A member of the ANSALDO Group 5800 Corporate Drive ... INTRODUCTION (See Figures 1-1 and 1-2) 1.2.1 General The MICROLOK PLUS Vital and Non-Vital Control Package is a multi-purpose,

00 UNION SWITCH llJ & SIGNAL INC. A member of the ANSALDO Group 5800 Corporate Drive Pittsburgh, PA 15237

SERVICE MANUAL 6500

Operation, Installation, Programming and Maintenance

MICROLOK PLUS TM

VITAL PLUS NON-VITAL CONTROL PACKAGE

NOTE

The Service Manuals for the US&S MICROLQKR and GENISVSR systems are required as supplements to this manual. Descriptions and illustrations common to the MICROLOK PLUS™ system and these earlier systems are cross-referenced back to the respective MICROLOKR and GENISVSR manuals. Check the cross-reference listing on page 1-1 to identify the specific manuals required.

September, 1990 A-09/90-100-2882-1 ID0280F

AN SAL DO

COPYRIGHT 1990, UNION SWITCH & SIGNAL INC. PRINTED IN USA

Trasporti

Revised and new pages of this manual are listed by page number and date:

Page No. Date Page No. Date

Section

I GENERAL 1.1 1.2 1. 2 .1 1.2.2 1. 2 .3 1. 2. 4 1.2.4.1 1.2.4.2 1. 2. 5 1.2.5.1 1.2.5.2 1. 2. 6 1.3 1.3.1 1. 3. 2 1.3.2.1 1.3.2.2 1.3.2.3 1.3.2.4 1.3.2.5 1.4 1.4.1 1. 4. 2 1.5 1. 5.1 1. 5.2 1.5.2.1 1.5.2.2 1.5.2.3 1.5.3 1. 5.4

CONTENTS

INFORMATION PURPOSE AND SCOPE OF MANUAL INTRODUCTION General Vital Section Basic Functions Non-Vital Section Basic Functions Serial Data Systems Vital Section Non-Vital Section Executive and Application Software Application Executive Power Requirements and Applications HARDWARE DESCRIPTION Card file Plug-In Printed Circuit Boards General Arrangement Vital CPU PCBs Vital I/0 PCBs Non-Vital Controller PCB Non-Vital I/0 PCBs AUXILIARY EQUIPMENT Vital Cut-Off Relay (VCOR) Serial Communications Adapter Panel SPECIFICATIONS Physical/Mechanical Electrical Power Supply converter Vital I/0 PCBs Non-Vital I/0 PCBs Environmental Miscellaneous

II INSTALLATION 2.1 SHIPMENT HANDLING 2.2 UNIT MOUNTING AND ENVIRONMENT 2.3 FACILITY WIRING 2.4 POWER AND GROUND CIRCUITS 2.4.1 Power Sources 2.4.2 Wiring and Surge/Noise Protection 2.4.3 Equipment Grounding 2.4.3.1 Rack and Cardfile Grounding 2.4.3.2 O Volts Connection to Earth Ground 2.4.3.3 Serial and Local Cable Connection to 2.4.4 Power Supply 5 Volt Adjustment 2.4.5 Auxiliary Power for RFL Modem 2.5 PCB PREPARATION 2.5.1 Vital CPU 2.5.2 Vital I/0 2.5.3 Non-Vital Controller

i

1-1 1-1 1-2 1-2 1-2 1-4 1-4 1-4 1-6 1-6 1-6 1-7 1-8 1-8 1-8 1-10 1-10 1-11 1-11 1-12 1-12 1-13 1-13 1-13 1-13 1-13 1-14 1-14 1-15 1-15 1-15 1-15

2-1 2-1 2-1 2-1 2-2 2-2 2-2 2-4 2-4 2-4

Earth Ground 2-4 2-6 2-7 2-7 2-7 2-7 2-8

CONTENTS (Cont'd)

Section

2.5.4 2.6 2.7 2.8 2.9 2.9.1 2.9.2 2.9.3 2.9.4 2.9.5 2.9.6 2.10 2 .11

Non-Vital I/0 PCBs PCB INSTALLATION ECHO ENABLE JUMPERS (VITAL I/0) VITAL SECTION LOCAL INTERFACES VITAL SECTION SERIAL INTERFACES Serial Ports Cabling General Notes Modem Recommendations Vital Master and Satellite EIA Interfaces Vital Section - Code System Interface current Loop Interface NON-VITAL SECTION LOCAL INTERFACES NON-VITAL SECTION SERIAL INTERFACE SPECIFICATIONS

III FUNCTIONAL DESCRIPTION 3.1 VITAL SECTION 3.2 NON-VITAL SECTION

IV APPLICATION PROGRAMMING

v

4.1 VITAL SECTION 4.2 NON-VITAL SECTION

FIELD MAINTENANCE 5.1 VITAL SECTION 5.1.1 General Requirements 5.1.2 Periodic Inspection 5.1.3 Troubleshooting Guide 5.1.3.1 Required Test Equipment and Materials 5.1.3.2 Power-Off Checks 5.1.3.3 Power-On Checks 5.1.3.4 5.1.3.5 5.1.3.6

5.1.3.7 5.1.3.8 5.1.4 5.2 5.2.1 5.2.2 5.2.2.1 5.2.2.2 5.2.2.3 5.3

Power-On System Tests Displaying and Clearing Error Codes Reading Error Codes, Error Code Descriptions and Troubleshooting PCB Descriptions Code System Interface Troubleshooting Retesting Guidelines NON-VITAL SECTION Basic Maintenance Systematic Troubleshooting Introduction Recommended Test and Repair Equipment Initial Checks and Diagnostics Via Board LEDs POWER SUPPLY DRAWER

VI SHOP MAINTENANCE 6.1 VITAL SECTION PCBS 6.2 NON-VITAL SECTION PCBS 6.3 POWER SUPPLY DRAWER

ii

2-8 2-8 2-8 2-9 2-10 2-10 2-10 2-12 2-12 2-14 2-16 2-16 2-17/18

3-1 3-1 3-1

4-1 4-1 4-3

5-1 5-1 5-1 5-1 5-1 5-1 5-2 5-2 5-3 5-3 5-5

5-7 5-9 5-9 5-10 5-10 5-10 5-10 5-10 5-11 5-13/14

6-1/2 6-1/2 6-1/2 6-1/2

CONTENTS (Cont'd)

Section

APPENDIX A A.1

PARTS LIST CARDFILE N451796-0102 A-2

A.2 A. 3 A.3.1 A.3.2 A.3.2.1 A.3.2.2

A.5 A.6 A.7

PLUG-IN PRINTED CIRCUIT BOARDS A-4 VITAL SECTION SERIAL LINK CABLE ASSEMBLIES A-5 Complete Assemblies A-5 Standard Components A-6 37-Pin D Connector/Cable Assemblies (Master/Satellite) A-6 Cable Assembly: Vital Code System Port to Non-Vital A-7 Controller VITAL SECTION LOCAL I/0 CABLE ASSEMBLIES A-8 NON-VITAL SECTION SERIAL AND LOCAL CABLE ASSEMBLIES A-8 DEVELOPMENT SYSTEM HARDWARE AND SOFTWARE A-8

