interface to outdoor plate assembly, J3
External alarm inputs, J4
Remote control panel (RCP) link, J5
Serial I/O loop connector, J6
RS-232/-422/-485 Serial I/O, J7
Parallel I/O, J8
Details of each group are discussed below. See Figure 2-1 for the
locations of these I/O connections.
2-4 Installation
DMAN-14576 Rev. D
J1, J2: Line Inputs

LINE 87-265 V
J3: Control Cable Interface
47-63 Hz
J3
PLATE ASSY
J1
For continued protection against fire,

replace only with same type and rating
of fuse.
PN
CPN
Refer servicing to qualified personnel.
SN
MADE IN U.S.A.
J4
EXT ALM
J5
RCP LINK
J6
LOOP
J7
SERIAL I/O
J8 PARALLEL I/O
J2
Consult operation and maintenance
manual for correct fuse rating.
J4: External Alarms
J5: RCP Link
J6: Loop
J7: Serial I/O
J8: Parallel I/O
Figure 2-1. Redundant System Controller Rear Panel Interfaces

2.5.1
J1, J2 Line Inputs

The AC line inputs and the internal switching power supplies are
fully redundant. Either input is capable of powering the system.
For maximum system reliability, connect each line input to a
separate AC power source. The second best option is to connect
each input to a different phase of a three-phase AC line. The third
option is to connect both inputs to the same AC line.
2.5.1.1
CAUTION
Power Requirements
Before plugging the controller into the AC line, verify that the
correct fuse(s) have been selected.
The 1:2 Redundant System Controller has worldwide AC input
capability. It can operate from a power source of 90 to 264 Vac, 47
to 63 Hz, single phase. The power supplies are autoranging; no
jumper or switch settings are required to operate at different
voltages.
Line input is through an internationally standardized IEC
connector. Select a cordset to match the power connectors in use
in the local area. The controller is supplied with a pair of North
American cordsets.
Fuses should be selected to match the voltage in use according to
Table 2-1. For North America, use one fuse in the hot side of the
line. For Europe, use two fuses. The controller is shipped from the
factory set up for North American fusing.
In equipment with older power entry modules (prior to September
2003), both AG and metric fuses are supplied, enclosed within the
power entry modules. In newer equipment (after September 2003),
metric fuses are typically provided in a small plastic bag taped
inside the chassis.
Installation 2-5
DMAN-14576 Rev. D
Table 2-1
Line Voltage

Fuse Ratings
Type
Rating
Size
100120 V
3.0 A
0.25" x 1.25"
MDL slo-blo
220240 V
2.0 A
5 x 20 mm
GDC slo-blo
To change from North American to European fusing:

(a) Disconnect the power cord(s) at the power entry module(s).
(b) Open the power entry module cover and remove the fuseholder.
Note that, on older power entry modules, the cover pops
straight out, and the fuseholder is attached to the cover with a
Phillips screw; on newer modules, the cover is hinged and
swivels out, revealing the fuseholder inside the power entry
module housing.
(c) The North American side of the fuseholder has one AG fuse
and a jumper bar; the European side holds two metric fuses.
Remove the AG fuse, turn the fuseholder upside down, and
install two metric fuses on the opposite side.
CAUTION
On newer modules, do not close the cover if both AG and

metric fuses are in place; the cover will be damaged. Only one
type of fuse can be installed for use in the newer modules. On
older modules, however, it is possible to install the fuseholder with
both AG and metric fuses in place; the orientation of the
fuseholder determines which fuses are used.
(d) Replace the fuseholder with the metric fuses facing into the
power entry module housing, and snap the cover into place.
2.5.2
J3 Control Cable Interface

Interconnect the Redundant System Controller and the switching
assembly using either the factory supplied control cable assembly
or a compatible customer-furnished cable. For details on cable
installation, refer to Section 2.3.3.
2.5.3
J4 External Alarm Inputs

The system can be configured to receive unit fault information
from an external circuit instead of, or in addition to, the internal
bias current monitors. (See Section 2.7.)
For example, when the Redundant System Controller is used in a
1:2 SSPA system, the internal current-monitoring circuitry of the
controller is not used. Instead, the controller monitors its external
alarm inputs for Units 1, 2 and 3. Each of these external alarm
2-6 Installation
DMAN-14576 Rev. D

inputs is wired through the summary alarm contacts of the
corresponding SSPA, and then back to controller ground. When
the SSPAs are not faulted, their Open-On-Fault summary alarm
contacts are closed, and the controller's external alarm inputs are
inactive (grounded). If an SSPA develops a fault, its Open-On-Fault
summary alarm contacts open, thus asserting (activating) the
corresponding external alarm input. If the controller is in AUTO
mode, it will drive the redundancy switch to remove the faulted
unit from the signal path and replace it with the non-faulted unit,
if possible.
External alarm inputs for Units 1-3, a spare, and an optional
Tracking Unit (or spare) are available at both J4 and at J3 (pins 21
thru 25). Corresponding alarm inputs from J3 and J4 are
combined (ORed) on the controller logic board.
To simplify connection between the controller and the switching
assembly, interface cables ordered from the factory for use with
systems that rely on external alarm inputs include wiring for the
Unit alarms. It is typically not necessary to provide a separate
connection to J4 in such systems, although the alarm inputs are
available there. External alarm inputs 6-8 (spare inputs), however,
are only available at J4. See Table 2-2.
Table 2-2
J4, External Alarm Inputs

5
4
9
Pin
Function
3
8
2
7
1
6
Notes
Ext alarm 1 in
Unit 1
Ext alarm 2 in
Unit 2
Ext alarm 3 in
Unit 3
Ext alarm 4 in
Spare
Ext alarm 5 in
Tracking Unit (or Spare, if no Tracking Unit)
Ext alarm 6 in
Spare
Ext alarm 7 in
Spare
Ext alarm 8 in
Spare
Ground
The external alarm inputs are optoisolator coupled for noise and
common mode ground loop rejection. A high or a floating, open
input is interpreted as a fault and activates the alarm. To indicate
normal (non-faulted) status, pull the line to ground with a switch,
a relay, a gate or a transistor. Active devices must be capable of
Installation 2-7
DMAN-14576 Rev. D

withstanding 5 V and sinking 5 mA. Standard CMOS (74Cxxx or
MC14xxx families), HCMOS (74HCxxxx), open-collector TTL, or
open drain CMOS are all suitable. The input will tolerate positive
voltages up to 30 V.
2.5.4
J5 RCP Link
Use J5 to interconnect the Redundant System Controller (RSC)
and the optional Remote Control Panel (RCP), if one is included in
your system. The interface cable is supplied with the Remote
Control Panel.
The RCP and RSC are usually connected using a supplied four
conductor (plus ground) cable. If you are using a supplied cable,
simply connect it between the RCP LINK connectors (J5) of the
RCP and RSC.
If a cable is to be constructed, it must be wired as shown below:
RSC pin
RCP pin
1 (RX+)
4 (TX+)
2 (RX-)
3 (TX-)
3 (TX-)
2 (RX-)
4 (TX+)
1 (RX+)
5 (GND)
5 (GND)
Both ends of the cable terminate in DSUB-9 female (socket)
connectors. Cable connector housings should always be firmly
screwed to the jackscrews on the rear panels of both units.
For best performance, high-quality, low-capacitance cable should
be used. The cable should be shielded, twisted pair construction,
with pins 1-2 on one pair, and pins 3-4 on another pair. A ground
conductor between the two units is required. The outer shield of
the cable should be connected to the connector housing at the
RSC end. Maximum cable length is approximately 4000 feet (1200
meters), using a good quality cable.
CAUTION
The RSC-RCP link interface is not isolated from chassis ground. If

the RSC and RCP are operated from separate AC lines (mains), you
must ensure that potential difference between the two units is
minimized to prevent damage.
Absolute maximum potential difference between the units is 7 volts.
If this difference is exceeded, communications may not work and
damage could result.
The interface between the RSC and RCP can be transmitted by
optical fiber, RF modems, or other methods of transmission which
can correctly duplicate the bidirectional interface. The interface is
standard four-wire RS-422 at 19200 baud, 8 data bits, 1 stop bit,
and no parity.
2-8 Installation
DMAN-14576 Rev. D
2.5.5
J6 Loop
The Loop connector, J6, duplicates the connections of the Serial
I/O connector, J7 (see Section 2.5.6). This allows multiple devices
to be daisy-chained on an RS-485 multi-drop serial I/O bus
without the need for Y cable adapters at each controller; see
Figure 2-2.
CONTROLLER
#1
SERIAL
I/O
J7
LOOP
J6
CONTROLLER
#2
SERIAL
I/O
J7
LOOP
J6
CONTROLLER
#3
SERIAL
I/O
J7
LOOP
J6
ETC.
M&C SYSTEM
Figure 2-2. Daisy-Chained Controllers Using RS-485 Serial I/O

2.5.6
J7 Serial I/O
The serial I/O interface for remote monitoring and control
supports RS-232, RS-422, or RS-485 (2-wire and 4-wire)
connections. The various interface selections share some lines, so
it is important to make sure the appropriate interface is selected
on the equipment. Any pins not used in the desired interface
should be left unconnected. Only one of these interfaces may be
used at a time.
All data is transmitted and received with 8 data bits, 1 stop bit, 1
start bit, no parity, and no software handshaking. The baud rate
is selectable using a setting on the front panel. (See Section 2.7,
Configuration.)
Selection of an interface is done using both the connector wiring
and a front panel setting on the controller. The pinout for the
interfaces is shown in Table 2-3.
Installation 2-9
DMAN-14576 Rev. D
Table 2-3
J7, Serial I/O Connector

5
4
9
Pin
3
8
2
7
1
6
Function
Notes
RS-232 (EIA/TIA-574) Full duplex, one unit on a bus.

5
Signal Ground
Connect to DTE signal SG.
Data In
Connect to DTE signal TD.
Data Out
Connect to DTE signal RD.
RS-422 Full duplex, one unit on a bus.

4
3
+ Data In
Data In
1
2
+ Data Out
Data Out
Ground
Termination
Transmit driver on continuously.
Connect to pin 4 to terminate receiver. Terminate units

on ends of bus.
RS-485 (4-wire) Full duplex, multiple units.

4
3
+ Data In
Data In
1
2
+ Data Out
Data Out
Ground
Termination
High impedance when not transmitting data, to allow

multiple units on a bus.
Connect to pin 4 to terminate receiver. Terminate units
on ends of bus.
RS-485 (2-wire) Half duplex, bidirectional bus, multiple units.

4&1
3&2
+ Data I/O
Data I/O
Ground
Termination
Connect indicated pins together for RS-485 interface.
Connect to pin 4 to terminate RS-485 bus. Terminate

units on ends of bus.
Service Request
6
7
8
CLOSED Svc Req

Common
OPEN Svc Req
2-10 Installation
Form C contacts, rated for

100 Vdc, 0.5 A, 3 W max.
(resistive load).
DMAN-14576 Rev. D
2.5.6.1
RS-232
The RS-232 pinout conforms to the DCE end of that specified in
EIA/TIA-574, which is typically used on desktop computers for 9pin COM ports. Since this uses the DCE end, it may be connected
either to a computer's 9-pin COM port via a straight through 9-pin
cable, or to a 25-pin COM port using a 9-pin-to-25-pin adapter.
Only three of the RS-232 lines are used: Signal Ground, Transmit
Data, and Receive Data. No handshaking lines are used.
The RS-232 specification allows full-duplex communication over
up to 50 feet of cable. One line is used for transmit data, the other
for receive. The distance can normally be extended by using lower
baud rates, or low capacitance cable. Only one driver is allowed on
either the transmit data line or the receive data line, so communication is possible between only two devices (i.e., the host
computer and one other device) on an RS-232 bus.
2.5.6.2
RS-422
The RS-422 specification allows for full duplex communication
over two differential pairs of wires: one pair for transmit data, the
other for receive. See Figure 2-3. Cables may be up to 4000 feet in
length using an RS-422 interface. RS-422 drivers are on all the
time, so only one of them is allowed on either pair of lines. This
avoids the problems of fail-safe biasing involved with RS-485 (see
below), but limits communication to only one device and the host
computer.
Unit
Host Computer
4
3
9
1
2
5
Figure 2-3. A Typical RS-422 Bus

There is a common mode voltage specification for RS-422, so it is
normally necessary to run a common ground line to both devices
on the bus.
The RS-422 pinout complements that on some popular PC plug-in
RS-422 interface cards, and can connect to them using a straight
through cable.
Installation 2-11
DMAN-14576 Rev. D

Terminations
In Figure 2-3, note the terminations on the receivers for the Host
Computer and the Unit on the bus.
This equipment uses an AC style termination, consisting of a 120ohm resistor and a 0.01 F capacitor in series. The termination is
enabled by connecting the TERMINATION pin (pin 9) to the RX+
input (pin 4).
For short cable runs, terminations may not be necessary.
2.5.6.3
RS-485 (4-wire)
The RS-485 specification is very similar to RS-422. It allows for
full duplex communication over two differential pairs of wires, one
pair for transmit data, the other for receive. See Figure 2-4. Cable
lengths up to 4000 feet are allowed using an RS-485 interface. The
difference between RS-422 and RS-485 (4-wire) is that in RS-485,
the transmit drivers may be switched on and off, allowing more
than one driver on a bus.
Host Computer
Unit 1
V+
V-
4
3
9
1
2
5
Unit 2
Last Unit
4
3
9
1
2
5
4
3
9
1
2
5
Figure 2-4. A Typical RS-485 (4-Wire) Bus

normally necessary to run a common ground line to all devices on
the bus.
through cable.
2-12 Installation
DMAN-14576 Rev. D

Terminations
Computer (First Unit) and the Last Unit on the bus. No other unit
(in this example, Unit 1 or Unit 2) should be terminated.
This equipment uses an AC style termination, consisting of a 120ohm resistor, and a 0.01 F capacitor in series. The termination is
enabled by connecting the TERMINATION pin (pin 9) to the +
Data I/O input (pin 4).
Fail-safe Biasing
Since the RS-485 transmitter is turned off when no data is being
sent (to support multiple units on the bus), the bus is left floating
between messages and may register as either a MARK or a
SPACE to the host computer. Some software cannot handle the
SPACE condition, so fail-safe biasing may be necessary. The level
of biasing depends on a number of factors, including the number
of units on the bus and the impedance of the termination. Typical
fail-safe biasing circuits are shown in Figure 2-4, enclosed in
dashed lines.
It is not necessary for the transmit driver in the host computer to
switch on and off, since it is the only driver on that pair of wires. If
this is the case, no fail-safe biasing is necessary on the transmit
output from the host computer.
This equipment has an internal biasing network on its receiver
inputs that guarantees a MARK state when the input is not
connected.
2.5.6.4
RS-485 (2-wire)
With an RS-485 interface, you can connect the transmit and
receive pairs together, and communicate in half duplex over only
one pair of wires. This mode of operation is called RS-485 (2-wire),
and is also supported by this equipment.
The host computer must switch its driver on to talk, and off to
listen for a response. The timing for turning the transmitter off
depends on the protocol that is being used. The transmitter must
be turned off by the earliest time that the unit may generate a
response.
See Figure 2-5. To use RS-485 (2-wire) with this connector pinout,
connect pins 1 and 4 together to form the positive (+) side of the
bus, and pins 2 and 3 together to form the negative () side. Cable
lengths up to 4000 feet are allowed using an RS-485 interface.
Installation 2-13
DMAN-14576 Rev. D
Host Computer
V+
Unit 1
4
V-
3
9
1
2
5
Unit 2
Last Unit
4
3
9
1
2
5
4
3
9
1
2
5
Figure 2-5. A Typical RS-485 (2-Wire) Bus

normally necessary to run a common ground line to all devices on
the bus.
through cable.
Terminations
Computer (First Unit) and the Last Unit on the bus. No other unit
(in this example, Unit 1 or Unit 2) should be terminated.
This equipment uses an AC style termination, consisting of a 120ohm resistor, and a 0.01 F capacitor in series. The termination is
enabled by connecting the TERMINATION pin (pin 9) to the +
Data I/O input (pin 4).
Fail-safe Biasing
Since nothing is driving the bus between messages, the bus is left
floating and may register as either a MARK or a SPACE to any
unit on the bus. This ambiguity may cause problems with
equipment of software that is not designed to receive a long
SPACE character, so fail-safe biasing may be necessary. The
level of biasing depends on a number of factors, including the
number of units on the bus and the impedance of the termination.
Typical fail-safe biasing circuits are shown in Figure 2-5, enclosed
in dashed lines.
2-14 Installation
DMAN-14576 Rev. D

