I have two 4 ways hooked up to my CH PCN 100 EM controller and 3 single face lights. The two 4 way lights do the standard G Y R pattern. 2 of the 3 single face lights did G GY R and the other one did just G Y R. I decided to make the third single face light match the other 2. This required me to reconfigure an extra cam on the cam shaft to make the green light stay on during the yellow. The controller had been working fine prior to this reconfiguration. Well, today was the first day I ran my signals for any length of time since I reconfigured that extra cam. Everything was fine until I noticed what I thought was a burned out bulb in a green on one of the 4 ways. Then I noticed the other side was off too.
The light eventually turned yellow and red and eventually back to green. This time the green lights were both on and stayed on. I watched for a while and eventually, the greens went out again. I checked the other 4 way that was hooked up to the PCN and it's greens on one side were also out when they were supposed to be on. Then right when I was about to take the controller apart and file those contacts, I noticed a really long yellow light. The cam shaft and dial were out of sync. What the heck is going on???
I watched for a bit and it sync'd back up and everything was fine for a bit. I took the controller apart and followed Jay's advice of filing and cleaning all the contacts that were involved in the two problems. I put it back together and the problem of the green lights going out repeated itself. It turns out the cam shaft was turning just a bit farther than it was supposed to and breaking the contact for that green signal. I took the controller apart again. I swapped two cams and reconfigured them the way they were supposed to be in their new locations on the shaft and put it back together again. No more green light problem, but the cam shaft was getting out of sync with the dial again. This time it was skipping past one point where it was supposed to stop, so I got a really short green light and a long yellow. Took it apart again, filed the contact for the cam that stops the cam shaft where it is supposed to stop and swapped out the metal insert in the cam where it would skip past where it was supposed to stop. I've been watching it cycle now for close to an hour and it seems to finally be working properly again. All because I wanted to reconfigure that one signal to do G GY R. Like I love to say...IF IT AIN'T BROKE, DON'T FIX IT!!!