APPENDIX B KEY COMPARISONS OF MICROLOK PLUS, MICROLOK, GENISYS

Figure

1-1

1-2

1-3

1-4

2-1

2-2

2-3

2-4

2-5

2-6

3-1

4-1

4-2

4-3

ILLUSTRATIONS

Basic Configuration and Applications

Serial Communication System Configurations

Application and Executive Software

Cardfile General Design and PCB Arrangements

Typical MICROLOK PLUS Power Input Wiring

Summary of MICROLOK PLUS Ground Circuits

Power Supply 5 Volt Output Check and Adjustment

Echo Enable Jumper Position Check

Serial Data Ports and Cables

Standard MICROLOK PLUS Vital Section/Non-Vital Interface

Vital Section serial Link to Non-Vital controller

Sample for Source Listing MICROLOK PLUS Vital Section Application Program

Sample Symbol Table for MICROLOK PLUS Vital Section Application Program

Sample Source Listing for MICROLOK PLUS Non-Vital Section Application Program

iii

1-3

1-5

1-7

1-9

2-3

2-5

2-6

2-9

2-11

2-15

3-2

4-2

4-3

4-6

Figure

4-4

5-1

5-2

5-3

A-1

A-2

ILLUSTRATIONS (Cont'd)

Sample Symbol Table for MICROLOK PLUS Non-Vital Section Application Program

Configuration of Vital Section LEDs

Typical Long Error Codes

Configuration of Non-Vital section LEDs

Cardfile Assembly

Code System/Controller Cable Assembly N451458-980X

MICROLOK PLUS Cardfile

vi

4-7/8

5-4

5-6

5-12

A-3

A-7

SECTION I GENERAL INFORMATION

1.1 PURPOSE AND SCOPE OF MANUAL

This manual provides and cross references information on the installation, programming, operation and field maintenance of the MICROLOK PLUS Vital and Non-Vital Control Package.

Because the MICROLOK PLUS system shares much of the hardware and software of the US&S MICROLOK and GENISYS systems, the service manuals for these other systems are extensively cross-referenced in this manual. Common descriptions and procedures are cited by section, and page number in the respective MICROLOK or GENISYS manual. If the MICROLOK PLUS system is only equipped with a vital section, the following US&S Service Manuals are required to supplement this manual (latest revision dates as of 8-1-90):

Manual No. & Rev. Date

SM-6400A (12/88)

SM-6400B ( 11/89)

SM-6400C (3/89)

Product

MICROLOK Vital Interlocking Control System



Scope

Application Logic Programming

Hardware Installation

Field Maintenance

If the MICROLOK PLUS system is equipped with a vital section and a non-vital section, the following US&S Service Manuals are also required to supplement this manual:

SM-6300A (7/89)

SM-6300B (6/90)

SM-6300C (9/88)

GENISYS Non-Vital Logic Emulator



Application Logic Programming

Hardware Installation and Field Maintenance

Shop Maintenance of Plug-In Printed Circuit Boards

Following is an example of the standard format for the cross-reference notations in this manual:

Subject

DC Lamp Driver PCB -Specifications

Topic covered in cross reference.

SM-6400B,

• US&S

Service Manual

No.

6500, p. 1-1

Cross Reference

section 2.8.2.2, page 2-25

• • Section Page no. Number or first in that page no. Manual of that

section

1.2 INTRODUCTION (See Figures 1-1 and 1-2)

1.2.1 General

The MICROLOK PLUS Vital and Non-Vital Control Package is a multi-purpose, microprocessor-based device designed for use in both vital and/or non-vital railroad control systems. It is typically used for smaller applications, such as a single end-of-siding, that do not require the large input/output capabilities of seperate vital and non-vital controllers. The device can be configured with a vital control section only, or with vital and non-vital control sections. (A non-vital-only configuration is also possible, but not typical.)

In a typical single end-of-siding application, both sections are utilized. The vital section controls the interlocking logic, manages switch machines, signals and track circuits in the control area; while the non-vital section provides an interface point for a local control panel, processes CTC office commands, and transmits indications from the vital section. Another typical end-of-siding configuration could consist of the vital section only, with code system inputs and outputs processed within the vital section (no local control panel).

The MICROLOK PLUS system is derived from the US&S MICROLOK Vital Interlocking Control System and the GENISYS Non-Vital Logic Emulator. It uses the same plug-in printed circuit boards (logic and interface), the same Executive software, and the same application logic compilers as the MICROLOK and GENISYS systems.

1.2.2 Vital Section Basic Functions

The vital section of MICROLOK PLUS unit is designed specifically for railroad vital interlocking applications. Its basic function is to process various inputs according to a program designed by the application engineer, and create the appropriate outputs. This program takes inputs, performs logic and timing functions on those inputs and produces an output. The program operates in the same manner as a conventional vital relay logic system.

Inputs and outputs consist of "local" and "serial". Local inputs typically include track circuit occupancy, state of switch machine point contacts, state of signal relay or mechanism contacts, and traffic and line circuits. Local outputs eventually interface to control signal mechanism drives, signal lamp drives, switch control contactors and traffic and line control circuits. Serial inputs and outputs typically carry vital and non-vital control and indication messages between the MICROLOK PLUS system and other vital and non-vital controllers, or between the vital and non-vital sections of the unit.

Local input options include standard off/on (bit 0/1) voltage inputs, or bi-polar voltage inputs (bit O or 1 for each polarity). Two voltage input ranges are available with these options: 12 or 24 Vdc (nominal). Local vital output options include standard (single pole) relay drive, or bi-polar relay drive. Lamp-compatible outputs are available to drive 18, 25 or 36 watt, 10 volt signal lamps.

6500, p. 1-2

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NON-VITAL CONTROL SYSTEM:

• MICROLOK PLUS (NON-VITAL SECTION)

•GENISYS

...

.·....___,,.,,,-,

VITAL CONTROL SYSTEM

(MASTER) • MICROLOK PLUS

(VITAL SECTION) •MICROLOK

...

SEE FIGURE 1-2 FOR COMPLETE SERIAL COMMUNICATION

LINK OPTIONS

NON-VITAL SERIAL LINK

VITAL CONTROL SYSTEM

(SA TE LUTE) • MICROLOK PLUS

(VITAL SEC, CODE) • MICROLOK (CODE)

NONVITAL LINK

~

NON-VITAL CONTROL SYSTEM (SATELLITE):


•GENISYS

j

NON-VITAL CONTROL SYSTEM (MASTER):


•GENISYS •OFFICE COMPUTER

.----------------------------~ NON-VITAL SERIAL LINKS j

+

12 VDC BATTERY

VITAL SERIAL LINK


r-

VITAL II NON Ill VITAL SATEL. VITAL MAST. PORT SA TEL. PORT

PORT

PRO· 1/0 CODE PERI· STD. Bl· DC I STD.

CESSOR BUS SYSTEM PHERAL OR POLAR LAMP INPUT

PCB INTERF. INTERF. PCB VOLT. RELAY DRIVER PCB

PCB PCB LIMITED DRIVER PCB

RELAY PCB

DRIVER

PCB

N I VITAL CPU I •14 I I VITAL 1/0

VITAL SECTION

I I v:~~L --t. t ! t}~t ~~ j 1

STD.