This equipment has an internal biasing network on its receiver
inputs that guarantees a MARK state when the input is not
connected.
2.5.6.5
Service Request
The service request is a Form C relay contact that indicates
whether a fault, or any other condition needing attention, has
occurred on the unit.
In normal operation, with no faults or alarms active, the relay is
energized. Pins 7 and 8 of J7 are closed (connected), and pins 6
and 7 of J7 are open. (The same is true at J6.)
When a fault or alarm becomes active, the relay is de-energized.
On both J6 and J7, pins 7 and 8 are then open, and pins 6 and 7
are closed. See Table 2-3.
The service request is indicated as soon as a fault occurs, and
clears either when acknowledged by serial I/O message, or when
all faults are successfully reset.
2.5.7
J8 Parallel I/O
Use this connector for external control and monitoring of the
system. Typical uses are for sending status information to a
centralized customer status monitoring system or for remotely
controlling the system from a nearby building.
To locate the correct pin on J8, see Table 2-4. For further details
of the interface, refer to Section 3.6.2.
Outputs are Form C dry relay contacts suitable for switching up
to 100 Vdc maximum, 0.5 A continuous (0.25 A during switching)
maximum current, or up to a 3 W resistive load. Suitable loads are
LEDs, incandescent lamps, relays or logic gates (with appropriate
pull-up or pull-down resistors).
Inputs are optoisolator coupled for noise and common mode
ground loop rejection. To activate an input, pull the line to ground
with a switch, a relay, a gate or a transistor. Active devices must
be capable of withstanding 5 V and sinking 5 mA. Standard CMOS
(74Cxxx or MC14xxx families), HCMOS (74HCxxxx), open-collector
TTL, or open drain CMOS are all suitable. The input will tolerate
positive voltages up to 30 V.
Installation 2-15
DMAN-14576 Rev. D
Table 2-4
J8, Parallel I/O Pinout

1
2
20
Group
Type
Unit 1 Status
Output
Unit 2 Status
Output
Unit 3 Status
Output
PS1 Status
Output
PS2 Status
Output
S1 Position
Output
S2 Position
Output
Auto/Manual
Output
Local/Remote Output
Remote
Control
Inputs
Input
3
21
4
22
5
23
6
24
7
25
8
26
9
27
10
28
11
29
12
30
13
31
14
32
15
33
16
34
17
35
18
36
Function
Pin
Closed on Fault
Common
Open on Fault
Closed on Fault
Common
Open on Fault
Closed on Fault
Common
Open on Fault
Closed on Fault
Common
Open on Fault
Closed on Fault
Common
Open on Fault
Position 1
Common
Position 2
Position 1
Common
Position 2
MANUAL
Common
AUTOMATIC
LOCAL
Common
REMOTE
Ground
Auto/Man Toggle
Unit 1 Pol 1 Select
Unit 3 Pol 1 Select
Unit 2 Pol 2 Select
Unit 3 Pol 2 Select
Fault Reset
25
6
26
7
27
8
16
36
17
28
9
29
10
30
11
31
12
32
37
18
19
13
33
14
34
15
35
24
5
4
3
2
1
23
19
37
Comments
See Note 1.
See Note 1.
See Note 1.
See Note 1.
See Note 1.
Unit 1 on-line, Pol 1


Common connected to
MANUAL when power is off
or when in Manual mode.
Common connected to
LOCAL when power is off
or when in Local mode.
Falling-edge-sensitive
inputs. Ground to activate.
See Note 2.
Note 1: Relays are shown in Faulted (power-off) state.

Contact rating: 100 Vdc / 0.5 A / 3 W maximum (resistive load).
Note 2: Open-circuit voltage at inputs is 5 V. Short-circuit current is 5 mA maximum.
Minimum pulse width is 10 ms.
2-16 Installation
DMAN-14576 Rev. D
2.6
2.6.1
Switching Assembly Interfaces

Plate Assembly Interfaces (LNA/LNB Systems)
Major I/O groups on the outdoor plate assembly normally
supplied with LNA or LNB systems are:
RF Inputs
RF Outputs
Offline I/O (Optional)
Test In (Optional)
Control Cable
See the outline drawing in Section 8, System Configuration, for
the locations of these I/O connections.
RF Inputs. The RF inputs typically are waveguide flanges, one for
each polarization. Use appropriate gaskets and mating flanges for
weatherproof seals. (Some systems, e.g., L-band systems, may use
coaxial connectors.)
RF Outputs. The RF outputs are typically coaxial connectors, one
for each polarization.
Offline I/O (Optional). Input and output ports for the off-line
Unit (LNA/LNB) are coaxial connectors. Terminate the off-line
output when not in use.
Test In (Optional). Signals applied to the test inputs are injected
into the on-line Units (LNAs/LNBs) via crossguide couplers on the
waveguide inputs. The test inputs are coaxial connectors.
Control Cable. Interconnect the outdoor plate assembly and the
indoor Redundant System Controller using the factory-supplied
control cable assembly. The cable connects to the plate assembly
at multipin MS connector J1. For details on cable installation, see
Section 2.3.3.
2.6.2
Switching Assembly Interfaces (SSPA and Other Systems)

Major I/O groups on the switching assembly normally supplied
with SSPA systems include:
RF Inputs
RF Outputs
Switch Motor Drive and External Alarms (Control Cable)
See the outline drawing in Section 8, System Configuration, for
the locations of these I/O connections.
RF Inputs. The RF inputs are typically coaxial connectors.
Installation 2-17
DMAN-14576 Rev. D

RF Outputs. The RF outputs typically are waveguide flanges. Use
appropriate gaskets and mating flanges for weatherproof seals.
(Some systems, e.g., L-band SSPAs, may use coaxial connectors.)
Switch Motor Drive and External Alarms. Interconnect the
redundancy switches, the unit summary alarm sources, and the
indoor controller using the factory supplied control cable
assembly. Connect P2 of the cable to switch S1-J1, connect P3 to
S2-J1, and connect P4, P5 and P6 to the summary alarm Openon-Fault contacts of Units 1, 2, and 3, respectively. For details on
cable installation, see Section 2.3.3.
2.7
Controller Configuration
All options of the controller are configured by software settings,
without using hardware jumpers. The configuration may be viewed
and changed from the front panel, or in most cases by using serial
I/O commands. Either way, the configuration may be viewed and
modified without opening the controller or removing it from its
rack.
When a Redundant System Controller is purchased in a complete
system, it will be factory configured to an appropriate state for
that system, which may differ slightly from the factory defaults
listed below. The configuration should be reviewed to verify desired
settings of serial I/O, priority channel, latched faults, and other
features.
When a Redundant System Controller is purchased as a standalone unit, it will be configured with the factory defaults listed in
the following sections. It will be necessary to review all
configuration settings to verify the controller is properly prepared
for use in a particular system.
2.7.1
From the Front Panel

The controller configuration can be quickly viewed and modified
from the front panel, using no tools and without a PC or software.
To enter configuration mode using the front panel controls, press
the SHIFT button twice. Portions of the FUNCTION and SETTING
windows will illuminate to show you are in configuration mode.
In configuration mode, one or two segments of the FUNCTION
window light to indicate the configuration function being accessed.
One or more segments of the SETTING window light to indicate the
setting of the function. For example, when indicator A is lit, the
serial I/O interface type is being accessed. In that case, SETTING
indicator 0, 1, 2, or 3 will light to indicate which of the four serial
I/O interfaces is selected.
2-18 Installation
DMAN-14576 Rev. D

Use the INC and DEC buttons to change the value of a configuration setting. In some cases, the buttons will increment and
decrement the value displayed as a binary number, so multiple
segments of the SETTING window will light. In other cases,
increment and decrement will change which single segment of the
SETTING window is lit.
Use the arrow button ( ) to proceed to the next sequential
configuration function. Pressing SHIFT will exit configuration
mode and save any changes which have been made.
2.7.2
Using Serial I/O

Serial I/O commands can be used to view and change most
configuration options of the controller. This is particularly useful
in systems where a Monitor & Control (M&C) system is interfaced
to the controller.
Refer to Appendix A for descriptions of the Serial I/O commands
to view and control the configuration settings. Remember that the
controller must be in Remote mode for all Serial I/O configuration
commands to have effect.
2.7.3
Detailed Descriptions
The configuration settings of the controller are described in the
following sections.
2.7.3.1
FUNCTION A: Serial I/O Interface

This configuration function controls the hardware interface for the
Serial I/O connector, which can be set for RS-232, RS-485 (4wire), RS-485 (2-wire), or RS-422.
Function A:
Serial Port Interface
Setting:
(Factory Default is RS-232)
0 = RS-232
1 = RS-485, 4-wire
2 = RS-485, 2-wire
3 = RS-422
The interface selected is transferred to the RCP-1200 remote

control panel (if present) and used for its Serial I/O port as well.
2.7.3.2
FUNCTION B: Serial I/O Address

This configuration function selects a Serial I/O address for the
controller.
If you are using a serial bus that is communicating with several
pieces of equipment simultaneously, each must be assigned a
unique address. The address is a number between 0 and 255.
Installation 2-19
DMAN-14576 Rev. D

Function B:
Serial I/O Address
Setting:
0 = 20 = 1
1 = 21 = 2
2 = 22 = 4
3 = 23 = 8
4 = 24 = 16
5 = 25 = 32
6 = 26 = 64
7 = 27 = 128
(Factory Default is 0
i.e., no Setting LEDs lit.)
Example:
SETTING
= ON (lit)
= OFF (unlit)
9 8 7 6 5 4 3 2 1 0
64 + 16 + 8 + 1 = 89
In this function, SETTING lights 0 through 7 each represent one

bit in a binary number. The Serial I/O address is determined by
adding up the value of all lights which are on. In the above
example, the address is 89.
NOTE
In a system with many devices on the same serial bus, do not use
address 0. Address 0 is a global address. Messages sent using an
address of 0 are obeyed by all units that receive the message.
Pressing the INC button will increase the address by one. Pressing
the DEC button will decrease it by one. As a shortcut, pressing the
INC and DEC simultaneously will change the setting to zero.
The address selected is transferred to the RCP-1200 remote
control panel (if present) and used for its Serial I/O port also.
2.7.3.3
FUNCTION C: Serial I/O Baud Rate

This configuration function selects the baud rate for the Serial I/O
port.
Function C:
Baud Rate
Setting:
0 = 300 baud
1 = 1200
2 = 2400
3 = 4800
4 = 9600
5 = 14400
6 = 19200
7 = 28800
(Factory Default is 19200 baud)
The baud rate selected is transferred to the RCP-1200 remote

control panel (if present) and used for its Serial I/O port as well.
2.7.3.4
FUNCTION D: Auto/Remote Options

This function controls configuration of the Auto-Disables-Manual
and Remote-Disables-Local options.
2-20 Installation
DMAN-14576 Rev. D

Function D:
Auto/Remote Options
Feature:
Setting:
0
1
2
3
(Factory Default is both disabled)
Auto
Disables
Manual
Remote
Disables
Local
no
no
yes
yes
no
yes
no
yes
When Auto-Disables-Manual is enabled (yes), the unit buttons,

the position control parallel I/O inputs, and the serial I/O switch
command will be ignored if the unit is in AUTO mode.
When Auto-Disables-Manual is disabled (no), the unit buttons,
the position control parallel I/O inputs, and the serial I/O switch
command will be obeyed, as long as the command selects a valid
position in that mode, as determined by any faults that might
exist on the units.
When Remote-Disables-Local is enabled (yes), all front panel
pushbuttons except PANEL TEST and LOCAL/REMOTE will be
ignored if the unit is in REMOTE mode.
When Remote-Disables-Local is disabled (no), front panel
buttons will operate normally, even when the unit is in REMOTE
mode. In REMOTE mode parallel I/O inputs, serial I/O
commands, and front panel controls will all be obeyed.
2.7.3.5
FUNCTION E: Current Window Width

This configuration function selects the window within which a
units current can vary before a Unit alarm is triggered.
Function E:
Alarm Window Width
Setting:
0 = 5%
1 = 10%
2 = 15%
3 = 20%
4 = 25%
(Factory Default is 10%)
The current window is set for an appropriate level at the factory if

the controller is shipped with a system, and should not be
adjusted unless you are experiencing problems, or are moving the
controller to another system which has a different current width
setting.
The window width can be set for 5%, 10%, 15%, 20%, or
25% of nominal current. These values mean that the measured
current can vary by this much above or below the nominal current
drawn by the unit at calibration, without an alarm occurring.
Installation 2-21
DMAN-14576 Rev. D
2.7.3.6
FUNCTION F: Auto Revert and Priority Channel

In the RSC-1200, this function does two things: it determines
whether the Auto Revert feature is enabled, and sets the Priority
Channel.
Function F:
Auto Revert and Priority (RSC-1200 1:2 controller only)

(Factory Default is neither set)
Feature:
Setting:
0
1
2
3
4
5
Auto Revert
Priority
no
no
no
yes
yes
yes
none
Pol 1
Pol 2
none
Pol 1
Pol 2
When Auto Revert is enabled (yes), the controller will always

switch the primary unit back on-line after it has been faulted and
subsequently restored to proper operation. This feature is most
useful in 1:2 systems, where the standby unit may not have as
good noise performance on a particular Pol, and you want to be
sure the best unit is always on-line. In a 1:2 system, the primary
unit for Pol 1 is Unit 1, and for Pol 2 is Unit 2.
Auto Revert only works if the controller is in AUTO mode (see
Section 3.5.6).
Note that if Latched faults are enabled (see Function AB, Section
2.7.3.11), a faulted unit remains faulted until reset by the
operator. In this case, Auto Revert will not automatically switch
the primary unit back on-line until faults are reset.
In a 1:2 system, Unit 3 is used as the standby unit for both
polarizations. If failures occur on both of the main units, the
Priority setting determines which Pol gets the standby unit if
failures are simultaneously detected on both on-line units. The
choices are None, Pol 1, or Pol 2.
2.7.3.7
When NONE is selected, if a failure occurs on both primary

units the standby unit will be switched to the channel where
the first fault was detected.
When Pol 1 is selected, if failures occur on both primary units

the standby unit will be switched to Pol 1.
When Pol 2 is selected, if failures occur on both primary units

the standby unit will be switched to Pol 2.
FUNCTION G: Channel Preference

In the RSC-1200, this function has no meaning. This function is
only used in the RSC-1100 (1:1) and RSC-1111 (Dual 1:1)
controllers.
2-22 Installation
DMAN-14576 Rev. D
2.7.3.8
FUNCTION H: Audible Alarm

This configuration function selects whether the controllers audible
alarm is enabled.
Function H:
Setting:
Audible Alarm
0 = Off
1 = On
(Factory Default is Off)
When the audible alarm is enabled (on), any controller fault will
cause the audible alarm to beep until silenced, or until the
controller determines the fault went away. The alarm can be
silenced by pressing any front panel button on the controller (or
the remote control panel, if present). The audible alarm will also
beep briefly during a panel test if it is enabled.
The Audible Alarm configuration is transferred to the RCP-1200
remote control panel, if present.
2.7.3.9
FUNCTION I: Controller Type (Read Only)

This configuration function displays the controller type. This
configuration function is display only. The setting cannot be
changed by the user.
Function I:
Setting:
Controller Type (display only) (Factory Default is RSC-1200)

0 = RSC1100 (1:1 redundant)
1 = RSC1200 (1:2 redundant)
2 = RSC1111 (Dual 1:1 redundant)
3 = UNKNOWN (Cannot determine type)
If the controller type is unknown, or does not match the front

panel type, it is probably because the controller type jumper on
the front panel has been mis-positioned. That jumper should not
normally be changed by a customer.
2.7.3.10 FUNCTION J: Hardware Options
This configuration function does two things: it indicates whether
optional hardware is configured in the controller; and it displays
the status of optional hardware, indicating whether it is properly
detected by the controller.
Function J:
Setting:
Hardware Option Status

0 = RSC Parallel I/O Board is configured
1 = Tracking Unit is configured
2 = Noise Diode 1 is configured
3 = Noise Diode 2 is configured
4 = spare (future use)
5 = Parallel I/O is detected
6 = Remote Control Panel (RCP) is detected
7 = RCP with Parallel I/O is detected
Installation 2-23
DMAN-14576 Rev. D

SETTING indicators 0 through 3 indicate the configuration status
of hardware for parallel I/O, the tracking unit, and noise diodes. If
an indicator is lit, the corresponding hardware is configured and
will be controlled by the controller. The INC and DEC buttons can
be used to change these settings.
When a Parallel I/O board is detected by the controller at power
up, its configuration is automatically turned on. If the parallel I/O
board is removed later, its configuration setting must be manually
turned off here, or the controller will generate a fault because of
the missing parallel I/O board.
When the Tracking Unit configuration is on, the controller will
power and monitor current to a tracking unit. The tracking unit
light on the front panel will be on. Serial I/O commands will report
status of the tracking unit. The tracking unit should not be
configured if it is not used. See Section 3.10 for more information.
When the Noise Diode configurations are on, the controller will
power and monitor voltage to noise diode outputs. The AUX1 and
AUX2 buttons will turn on and off the noise diode outputs. Serial
I/O commands will report status of the noise diodes and control
them. Noise diodes should not be configured if not used. See
Section 3.9 for more information.
SETTING indicators 5, 6, and 7 display the detected status of
optional hardware. The states of these indicators may not be
changed.
Indicator 5 lights when parallel I/O is configured and properly
detected by the controller.
Indicator 6 lights when an (optional) RCP-1200 remote control
panel is detected by the controller and is communicating properly.
Indicator 7 lights when a parallel I/O board is detected in an RCP1200 remote control panel connected to the controller.
SETTING indicators 4, 8 and 9 are reserved for future use.
Auto Configuration of Parallel I/O Board
When a controller containing a functioning parallel I/O board is
powered-on, the controller detects the parallel I/O board and
automatically sets its configuration to include parallel I/O. No
user changes to the configuration are needed. Configuration
choice FUNCTION J will light indicators Parallel I/O Configured
(SETTING 0) and Parallel I/O Detected (SETTING 5).
Once an RSC has detected and autoconfigured a parallel I/O
board, it will generate a controller fault if the parallel I/O board is
removed or cannot be detected due to a fault or failure. If the
board cannot be detected, configuration choice FUNCTION J will
not light the Parallel I/O Detected indicator.
2-24 Installation
DMAN-14576 Rev. D