INPUT

PCB

Bl·

POLAR

CONFIG.

j

24 VDC SUPPLY I llo POWER SUPPLY CONVERTER

. ••••

... •

~----------------------------~ NON-VITAL LOCAL CIRCUITS

M S PORTS

rB L- ... ---

CON· I RELA y. I OPTO TROLLER OUTPUT INPUT

PCB PCB PCB

a..__ NON-VITAL ...---- SECTION ____.

I I

CONTROL RELAY COILS

~B INDICATION RELAY

CONTACTS N

12 VDC BATTERY

TOTAL 1/0 SLOTS: 10

D ~ NON-VITAL

BUS

1.2.3 Non-Vital Section Basic Functions

The non-vital section of MICROLOK PLUS unit can perform the functions of various non-vital relay logic and digital logic systems, according to a program designed by the application engineer. This program takes inputs, performs logic and timing functions on those inputs and produces an output. The program operates in the same manner as a conventional non-vital relay logic system.

Inputs and outputs consist of •1ocal" and "serial•. Local inputs include all non-vital relay or switch contact signals, such as from a local control panel or code system field circuits. Local output options include internally strobed or non-strobed delivery and constant state at power off. Serial inputs and outputs typically carry non-vital control and indication messages between the MICROLOK PLUS system and other vital and non-vital controllers, or between the non-vital and vital sections of the unit.

1.2.4 Serial Data Systems (See Figure 1-2)

1.2.4.1 Vital Section

The MICROLOK PLUS unit is equipped with •ports• for serially communicated data. The vital section includes a Master port that enables the device to serve as the managing unit of a vital Master/Satellite system. Up to 16 Satellite units can be controlled from this port. The Satellite units for such a system might include additional MICROLOK PLUS or MICROLOK units, or a combination of both. The vital Satellite port enables the unit to function as a Satellite to another Master unit (MICROLOK PLUS or MICROLOK).

A 20 mA current loop option is also available for vital or non-vital serial communications between the MICROLOK PLUS system and related systems installed in different wayside houses. This option is designed for maximum noise immunity and may be operated over a maximum distance of 10,000 feet (total loop length). A separate current Loop Adapter Panel, not included with the basic MICROLOK PLUS unit, is required for this option (refer to section 1.4.2).

When required by the application, the vital section of the MICROLOK PLUS unit can incorporate a non-vital port for communications with a non-vital controller such as the US&S GENISYS system or the unit's own non-vital section. This port is typically used when the external GENISYS unit or MICROLOK PLUS non-vital section is used as the field unit in an office/field code system, or the interface to a local control panel. In this configuration, the non-vital controller serves as the Master unit and the MICROLOK PLUS vital section as a Satellite to that Master.

Vital serial link communications are formatted to EIA RS-423 standards, and aerated to operate under the RS-232C standards. This enables the MICROLOK PLUS vital serial ports to be interfaced to an EIA-compatible modem for remote communications.

6500, p. 1-4

VITAL MASTER/SATELLITE SERIAL LINK - CENTRALIZED CONTROL (ALL EIA RS-423)

MASTER

VITAL SECTION

N-VITAL SECTION

MICROLOK PLUS

SATELLITE #1

VITAL SECTION

N-VITAL SECTION

MICROLOK PLUS

SATELLITE #2

VITAL SECTION

N-VITAL SECTION

MICROLOK PLUS

v SP

SATELLITE #3

MICROLOK (CPU)

UP TO 16

MICROLOK

PLUS AND/OR

MICROLOK

SATELLITES

VITAL MASTER/SATELLITE SERIAL LINK - DISTRIBUTED CONTROL (ALL EIA RS-423)

VITAL SECTION

N-VITAL SECTION

MICROLOK PLUS

VITAL SECTION

N-VITAL SECTION

MICROLOK PLUS

v v SP MP

MICROLOK (CPU)

CURRENT LOOP INTERFACE (VITAL LINK)

VITAL SECTION

N-VITAL SECTION

MICROLOK PLUS

r----------------------------1 r----------------------------1

VITAL SECTION

MASTER

VITAL SECTION

EIA RS-423

SERIAL COMM. ADAPTER

N-VITAL SECTION

MICROLOK PLUS

L----------------------------l

20 mA CURRENT LOOP

10,000 FT. CABLE LENGTH MAX.

(PER LOOP)

MICROLOK PLUS

VITAL SECTION

SA TEL

N-VITAL SECTION

L----------------------------NON-VITAL INTERFACES (INTERNAL AND EXTERNAL) TO VITAL SECTION (ALL EIA RS-423)

N-VITAL SECTION

VITAL SECTION

N-VITAL SECTION

VITAL SECTION

M S NVP

N-VITAL SECTION

VITAL SECTION

N-VllAL SECTION

M S NVP

MICROLOK PLUS MICROLOK PLUS MICROLOK PLUS MICROLOK PLUS GENISYS OR COMPUTER

INTERFACES TO NON-VITAL SECTION (EIA OR TTL)

MASTER SATELLITE tfl SATELLITE #2 SATELLITE #3

ABBREVIATIONS M S NVP

M S M S NVP

M S NVP

v SP

VITAL SATELLITE PORT

NV NON-VITAL P PORT

v MP

VITAL MASTER PORT

M S MASTER & SATEL. NVP NON-VITAL

PORTS

GENISYS OR COMPUTER

MASTER

VITAL SECTION

M S NVP

N-VITAL SECTION

MICROLOK PLUS

VITAL SECTION

NVP

N-VITAL SECTION

MICROLOK PLUS

SATELLITE #1

VITAL SECTION

M S NVP

N-VITAL SECTION

MICROLOK PLUS

VITAL SECTION

N-VITAL SECTION

MICROLOK PLUS

M S NVP

SATELLITE #2

GENISYS

VITAL SECTION

N-VITAL SECrlON

MICROLOK PLUS

UP TO 255 MICROLOK PLUS

AND/OR GENISYS UNITS

(PRACTICAL LIMIT: 50 UNITS)

PREFERRED CONFIGURATION:

DISTRIBUTED CONTROL

(SEE VITAL EXAMPLE ABOVE)

Figure 1-2. Serial Communication System Configurations

6500, p. 1-5

1.2.4.2 Non-Vital Section

The non-vital section of MICROLOK PLUS incorporates a Master port that enables the device to serve as the managing unit of a non-vital Master/Satellite system. Up to 255 Satellite units can be controlled from this port, although the practical upper limit is about 40 to 50 units. The Satellite units for such a system might include additional MICROLOK PLUS or GENISYS units, or a combination of both. The non-vital Satellite port enables the unit to function as a Satellite to another Master unit. The Master unit can include another MICROLOK PLUS unit (non-vital section), a GENISYS system or an office mainframe or microcomputer.

When the application requires a serial link between the non-vital and vital sections of the MICROLOK PLUS unit, the non-vital Master port is used for this purpose, while the Satellite is used for external communications.

Non-vital serial link communications are formatted to EIA RS-423 standards, and aerated to operate under the RS-232C standards. This enables the MICROLOK PLUS non-vital vital serial ports to be interfaced to an EIA-compatible modem for remote communications.

1.2.5 Executive and Application Software (See Figure 1-3)

Each section (vital and non-vital) of the MICROLOK PLUS unit incorporates its own, independent Application and Executive software. These are contained in EPROM chips on the logic boards of the respective sections.

1.2.5.1 Application

The Application software or logic in each section is developed for the specific installation, either by US&S or the customer. The source program is written and "compiled" on a computer, using a language that enables the system logic to be expressed in terms familiar to the railroad engineer. The finished program is converted into a form that can be entered or "burned" into the EPROM chips.

The MICROLOK PLUS vital application logic can be developed using the optional MICROLOK Development System (M.D.S.), which consists of a personal computer, EPROM programmer, EPROM eraser, and software program disks. This system allows the user to conduct all phases of application program development, including compilation on a personal computer, debugging, and final checking (simulation) and programming into the vital application logic EPROMs.

The non-vital application logic can be developed using the optional GENISYS Development System (G.D.S.). This system provides the same program development, testing and EPROM-loading features as the M.n.s., and uses the same programming and loading equipment. However, the G.D.S. uses different development software for its non-vital logic function.

6500, p. 1-6

MICROLOK AND GENISYS DEVELOPMENT SYSTEMS

PC

• COMPILE AND SIMULA TE APPLICATION LOGIC.

lliO[OOIJD=CABLE D -· (g)

I ~========= I - - -:

PERIPHERAL PCB N451441-5502

• THREE EXECUTIVE EPROMS (IC20, 21, 22)

• UP TO THREE APPLICATION LOGIC EPROMS (IC 15, 16, 19)

• USES MICROLOK DEVELOPMENT SYSTEM FOR APPLICATION LOGIC EPROMS

CODE SYSTEM INTERFACE PCB N451441-5302

• ONE EXECUTIVE EPROM (IC14)

• DOES NOT USE APPLICATION LOGIC EPROMS OR DEVELOPMENT SYSTEM

CPU PCB

1/0 BUS

INTERF.

PCB

•

CODE PERI· SYS. PHERAL

INTERF. PCB

PCB

VITAL SECTION

VITAL

110

PCBS

. . . . ~

~

EPROM PROGRAMMER

• CHECK EPROM

---

• LOAD APPLICATION LOGIC.

--- - - - "'---J""

APPLICATION LOGIC EPROM

BK X 8

DEVELOPMENT SYSTEM SOFTWARE FOR PC

• COMPILER PROGRAMS • SIMULATOR PROGRAM • EPROM PROGRAMMER DRIVER

CONTROLLER PCB N451441-5602

• ONE EXECUTIVE EPROM (IC29)

CON· NON· • APPLICATION OPTION: CODE SYS. TROLLER VITAL

PCB 110

PCBS

• • NONVITAL

SECTION

I

EMULATION, OR:

• UP TO 5 APPLICATION LOGIC EPROMS (IC 24, 25, 26, 27, 28)

• USES GENISYS DEVELOPMENT SYSTEM FOR APPLICATION LOGIC EPROMS

Figure 1-3. Application and Executive Software

1.2.5.2 Executive

The executive software of the vital and non-vital sections of MICROLOK PLUS are are common to all units.

The vital section Executive software contains routines designed to (a) verify the states of vital inputs and outputs, (b) insure that all vital outputs are fully controllable, and (c) remove power to vital outputs in all cases where a system failure has occurred. Vital assurance is applied to local inputs and outputs, and to serial communications with other external systems. The Executive software also performs input, internal and output logic operations defined in the vital application logic, as well as diagnostic routines at different operational levels.

The non-vital section Executive software performs input, internal and output logic operations defined in the non-vital application logic.

6500, p. 1-7

1.2.6 Power Requirements and Applications

All configurations of the MICROLOK PLUS unit require a 24 Vdc (nominal) external power source. This power is regulated and converted by the Power Supply Converter Drawer to provide operating power for the vital and/or non-vital board electronics. The converter is simultaneously capable of powering two or three transmitter and receiver boards in a RFL type modem (remote serial link). This arrangement eliminates the need for a separate power supply converter for the modem.

When the MICROLOK PLUS system is interfaced to vital relay and lamp drive circuits, a separate 12 Vdc (nominal) power source is required. This source provides power for all Relay Driver and DC Lamp Driver PCB outputs. The 12 Vdc is supplied through the Vital cut-Off Relay to the vital input/output section of the cardfile.

When the MICROLOK PLUS system is interfaced to non-vital relay-output circuits, a separate 12 Vdc (nominal) power source is required. This power is carried through the relay contacts of the relay-output boards to relay coils of the external circuits.

1.3 HARDWARE DESCRIPTION

1.3.1 Cardfile

The MICROLOK PLUS package is housed in a single PCB cardfile (17 slots) with a combination hinged and removable front cover. Circuit board installation options and LED configurations are shown on a label attached to the inside of the cover. The cardfile is typically mounted in a standard 19 inch equipment rack, but may also be shelf mounted. The unit incorporates a slide-out drawer containing the unit's power supply converter. (No external power supply panel or plug-in converter board is required.) Two strain relief bars (movable) are also provided for serial and local I/0 cabling.

All of the MICROLOK PLUS PCBs plug into a common, printed circuit motherboard permanantly attached to the rear of the cardfile. The motherboard incorporates a connnon power bus that delivers operating power to all boards. However, the vital and non-vital motherboard data buses are separate.

As viewed from the rear of the cardfile, the four right-hand MICROLOK PLUS boards (vital logic) plug into both the bottom and top motherboard connectors. The upper or "A" connectors translate three of these four boards to 37 and 25-pin, "D" style connectors on the back or the motherboard. These serve as the vital and non-vital serial data ports for the vital section of the MICROLOK PLUS unit.

The "A" connector edges of the remaining boards project through slots along the top of the cardfile backplane. These slots allow attachment of 44-way PCB edge connectors for vital and non-vital local I/0 cabling, and for the serial link cable to the non-vital logic board.

The MICROLOK PLUS motherboard contains two Faston terminals ("RLY (+)" and RLY (-)") near the "D" connectors. Wiring to these terminals is connected to an external relay that serves as the system's vital cut-off relay, or VCOR.

6500, p. 1-8

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VITAL SECTION PCBS - CPU FRONT NON-VITAL SECTION PCB - LOGIC

SLOT PART NO. DESCRIPTION A B C D E F G H K L M N OPQ SLOT PART NO. DESCRIPTION A N451441·5701 PROCESSOR NON-VITAL SECTION 0 N451441·5602 CONTROLLER B N451441·6001 1/0 BUS INTERFACE

c N451441·5302 CODE SYSTEM INTERFACE D N451441·5502 PERIPHERAL

INSTALLATION

PROCESSOR SLOT A, ALL VITAL APPLICATIONS 110 BUS INTERFACE SLOT B, ALL VITAL APPLICATIONS CODE SYSTEM INTERFACE SLOT C, WHEN REQ'D BY APPLICATION PERIPHERAL SLOT D, ALL VITAL APPLICATIONS

J,T~L ~ 111 CPU

~-- ..... VITAL "W I I I

-.1 I I VITAL SECTION

INSTALLATION

SLOT 0, ALL NON-VITAL APPLICATIONS

NON-VITAL SECTION PCBS - 1/0

SLOT PART NO. DESCRIPTION

P, Q N451441·3601 CONTROL DEVLIVERYT N451441·7101 CONSTANT DELIVERY

VITAL SECTION PCBS - 1/0 N451441-4701 CONTROL & DELIVERY

N451441·7202 OPTO·INPUT (HIGH THRESHOLD)