Removing the parallel I/O board from a controller which has
already detected and autoconfigured it requires manual reconfiguration:
a) With the RSC on, enter configuration mode.
b) Use the button to go to the options selection, FUNCTION J.
c) Change Parallel I/O Configure (SETTING 0) to off (using INC /
DEC).
d) Turn off power.
e) Remove the parallel I/O board.
Now when the controller is powered on, the parallel I/O board will
not be detected or autoconfigured. Configuration choice
FUNCTION J will not light either indicator Parallel I/O Configured
or Parallel I/O Detected.
Auto Configuration of Remote Control Panel (Option)
When a controller detects that a Remote Control Panel (RCP) is
connected and correctly communicating, Configuration choice
FUNCTION J will light indicator RCP Detected (SETTING 6).
If the RCP is disconnected or powered off during RSC operation,
Configuration choice FUNCTION J will turn off indicator RCP
Detected. No controller fault will be generated, as RCP presence is
not considered necessary for RSC operation.
Auto Configuration of Remote Control Panel PIO
When a controller detects that an RCP is connected, correctly
communicating, and equipped with a parallel I/O board,
Configuration choice FUNCTION J will light indicator RCP Parallel
I/O Detected (SETTING 7).
If the RCP is not equipped with a parallel I/O board, or the RCP is
disconnected or powered off during RSC operation, Configuration
choice FUNCTION J will turn off indicator RCP Parallel I/O
Detected. No controller fault will be generated, as presence of the
RCP or its parallel I/O board is not considered necessary for RSC
operation.
2.7.3.11 FUNCTION AB: Latched Faults

This configuration function selects whether Latched Faults are
enabled or disabled.
Function AB:
Setting:
Latched Faults (Factory Default is enabled)

0 = disabled
1 = enabled
When Latched Faults is enabled, ALL faults are latched. This

means that a fault will continue to be reported, even after the
condition that caused it goes away. This applies to both controller
Installation 2-25
DMAN-14576 Rev. D

faults and unit faults. Faults will only cease to be reported if they
are reset by pressing the FAULT RESET button, pulling the
parallel I/O fault reset input low, or issuing a fault reset serial I/O
command AFTER the fault condition has been corrected.
When Latched Faults is disabled, faults will stop being reported
when the condition that caused them goes away.
Note that regardless of this setting, both latched faults and
existing faults are reported via the serial I/O port.
2.7.3.12 FUNCTION BC: External Alarm Inputs 5-8

This function determines which of External Alarm Inputs 5
through 8 are enabled. See Section 2.5.3 for more information on
the External Alarm Inputs.
Function BC:
External Alarm Inputs 5-8
Setting:
0 = External Alarm Input 5

(Factory Default is all off)
Each indicator which is lit indicates that the corresponding alarm

is enabled. Even when an alarm is disabled, its status may still be
read using serial I/O commands, which allows it to be used as a
general-purpose input.
If the tracking unit is configured (see Function J, Section
2.7.3.10), it should have either an internal or an external alarm (or
both) enabled. If not, a tracking unit fault will never be reported. If
the tracking unit is not configured, the external tracking unit
alarm input (input 5) will never cause a tracking unit alarm, even
if it is enabled here.
2.7.3.13 FUNCTION CD: External Alarm Inputs 1-4
This function determines which of External Alarm Inputs 1
through 4 are enabled. See Section 2.5.3 for more information on
the External Alarm Inputs.
Function CD:
(Factory Default is all off)*
Setting:

3 = External Alarm Input 4 (Not used in RSC-1200)
* However, when the RSC-1200 is supplied with an SSPA system,

External Alarm Inputs 1, 2, and 3 are Enabled (On).
Each indicator which is lit indicates that the corresponding alarm

is enabled. Even when an alarm is disabled, it may still be read
using serial I/O commands, which allows it to be used as a
2-26 Installation
DMAN-14576 Rev. D

general-purpose input. In general, either an internal or external
alarm (or both) should be enabled for each unit in use. If not, that
unit cannot be automatically switched off-line by the controller.
In the RSC-1200, the external alarm input for Unit 4 will never
cause a Unit alarm, even if it is enabled here.
2.7.3.14 FUNCTION DE: Internal Alarm 1-4 and Tracking

This function determines which internal Unit alarms are enabled.
Function DE:
Setting:
Internal Alarms 1-4 and Tracking Unit Alarm

(Factory Default is 1, 2, and 3, on; 4 & Tracking, off)*
0 = Internal Alarm, Unit 1
3 = Internal Alarm, Unit 4 (not used in RSC-1200)
4 = Tracking Unit Alarm
* When the RSC-1200 is supplied with an SSPA system, Internal

Alarm Inputs 1, 2, and 3 are Disabled (Off); and/or, when the system is
factory equipped with a tracking unit, the Tracking Unit Alarm is Enabled
(On).
Each indicator which is lit indicates that the corresponding

internal Unit alarm is enabled. In general, either an internal or
external alarm (or both) should be enabled for each unit in use. If
not, that unit cannot be automatically switched off-line by the
controller.
In the RSC-1200, the internal alarm for Unit 4 will never generate
a fault, even if it is enabled here. If the tracking unit is disabled in
Configuration Function J, the internal tracking unit alarm will
likewise never cause a fault, even if enabled here.
2.7.3.15 FUNCTION EF: External Alarm Input Status (Read Only)
This function displays the states of the External Alarm inputs. See
Section 2.5.3 for more information on the External Alarm Inputs.
Function EF:
Setting:

(no factory default)
Each indicator which is lit represents an input which is active (not

grounded). The indicators will always light if an input is active,
even if that input is disabled by Configuration Function BC or CD.
This configuration setting cannot be changed.
Installation 2-27
DMAN-14576 Rev. D
2.7.3.16 FUNCTION FG: Parallel I/O Input Status (Read Only)

This function displays the states of the parallel I/O inputs, if the
parallel I/O board is installed. See Section 3.6.2 for more
information on the parallel I/O. Each indicator which is lit
represents an input which is active (not grounded).
2.7.3.17 FUNCTION GH: Parallel I/O Output Status (Read Only)
This function displays the states of the parallel I/O output relays,
if the parallel I/O board is installed. See Section 3.6.2 for more
information on the parallel I/O. Each indicator which is lit
represents a relay which is energized.
2.7.3.18 FUNCTION HI: Controller Software Version (Read Only)
This configuration function displays a code representing the version
of software currently running on the controller. The code is the low
10 bits of 3 binary-coded-decimal (BCD) digits. (See Figure 2-6.)
Binary Coded
Decimal (BCD) Digits
=0
=1
=2
=3
=4
=5
=6
=7
=8
=9
Key
= ON (lit)
= OFF (unlit)
Example:
Decimal 352 (or 752)
is displayed as:
SETTING
9 8 7 6 5 4 3 2 1 0
3
(or 7)*
* The first digit is ambiguous because only

2 of the 4 bits needed can be displayed.
Figure 2-6. Binary Coded Decimal (BCD) Digit Code Chart

2.7.3.19 FUNCTION IJ: RCP Software Version (Read Only)
This configuration function displays a code representing the version
of software currently running on the optional remote control panel,
if present. The RCP must be connected and properly communicating with the controller for this code to be available. The code is
the low 10 bits of 3 BCD digits.
2-28 Installation
DMAN-14576 Rev. D
Section 3
3.1
Operation
To operate the Redundant System Controller, use the information
contained in this section.
3.2
To determine the function of a particular control or indicator,

see Description of Controls and Indicators, Section 3.2.
To read an overall description of how to operate the unit, see

Sections 3.3 through 3.10.
Description of Controls and Indicators
3.2.1
Rear Panel
Turn power on and off using the two rear panel power switches.
There is one switch per AC line input. Normally both power
supplies operate simultaneously. If one fails, the other will
continue to power the system.
AC Line Power Switches
LINE 87-265 V
47-63 Hz
J3
PLATE ASSY
J1
For continued protection against fire,

replace only with same type and rating
of fuse.
PN
CPN
Refer servicing to qualified personnel.
SN
MADE IN U.S.A.
J4
EXT ALM
J5
RCP LINK
J6
LOOP
J7
SERIAL I/O
J8 PARALLEL I/O
J2
Consult operation and maintenance
manual for correct fuse rating.
Figure 3-1. Redundant System Controller Rear Panel

3.2.2
Front Panel
Operation of the front panel controls is briefly described in
Figure 3-2.
3.2.2.1
Front Panel Display Modes and Operation

There are four display modes:
Normal
Calibration
Configuration
Fault Display
Operation 3-1
DMAN-14576 Rev. D
FAULTS
1:2 REDUNDANT
SYSTEM CONTROLLER
CONTROLLER
PS 1
INPUTS
OUTPUTS
UNIT 1
CAL
POL 1
UNIT 3
POL 1
CAL
POL 2
CONTROLS
LOCAL
REMOTE
PS 2
RSC-1200
RCP
POL 2
UNIT 2
FAULT
RESET
PANEL
TEST
FAULTS
OFFLINE
CONTROLS
LOCAL
REMOTE
CONTROLLER
PS 1
PS 2
RCP
PS1 and PS2 - Glow red when

corresponding power supply voltage
is out of tolerance.
RCP - Glows red to indicate a fault
with the Remote Control Panel, if one
is connected.
FAULT
RESET
PANEL
TEST
Fault Reset - After taking corrective

action, press to clear latched faults.
From Configuration mode (selected
with the SHIFT button), press to enter
Fault Display mode.
Panel Test - Press to cycle through
test of all front panel indicators and
audible alarm (if enabled).
Path indicator arrows show primary
(green) and secondary (yellow) signal
routing through switches for each
polarization.
UNIT 1
CAL
SHIFT
CAL
OFFLINE
Controller - Glows red when a

controller fault is detected.
Unit - In Manual mode, press to

select an on-line Unit*.
Corresponding indicator glows green
when Unit is operating normally (not
faulted), and red when a fault has
been detected.
CAL - In Calibration mode (selected with the SHIFT

button), press a Unit button to set the nominal current
for that Unit. Units do not switch in CAL mode.
This should be done after changing a Unit, or whenever
the controller is first connected to a new plate assembly.
Upon successful calibration of the nominal current the
Unit indicator will flash green three times.
AUTO
MANUAL
INC
ABCDE F GH I J
SETTING
9876543210
DEC
Local/Remote - In Local mode,

control is from the front panel. In
Remote mode, control is through the
serial I/O or parallel I/O interfaces.
Remote Panel Lockout - In Configuration mode

(selected with the SHIFT button), press Local/ Remote
to enter or exit the Remote Panel Lockout mode
(blinking REMOTE LED). This mode disables control
from the optional Remote Control Panel.
Auto/Manual - In Auto mode,
internal control logic causes
automatic switchover to the standby
Unit if a fault is detected in the on-line Unit. In Manual
mode, the on-line Unit is selected from the contrller
front panel.
AUTO
MANUAL
Shift - From normal display mode,

press once to enter Calibration
mode; from Calibration mode, press
a second time to enter Configuration mode. From
Configuration mode, press once to return to normal
display mode.
SHIFT
FUNCTION
A BCDE FGH I J
Function A-J - In Configuration mode, these indicate

which function is displayed. In Fault Display mode,
these indicate which fault code group is displayed.
Arrow - Press to advance through function or fault code
group selections.
INC
SETTING
9876543210
DEC
INC/DEC - In Configuration mode,

press to increase or decrease the
setting value. (INC/DEC have no
effect in other display modes.)
Setting 9-0 - In Configuration mode, these indicate the

set value of the function. In Fault Display mode, these
show the fault code values for the group.
* Unit = LNA or LNB, or other controlled device.
Figure 3-2. Redundant System Controller Front Panel
3-2 Operation
FUNCTION
DMAN-14576 Rev. D

In the Normal display mode, the signal path graphics, Unit LEDs,
and switch LEDs indicate the path of the signal(s) though the
system.
In Normal display mode,
Unit select buttons are active and can cause a switch.
The LOCAL/REMOTE and AUTO/MANUAL LEDs indicate the
selected operating mode status, and these switches are active;
pressing a switch toggles the operating mode state.
The FUNCTION and SETTING displays are blank.
For the switch LEDs,
Single green LEDs indicate the primary signal path.
Single yellow LEDs indicate the secondary or alternate path.
All yellow LEDs indicate that a switch is in progress.
All red LEDs indicate that the controller cannot detect the
switch position.
For the Unit LEDs:
Green indicates normal operation, current within limits
Red indicates a current or other fault
Unlit means that the Controller is not configured for that unit;
or that a controller fault exists that prevents the unit from
receiving power.
If a tracking unit is configured and operating, its LED will operate
the same as the Unit LEDs, except in the case of a tracking unit
power fault, which will light the Tracking Unit LED red.
Pressing SHIFT from Normal mode will enter Calibration mode.
In the Calibration display mode, Unit LEDs flash on and off to
indicate that the Calibration mode is active and nominal Unit
currents may be set. Except as described below, other portions of
the display are the same as in Normal mode.
For the Unit LEDs,
Flashing green means that the current is within limits and new
current may be set.
Flashing red means that the current is outside the limits and a
new current may be set.
In the Calibration display mode, pressing a Unit button calibrates
the current for that unit, and does not cause a switch. See Section
3.4, Calibrating Nominal Currents.
Pressing SHIFT from Calibration mode will enter the Configuration
mode; pressing FAULT RESET from the Calibration mode will
enter the Fault Display mode.
In the Configuration display mode, one or two segments of the
FUNCTION display bar will be lit, and segments of the SETTING
Operation 3-3
DMAN-14576 Rev. D

display bar light to indicate configuration settings and status.
Refer to Section 2.7, Configuration, for further details of the
configuration function choices and settings. You enter the
Configuration display mode from the Normal display mode by
pressing SHIFT twice in succession.
In the Configuration display mode,
Switch indicator LEDs and Unit LEDs continue to indicate
system status the same as in Normal mode, but pressing Unit
buttons will not cause a switch.
Pressing the button steps through configuration and
diagnostic function choices.
The INC and DEC buttons can be used to increment or
decrement configuration choices.
Pressing LOCAL/REMOTE alternately enables or disables the
Remote Panel Lockout feature and returns the panel to Normal
display mode.
The AUTO/MANUAL button has no effect.
Pressing SHIFT returns the panel to Normal display mode.
In the Fault Display mode, all but one segment of the FUNCTION
bar will be lit; the unlit segment indicates which fault group state
is being displayed by the SETTINGS bar. Segments of the
SETTINGS bar may light to indicate active faults. You enter the
Fault Display mode from the Normal mode by pressing SHIFT,
then FAULT RESET.
In the Fault Display mode,
Switch indicator LEDs and Unit LEDs continue to indicate
system status the same as in Normal mode, but the Unit
buttons and the LOCAL/REMOTE and AUTO/MANUAL
buttons have no effect.
Pressing the button steps through fault group choices. Refer
to the Fault Group Descriptions chart in Appendix C to
interpret the display.
Pressing SHIFT or FAULT RESET will return the panel to
Normal display mode.
3.3
Power Up
Power is applied by switching both power supplies on, using the
switches on the rear panel (Figure 3-1).
When the unit is powered up, several internal tests are performed.
These tests include various memory tests of the microprocessor
and a test of the motor drive circuitry. If all is well after these tests
are completed, the controller will commence operation.
3-4 Operation
DMAN-14576 Rev. D

If you power the unit up one supply at a time, and faults are
latched, a controller fault may be reported. Although one supply is
sufficient to power the controller, when it detects that the other
supply is off, it reports a fault. To clear this fault, simply press the
FAULT RESET button.
NOTE
3.4
It is normal for each switching power supply in the controller to

emit a single high-pitched chirp or squeak a second or so after
input power is applied. If this sound continues or occurs
repeatedly, it indicates a power supply overload. Turn off power
and inspect for incorrect wiring, foreign objects which have
entered the controller chassis, or other problems which could
cause excessive current draw.
Calibrating Nominal Currents (LNA/LNB Systems)

The first time the controller is powered up when attached to a new
plate assembly, or after replacing a unit (i.e., LNA or LNB), it will
be necessary to calibrate the nominal currents for the Units. This
can be done individually for each unit, including a tracking unit if
installed, using the front panel.
NOTE
If the Local Lockout mode (see 3.5.4) is in effect, you will not be
able to calibrate the Unit currents from the front panel.
First, you should verify that the Units are operating properly.
Power the system up and ignore any Unit faults that may be
reported.
Once operation of the Units has been verified, press the SHIFT
button once to enter Calibration mode. All Unit indicator LEDs will
begin flashing. Press the button representing the unit whose
nominal current you wish to set. Repeat this process for each unit
on the plate assembly. (Note that, when in Calibration mode,
pressing a Unit button will NOT cause the system to switch.)
The nominal LNA/LNB current will be determined and
automatically set. If this is done successfully, the Unit indicator
LED will flash green three times. If the unit is drawing less than
50 mA, or greater than 600 mA, the nominal value will NOT be set,
the indicator will light steady red, and a Unit fault will be reported.
If you have selected the latched fault option, press and release the
FAULT RESET button to clear any faults.
NOTE
The controller will automatically return to normal display mode

after approximately 15 seconds if no button is pressed.
Operation 3-5
DMAN-14576 Rev. D
3.5
Modes of Operation
The controller is capable of operation in a variety of modes.
3.5.1
Local and Remote modes affect whether or not the controller

will respond to commands received by either the parallel I/O or
serial I/O ports.
Local Lockout mode (blinking REMOTE indicator), which

disables control from the front panel, can be initiated only by a
serial I/O command.
Remote Panel Lockout mode (blinking LOCAL indicator) can be

set from the front panel to disable control from the optional
Remote Control Panel.
Auto and Manual modes affect whether or not the controller

will automatically switch to the standby unit to replace a
faulted unit.
Local Operation
Local mode is in effect when the LOCAL indicator is lit. In Local
mode, commands received via the parallel I/O port, and, with
certain exceptions, the serial I/O port, will be ignored. The status
of the controller will still be indicated via the Form C parallel
outputs, and messages addressed to the serial port will still be
able to fetch status information.
Local mode is controlled only by the LOCAL/REMOTE button on
the front panel. There is no way to switch this mode either by
serial or by parallel I/O, although both provide the status of
LOCAL/REMOTE mode.
NOTE
If the Local Lockout serial I/O command is issued while the

system is in Remote mode, you will not be able to select Local
mode from the front panel until Local Lockout is disabled by serial
I/O command. See Section 3.5.4.
The Local/Remote mode setting is remembered, even if power to
the controller is lost.
3.5.2
Remote Operation
Remote mode is in effect when the REMOTE indicator is lit. In
Remote mode, commands received via the parallel I/O or serial
I/O ports will be obeyed. If the Remote Disables Local option is
enabled (see 3.5.3), all buttons on the front panelexcept
LOCAL/REMOTE and PANEL TESTwill be ignored.
3-6 Operation
DMAN-14576 Rev. D

Serial I/O and parallel I/O are both equal in priority, and
commands received from them will be processed in the order they
are received. For example, if the controller is in Manual mode, and
the AUTO/MANUAL parallel I/O input is pulled low at the same
instant as a switch to AUTO mode is received via serial I/O, the
result will simply depend on which is processed first. See Section
3.6 for more information on the serial and parallel I/O interfaces.
Remote mode can be set only by using the LOCAL/REMOTE
pushbutton on the front panel.
The Local/Remote mode setting is remembered, even if power to
3.5.3
Remote Disables Local Option

When the Remote Disables Local option is enabled, front panel
controlsother than LOCAL/REMOTE and PANEL TESTwill not
function if the system is in Remote mode.
This option can be enabled or disabled by serial I/O command (see
Appendix A) or by manually selecting or clearing this option when
the system is configured (see Section 2.7).
The Remote-Disables-Local setting is remembered, even if power to
3.5.4
Local Lockout
A serial I/O command can be issued, while the controller is in
Remote mode, that locks out the front panel. In this mode,
PANEL TEST is the only active button on the front panel. You will
not be able to reset faults, control the switch positions, set
nominal currents, switch Auto/Manual modes, enable Remote
Panel Lockout, or switch to Local mode if Local Lockout is in
effect.
Local Lockout is indicated by a flashing REMOTE indicator on the
front panel. If you have the optional Remote Control Panel, it will
also be locked out.
NOTE
The Local Lockout command can only be issued by a serial I/O

command while the unit is in Remote mode, and can only be
cancelled by serial I/O command. See Appendix A, Serial I/O
Protocol, for more information.
The Local Lockout setting is remembered, even if power to the
controller is lost.
Operation 3-7
DMAN-14576 Rev. D
3.5.5
Remote Panel Lockout

If you are using the optional Remote Control Panel, you can
temporarily lock out commands from the Remote Panel by
enabling the Remote Panel Lockout feature. To do so, press Shift
once, and then press LOCAL/REMOTE. Remote Panel Lockout is
indicated by a flashing LOCAL indicator on the front panel. (The
LOCAL indicator on the Remote panel will be flashing as well.)
While Remote Panel Lockout is enabled, the indicators on the
Remote Control Panel will continue to show correct status
information, but none of the controls (other than PANEL TEST)
will function at the Remote panel.
To disable Remote Panel Lockout and enter Local mode, press
Shift once, and then press LOCAL/REMOTE. To disable Remote
Panel Lockout and enter Remote mode, simply press
LOCAL/REMOTE.
If Local Lockout mode (see 3.5.4) is in effect, you will not be able to
activate Remote Panel Lockout.
The Remote Panel Lockout setting is remembered, even if power to
3.5.6
Auto Mode
Auto mode is active when the AUTO indicator is lit. In AUTO
mode, a fault occurring on an on-line unit will cause the controller
to automatically switch the standby unit on line to replace the
faulted one.
If the Auto Disables Manual option (see 3.5.7) is enabled, unit
switch commands from the front panel, parallel I/O or serial I/O
will be ignored in Auto mode. If this option is NOT enabled, any
switch command received from any source will only be obeyed if it
results in a valid position based on the current fault status of the
units. In other words, the controller cannot select a faulted unit to
be on-line in Auto mode.
The controller can be placed in Auto mode using the
AUTO/MANUAL button on the front panel, the AUTO/MANUAL
parallel input, or a serial I/O command.
NOTE
If the Remote Disables Local option (see 3.5.3) is enabled, it will

be necessary to place the controller in Local mode before using the
front panel button. It will also be necessary to place the controller
in Remote mode before using parallel or serial I/O to switch
Auto/Manual mode.
select Auto mode from the front panel.
3-8 Operation
DMAN-14576 Rev. D

The Auto Mode setting is remembered, even if power to the
controller is lost.
3.5.7
Auto Disables Manual Option

When the Auto Disables Manual option is enabled, unit switch
commands from the front panel, parallel I/O, or serial I/O will be
ignored in Auto mode. Switching will occur ONLY if an on-line unit
develops a fault and the standby unit is not faulted.
This option can be enabled or disabled by serial I/O command (see
Appendix A) or by manually selecting or clearing this option when
the system is configured (see Section 2.7).
The Auto-Disables-Manual setting is remembered, even if power to
3.5.8
Manual Mode
Manual mode is active when the MANUAL indicator is lit. In this
mode the controller never switches without receiving a command
from the front panel, parallel I/O, or serial I/O. If an on-line unit
is faulted, either you, or your status monitoring system, must
switch to the standby unit.
The controller can be placed in Manual mode using the
AUTO/MANUAL button on the front panel, the AUTO/MANUAL
parallel input, or a serial I/O command.
NOTE
If the Remote Disables Local option (see 3.5.3) is enabled, it will

be necessary to place the controller in Local mode before using the
front panel button. It also will be necessary to place the controller
in Remote mode before using parallel or serial I/O to switch
Auto/Manual mode.
select Manual mode from the front panel.
The Auto/Manual mode setting is remembered, even if power to
In Manual mode, Unit buttons operate as follows.
Main Unit 1:
Online:
Press its button to take it offline and replace it with Standby
Unit 3. NOTE: If Standby Unit 3 was in use by Pol 2, it will be
removed from Pol 2.
Offline:
Press its button to put it online for Pol 1.
Operation 3-9
DMAN-14576 Rev. D

Main Unit 2:
Online:
Press its button to take it offline and replace it with Standby
Unit 3. NOTE: If Standby Unit 3 was in use by Pol 1, it will be
removed from Pol 1.
Offline:
Press its button to put it online for Pol 2.
Standby Unit 3:
Online:
Press its button to take it offline. The Pol which was using it
will return to its Main unit.
Offline:
Its button has no effect.
In Auto mode, operation will be similar to that described above,
but a particular switch may be prevented if:
One or more units are faulted.
A priority channel is configured.
Auto Disables Manual is enabled.
Auto Revert is enabled.
3.5.9
Manually Moving Switches in Manual or Auto Modes

In most installations, the redundancy switches may be manually
rotated to select a desired position. While a switch is being moved,
the front panel indicators for the switch will all light yellow.
If the controller is in Manual mode, the switch will remain where it
is manually positioned, regardless of the fault status of the units,
and no switch fault will occur.
If the controller is in Auto mode, the switch may immediately be
switched back into its original state, depending on the fault status
of the units.
A side effect of turning a switch while the controller is in Auto
mode may be that a controller fault occurs. One condition that
causes a controller fault is that an attempt to switch fails, so if
Auto mode tries to switch while someone is physically holding or
turning the motor, a fault will occur.
If faults are not latched, a fault caused by holding or turning the
switch will automatically clear the next time a switch is
successfully completed by the controller. Otherwise, it will be
necessary to clear the fault by pressing and releasing the FAULT
RESET button on the front panel.
3-10 Operation
DMAN-14576 Rev. D
3.6
Remote I/O Interfaces
3.6.1
Serial I/O
A serial port is provided on the rear panel that allows the unit to
be controlled and monitored remotely, using an RS-232, RS-485,
or RS-422 bus. (J7; see Table 2-3.)
Most command messages, except those directly related to serial
I/O functions and configuration, are ignored if the controller is in
Local mode. However, any status information or measurements
are always available, regardless of the mode settings.
See Appendix A, Serial I/O Protocol, for complete information on
the serial I/O interface. The system responds only to correctly
formatted messages, as described in Appendix A, and never sends
out data unless polled.
3.6.2
Parallel I/O
The parallel I/O port consists of several Form C relay contacts
that provide status information, and opto-isolated inputs to
control the system.
All parallel I/O inputs are completely disabled if the controller is
in Local mode; however, the status outputs still function normally.
The parallel I/O output drivers have a time-out function. If not
regularly updated by the microprocessor, all contacts will go to
their power-off or fault state. This provides an indication that
something is wrong if the microprocessor fails. Without this timeout function, there would be no indication on the parallel I/O port
that something was wrong.
The following sections describe the status and control lines
available on the parallel I/O connector. (J8; see Table 2-4.)
3.6.2.1
Parallel I/O Outputs

Unit Status
One Form C relay contact is available for each monitored unit in
the system. The contacts are used to indicate faults on the unit
they represent. These contacts follow the state of the Unit status
LEDs on the front panel; i.e., when the Unit status LED is red, the
relay contacts will indicate a fault.
Four sets of contacts are present regardless of whether this is a
1:1, 1:2, or Dual 1:1 controller. Only the first two are used for 1:1,
the first three for 1:2, and all four for Dual 1:1 systems.
These contacts will indicate faults when power is removed.
Operation 3-11
DMAN-14576 Rev. D
Power Supply Status

One set of Form C contacts is available for PS1, and one for PS2.
These contacts are used to indicate that the voltage from a
particular supply is outside the 13.5 to 16.5 V range.
These contacts follow the state of the PS1 and PS2 indicators on
the front panel. When a PS status indicator is lit, the
corresponding relay contacts will indicate a fault.
These contacts will indicate faults when power is removed.
Unit Switch Position
Two sets of Form C contacts are present. The first set indicates
whether the standby or main unit is on-line for Pol 1; the second
set is for Pol 2.
These contacts will go to the MAIN position (Position 1) when
power is removed.
In a 1:2 system, when the switches are positioned so that Unit 1 is
connected to Ppl 2, both sets of contacts will indicate STANDBY
(Position 2).
AUTO/MANUAL Status
One set of Form C contacts represents whether the system is in
Auto or Manual mode.
When power is removed, this contact is in the MANUAL position.
LOCAL/REMOTE Status
One set of Form C contacts represents whether the system is in
Local or Remote mode.
When power is removed, this contact is in the LOCAL position.
3.6.2.2
Parallel I/O Inputs

All parallel I/O inputs are completely disabled if the controller is
in Local mode; however, the status outputs still function normally.
AUTO/MANUAL Toggle Input
This input will toggle between Auto mode and Manual mode on
falling edges, provided that the controller is in Remote mode.
Position Control Inputs
Two inputs for each Pol, which operate on falling edges only,
control whether the MAIN or STANDBY unit is switched to the Pol.
3-12 Operation
DMAN-14576 Rev. D

These inputs only function in Remote mode. They will also only
function in Manual mode if the Auto Disables Manual option is
enabled.
Fault Reset Input

A falling edge on this line resets all faults as described under
Section 3.7. This input only functions in Remote mode.
3.7
Handling Faults
A Unit LED on the front panel which lights red indicates a fault.
One indicator exists for each unit and lights red when the unit's
current is too low or too high (if internal alarms are enabled), or
when the corresponding external fault input is open (if external
alarms are enabled).
There are also fault indicators labeled CONTROLLER, PS 1, PS 2,
and RCP. These indicators light when any of a number of internal
conditions occur that indicate a problem with the Controller, or
either of its power supplies, or with the Remote Control Panel, if
one is connected.
All of these fault indicators may be either latched or not,
determined by configuration setting (see Section 2.7.3.11). If
latched, the indicators will continue to show a fault until reset,
even after the condition that caused the fault goes away. Latched
faults must be reset by command from the front panel, parallel
I/O, or serial I/O. Note that the fault reset command will not clear
the fault indicator if the fault condition still exists.
If faults are not latched, the fault indicator will light when the
condition occurs, and turn off when the condition goes away.
Some controller faults, however, will not clear themselves, since
they indicate one time events, and there is no way of detecting
that the problem has gone away.
To reset faults from the front panel, in Local mode, simply press
the FAULT RESET button. However, if the system is in Remote
mode and the Remote Disables Local option is enabled, the
RESET command must be issued via serial I/O or parallel I/O.
3.7.1
Unit Faults
If a Unit fault indicator is red, you should first know whether the
controller is configured to use internal alarms, external alarms, or
both. Serial I/O can be a great help in determining the source of a
unit fault, since this is the only means of obtaining the unit bias
current measurements and other information.
If a Unit fault indicator is unlit, it indicates either the controller is
not configured for that unit or there is a fault condition that
Operation 3-13
DMAN-14576 Rev. D

prevents that unit from receiving power. If the CONTROLLER fault
LED is lit, check for a unit power fault (see Section 3.7.4). If not,
verify the controller type is being properly recognized (Function I;
see Section 2.7.3.9).
If the controller is in AUTO mode when a fault occurs in an on-line
unit, and an unfaulted standby unit is available to replace it, the
failed unit will be automatically switched off-line and the standby
unit switched in. You may remove the failed unit from the plate
assembly, and repair or replace it.
NOTE
3.7.2
With latched faults, the fault indication will continue to be

reported even after the failed unit is repaired or replaced, until
faults are RESET.
Power Supply Faults

A power supply fault is indicated when the voltage level is below
13.5 V or above 16.5 V. It is important to note that the system will
continue to operate properly with only one power supply
functioning. A power supply fault may occur if you power the unit
up one supply at a time. A power supply fault will also result in a
Controller fault; see 3.7.3.
This fault can only be cleared if the power supply voltage is
corrected. First check that both rear-panel power switches are on.
Check the AC line fuses and power cords. If the fault still cannot
be reset, check the power supplies and adjust them if needed (see
Section 5.4.1).
3.7.3
Controller Faults
Several problems with the controller itself will cause a controller
fault. When a controller fault occurs, the specific fault code can be
viewed from the front panel, by pressing SHIFT, then FAULT
RESET, or by using serial I/O. See Section 3.7.4 for more
information.
Once you have determined the specific fault, look for obvious
problems in the area indicated. For example, if the specific fault is
a power supply 1 failure, check the power switch, wiring, and
fuses for power supply 1. To clear the fault after trying to correct a
problem, make sure the unit is in LOCAL mode, and press the
FAULT RESET button to reset the fault.
If pressing FAULT RESET does not work, or the controller fault
occurs frequently or repeatedly, a serious problem probably exists
that needs further troubleshooting.
3-14 Operation
DMAN-14576 Rev. D

The following sections describe the various conditions that can
cause a controller fault.
3.7.3.1
Microprocessor Failure
Hardware on the front panel board will illuminate the
CONTROLLER fault LED if no update is received from the
microprocessor for a few seconds. The PANEL TEST button lights
all LEDs, but this function is actually performed by the microprocessor, so if pressing the PANEL TEST button has no effect,
then either the microprocessor has stopped functioning, or
something is wrong with the front panel board.
Another indication that the microprocessor is not functioning is
that all the parallel I/O relay contacts will go to their power-off
state. A similar hardware time-out circuit exists on the relay
drivers.
Since the microprocessor handles serial I/O, no responses will be
received to serial I/O messages if the microprocessor fails.
3.7.3.2
Microprocessor Memory Test(s) Failed

A self-test is performed on ROM and RAM at power-up. These tests
can also be run from a serial I/O command. If any of these
memory tests fail, a controller fault is reported.
ROM is memory that contains the program that runs the
controller. RAM memory contains data such as measurements
that occur during normal operation.
This fault can be cleared only by a successful test of whichever
area of memory failed.
3.7.3.3
EEPROM Write Failed

Whenever you reset the nominal unit currents, or change one of
the mode settings, this information must be written to EEPROM.
EEPROM is memory that retains the data even when power is
removed. Data is verified as it is written, and if a failure occurs,
this fault is reported.
If this happens, it is an indication that the EEPROM memory may
be wearing out. This is not likely to happen during normal
operation.
This fault can be cleared by a successful write to EEPROM, or by a
fault reset command.
Operation 3-15
DMAN-14576 Rev. D
3.7.3.4
Invalid or Spurious Interrupt