SLOT PART NO. DESCRIPTION N451441·5802 OPTO·INPUT (WIDE RANGE)

f • N N451441·6501 STANDARD RELAY DRIVER INSTALLATION N451441·8601 STANDARD RELAY DRIVER W/LEDS ONE RELAY-OUTPUT: SLOT P N451441·7401 VOLT.·LIMIT. RELAY DRIVER ONE OPTO·INPUT: SLOT P N451441·8501 VOLT.·LIMIT. RELAY DRIVER W/LEDS ONE RELAY·OUTPUT AND ONE OPTO·INPUT: N451441·6601 Bl·POLAR RELAY DRIVER RELAY IN SLOT P, OPTO IN SLOT Q N451441·8701 Bl·POLAR RELAY DRIVER W/LEDS N451441·6702 DC LAMP DRIVER, 18 W LAMP N451441·6703 DC LAMP DRIVER, 25 W LAMP N451441·7301 DC LAMP DRIVER, 36 W LAMP N451441·6402 STANDARD INPUT, 12 V NOM.

+12V ·12V +SV ·SV 24V OUTPUT OUTPUT OUTPUT OUTPUT INPUT

44·WAY PCB VITAL CODE VITAL

LED LED LED LED LED EDGE CONNECTORS MASTER SYSTEM SLAVE

(VITAL 1/0 AND PORT PORT PORT N451441 ·6403 STANDARD INPUT, 24 V NOM. N451441 ·8802 STANDARD INPUT, 12 V NOM., W/LEDS

POWER SUPPLY DRAWER ALL NON-VITAL PCBS) 37·PIN "D" 25·PIN "D" 37·PIN "D"

N451441·8803 STANDARD INPUT, 24 V NOM, W/LEDS

INSTALLATION: SEE EXAMPLES BELOW

CARD SLOT ID --+- 0 P Q N M

VITAL 1/0 INSTALLATION EXAMPLES

EXAMPLE: 6 OUTPUT PCBS ONLY

I I I 1::: ' ' I ~1111

VITAL 1/0 "ft: j j j I I I I I I I I I I I I I I I I

I I I

L 1 ST OUTPUT PCB IN SLOT E

'--y-)

t NO EMPTY SLOTS

BETWEEN PCBS

EXAMPLE: 5 INPUT PCBS ONLY

I I I ! ! ! I VITAL 1/0 "ft: j j j

I I I I I I I I I I I I I I I I I I I I I I I I I I I

1 ST INPUT PCB IN SLOT E

'--y-)

t NO EMPTY SLOTS

BETWEEN PCBS

EXAMPLE: 4 OUTPUT PCBS 3 INPUT PCBS

I II I I ! I VITAL 1/0 "ft: j j j

I I I I I I I I I

1ST INPUT PCB IN SLOT I

1ST OUTPUT PCB IN SLOT E

~

NO EMPTY SLOTS BETWEEN PCBS

MOTHERBOARD (COVER OFF)

24 V INPUT TERMINALS

REAR

VCOR OUTPUT TERMINALS

1.3.2 Plug-In Printed Circuit Boards

1.3.2.1 General Arrangement

A. Vital Section

Slots A through D of the MICROLOK PLUS cardfile contain the vital section logic or "CPU".

a. All MICROLOK PLUS units used for vital control applications are always equipped with a Processor PCB in slot A and a Peripheral PCB in slot D.

b. When the unit is connected to another vital controller (MICROLOK PLUS or MICROLOK) through a serial data link, or local vital inputs/outputs are required, an I/0 Bus Interface PCB is installed in slot B.

c. When the unit is connected to an external non-vital controller (GENISYS) or cross-connected to its own non-vital section, a Code System Interface PCB is installed in slot c.

When the MICROLOK PLUS system is interfaced to vital local circuits, various arrangements of vital-output (relay-driver, lamp-driver) and vital-input boards are installed in slots E through N, according to the application.

a. When the application requires relay and/or lamp driver boards only, these are always installed starting in slot E.

b. When the application requires vital input boards only, these are also installed starting in slot E.

c. When the application requires both vital output (relay and/or lamp driver) and vital input boards, the output boards are always installed starting in slot E. The first input board is installed after the last output board.

d. No empty slots are permitted between vital output and input boards.

B. Non-Vital Section

Slots O through Q contain the MICROLOK PLUS non-vital section boards.

All MICROLOK PLUS units used for non-vital control functions are equipped with a Controller PCB in slot o.

When the MICROLOK PLUS unit is interfaced to non-vital local circuits, different combinations of non-vital relay-output and optical-input boards are installed in slots P and Q, according to the application.

a. When the application requires only one relay-output or optical-input board, this board is always installed in slot P.

b. When the application requires one relay-output and optical-input board, the relay-output board is always installed in slot P and the optical-input board is always installed in slot Q.

6500, p. 1-10

1.3.2.2 Vital CPU PCBs

The MICROLOK PLUS vital section uses the same Vital CPU boards as the MICROLOK system. For general descriptions of these boards, refer to:

Subject Cross Reference

Processor PCB (N451441-5701) SM-6400C, section 3.3.8.1, page 3-57

Peripheral PCB (N451441-5502) SM-6400C, section 3.3.8.2, page 3-60

NOTE

The Failover circuitry and LOCK-ON/AUTO/LOCK OFF switch on the Peripheral PCB are not used in the MICROLOK PLUS unit.

I/0 Bus Interface PCB (N451441-6001)

Code System Interface PCB (N451441-5302)

1.3.2.3 Vital I/0 PCBs

SM-6400C, section 3.3.8.3, page 3-64

SM-6400C, section 3.3.8.4, page 3-67

The MICROLOK PLUS vital section uses the same Vital I/0 boards as the MICROLOK system. For general descriptions of these boards, refer to:


Standard Relay Driver PCBs (N451441-6501 and -8601)

SM-6400C, section 3.3.8.5, page 3-72

Voltage-Limited Relay Driver (PCBs N451441-7401 and -8501)

SM-6400C, section 3.3.8.5, page 3-72

Bipolar Relay Driver PCBs (N451441-6601 and -8701)

SM-6400C, section 3.3.8.6, page 3-75

DC Lamp Driver PCBs (N451441-6702, -6703 and -7301)

SM-6400C, section 3.3.8.7, page 3-78

Standard Input PCBs SM-6400C, section 3.3.8.8, page 3-85 (N451441-6402, -6403, -8802, -8803)

The May 1987 (revised March, 1989) edition of SM-6400C only describes the following vital I/0 boards:

Standard Relay Driver Voltage-Limited Relay Driver Bipolar Relay Driver Standard Input Standard Input

6500, p. 1-11

US&S Part No.

N451441-6501 N451441-7401 N451441-6601 N451441-6402 N451441-6403

Both MICROLOK and MICROLOK PLUS also use new vital I/0 boards equipped with LEDs on the individual input or output lines. These boards are as follows:

US&S Part No.