This fault indicates a hardware or firmware problem with the
microprocessor. If this fault occurs repeatedly, the unit should be
returned for repair.
This fault is cleared by a fault reset command.
3.7.3.5
Spurious Reset
This fault indicates a hardware or firmware problem with the
microprocessor. A likely cause of this fault is a failure of the
crystal oscillator circuit for the microprocessor.
3.7.3.6
Stack Overflow
This fault would most likely be caused by a bug in the firmware.
Contact the factory if this fault occurs.
3.7.3.7
Controller Type Unknown

This fault indicates that the front panel connected to the controller
is not configured for a valid controller type (1:1, 1:2, or Dual 1:1).
The controller type is normally read from a jumper setting on the
front panel PCB. This fault could occur if the jumper is moved, or
if the front panel board is damaged or defective. The jumper is
installed at the factory, and should never be moved.
If the controller type is unknown, NONE of the position indicators
will be lit, nor will any Unit status indicators light.
This fault is cleared only by attaching a good front panel with the
type jumper properly installed.
3.7.3.8
Low Power Supply Voltage

This fault indicates that one of the two power supplies has
dropped outside the 13.5-to-16.5-volt range. If the condition
continues to exist, you will observe that one of the indicators (PS1
or PS2) is lit. This fault may occur if you power the unit up one
supply at a time.
First check that the power supply is turned on. Check the AC line
fuses and power cord. If the fault still cannot be reset, check the
power supplies, and adjust them if needed (see Section 5.4.1).
This fault can only be cleared if the power supply voltage is
corrected.
3-16 Operation
DMAN-14576 Rev. D
3.7.3.9
Switch Attempt Failed

If the controller tries to switch to another unit, either because of a
command or because a unit has faulted in AUTO mode, and the
switch does not move, this fault is reported. If the switch was
initiated by a command, the attempt is only made once. If the
controller is switching because of AUTO mode, it will continue to
attempt to switch.
If this fault was generated because a command failed, it should be
obvious, as you will observe that the system did not switch as you
requested. If this fault was generated because an AUTO mode
switch failed, you may observe that a faulted unit is not being
switched off-line from the front panel indicators.
3.7.3.10 Drive Circuitry Test Failed

The circuitry to generate and control the drive voltage for the
motorized switch is tested at power-up, at intervals during
operation, and during any switch cycle. This test is also performed
when the self-test serial I/O command is issued. If this test fails,
this controller fault occurs.
A likely cause is the power capacitors (C1, C2) being disconnected.
This fault can be cleared if the drive circuitry passes its self-tests.
3.7.4
Fault Display Mode

Fault codes can be viewed from the front panel. To enter Fault
Display mode: from normal operation mode, press SHIFT, then
FAULT RESET. In Fault Display mode, all but one segment of the
FUNCTION display will be lit; the unlit segment indicates which
group of faults is being displayed.
Press the blue arrow button to step through the fault display
groups (A-J). The LEDs in the SETTING display show the fault
code(s) for that group. Refer to Appendix C for information on how
to interpret the Fault Codes.
To return to normal operation from Fault Display mode, press
SHIFT or FAULT RESET.
3.7.5
RCP (Remote Control Panel) Fault

The RCP fault indicator lights when the Remote Control Panel
connected to this controller has detected a fault condition. This
indicator can only light when the communication link between the
RSC and RCP is valid, so this indicator will NOT light if the RCP
becomes disconnected or RSC/RCP communication fails for some
other reason.
Operation 3-17
DMAN-14576 Rev. D

Fault Codes for the Remote Control Panel may be viewed from the
RSC front panel (see Section 3.7.4, above) or from the RCP (see the
RCP manual supplement).
RCP faults are latched by the Remote Control Panel itself, and
must be cleared by pressing the FAULT RESET button on the RCP
front panel. Pressing FAULT RESET on the RSC front panel, or
asserting the FAULT RESET parallel I/O input will NOT clear RCP
faults.
3.8
Emergency Power
Repairs can be made to the controller without interruption of
service if the emergency LNA/LNB power provision is used. Before
switching the controller off, apply +15 Vdc to connector P3, which
is attached to the controller end of the plate assembly cable. With
+15 Vdc applied, the controller can be powered down and removed
for repair without interruption of service.
NOTE
3.9
Some repairs, such as replacement of the controllers front panel,

can be performed without removing power from the controller. See
Section 5.6.1 for more information on making on-line repairs.
Noise Diode (OPTION)

The controller provides two current-limited outputs which can be
used to power noise diodes. One or both outputs can be enabled in
the controllers configuration (see Section 2.7). Each output can
nominally provide up to 25 mA of current at +15 V.
NOTE
If only one noise diode is configured, it should be noise diode 1.

When a noise diode is configured, its output is not turned on
automatically. During operation, a noise diode output may be
turned on or off by pressing the appropriate AUX 1 or AUX 2
button in the lower left corner of the controller front panel.
Pressing AUX 1 will toggle Noise Diode 1 power, and AUX 2 will
toggle Noise Diode 2. The top AUX 1 LED will light to indicate the
Noise Diode 1 output is active. The top AUX 2 LED will light to
indicate the Noise Diode 2 output is active.
NOTE
3-18 Operation
In some versions of the controller, the AUX 1 and AUX 2 buttons

and LEDs may be programmed for other functions and may not
act as described here.
DMAN-14576 Rev. D
3.10 Tracking Unit (OPTION)

If the tracking unit option is configured, the controller provides a
+15 V output to power a tracking LNA, LNB, or other unit. The
current drawn by the tracking unit is compared to limits set by
calibration, just like the other units. The same current window is
used for all units.
The tracking unit is calibrated by pressing SHIFT and then the
Tracking Unit button while its indicator LED is flashing. If
calibration is successful, the Tracking Unit LED flashes three
times; if it fails, the LED lights steady red. If the LED is not lit, the
tracking unit is not configured.
Faults for the tracking unit may be configured as internal,
external, both or none. If external is used, the input is External
Alarm #5 (see Table 2-2). Tracking unit faults are latched or unlatched depending on the configuration setting, just as other
faults. Behavior of the tracking unit is virtually the same as other
units, except that failure of the tracking unit will not cause a
switch.
Operation 3-19
DMAN-14576 Rev. D
3-20 Operation
DMAN-14576 Rev. D
Section 4
4.1
Theory of Operation
To understand how the 1:2 Redundant System Controller works,
use the information contained in this section. The description is
organized by major subassemblies, with the first section
describing the overall system and the interconnection between
units.
4.2
To understand the theory from the system level, see

System Level Description, Section 4.2.
To understand the operation of the switching assembly, see

Switching Assembly Description, Section 4.3.
To understand the operation of the interconnecting control

cable, see Control Cable Description, Section 4.4.
To understand the operation of the Redundant System

Controller, see Controller Description, Section 4.5.
System Level Description

A typical 1:2 redundant system consists of three major
subassemblies: a switching assembly which contains the
redundant units (LNAs, LNBs, or SSPAs, etc.) and motorized
redundancy switches; the Redundant System Controller which
contains controls and indicators, monitoring circuits, and
switching logic; and a control cable assembly to interconnect the
controller and the switching assembly. An optional Remote Control
Panel is also available but is not described here.
In LNA/LNB systems, power for the 1:2 system originates in the
controller and is supplied to the outdoor plate assembly via the
interconnecting control cable. For redundancy, two supplies are
used and may be wired to independent AC power sources if
available. Supply outputs are arranged so that either supply is
capable of powering the entire system, so the failure of one supply
will not put the system off the air.
All parts of the LNA/LNB system run from +15 V generated in the
controller, including the LNA/LNB power, the displays and
indicators and the control logic. +30 V for the motorized waveguide
switch is generated on the logic board by the switch driver
circuitry.
For details of the individual subsystems, see the following
subsystem descriptions.
Theory of Operation 4-1
DMAN-14576 Rev. D
4.3
Switching Assembly Description

Refer to the system schematic or plate assembly schematic in
Section 8, System Configuration.
The switching assembly contains the three units and the
motorized switches used to switch between them. Depending upon
system configuration, it may also contain optional transmit reject
filters, directional couplers, isolators, and test ports.
The main signal path is through the input switch (or power
divider, in some installations), through the on-line unit (e.g., LNA,
LNB, or SSPA), and through the output switch to the system
output. In 1:2 systems, two such paths are present, one for each
Pol; a third unit is on standby, able to be switched into either of
the two paths (1:2 redundancy).
Motorized switches are used to insert and remove units from the
signal paths. Typically, these are dual-ganged waveguide/coaxial
switches that simultaneously switch the Pol input and output
from one unit to the other. In some installations, the input signal
is provided continuously to all three units through a power
divider, and only the output paths are switched. Proper
termination of the off-line output is required in that case.
The 30-volt pulsed power required to operate each switch is
supplied by the controller. To activate a switch, +30 V is applied to
the common lead of the motor (pin B) and then one of the two
position select leads is grounded (pin A or C). The motor switches
to the other position and then shuts itself off. The pulsed power
source applies power to the switch for 300 ms; normal switching
time is 100 ms.
The latching feature of the motorized switch is used by the
controller to sense switch position; the indicator contacts are not
used.
In LNA/LNB systems, +15 V power for the LNAs or LNBs is
supplied by the controller and fed over the interconnecting control
cable. Separate lines are used for each LNA/LNB so that the
controller can monitor the current drawn by each. +15 V power for
optional noise diodes or a tracking unit can also be fed over the
interconnecting cable.
4.4
Control Cable Description

The interconnection between the switching assembly and the
indoor controller is via a single control cable assembly. In
LNA/LNB systems, this multiconductor cable carries power to the
units, optional noise diode(s), and motorized waveguide switches,
and returns switch and unit status information to the controller.
In SSPA systems, this cable is much simpler in construction,
4-2 Theory of Operation
DMAN-14576 Rev. D

carrying power only to the redundancy switches and returning the
units external alarm inputs. The principles in the following
discussion apply to both types of cables.
Refer to drawing 10899, Control Cable Assembly, in Section 6,
Drawings, for details of the LNA/LNB system cable. A variety of
cable types are used, depending upon cable length and type of
service. Primary requirements on the cable are that it have the
correct type of outer jacket for the intended use and that its dc
resistance is low enough.
For a discussion of the types of outer jackets and their
recommended uses, see Interconnecting Control Cable
Installation, Section 2.3.3.
Ku-band switches typically draw 1 ampere while switching; C- and
X-band switches, which are larger, typically draw 2 amperes. The
motorized waveguide/coaxial switches can tolerate a voltage drop
in the cable of up to 4 volts; therefore, the total dc resistance of
the interconnecting cable circuit must be less than 4 ohms for Kuband switches or 2 ohms for C- and X-band switches. Since the
circuit consists of a supply line and a return line, each can
contribute half of this resistance. To further reduce resistance,
each line to the switch consists of two conductors in parallel.
Thus, the total circuit resistance is the same as the resistance of
one conductor.
For example, the resistance of 18 AWG stranded wire is 6.48 ohms
per 1000 feet. Thus, one 616 ft. long wire has 4 ohms resistance.
Two in parallel give 2 ohms. One pair out and one pair back
results in a total circuit resistance of 4 ohms. Thus, up to 616 ft.
of #18 AWG cable is acceptable for Ku-band switches; or, up to
308 ft. for C- and X-band switches.
Suggested part numbers for Belden and Alpha cables are listed in
the table on drawing 10899. For Ku-band switches, the drawing
recommends #18 AWG for lengths up to 500 ft (150 m) and #16
for lengths of 500-1000 ft (150-300 m). For C- and X-band
switches, use #18 AWG for lengths up to 250 ft (75 m), and #16
for 250-500 ft (75-150 m).
4.5
Controller Description
For help in understanding the following description, refer to the
controller schematic diagram, drawing 11074, in Section 6,
Drawings.
The controller provides the intelligence in the system. In systems
where the controlled units are powered by the controller (such as
LNA/LNB systems), it measures the current drawn by the units,
determines whether the current drawn is acceptable and, if not,
reports the unit fault and switches the good unit on-line to replace
DMAN-14576 Rev. D

the failed one. In other systems (such as SSPA systems), the
controller monitors the status of the external alarm inputs to
determine whether to switch units. (The controller is capable of
monitoring both internal and external alarms, when so
configured.)
The controller consists of the front panel board, the main logic
board, two power supplies, and two capacitors that are charged up
to drive the motorized switch.
4.5.1
Power Supplies
Two power supplies in a fully redundant configuration supply all
of the power required by the system. Each supply produces +15 V
at 3 A and is fully capable of powering the entire system if the
other supply fails. Each is a commercial switching supply with
foldback current limiting. The line power is supplied via an
international power entry module. Line voltages of 90 to 264 Vac
can be used.
4.5.2
Front Panel Board

The front panel board supports the pushbuttons and lamps
accessible from the front of the unit. The same board is used for
1:1, 1:2, and Dual 1:1 controllers, but is populated with different
lamps and switch logic. A jumper on this board identifies which
type of front panel is installed. This is the only board which
changes for the different types of controllers.
A clocked serial link exists between the front panel board and the
main logic board.
4.5.3
Firmware
All of the logic that determines how the units will be switched in
Auto mode, the switch circuitry timing, serial I/O, parallel I/O,
and front panel interfacing is implemented in the firmware of the
microprocessor. Much of this information is discussed in other
sections of the manual.
The logic for Auto mode switching in a 1:2 system is somewhat
complex. Refer to Table 4-1 for more information. In the table,
each possible case of Unit Fault, Priority Channel setting, and
Auto Revert setting is listed as a separate line; Prior Position
describes the system state prior to a switch command; and
Switch Command lists what each Pol will switch to in that case.
Even in those cases where the prior position is not known, the
controller will still attempt to switch into the desired result state,
just in case the hardware that detects the switch position has
failed.
DMAN-14576 Rev. D
Table 4-1
AUTO Mode Truth Table

Faults
Priority
Auto
Prior Position
Switch Command
Unit 1
Unit 2
Unit 3
Channel
Revert
Pol 1
Pol 2
Pol 1
Pol 2
NO
NO
NO
NO
NONE
NONE
"
"
"
"
YES
Unit 1
Unit 2
NONE
NONE
"
"
"
"
"
Unit 3
Unit 1
Unit 2
"
"
"
"
"
Unit 3
Unit 1
Unit 2
YES
NO
NO
Unit 1
Unit 3
Unit 2
"
"
"
"
"
Unit 3
Unit 1
Unit 3
Unit 2
"
"
"
"
"
Unit 3
Unit 2
NONE
NONE
NO
YES
NO
Unit 2
Unit 1
Unit 3
"
"
"
"
"
Unit 1
Unit 3
NONE
NONE
"
"
"
"
NO
Unit 3
Unit 1
NONE
NONE
"
"
"
"
YES
Unit 3
Unit 1
Unit 1
Unit 3
NO
NO
YES
Unit 3
Unit 1
Unit 2
"
"
"
"
"
Unit 1
Unit 3
Unit 1
Unit 2
"
"
"
"
"
Unit 1
Unit 2
NONE
NONE
YES
YES
NO
Unit 1
Unit 3
Unit 2
"
"
"
"
"
Unit 3
NONE
NONE
"
"
"
Unit 3
Unit 1
Unit 3
"
"
"
"
"
Unit 1
Unit 2
Unit 1
Unit 3
"
"
"
"
"
Unit 1
Unit 3
NONE
NONE
"
"
"
NONE
Unit 1
Unit 2
Unit 3
Unit 2
"
"
"
"
"
Unit 3
NONE
NONE
"
"
"
"
"
Unit 1
Unit 3
NONE
NONE
YES
NO
YES
Unit 1
Unit 3
NONE
Unit 2
"
"
"
"
"
Unit 3
Unit 1
NONE
Unit 2
"
"
"
"
"
Unit 2
NONE
NONE
NO
YES
YES
Unit 3
Unit 2
Unit 1
NONE
"
"
"
"
"
Unit 1
NONE
NONE
"
"
"
Unit 3
Unit 1
Unit 1
NONE
"
"
"
Unit 3
Unit 1
NONE
NONE
"
"
"
NONE
NO
Unit 3
Unit 1
NONE
NONE
"
"
"
"
YES
Unit 3
Unit 1
Unit 1
NONE
YES
YES
YES
NONE
NONE
X = Don't care
DMAN-14576 Rev. D

If switch commands are received in AUTO mode, they will be
obeyed only if the Auto Disables Manual option is not enabled.
However, a switch command will still be ignored if it results in a
state that would immediately cause Auto mode to switch again.
For example, in a 1:2 system, if Unit 3 were faulted, any command
that would switch Unit 3 on-line on either Pol 1 or Pol 2 will be
ignored, since the controller would immediately switch it off-line
again.
DMAN-14576 Rev. D
Section 5
5.1
Maintenance
To maintain, repair or verify performance of the 1:2 Redundant
LNA/LNB System, use the information contained in this section.
5.2
For a list of test equipment and accessories recommended for

maintenance, see Recommended Equipment, Section 5.2.
Preventive Maintenance Procedures are in Section 5.3.