Standard Relay Driver Voltage-Limited Relay Driver Bipolar Relay Driver Standard Input

N451441-8601 N451441-8501 N451441-8701 N451441-8802 N451441-8803 Standard Input

The descriptions of the vital I/0 boards in sections 3.3.8.5, 3.3.8.6 and 3.3.8.8 of SM-6400C are applicable to the above boards, except that no reference is made to LEDs on the I/0 lines.

1.3.2.4 Non-Vital Controller PCB

The MICROLOK PLUS non-vital section uses the same Controller PCB as the GENISYS system. For a general description of this board, refer to:


Controller PCB (N451441-5602) SM-6300C, section 1.2.2.1, page 1-4

1.3.2.5 Non-Vital I/0 PCBs

The MICROLOK PLUS non-vital section uses the same non-vital I/0 PCBs GENISYS system. For general descriptions of these boards, refer to:

Subject

Constant Delivery PCB (N451441-7101)

Control Delivery PCB (N451441-3601)

Control and Delivery PCB (N451441-4701)

Optical-Input PCB - High Threshold Type (N451441-7202)

Optical-Input PCB - Wide Range Type (N451441-5802)

Cross Reference

SM-6300C, section 1.2.2.2, page 1-5





6500, p. 1-12

1.4 AUXILIARY EQUIPMENT

1.4.1 Vital Cut-Off Relay (VCOR)

The MICROLOK PLUS system requires an external vital relay to serve as the cut-off mechanism for its vital outputs. This relay is controlled by the vital section microprocessor (Processor PCB) and is operated by a separate driver circuit on the I/0 Bus Interface PCB. A US&S PN-150HD relay is used for this purpose. For a general description of this relay, refer to:

Subject

Vital Cut-Off Relay (VCOR) PN-150HD (N322505-701)

Cross Reference

SM-6400B, section 1.2.2.4, page 1-9

1.4.2 Serial Communications Adapter Panel N451460-3001

When the MICROLOK PLUS application requires a 20 mA Current Loop communications link to another controller (i.e. in separate wayside houses), the system is augmented with the Serial Communications Adapter Panel.

For a general description of the Serial Communications Adapter Panel, refer to:

Subject

Serial Communications Adapter Panel (N451460-3001)

Cross Reference

SM-6400B, section 1.2.2.5, page 1-10

NOTE

When used with MICROLOK PLUS, the Serial Communications adapter panel requires a separate external power source.

1.5 SPECIFICATIONS

1.5.1 Physical/Mechanical

Cardfile Dimensions:

Cardfile Mounting:

Cardfile Access:

Standard 19" rack or shelf

To plug-in PCBs: Hinged/removable front cover.

To power supply converter: Slide-out drawer.

To motherboard PCB backplane connectors and jumpers: Removable cover.

6500, p. 1-13

External Connections:

1.5.2 Electrical

1.5.2.1 Power Supply Converter

Power Input:

Power Supply Output:

Fuse:

Overvoltage Protection:

Common Mode Filtering:

Differential Mode Filtering:

Vital Section/CPU:

Two 37-pin "D" connectors, female (vital Master and Satellite ports)

One 25-pin "D" connector, female (vital interface to non-vital controller for EIA/code system interface)

Vital Section I/0:

Slots for up to ten 44-pin PCB edge connectors (vital local input and local output drive)

Non-Vital Section (Controller and I/0)

Slots for up to three 44-pin PCB edge connectors (serial and local I/0)

Power Supply Converter (Drawer)

Two dual-Faston terminals (male) for 24 Vdc power input.

One AAR stud on rear of cardfile (for earth ground)

19.8 to 32.4 Vdc (24 Vdc nom.)

120 Vac input, externally converted to 24 Vdc output@ 7 amps

24 Vdc external battery source@ 7 amp/hr.

12 Vdc available for RFL modem 270 mA on +12 Vdc 135 mA on -12 Vdc

Fuse: 6.25 amp, 250 Vdc, 3 AG style

Transzorb on input, overvoltage clamping on +5V output

Provided on power input and outputs

Provided on power input

6500, p. 1-14

Power Converter Characteristics:

1.5.2.2 Vital I/0 PCBs

Isolation (input to output): 500V Isolation (terminal to case): 500V Switching frequency: 200 kHz, typ. Efficiency: 80%, typ. Fault protection: Reverse polarity, overvoltage (clamping) main, short circuit (indefinite, autorecovery)

The MICROLOK PLUS vital section uses the same vital I/0 PCBs as MICROLOK. For electrical specifications on these PCBs, refer to:

Subject

Standard, Voltage-Limited and Bipolar Relay Driver PCBs -Specifications

DC Lamp Driver PCB -Specifications

1.5.2.3 Non-Vital I/0 PCBs

Cross Reference

SM-6400B, section 2.8.2.1, page 2-21

SM-6400B, section 2.8.2.2, page 2-25

The MICROLOK PLUS non-vital section uses the same non-vital I/0 PCBs as GENISYS. For electrical specifications on these PCBs, refer to the following:

Subject

Control Delivery, Constant Delivery, Control and Delivery PCBs - Specifications

Optical-Input PCBs -Specifications

1.5.3 Environmental

Temperature Range:

Cardfile Cooling:

1.5.4 Miscellaneous

Vital Section CPU Capacity:

Vital Section I/0 Capacity:

Cross Reference



-400 to +7o0c@ 90% noncondensing humidity

Convection through louvers

Up to four PCBs (application dependent)

Up to 10 PCBs (application dependent)

6500, p. 1-15

Non-Vital Section Capacity:

Master/Satellite System Capacities:

Up to three PCBs (application dependent)

Vital section: Up to 16 MICROLOK PLUS or MICROLOK Satellite units on Master port.

Non-Vital Section: Up to 255 MICROLOK PLUS or GENISYS units on Controller PCB Master port. Practical limit: 50 Satellite units.

Serial Comm. Modes, Vital Section: - Vital Master and Satellite Ports:

Serial Comm. Modes, Non-Vital Section:

Serial Interfaces, Vital Section:

Serial Interfaces, Non-Vital Section:

Serial Bit Rates, Vital Section:

Full duplex (standard)

Data Security: BCH, 24 Bits

Non-Vital Port: Half or full duplex

Half or full duplex

Vital Master and Satellite Ports:

EIA RS-423, RS-232C compatible

Optional: 20 mA current loop (EIA converted at optional Serial Communications Adapter)

Non-Vital Port: EIA RS-423, RS-232C compatible

EIA RS-423, RS-232C compatible

Optional: 20 mA current loop (EIA converted at optional Serial Communications Adapter)

Vital Master and Satellite Ports:

EIA: 150, 300, 600, 1200, 1800, or 2400

20 mA current loop: Distance d~e~e~

Non-Vital Port:

EIA: 50, 75, 110, 134, 150, 300, 600, 1200, 1800, 2400, 3600, 4800, 7200 or 9600

20 mA current loop: Distance dependent

6500, p. 1-16

Serial Bit Rates, Non-Vital

current Loop Total Cable Length:

Maintenance Aids:

Top Part Numbers:

Cardfile w/P. s. and Cable Cardfile wo/P. s. P. s. Drawer Power Input Cable

Vital Section:

Processor PCB I/0 BUS Interface PCB Code System Interface PCB Peripheral PCB

Standard Input (wo/LEDs) Standard Input (wo/LEDs) Standard Input (w/LEDs) Standard Input (w/LEDs) standard Relay Driver (wo/LEDs) Standard Relay Driver (w/LEDs) Volt.-Ltd. Relay Driver (wo/LEDs) Volt.-Ltd. Relay Driver (w/LEDs) Bipolar Relay Driver (wo/LEDs) Bipolar Relay Driver Cw/LEDs) DC Lamp Driver DC Lamp Driver DC Lamp Driver

Non-Vital Section:

Controller Control Delivery Constant Delivery Control and Delivery Indication Opto (High Threshold) Indication Opto (Wide Range)

EIA: 50, 75, 110, 134, 150, 300, 600, 1200, 1800, 2400, 3600, 4800, 7200 or 9600

20 mA current loop: Distance dependent

10,000 feet (max.)

Plug-In PCBs (for PCB swapping) Diagnostic/Status LEDs PCB test points IC plug-in sockets (for res with 24 or more pins)

- N451796-0102 N451796-0101 N451796-0301 N451795-1401

N451441-5701 N451441-6001 N451441-5302 N451441-5502

N451441-6402 (12 V nom. input) N451441-6403 (24 V nom. input) N451441-8802 (12 V nom. input) N451441-8803 (24 V nom. input) N451441-6501

- N451441-8601 N451441-7401 N451441-8501 N451441-6601 N451441-8701 N451441-6702 (18 W lamp) N451441-6703 (25 w lamp) N451441-7301 (36 w lamp)

N451441-5602 - N451441-3601 - N451441-7101

N451441-4701 N451441-7202 N451441-5802

6500, p. 1-17

Misc.

Serial Communications Adapter PN-150HD Relay (VCOR) Application Logic Blank EPROM* Serial Link Cables

N451460-3001 N322505-701 J715029-0409 (Refer to section A.3.1)

*Used for both Vital and Non-Vital section application logic

6500, p. 1-18

2.1 SHIPMENT HANDLING

SECTION II INSTALLATION

The MICROLOK PLUS cardfile is shipped without plug-in PCBs. These PCBs are delivered in separate packages, with types and quantities determined by the application. If storing MICROLOK PLUS equipment for an extended period prior to installation, make certain storage area temperatures keep within the range of -40 to +as0 c. If any equipment is damaged in shipping, do not attempt to make repairs. Such equipment should be returned to US&S for repair or replacement.

For testing of newly received or stored MICROLOK PLUS hardware, refer to:


Equipment Retesting Guidelines SM-6400C, section 3.4, page 3-108

2.2 UNIT MOUNTING AND ENVIRONMENT

The MICROLOK PLUS cardfile is designed for mounting in a standard 19 inch equipment rack. The unit may also be shelf-mounted.

Environmental requirements for the MICROLOK PLUS unit are the same as those for the MICROLOK rack. For environmental recommendations, refer to:


Equipment Environment SM-64008, section 2.2, page 2-1

2.3 FACILITY WIRING

Facility wiring practices for the MICROLOK PLUS unit are the same as those for the MICROLOK system. For circuit practices, refer to:


Facility Wiring Practices SM-64008, section 2.3, page 2-2

6500, p. 2-1

PO:;;T~N:UT { 824-1 #10 t4

TERMINALS 824 ON

POWER SUPPLY If DRAWER

(CARDFILE N24-I #10 ELECTRONICS) a,-----------,.==::::::ir------°', 1:,,..,.-•3

824

.,,, N

24 TRANSZORBS (QTY = 2) i'

N24

VCOR ~--_.___..--_- - - - - , I 812-2

812-ZA

7(

N12-2

N12-2A

TO VITAL 1/0 WIRING ONLY

812~3

B12-3A

N12-3

N12-3A

NON-VITAL SECTION

_j_ TO EARTH GROUND

® TWISTED PAIR WIRES

4 e TERMINAL STRIP

~ '11 : CONNECTOR STRAP

ALL WIRING #12 UNLESS OTHERWISE INDICATED

PROVIDE SEPARATE B TERMINAL FOR EACH

VITAL OUTPUT. STRAP TOGETHER

PROVIDE SEPARATE N TERMINAL FOR EACH

VITAL OUTPUT. STRAP TOGETHER

NON-VITAL OUTPUT RELAY

TYPE 5KP40A

II

US&S PART NO. J792736-0036

#10

0.1 to 0.15 mFd 50V(HIQ)

#10 ,:.,"

TRANSZORBS (QTY = 2) TYPE 5KP16A

.,, ,

US&S PART NO. J792736-0030

W:---

#6 812

3 #6 N12

KEEP WIRE RUNS FROM BATTERY TO USSP AND FROM USSP TO MICROLOK PLUS TERMINAL STRIP AS SHORT AS POSSIBLE.

z

44-WAY CONN.

y

STANDARD RELAY DRIVER VOL T.-LIMIT. RELAY DRIVER Bl-POLAR RELAY DRIVER DC LAMP DRIVER

~---1-----;.._ ___ _:...,, •4.;----

II

W:---

""'

21 I

I 4 L-------...l

STANDARD MICROLOK 1/0 CABLES

4

#14

#14 3

USSP-11 32 VD( 15 AMP

N451552-0515

VITAL SECTION

#10 824

#10 N24

n ~'------·--------'(4: ON-BOARD RELAY M - 1FORBCONTACT II

W:::::a

II

W:::::a

REFER TO SECTION 2.10

FOR BOARD APPLICA·

44-WAY CONN.

1..-------STANDARD GENISYS 1/0 CABLES

I I

: CONTROL DELIVERY I CONSTANT DELIVERY : CONTROL & DEVLIVERY I I ON-BOARD RELAY

: HEEL

L--------

Figure 2-1. Typical MICROLOK PLUS Power Input Wiring

6500, p. 2-3

2.4 POWER AND GROUND CIRCUITS

2.4.1 Power Sources

The MICROLOK PLUS system requires a single 24 Vdc source for operating power. Basic power specifications are the same as those for the MICROLOK system. For power input specifications, refer to:

S~j&t Cross Reference

Power source Specifications SM-6400B, section 2.4.1, page 2-2

NOTES

The input voltage range for the MICROLOK PLUS power supply converter is 19.8 to 32.4 Vdc, 24 Vdc nominal.

SM-6400B, section 2.4.1, page 2-2: The vital I/0 power requirements described in this section are applicable to the vital section of the MICROLOK PLUS unit.

When the non-vital section of MICROLOK PLUS is interfaced to local relay I/0 circuits, a separate 12 Vdc power source is required to energize individual inputs and outputs. If the vital section includes local relay and/or lamp driver outputs, the 12 Vdc power bus for these outputs can also be used to power the non-vital relay circuits. Make certain to wire the non-vital relay load according to Figure 2-1 of SM-6400B (as "OTHER LOAD").

2.4.2 Wiring and Surge/Noise Protection

Wiring and surge/noise recommendations for the MICROLOK PLUS unit are the same as those for the MICROLOK system. For these recommendations, refer to:

Subject

Wiring and Surge/Noise Protection

Cross Reference

SM-6400B, section 2.4.2, pages 2-3 through 2-5

NOTES

Section 2.4.2.2, part c, Note 3: The MICROLOK PLUS 24 Vdc power input does not require a HI-Q filtering capacitor.