Follow these regularly to keep the equipment in peak operating
condition.
Instructions for periodic checks are in Performance Checks,

Section 5.4.
To verify that the equipment is operating properly, see

Performance Verification, Section 5.5.
For service and repair information, see Troubleshooting,

Section 5.6.
Recommended Equipment
Equipment recommended for use during maintenance and
alignment procedures is listed in Table 5-1, Recommended Test
Equipment. Alternate items may be substituted if the listed item is
unavailable.
Table 5-1
Recommended Test Equipment
Model Number
Item
Tek 2235
Oscilloscope, dual trace
Fluke 77
Digital Multimeter (DMM)

120 ohms, 2 W, 5% resistor
1000 ohms, 0.25 W, 5% resistor
Insulated Alignment Tool, flat blade, 1/8 in (3 mm)
Brush, small (for general cleaning)
5.3
Preventive Maintenance Procedures

The following procedures keep the equipment in top working order
and should be performed at least once yearly. It is recommended
that a log be kept.
First, gain access to the interior of the unit. Remove the unit from
the rack or, if it is mounted on slides, slide it out. Remove the top
Maintenance 5-1
DMAN-14576 Rev. D

cover by loosening the captive screws at both sides of the cover.
Lift the cover off.
WARNING
Disconnect both line cords before working on the interior of the

unit. Capacitors within the unit may still be charged after power
cables have been disconnected. Discharge with 1000 ohmsresistor
before touching.
Do the following:
Periodic cleaning - keep the interior free of dust and dirt. A
vacuum cleaner and a small, soft brush are helpful.
Check power supply voltages - Check and adjust the power
supply voltages using the procedure in Section 5.4.1.
Check Unit Current settings - Check the Unit Nominal
Currents using the procedure in Section 5.4.2.
5.4
Performance Checks
The following procedures are contained in this section:
Check Power Supply Voltages
5.4.1
Check Unit Nominal Currents
5.4.2
Periodically, you should check the power supplies, adjust them if
the voltage has drifted, and reset the unit nominal currents. If you
are using the serial I/O port, you can measure the power supply
voltages, unit currents, and read unit nominal currents settings
without opening the chassis. If the power supplies measure
15.0 0.1 volts, and the unit currents are within 4 mA of the
nominal value, no adjustments are needed.
If you are not using serial I/O, it will be necessary to open the
chassis. First, remove the unit from the rack or, if it is mounted
on slides, slide it out. Remove the top cover by loosening the
captive screws along the sides. Lift the cover off.
WARNING
Adjustments described in this section are performed with power

applied and protective covers removed. Always be careful not to
come into contact with dangerous voltages while performing these
procedures and never work alone.
The adjustment procedures described can be performed while the
unit is operating without interruption of service.
5-2 Maintenance
DMAN-14576 Rev. D
5.4.1
Check Power Supply Voltages

Do this every 12 months. Set the power supply output voltages as
follows:
a) Turn PS2 off.
NOTE
This will result in a controller fault and a PS2 fault. If the audible
alarm is enabled, it will sound. To silence the audible alarm, press
any button on the front panel.
b) Connect the positive lead of a DMM to TP1 on the logic board,
and the negative lead to the chassis.
c) Carefully insert an insulated adjustment tool through the cover
of PS1 to reach its Vadj pot.
d) Adjust the Vadj pot on PS1 for +15.0 0.1 Vdc at TP1.
e) Turn PS2 back on, and turn PS1 off.
NOTE
f ) Use the adjustment tool to adjust the Vadj pot on PS2 for
+15.0 0.1 Vdc at TP1.
g) Turn PS1 back on.
h) If faults are latched, put the unit in Local mode, and reset
faults by pressing the FAULT RESET button. If desired, put the
unit back in Remote mode.
5.4.2
Checking Unit Nominal Currents

If you are using serial I/O, you can send a message to view the
measured unit currents, and the unit nominal current settings. If
the measured currents are close to the nominal settings, it is not
necessary to reset these nominal currents.
You may wish to calibrate unit currents by following the procedure
in Section 3.4.
If you are not using serial I/O, you must calibrate unit currents by
following the procedure in Section 3.4.
5.5
Performance Verification
Use the procedures in this section to verify that controller
hardware is operating as expected.
Maintenance 5-3
DMAN-14576 Rev. D

The procedures should be used as a tool for incoming inspection
before initial installation or whenever any problems are detected
and the system hardware is suspected as a source of the
problems.
Use a copy of the Measured Test Data form in Section 8, System
Configuration, as a checklist and to record results of the
measurements.
The procedures used are:
Power Supply Tests
Unit Current Limiter Tests
Unit Current Monitor Tests
External Alarm Input Tests
Capacitor Charge Current Limiter Test
Front Panel Tests
Plate Assembly Tests
Parallel I/O Output Tests
Parallel I/O Input Tests
Serial I/O Tests
RCP Link Port Tests
RF Tests
NOTE
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
5.5.9
5.5.10
5.5.11
5.5.12
These tests cannot be performed with the system on-line. Certain

procedures will interrupt service to one or more units. Remove the
system from service before doing performance verification tests.
Some tests require access to the outdoor plate assembly. Place the
assembly on the bench next to the control panel.
WARNING

with the power cable connected. Discharge capacitors with 1000
ohmsresistor before touching.
Gain access to the interior of the control panel by loosening the
captive screws on the cover and lifting the cover off. Refer to
drawing 9683 in Section 6, Drawings.
NOTE
5-4 Maintenance
Do the tests in the order presented. Some later tests depend on

the results and settings done in previous tests.
DMAN-14576 Rev. D
5.5.1
Power Supply Tests

a) Connect line cords from J1 and J2 to a source of AC power.
b) Turn on PS1, but not PS2.
NOTE
c) Connect the positive lead of a DMM to TP1 on the logic board,
and the negative lead to the chassis.
d) Carefully insert an insulated adjustment tool through the cover
of PS1 to reach its Vadj pot.
e) Adjust the Vadj pot on PS1 for +15.0 0.1 Vdc at TP1.
f ) Turn off PS1 and turn on PS2.
NOTE
g) Use the adjustment tool to adjust the Vadj pot on PS2 for
+15.0 0.1 Vdc at TP1.
h) Turn PS1 back on so that both supplies are operating. Press
FAULT RESET to clear the controller fault.
If the supplies fail to adjust, and especially if the voltage is close to
0 Vdc, they are probably in current limiting. Refer to
Troubleshooting, Section 5.6 and eliminate the source of the
problem before continuing.
5.5.2
Unit Over-current Protection Tests

Electronic shutdown circuitry protects unit power circuitry in case
a unit or the interconnecting cable shorts. Without this protection,
a short at one unit would disable the power supply and cause
failure of the entire system. Circuitry will interrupt power to a unit
if a maximum current of approximately 600 mA is exceeded. This
procedure tests for correct functioning of the shutdown circuitry.
a) Connect the plate cable to J3 of the controller.
b) Ensure that all unit currents are set properly.
c) Clear any Unit alarms which are present. Verify that all Unit
indicators are green.
d) Configure Latched Faults to disabled.
Maintenance 5-5
DMAN-14576 Rev. D

e) Set the DMM to measure current on a 3 A or greater range.
f ) Connect the positive lead of the DMM to TP5 and the negative
lead to the chassis.
g) Verify that < 10 mA current is flowing and that the Unit
indicator is unlit. If all front panel indicators go out during this
test, or the controller resets, there is a problem with the logic
board.
h) Disconnect the positive lead from TP5. Verify that the Unit
indicator turns green.
i ) Repeat steps f ) through h) using TP7 and TP9.
j ) If a tracking unit is configured and connected, repeat steps f )
through h) for the tracking unit, connecting to TP2. Note that,
for the tracking unit only, the front panel indicator will light
red in step g).
5.5.3
Unit Current Monitor Tests

The microprocessor monitors the current drawn by each unit by
measuring the voltage across a sense resistor in the supply lead to
each unit. A circuit scales the sensed voltage across the resistor to
an appropriate value for the A/D converter.
Each circuit should be tested, using the following test points.
Unit 1: Load on TP5, measure TP4
If a tracking unit is configured, test it as well:
Tracking Unit: Load on TP2, measure across C44 (near TP10)
CAUTION
When connecting to test points, be careful not to short to

surrounding circuitry. Doing so can cause permanent damage to
the circuitry.
a) Disconnect the plate cable from J3 of the controller.
b) Measure the 120 ohm, 2 W resistor, record the resistance.
c) Connect the 120 ohm resistor between TPLOAD and ground
(chassis). This represents a unit load, and draws approximately
120 mA.
d) Measure the voltage at TPLOAD with respect to ground. Divide by
the resistance of the 120 ohm resistor to get the actual current
drawn by the load.
e) Measure the voltage at TPMEASURE with respect to ground.
Multiply by 200 to get the current (in mA) that this voltage
5-6 Maintenance
DMAN-14576 Rev. D

represents. This current should be within 5% of the actual
current measured in step d)
f ) Repeat steps c-e for each pair of test points listed above.
Before returning the unit to service, refer to Section 5.4.2 to set
the nominal unit currents, if necessary.
5.5.4
External Alarm Input Tests

External alarm inputs are used by some systems as an alternate
method of indicating unit failure. A typical example is a phaselocked LNB, where an alarm must be generated if the LNB loses
phase lock. The following procedure checks the function of the
external alarm circuitry.
External alarm inputs can be tested via the front panel.
a) Refer to Section 2.7 and note the current configuration settings
for internal and external alarms, and latched faults. Then
configure the controller as follows:
ENABLE all of External Alarms 1-4,
ENABLE all of External Alarms 5-8,
b) Go to Configuration Function EF, which displays External
Alarm Input status.
c) Individually connect pins of J4 to ground as shown below. As
you do this, watch the SETTINGS bargraph indicators. An
indicator should go out as each pin is shorted to ground, and
light again as the pin is opened.
J4 pin 1 controls SETTINGS indicator 0
d) If all indicators function as described, all External Alarm
Inputs are functioning correctly.
e) Restore the controller configuration noted in step a).
5.5.5
Capacitor Charge Current Limiter Tests

The power capacitors used to drive the switch motors are charged
in two stages. The first stage is an initial slow charge, which
brings the capacitors to approximately 7 V. The second stage
roughly doubles the charging current, to quickly bring C1 and C2
to full voltage.
Maintenance 5-7
DMAN-14576 Rev. D

The following procedure checks the current limiter for the fast
charging stage.
a) Turn off the controller and wait one minute for the capacitors
to discharge.
b) Set the DMM to measure dc current and to a range of 3 A or
greater.
c) Connect the negative lead to the chassis and the positive lead
to TP3.
d) Turn on the controller and observe the current through the
DMM.
e) After approximately 5 seconds, the meter should read about
450-550 mA. After approximately 5 more seconds, the reading
should increase to 900-1100 mA and remain at that level.
f ) Disconnect the DMM and reconfigure the leads to measure dc
voltage.
CAUTION
Leaving the DMM set for current measurement may cause damage
to circuitry.
If the front panel indicators go out or the controller resets during
this test, there is a malfunction in the fast charging current
limiter, and the logic board should be swapped or replaced.
The next few steps check the remainder of the circuitry associated
with C1 and C2.
g) Connect the DMM leads to the two terminals of one of the
power capacitors. Turn both power supplies on and verify that
the capacitor voltage rises to greater than 14 V within 10
seconds. This verifies that the capacitors charge properly.
h) Turn off both power supplies, and verify the capacitor voltage
discharges to < 3 V within 10 seconds. This checks the
discharge circuit for the capacitor.
i ) Repeat the above two steps with the DMM leads connected to
the other power capacitor. Similar results should be observed.
5.5.6
Front Panel Tests

This procedure tests all front panel lights, the audible alarm
beeper, and all front panel buttons.
a) Using front panel configuration, enable and disable audible
alarms several times (this verifies operation of the SHIFT, ,
INC and DEC buttons). Leave the audible alarm enabled.
b) Exit configuration mode, and press the PANEL TEST button.
5-8 Maintenance
DMAN-14576 Rev. D

c) Observe that all LEDs light. Multicolor LEDs will first light
green, then light red, then light amber (yellow). Single color
LEDs will remain lit the same color during the entire test.
d) Observe that the audible alarm beeper sounds briefly at the
end of the test.
e) Press the LOCAL/REMOTE button several times, verifying the
LOCAL and REMOTE LEDs toggle state.
f ) Verify there are no Unit alarms which would cause and
undesired switch, then press the AUTO/MANUAL button
several times, verifying the AUTO and MANUAL LEDs toggle
state.
g) With the controller in LOCAL mode and MANUAL mode, press
each Unit button, verifying that it causes the expected switch.
h) Press the SHIFT button, and then the FAULT RESET button, to
enter Fault Display mode. All but the FUNCTION A bargraph
indicators should light. Press FAULT RESET again to exit Fault
Display mode.
i ) If a tracking unit is present, configured, and operating
properly, press the SHIFT button to enter calibration mode.
Press the Tracking Unit button within 5 seconds. If calibration
mode is exited (Unit indicators stop flashing), the tracking unit
button is operating properly.
j ) If noise diodes are configured, press the AUX1 and AUX2
buttons several times, making sure they toggle the top LED in
the AUX1 and AUX2 buttons.
k) If a Remote Control Panel is present, repeat the above tests
from that front panel.
l ) Disable the audible alarm, if it is no longer desired.
5.5.7
Plate Assembly Tests (LNA/LNB Systems)

This series of tests checks the wiring of the control cable, the
operation of the waveguide switch and the unit dc power circuitry
and current monitors. Refer to the plate assembly drawing in
Section 8, System Configuration, for help in identifying
components.
a) Turn power off and connect the control cable assembly between
the control panel (J3) and the plate assembly (J1).
b) Turn power back on. Turn the control knobs on the waveguide/
coaxial switches so that Unit 1 is on-line on Pol 1, and Unit 2
is on-line on Pol 2. Verify that the front panel indicators show
Unit 1 and Unit 2 are on-line.
Maintenance 5-9
DMAN-14576 Rev. D

c) Rotate the knob on switch S1 to the other position, selecting
Unit 3 on Pol 1. Verify that the front panel indicators show
Unit 3 is on-line on Pol 1. Rotate the knob back to the first
position to put Unit 1 on-line again. Verify that all arrow
indicators for Pol 1 turn amber (yellow) while the switch is
being rotated.
d) Rotate the knob on switch S2 to the other position, selecting
Unit 3 on Pol 2. Verify that the front panel indicators show
Unit 3 is on-line on Pol 2. Rotate the knob back to the first
position to put Unit 2 on-line again. Verify that all arrow
indicators for Pol 2 turn amber (yellow) while the switch is
being rotated.
e) Disconnect the cable to switch S1 and verify that all arrow
indicators for Pol 1 turn red. Some arrow indicators for Pol 2
may change between amber and green, but none should turn
red. Reconnect the cable and verify the indicators return to
normal.
f ) Disconnect the cable to switch S2 and verify that all arrow
indicators for Pol 2 turn red. Some arrow indicators for Pol 1
may change between amber and green, but none should turn
red. Reconnect the cable and verify the indicators return to
normal.
g) Press each of the front panel Unit buttons in turn and verify
that the controller switches to the correct Unit.
h) Calibrate the nominal currents for each Unit as described in
Section 3.4.
i ) Disconnect the power connector from Unit 1 and verify that the
front panel Unit 1 indicator lights red.
j ) Reconnect Unit 1 power. If Faults are Latched, press FAULT
RESET to clear the Unit fault.
k ) Repeat steps i ) and j ) for Unit 2 and then for Unit 3.
5.5.8
Parallel I/O Output Tests

This procedure checks out the parallel I/O form 'C' relays and
interconnections to rear panel connector J8. Refer to Table 2-4 for
pinouts and to Section 3.6.2 for a functional description of each
status output.
a) Using an ohmmeter, check continuity from J8-6 to J8-26.
Simulate a Unit 1 failure by disconnecting the dc power
connector from Unit 1. Verify no continuity between pins 6 and
26 and continuity between pins 6 and 25. Restore power to
Unit 1.
5-10 Maintenance
DMAN-14576 Rev. D

b) Similarly, for each Unit status output listed in Table 2-4,
repeat the procedure described in step a).
c) Using an ohmmeter, check continuity from J8-9 to J8-29. Turn
off PS1. Verify no continuity between pins 9 and 29 and
continuity between pins 9 and 28. Turn PS1 back on.
d) Check PS2 status as in step c), using J8 pins 30, 11, and 10.
e) In a similar manner, check the S1 and S2 position,
Auto/Manual, and Local/Remote outputs as listed in Table 24.
f ) Check the Service Request output on the serial I/O and LOOP
connectors, J6 and J7. With no controller fault present, there
should be an open circuit between pins 6 and 7 of both J6 and
J7. There should be continuity between pins 7 and 8 of both J6
and J7.
g) Create a controller fault by turning off one power supply. With
the fault present, there should be continuity between pins 6
and 7 of both J6 and J7. There should be an open circuit
between pins 7 and 8 of both J6 and J7.
NOTE
5.5.9
If you are using a Remote Control Panel with parallel I/O, repeat
the above tests on its J8, J6, and J7 as well.
Parallel I/O Input Tests

Inputs on connector J8 allow the system to be controlled by
external circuitry. All inputs are actuated by a closure to ground.
The operation of the parallel I/O inputs can be verified from the
front panel.
a) Go to Configuration Function FG to Display Parallel I/O Input
status.
b) One at a time, successively ground each input pin of J8 as
listed in the table below.
c) When an input is grounded, its corresponding indicator on the
SETTINGS bargraph should go off. When the input is opened,
its corresponding indicator should go on.
J8
SETTINGS
Pin #
Indicator
Parallel I/O Input
AUTO/MANUAL Toggle
5
2
Pol 1 Main Unit Select
4
3
Pol 1 Standby Unit Select
3
4
Pol 2 Main Unit Select
2
5
Pol 2 Standby Unit Select
1
6
FAULT RESET
23
7
Maintenance 5-11
DMAN-14576 Rev. D
5.5.10
Serial I/O Tests

To test the serial I/O port, you need a computer running a
program capable of sending messages to the controller and
receiving the response.
a) Use configuration functions to set the controller serial I/O for
RS-232, 19200 baud, and address 01.
b) Connect the computers RS-232 port to J7. See Table 2-3 for
the pinout.
c) Send a message to the controller that will have a response.
Make sure all bytes are received. For example (assuming the
controller is on address 01), send:
02 06 01 07 08 03
The response should start with an 02, end with an 03, and
contain a 32, which indicates the device type, which is a
controller. See Appendix A for more information on serial I/O
messages.
To test other serial I/O interface modes, you will need an RS-232
to RS-422/RS-485 converter or a PC card with an RS-422/RS-485
interface. The program running on the PC must be capable of
switching the converters output driver on or off to test the
controller in RS-485 2-wire mode.
If it is desired to test serial I/O in another interface mode:
1) Disconnect the serial I/O cable
2) Use configuration functions to set the controller for the new
interface (RS-422, RS-485 2 wire, or RS-485 4 wire)
3) Connect the correct interface cable from the PC serial port to
the controller port. See Table 2-3 for pinout.
4) Send a serial I/O message as described in step c) above.
5.5.11
RCP Link Port Tests

The Remote Control Panel (RCP) link is continuously tested for
proper operation whenever a remote unit is connected.
There are no additional tests of the RCP Link port.
5.5.12
RF Tests
Use a copy of the system Measured Test Data form in Section 8,
System Configuration, to record RF test data. It is assumed that
the reader is familiar with standard microwave test techniques
such as gain, VSWR, intermodulation and noise figure, and has
access to the proper test equipment. No details of these tests are
5-12 Maintenance
DMAN-14576 Rev. D

given here. Refer to the manuals of your microwave test equipment
for measurement details, if necessary.
The following RF parameters are typically measured:
Gain, gain flatness
VSWR
Noise temperature (LNA/LNB systems only)
Power output at 1 dB compression
Third order intercept point
Using the test data form, plot the swept gain response. Record two
traces on each of two plots. Make one set of plots for Pol 1 and
another set for Pol 2. In each set, plot the gain for both the main
and standby units. Draw arrows from the traces to the identifying
labels next to the plots.
Likewise, plot input and output return loss for both units in each
Pol; and, for LNA/LNB systems, plot noise temperature for each
unit on each Pol. Again, plot traces for both the main and standby
units on the same plot and identify each with arrows.
This completes the Performance Verification. If all of the
procedures from Section 5.5.1 through 5.5.12 are completed
satisfactorily, then the 1:2 Redundant System complies with
factory specifications.
5.6
Troubleshooting
Use this section to help isolate faults in the equipment and to
perform repairs.
WARNING

with the power cable connected. Discharge capacitors before
touching.
Before starting, look first for the following common problems.
Are you certain that the problem has been isolated to this piece
of equipment? Perform tests to verify that the problems being
experienced are not caused by some other part of the system.
Are you certain the controller is configured correctly?
Is power applied and are fuses ok?
Are power supply voltages correct?
If evidence points to a problem with the controller, several service
options are available. If you wish to return the unit to the factory
for service, refer to Section 7 for Warranty Information and Return
Procedures.
Maintenance 5-13
DMAN-14576 Rev. D

If you can isolate a controller problem to one board, for example,
the front panel or parallel I/O board, you can simply replace the
suspected board. Contact the factory for replacement boards for
the controller.
If you have spare boards available, you may be able to isolate a
problem to one board by replacing boards one at a time, and
noting when the problem is corrected. Contact the factory for
spare boards for the controller.
Refer to the appropriate parts lists and assembly drawings in
Section 6, Drawings, or Section 8, System Configuration, to help
find the appropriate board to swap or replace.
Following repairs, the Performance Verification tests of Section 5.5
may be used to verify that the equipment is fully operational.
NOTE
5.6.1
Troubleshooting controller circuit boards is beyond the scope of

this manual. Problems within boards should be resolved by
swapping or replacing boards, or returning them for factory test
and repair. Customers are advised not to attempt board-level
servicing of the controller.
On-Line Repairs
The following kinds of repairs can be made to the system without
interruption of service:
5-14 Maintenance
Unit Replacement. A defective unit can be replaced. First,

switch the defective unit off-line. With the system switched to
the good unit, unplug the power connector, disconnect the RF
output cable, disconnect the mounting screws and the input
connector, and remove the defective unit.
Power Supply Replacement. Either of the two power supplies

can be disconnected and replaced. Turn off the supply and
disconnect the line cord from the power entry module for the
supply being replaced. Slightly loosen the screws holding the
small metal cover over the AC input terminals of the supply
and slide it to the side. Carefully unplug the AC power input
connector. Carefully noting its position, unplug the DC power
output connector. Remove the two power supply mounting
screws and lift the supply from the chassis. Install the new
supply, making sure to install the AC input power and DC
output power connectors properly.
Front Panel Repairs. The front panel board can be removed

without interrupting service, although removing it will cause a
controller fault. Carefully disconnect the flat cable at front
panel connector J1. Front panel indicators will go out, but the
system will remain operational in the LOCAL and AUTO modes.
DMAN-14576 Rev. D

Disconnect the power cable at front panel connector J3.
Remove the chassis handles and lift the front panel from the
chassis.
NOTE
It is possible that reconnecting the front panel with power on will

cause the controller to reset. Do not reconnect the front panel with
power on if a controller reset is undesirable.
First reconnect the power cable to front panel connector J3.
Then very carefully align the flat ribbon cable connector to
front panel connector J1 and plug it in place. Front panel
indicators should light. Reset the controller fault due to the
missing front panel.
5.6.2
Other Repairs. To make other repairs to the control panel, use

the emergency unit power connector to supply power to the
Units and then disconnect and remove the control panel. The
procedure is given below.
Emergency Unit Power (LNA/LNB Systems)

To make repairs without interrupting service, use the emergency
power provision:
1) Locate Emergency Power connector P3 on the plate cable
connected to J3 of the controller. Refer to Figure 5-1 and to
cable drawing 10899 for details.
DISCONNECT
CONTROL CABLE ASSY
J3
P1
P3
J3
EMERGENCY
LNA/LNB POWER
+
CONTROL PANEL
DC SUPPLY
15-17 V
P2 J 1
PLATE ASSY
P3 KEY:
PIN 2 (CENTER PIN) . . . . . . . . . . . +15 V (RED WIRE)
PINS 1, 3 (OUTSIDE PINS) . . . . . . . GND (BLACK WIRES)
Figure 5-1. Emergency Unit Power

2) Connect a dc power supply to P3. For convenience, a mating
connector is supplied with the cable assembly.
3) Adjust the dc supply to 12 V and plug the mating connector
into P3.
Maintenance 5-15
DMAN-14576 Rev. D

4) Put the system in MANUAL mode to prevent automatic
switching and then slowly turn up the voltage on the dc supply
until the Unit alarm indicators come on. At this voltage, the
external dc supply is powering the amplifiers.
5) Disconnect P1 from J3 on the rear of the control panel and
remove the controller for service.
NOTE
Internal power from the control panel and external emergency

power inputs are diode isolated from each other. When the
external supply is less than 15 V, the internal supplies will power
the Units (LNAs/LNBs). When it is greater than 15 V, the external
supply will take over.
Note that you may leave the emergency power connected to P3
continuously. It will provide a third level of redundancy to the two
internal power supplies.
5.6.3
Board Removal
Front Panel:
The front panel is intended to be replaced as a unit consisting of

the membrane panel keypad, metal support panel, and circuit
board.
To remove the front panel assembly, unplug the flat cable at front
panel connector J1. Release the latch on the power cable at front
panel connector J3, and unplug that connector. Remove the four
screws holding the chassis handles in place, and lift the front
panel from the chassis.
Logic Board:
To remove the logic board, first disconnect all cables from J4, 5, 6,
and 7. Unplug all cables, making sure to fully release the catches
used on some of the cables. Remove the screws holding the board
to the standoffs, and lift the board from the chassis.
Parallel I/O Board:
First disconnect any cable from J8. Unplug the cable at connector
J1. Remove the screws holding the board to the standoffs, and lift
the board from the chassis.
5-16 Maintenance
DMAN-14576 Rev. D
Section 6
6.1
Drawings
This section contains drawings needed to maintain and service the
1:2 Redundant System Controller. Refer to Section 8, System
Configuration, for plate assembly drawings.
Table 6-1
Drawing Type
Refer to the Drawing Index, Table 6-2 to locate a particular

drawing.
Drawing types are briefly described below.

Drawing Types
Description
Block Diagram
Depicts overall signal flow through a subassembly with major

circuit groups shown as blocks. Sometimes annotated with
signal levels.
Schematic
Standard electronic schematics with appropriate reference

designators on components.
Assembly Drawing
Pictorial view of a circuit board, subassembly or unit.

Components on the assembly drawing are identified by
schematic designator or by item number. Item numbers refer
to the Bills of Materials.
Bill of Materials
(BOM)
Shows quantities, manufacturer and manufacturers part

number of each item of an assembly.
All original drawings which were C size or larger have been
reduced for inclusion in this manual
Revisions to drawings are identified in the revision block in the
upper right corner of the drawing. The initial release of a drawing
has no revision. The first revision is A, the second B, and so on.
6.2
Drawing Index
Refer to Table 6-2 to locate a drawing. Drawings are inserted in
the order in which they appear in the Table.
Drawings 6-1
DMAN-14576 Rev. D
Table 6-2
Drawing Number

Drawing Index
Description
6441-4
Block Diagram, 1:2 Redundant System (Typical, LNA)
10899-1, -2, -3
Control Cable Assembly (LNA/LNB Systems)
13032-1
Cable Assembly, Motor Drive and External Alarms (SSPA and

Other Systems)
11074-2
Schematic Diagram, RSC/RCP
9683-10, -3
Assembly, RSC/RCP Controller
ARLC-9683-2002
BOM, Assy, LR-1200 Controller, AC w/ Chassis Slides
AMAX-9683-104
BOM, Base Assembly, RSC/RCP Controller, AC Input
AMAX-8848-1
BOM, Sub-Assy, Chassis Slides, 22 w/ 4 Slot Bracket
9860-1
Assembly, Front Panel, 1:2
NOTE
6-2 Drawings
Also see Section 8, System Configuration, for information on

specific options included with your system.
DMAN-14576 Rev. D
Section 7
7.1
Warranty
General Dynamics SATCOM Technologies warrants all equipment
to be free of defects. Specific warranty policies along with technical
support, repair and return procedures are listed in this section.
7.2
For help installing, maintaining or servicing the unit, see

Technical Support, Section 7.2.
For terms and conditions of the warranty, see Warranty,

Section 7.3.
Before returning any equipment for factory service, see Return

Procedures, Section 7.4.
Technical Support
Technical support is available by calling General Dynamics
directly at (814) 238-2700 between 8 a.m. and 5 p.m. USA Eastern
time. Before calling, please have your technical manual in front of
you and the model and serial number of the relevant equipment.
7.3
Warranty
General Dynamics warrants that its products will be in accordance
with the written specifications, will be the kinds and quality
described in the agreement, and will be free from defects in material
and workmanship, under normal use and service, when correctly
installed and maintained, for a period of three (3) years from the
date of shipment.
General Dynamics liability is limited solely, at its discretion, to
replacing, repairing or issuing credit for products which become
defective during the warranty period. General Dynamics must be
notified by the buyer, in writing, of any discrepancy before any
action may be taken. The buyer must provide General Dynamics
with the opportunity to inspect and test the product(s) alleged to
be defective.
Under no circumstances shall General Dynamics be held liable for
any defective product(s) if examination of the product(s) shows
that the defect was caused by misuse, abuse, improper
installation or application, improper maintenance or repair,
alteration, accident or negligence in use, storage, transportation or
handling.
Warranty 7-1
DMAN-14576 Rev. D
7.4
Return Procedures
Before returning any materials to General Dynamics SATCOM
Technologies, the buyer must complete all of the following tasks:
Contact either General Dynamics directly or the appropriate

sales representative for issuance of a Return Materials
Authorization (RMA) number. If the sales representative is
contacted, they will in turn contact General Dynamics for
approval to return materials.
Supply sufficient information regarding the reason(s) for

return.
Supply the date and purchase order number through which

the materials in question were purchased.
Supply the location to which the materials are to be returned.
Include a name and phone number of an individual to contact

in case of questions regarding the return materials.
Materials approved for return must be accompanied by the

information requested above. All materials must have an RMA
number.
NOTE
Unauthorized returned materials will not be accepted by

General Dynamics and will be shipped back to the buyer at the
buyers expense.
All returned materials must arrive with postage, duties and all
handling costs prepaid by the buyer. General Dynamics will
evaluate the returned materials to determine responsibility and
will advise the buyer of any repair or replacement charges that
apply.
Contact General Dynamics at
voice:
(814) 238-2700
or, fax:
(814) 238-6589
Shipping Address:
60 Decibel Road, Suite 200
State College, PA 16801 USA
7-2 Warranty
DMAN-14576 Rev. D
Section 8
8.1
System Configuration
This section contains configuration information for your system as
it was shipped from the factory. Such information typically
includes a drawing section which contains drawings peculiar to
your plate assembly, and may include manual supplements for
any optional equipment ordered, or information on ancillary
equipment.
System Configuration 8-1
DMAN-14576 Rev. D
8-2 System Configuration
DMAN-14576 Rev. D
Appendix A
Serial I/O Protocol
Document 11667,
Serial I/O Protocol for Redundant System Controller
Serial I/O Protocol A-1
DMAN-14576 Rev. D
A-2 Serial I/O Protocol
DMAN-14576 Rev. D
Appendix B
Glossary
Term
Definition
Ampere
AC or ac
Alternating current
AUTO or Auto
Automatic; refers to mode of operation
Degrees Celsius
CMOS
Complementary Metal-Oxide Semiconductor
DC or dc
Direct current
DMM
Digital multimeter
EEPROM
Electrically erasable, programmable read-only memory
EIA
Electronic Industries Association
EXT
External
ft
Feet
GHz
Gigahertz
GND
Electrical ground; earth
Hz
Hertz
IC
Integrated circuit
IEC
International Electrotechnical Commission
in
Inches
INT
Internal
I/O
Input/output
Degrees Kelvin
LED
Light emitting diode
LNA
Low noise amplifier
LNB
Low noise block converter
LOC
Local; refers to mode of operation
Meter
mA
Milliampere
MAN or Man
Manual; refers to mode of operation
mm
Millimeter
ms
Millisecond
(continues )
Glossary B-1
DMAN-14576 Rev. D
Term
Definition
mV
Millivolt
PCB
Printed circuit board
PIO
Parallel I/O
POL or Pol
Polarization
Pos
Position
p-p
Peak-to-peak
PVC
Polyvinyl chloride
RAM
Random access memory
RCP
Remote Control Panel
REM or Rem
Remote; refers to mode of operation
RF
Radio Frequency
ROM
Read-only memory
RSC
Redundant System Controller
RX or Rx
Receive
SEL
Select
SIO
Serial I/O
S/N
Serial number
SSPA
Solid-state power amplifier
STD or Std
Standard
TTL
Transistor-transistor logic
TX or Tx
Transmit
UV
Ultraviolet
Volt
Vac
Volts alternating current
Vdc
Volts direct current
VSWR
Voltage standing wave ratio
1:1
Redundant configuration where there is one standby unit for

one main unit
1:2
Redundant configuration where there is one standby unit for

two main units
Dual 1:1
Redundant configuration with two independent 1:1 systems

controlled by a single controller
B-2 Glossary
DMAN-14576 Rev. D
Appendix C
Fault Group
A
Fault Codes
Fault Number
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
Name
power supply 1
power supply 2
front panel not detected
parallel I/O not detected
ADC diagnostics
unknown controller model
drive failure
service relay
serial port driver voltage
serial port driver loopback
capacitors too low
hiside drive 1
hiside drive 2
front panel readback
unit 1 power
unit 2 power
unit 3 power
unit 4 power
tracking unit power
noisediode 1 power
noisediode 2 power
switch 1 failed
switch 2 failed
switch 1 disconnected
switch 2 disconnected
illegal opcode
spurious reset
stack overflow
invalid interrupt
watchdog timer failure
ROM checksum
RAM test
EEPROM read
EEPROM checksum
EEPROM write
EEPROM backup
processor_ADC
pio_RELAY1
pio_RELAY2
(continues )
Fault Codes C-1
DMAN-14576 Rev. D
Fault Group
F
G
H
Fault Number
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7

Name
pio_RELAY3
pio_RELAY4
pio_RELAY5
pio_RELAY6
pio_RELAY7
pio_RELAY8
pio_RELAY9
pio_RELAY10
(not used)
RCP ROM checksum
RCP RAM
RCP invalid interrupt
RCP spurious reset
RCP stack overflow
RCP illegal opcode
RCP front panel
RCP link lost
RCP service relay
RCP serial volts
RCP ADC
RCP parallel I/O
RCP pio_RELAY1
RCP pio_RELAY2
RCP pio_RELAY3
RCP pio_RELAY4
RCP pio_RELAY5
RCP pio_RELAY6
RCP pio_RELAY7
RCP pio_RELAY8
RCP pio_RELAY9
RCP pio_RELAY10
-
A0, A1 Power Supply 1, 2

These faults indicate that one of the two power supplies has dropped outside the 13.5-to16.5-volt range. If the condition continues to exist, you will observe that one of the
indicators (PS1 or PS2) is lit. Either fault may occur if you power the unit up one supply
at a time.
First check that the power supply is turned on. Check the AC line fuses and power cord.
If the fault still cannot be reset, check the power supplies, and adjust them if needed (see
Section 5.4.1).
These faults can only be cleared if the power supply voltage is corrected.
C-2 Fault Codes
DMAN-14576 Rev. D
A2 Front Panel Not Detected

This fault indicates the controller cannot properly communicate with the front panel.
Normally, this fault code will not be seen from Fault Display mode, because the fault
would prevent the front panel display from working at all.
If this fault occurs, press the PANEL TEST button to see if the LEDs light. Press buttons
to check that they function. If the front panel does not operate as expected, check the
cables between the logic board and front panel.
This fault can only be cleared if the front panel is correctly detected.
If this fault occurs repeatedly, the front panel board, its cable, and possibly the main logic
board or entire controller, should be replaced.
A3 Parallel I/O Not Detected
This fault indicates the controller cannot properly communicate with a Parallel I/O board,
when one is configured to be present.
This fault is most likely to occur because a controller is used with a Parallel I/O board
installed, and the board is then removed from the controller. If that is the case, manually
change the controller configuration so the controller does not expect a Parallel I/O board
(see 2.7.3.10 Configuration Function J).
This fault may also occur due to a failure of the Parallel I/O board (if present), or cabling
between the main logic board and Parallel I/O board. Press a front panel button such as
Local/Remote and use an ohmmeter to determine if the Local/Remote contacts of the
Parallel I/O Outputs change state. If possible, place the controller in Remote mode, and
use the Parallel I/O inputs to try to change between Auto and Manual mode. If possible,
execute the Serial I/O Self Test command, which tests each relay on the Parallel I/O
board. If a fault is reported for every relay, check the cable between the main logic board
and Parallel I/O board.
This fault can only be cleared if the Parallel I/O board is detected correctly, or if Parallel
I/O is not configured.
If this fault occurs repeatedly, the Parallel I/O board should probably be replaced.
A4 ADC Diagnostics
This fault indicates the Analog to Digital Converter (ADC) used to measure currents and
voltages within the controller has failed a self test. This is an unlikely fault.
If this occurs, measurements made by the controller could be invalid. Unit alarms could
occur when Units are actually operating correctly, or Power Supply faults could be
reported when the power supplies are operating correctly. If this fault occurs repeatedly,
the main logic board or entire controller should be replaced.
This fault can only be cleared if the ADC passes its self tests.
Fault Codes C-3
DMAN-14576 Rev. D
A5 Unknown Controller Model

This fault indicates that the front panel connected to the controller is not configured for a
valid controller type (1:1, 1:2, or Dual 1:1). The controller type is normally read from a
jumper setting on the front panel PCB. This fault could occur if the jumper is moved, or if
the front panel board is damaged or defective. The jumper is installed at the factory, and
should never be moved.
If the controller type is unknown, NONE of the position indicators will be lit, nor will any
unit status indicators light.
This fault is cleared only by attaching a good front panel with the type jumper properly
installed.
A6 Drive Failure
(Not currently used.)
A7 Service Relay Failure
This fault indicates the Service Relay may not be operating correctly. Using an ohmmeter,
check whether the Service Relay contacts are in the correct position. With no faults
reported, the relay should be energized. With any fault reported, the relay should be deenergized.
If this fault occurs repeatedly, the main logic board or entire controller should be
replaced.
B0, B1 Serial Port Driver Voltage, Serial Port Driver Loopback
These faults indicate a problem with the driver chip used for the Serial I/O and RCP Link
interfaces. If you are using Serial I/O or a Remote Control Panel, communication
problems may occur.
Check cabling to Serial I/O and RCP Link connectors, looking for shorts on the wiring or
any other conditions which could cause excessive current to flow through the ports.
These faults can only be cleared if the serial drivers pass their self-tests.
If either of these faults occurs repeatedly, the main logic board or entire controller should
be replaced.
B2 Capacitors Too Low
This fault indicates that capacitors used to store energy for driving the waveguide
switches cannot generate sufficient voltage to switch. In that case, the controller could be
unable to switch between Units.
The most likely cause of this fault is a wiring problem between the main logic board and
the power capacitors. Verify that the cable between the two is correctly attached.
This fault can only be cleared if the capacitors generate the correct voltage.
C-4 Fault Codes
DMAN-14576 Rev. D
If this fault occurs repeatedly, the main logic board, power capacitors, or entire controller
should be replaced.
B3, B4 Hiside Drive 1, 2
These faults indicate an internal self-test of the waveguide switch drive circuitry has
failed.
The most likely cause of these faults is a wiring problem with the plate cable or plate
assembly. Verify that cabling is correct, and that there are no shorts on the plate cable or
plate wiring. Although the controller drive circuitry is well protected, a fault on the plate
wiring could perhaps damage the drive circuitry.
These faults can only be cleared if the drive circuitry passes the internal tests.
be replaced.
B5 Front Panel Readback
This fault indicates an internal self-test of the front panel circuitry has failed. This is an
unlikely fault.
If this fault occurs repeatedly, the front panel or entire controller should be replaced.
B6, B7, C0, C1 Unit 1, 2, 3, 4 Power
These faults indicate that the circuitry which supplies power to one or more Units cannot
be controlled properly.
The most likely cause of this fault is a problem with Unit wiring in the plate cable or plate
assembly. Verify that cabling is correct, and that there are no shorts on the plate cable or
plate wiring. Although the controller circuitry is well protected, a fault on the plate wiring
could perhaps damage the drive circuitry.
These faults can only be cleared if the Unit power circuitry works properly.
If any of these faults occurs repeatedly, the main logic board or entire controller should be
replaced.
C2 Tracking Unit Power
When the Tracking Unit is configured, this fault indicates that the circuitry which
supplies power to the Tracking Unit cannot be controlled properly.
The most likely cause of this fault is a problem with Tracking Unit wiring in the plate
cable or plate assembly. Verify that cabling is correct, and that there are no shorts on the
plate cable or plate wiring. Although the controller circuitry is well protected, a fault on
the plate wiring could perhaps damage the drive circuitry.
This fault can only be cleared if the Tracking Unit power circuitry works properly.
Fault Codes C-5
DMAN-14576 Rev. D
If this fault occurs repeatedly, the main logic board or entire controller should be
replaced.
C3, C4 Noise Diode 1, 2 Power
When Noise Diode 1 or 2 is configured, either fault indicates that the circuitry which
supplies power to the Noise Diode cannot be controlled properly.
The most likely cause of this fault is a problem with Noise Diode wiring in the plate cable
or plate assembly. Verify that cabling is correct, and that there are no shorts on the plate
cable or plate wiring.
Either fault can only be cleared if the Noise Diode power circuitry works properly.
be replaced.
C5, C6 Switch 1, 2 Failed
These faults indicate an attempt to electrically move a waveguide switch has failed.
If the controller tries to switch to another unit, either because of a command or because a
unit has faulted in AUTO mode, and the switch does not move, this fault is reported. If
the switch was initiated by a command, the attempt is only made once. If the controller is
switching because of AUTO mode, it will continue to attempt to switch.
If the fault was generated because a command failed, it should be obvious, as you will
observe that the system did not switch as you requested. If the fault was generated
because an AUTO mode switch attempt failed, you may observe from the front panel
indicators that a faulted unit is not being switched off-line.
The most likely cause of this fault is a switch that is stuck or is being manually held at
the plate. Other possible causes are a wiring fault (e.g., excessive wire resistance), low
supply voltage, or defective power capacitors, although the latter two problems should
cause other fault codes to occur.
These faults can only be cleared after the controller has successfully performed a switch.
If either fault occurs repeatedly, and no problem is found with plate wiring or the
waveguide switch(es), the main logic board, power capacitors, or entire controller should
be replaced.
C7, D0 Switch 1, 2 Disconnected
These faults indicate the position of a waveguide switch cannot be detected. All indicator
arrows will be lit red on the Pol which is affected.
The most likely causes of the fault are a disconnected switch or a defect in the wiring to
the switch.
Either fault can only be cleared if the controller properly detects the position of the
switch.
C-6 Fault Codes
DMAN-14576 Rev. D
If either of these faults occurs repeatedly, and no problem is found with plate wiring or
the waveguide switch(es), the main logic board or entire controller should be replaced.
D1 thru D5 Various Microprocessor Faults
These faults indicate a hardware or firmware problem with the microprocessor. If any of
these faults occurs repeatedly, the unit should be returned for repair.
These faults are cleared by a fault reset command.
D6, D7 ROM Checksum Test, RAM Test
A self-test is performed on ROM and RAM at power-up. These tests can also be run from a
serial I/O command. If any of these memory tests fail, a controller fault is reported.
ROM is memory that contains the program that runs the controller. RAM memory
contains data such as measurements that occur during normal operation.
These faults can be cleared only by a successful test of whichever area of memory failed.
E0 thru E3 EEPROM Errors
Whenever you reset the nominal unit currents, or change one of the mode settings, this
information must be written to EEPROM. EEPROM is memory that retains the data even
when power is removed. Data is verified as it is written, and if a failure occurs, one or
more of these faults may be reported.
If this happens, it is an indication that the EEPROM memory may be wearing out. This is
not likely to happen during normal operation.
These faults can be cleared by a successful write to EEPROM, or by a fault reset
command.
E4 Processor ADC
This fault indicates a self-test of the Analog to Digital Converter in the microprocessor has
failed. This is an unlikely fault.
The microprocessor ADC is used only for internal diagnostics. A failure would probably
cause false faults of the Service Request Relay and Serial Port Driver.
This fault can only be cleared if the microprocessor ADC passes its internal tests.
If this fault occurs repeatedly the main logic board or entire controller should be replaced.
E6, E7, F0 thru F7 Parallel I/O Relays 1 thru 10
These faults indicate a Parallel I/O relay is not in the expected state.
These faults will only be indicated after the Serial I/O Self Test command is issued. These
faults are not used if Parallel I/O is not present. If this fault occurs on all relays, check
the cable between the main logic board and Parallel I/O board.
Fault Codes C-7
DMAN-14576 Rev. D
These faults can be cleared after the Serial I/O Self Test command is completed.
If any of these faults occurs repeatedly, the Parallel I/O board should be replaced.
H0, H1 RCP ROM Checksum Test, RCP RAM Test
A self-test is performed on RCP ROM and RAM at power-up. If any of these memory tests
fail, an RCP fault is reported.
ROM is memory that contains the program that runs the controller. RAM memory
contains data such as measurements that occur during normal operation.
These faults can be cleared only by turning RCP power off and back on.
H2 thru H5 Various RCP Microprocessor Faults
These faults indicate a hardware or firmware problem with the microprocessor in the
RCP. If any of these faults occurs repeatedly, the logic board should be replaced, or the
RCP should be returned for repair.
These faults are cleared only by turning RCP power off and back on.
H6 RCP Front Panel Not Detected
This fault indicates the RCP cannot properly communicate with its front panel. Normally,
this fault code will not be seen from Fault Display mode, because the fault would prevent
the front panel display from working at all.
If this fault occurs, press the PANEL TEST button to see if the LEDs light. Press buttons
to check that they function. If the front panel does not operate as expected, check the
cables between the logic board and front panel.
This fault can only be cleared if the front panel is correctly detected.
If this fault occurs repeatedly, the front panel board, its cable, and possibly the main logic
board or entire controller, should be replaced.
H7 RCP Link Lost
This fault indicates the RCP no longer detects a communications link to the RSC, which
was previously detected.
The most likely causes of this fault are (1) loss of power to the RSC, or (2) a problem with
the cable between the RSC and the RCP.
If you verify the cable connection and power up status, it is possible the logic board of
either the RCP or the RSC has failed. Examine the fault codes of both units for a Serial
Volts fault (see RSC code B0 or RCP code I1), which may indicate damage to the serial
driver circuits.
C-8 Fault Codes
DMAN-14576 Rev. D
I0 RCP Service Relay Failure

This fault indicates the RCP Service Relay may not be operating correctly. Using an
ohmmeter, check whether the Service Relay contacts on J7 are in the correct position.
With no faults reported, pins 7 and 8 of J7 should be connected (closed), and pins 6 and 7
should be open. With any fault reported, pins 6 and 7 should be connected (closed), and
pins 7 and 8 should be open.
If this fault occurs repeatedly, the main logic board or entire RCP should be replaced.
I1 RCP Serial Port Driver Voltage
This fault indicates a problem with low voltage on the driver chip used for the Serial I/O
and RCP Link interfaces. Communication problems may occur.
Check cabling to Serial I/O and RCP Link connectors, looking for shorts on the wiring or
any other conditions which could cause excessive current to flow through the ports.
These faults can only be cleared if the serial drivers pass their self-tests.
If either of these faults occurs repeatedly, the main logic board or entire RCP should be
replaced.
I2 RCP Processor ADC
This fault indicates a self-test of the Analog to Digital Converter in the RCPs microprocessor has failed. This is an unlikely fault.
The microprocessor ADC is used only for internal diagnostics. A failure would probably
cause false faults of the Service Request Relay and Serial Port Voltage.
This fault can only be cleared if the microprocessor ADC passes its internal tests.
If this fault occurs repeatedly the main logic board or entire RCP should be replaced.
I3 RCP Parallel I/O Not Detected
This fault indicates the RCP cannot properly communicate with its Parallel I/O board,
when one is expected to be present.
This fault also occur due to failure of the Parallel I/O board (if present), or the cable
between the main logic board and Parallel I/O board. Press a front panel button such as
Local/Remote and use an ohmmeter to determine if the Local/Remote contacts of the RCP
Parallel I/O Outputs change state. If possible, place the controller in Remote mode, and
use the RCP Parallel I/O inputs to try to change between Auto and Manual mode. If none
of the Parallel I/O inputs or outputs are functioning, the cable or Parallel I/O board may
be bad. If only certain inputs or outputs have failed, the Parallel I/O board is probably
bad.
This fault can only be cleared if the Parallel I/O board is detected correctly.
If this fault occurs repeatedly, the Parallel I/O board should probably be replaced.
Fault Codes C-9
DMAN-14576 Rev. D
I4 thru I7, J0 thru J5 RCP Parallel I/O Relays 1 thru 10

These faults indicate an RCP Parallel I/O relay is not in the expected state.
These faults are indicated if an internal check of an RCP Parallel I/O relay fails. These
faults are not used if Parallel I/O is not present in the RCP. If this fault occurs on all
relays, check the cable between the main logic board and Parallel I/O board in the RCP.
These faults can be cleared only after the internal check of the relay is successfully
completed.
If any of these faults occurs repeatedly, the RCP Parallel I/O board should be replaced.
C-10 Fault Codes
DMAN-14576 Rev. D
Notes

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What is the purpose of the equipment described in the manual?

What is the purpose of the equipment described in the manual?

What interfaces does the controller have?

What interfaces does the controller have?

1:2 Redundant System Controller

Operation and Maintenance Manual

1:2 Redundant System Controller

This title strip goes in the outside spine of the binder.

1:2 Redundant System Controller

60 Decibel Road, Suite 200 State College, PA 16801 USA

1:2 Redundant System Controller

General Information ......................................................... 1-1

How to Use This Manual ........................................................1-1

Operation ......................................................................... 3-1

1:2 Redundant System Controller

Theory of Operation ......................................................... 4-1

General Introduction ............................................................. 4-1

Maintenance .................................................................... 5-1

General Introduction ............................................................. 5-1

1:2 Redundant System Controller

Drawings .......................................................................... 6-1

Warranty .......................................................................... 7-1

System Configuration....................................................... 8-1

Serial I/O Protocol ........................................................... A-1

Glossary ........................................................................... B-1

Fault Codes ...................................................................... C-1

Table of Contents iii

1:2 Redundant System Controller

Model RSC-1200 1:2 Redundant System Controller ........................................ 1-3

List of Equipment and Accessories Normally Supplied .................................... 1-3

1:2 Redundant System Controller

How to Use This Manual

Failure to ground the equipment as described will cause a

General Information 1-1

1:2 Redundant System Controller

Adjustments described in this manual are performed with power

Equipment and Accessories Supplied

1-2 General Information

1:2 Redundant System Controller

LINE CORDS (2)

Figure 1-1. Model RSC-1200 1:2 Redundant System Controller

List of Equipment and Accessories Normally Supplied

Indoor Redundant System Controller

Line Cord, USA

Operation and Maintenance Manual

General Information 1-3

1:2 Redundant System Controller

Input and/or output directional couplers

Refer to Section 8, System Configuration, for the exact

1-4 General Information

1:2 Redundant System Controller

Inspect the equipment before installation. See Inspection,

1:2 Redundant System Controller

Outdoor Plate Assembly (LNA/LNB Systems)

Other Systems (SSPA Systems, etc.)

1:2 Redundant System Controller

Interconnecting Control Cable

1:2 Redundant System Controller

Use of Shielded Cables