Figure 2-1 on the following page is a typical power input wiring schematic for the complete MICROLOK PLUS system. Refer to this figure in place of Figure 2-2 of the MICROLOK manual SM-6400B.

6500, p. 2-2

2.4.3 Equipment Grounding (See Figure 2-2)

2.4.3.1 Rack and Cardfile Grounding

When the MICROLOK PLUS unit is installed in an equipment rack (rather than shelf mounted), rack grounding requirements are the same as those for the MICROLOK system. For these requirements, refer to:

S~j&t Cross Reference

Equipment Rack Grounding SM-6400B, section 2.4.3.1, page 2-6

NOTES

The MICROLOK PLUS cardfile is equipped with a single AAR stud for chassis grounding to the equipment rack. Run a minimum of #6 wire from the stud to the rack prime ground stud. Keep this wire as short as possible.

2.4.3.2 0 Volts Connection to Earth Ground

MICROLOK PLUS does not require an AC ground (0 volts connection to earth ground through capacitor) for noise protection; this is provided internally.

However, if the unit is used with a Serial Communications Adapter Panel or vital serial link modem, 0 volts on these units should be connected together and run to the rack prime ground stud through a 0.1 to 0.15 mFd, 200 volt (or greater) capacitor. Acceptable types of capacitors include polystyrene, polypropylene, polycarbonate or metalized polyester (Mylar). When the installation is complete, check the O volts to make sure it is still electrically isolated from the prime ground.

2.4.3.3 Serial and Local Cable Connection to Earth Ground

Each of the MICROLOK PLUS vital section serial communications cables (Master, Satellite and non-vital link) must be shielded. Connect the shields on these cables to earth ground on one end only. For vital serial interface cable schematics, refer to:

Subject

Vital Serial Cable Schematics

Cross Reference


NOTE

The redundant-CPU schematics in this section are not applicable to the MICROLOK PLUS system.

6500, p. 2-4

The serial and local I/0 cables to the non-vital PCBs should be provided shielding, especially if the MICROLOK PLUS unit is being used in a high-noise environment. When using shielded cable, connect one end only to earth ground. For non-vital serial and local interface cable schematics, refer to:


Non-Vital Serial Cable Schematics

Non-Vital Local Cable Schematics

MICRO LOK PLUS

#16

.......-ov ' FAS TON

' " CONTINUE OV BUS TO ANY OTHER UNITS (I.E. MODEM)

SERIAL COMM. ADAPTER

(WHEN REQ'D BY APPL.)

CHASSIS GROUND

0.1 TO 0.15 MFD CAPACITOR

#6

PRIME GROUND BUS

SM-63008, section 2.5.3.4, pages 2-18 and 2-19

SM-63008, section 2.5.3, pages 2-13 through 2-1 7

VITAL SECTION SERIAL CABLES

----~ ~--I I I GROUND AT I I I I ONE END I I I

3~;1Ni ONLY ~ 25-PIN 4+-t-+-1-------+-+-+--++

"D" I I

____ .... MICROLOK PLUS

CHASSIS GROUND ESTABLISHED AT "D" CONNECTOR SCREW (CHECK TIGHTNESS)

NON-VITAL SECTION SERIAL CABLE

----~ 44_WAY : GROUND AT

I I I I I

I I I ::l!D ~g~~v'ND ~ms I I I I I

GND OR 1 '

COMM : "' I CHASSIS GROUND ESTABLISHED

____ ..., AT GND OR COMM TERMINAL.

MICROLOK PLUS

I I ,... __

Figure 2-2. Summary of MICROLOK PLUS Ground Circuits

6500, p. 2-5

2.4.4 Power Supply 5 Volt Adjustment (See Figure 2-3)

A field-adjustable, trim potentiometer is provided inside the Power supply Drawer to refine the 5 volt output of the power supply converter. The 5 volt output powers the cardfile internal electronics. To access the potentiometer, slide out the drawer several inches. This can be done with power turned on.

1. Connect a digital voltmeter leads to test points TPl and TP2 to verify that input power is in the range of 19.8 to 32.4 Vdc.

2. Move the voltmeter leads to test points TP3 and TP4 to read converter module +5 volt output.

3. Adjust potentiometer as required so that converter module output (as shown on voltmeter) falls between 5.00 and 5.25 Vdc.

4. Optional step: Move voltmeter leads to +5V and OV test points on each PCB in the cardfile. This will verify that each is receiving the proper voltage level. The test points (on most PCBs) are accessible near the front edge of each PCB. Do not pull out PCB to access the test points.

TP6 ·12V O R4

[:=:::J

INCREASE R4

VOLTAGE C----~ •101

DECREASE ;_;, VOLTAGE

TRIM VOLTAGE

POT

POWER SUPPLY DRAWER

(SLIDE OUT)

Q TP4 +5V

TO TEST POINTS AS REQ'D

TP3Q ov

TP7 0 ·5V

TP2 0 N24

'-------1GND

~--------~ +

QTP1 824

DIGITAL VOLTMETER

Figure 2-3. Power supply 5 Volt output Check and Adjustment

6500, p. 2-6

2.4.5 Auxiliary Power for RFL Modem

MICROLOK PLUS is capable of powering two or three transmitter and receiver boards in an RFL modem used in the vital and/or non-vital serial link(s). This eliminates the need for a separate power connection and converter board in the modem. Auxiliary power from MICROLOK PLUS is provided through Faston terminals on the Power Supply. Output specifications are: 270 mA on +12 Vdc, 135 mA on -12 Vdc. This power source may also be used to operate other types of modems and devices used in conjunction with the MICROLOK PLUS non-vital serial interface; contact US&S for addition information.

2.5 PCB PREPARATION

2.5.1 Vital CPU

MICROLOK PLUS uses the same vital CPU boards as MICROLOK. For vital CPU board set-up procedures, refer to the following:

Subject

Peripheral PCB (N451441-5502) Switch/Jumper Set-Up

Cross Reference

SM-6400B, section 2.5.1.1, page 2-10

NOTE

The LOCK ON/AUTO/LOCK OFF switch (SW5) on the Peripheral PCB is not used in MICROLOK PLUS. However, always keep this switch in the AUTO position. If the LOCK LED is on, SW5 is not in the required AUTO position.

Peripheral PCB (N451441-5502) EPROM Installation

Code System Interface PCB (N451441-5302) Switch/Jumper Set-Up

SM-6400B, section 2.5.1.2, page 2-12

SM-6400B, section 2.5.1.3, page 2-13

The Processor and I/0 Bus Interface PCBs do not require any adjustments prior to installation in the MICROLOK PLUS cardfile.

2.5.2 Vital I/0

None of the vital input or output PCBs used in the MICROLOK PLUS cardfile requires any adjustments prior to installation.

6500, p. 2-7

2.5.3 Non-Vital Controller

MICROLOK PLUS uses the same non-vital Controller PCB as GENISYS. For set-up of the Controller PCB, refer to the following:

Subject

Controller PCB (N451441-5602) EPROM Installation

Controller PCB (N451441-5602) Switch/Jumper Set-Up

Cross Reference

SM-6300B, section 2.2.1, page 2-1

SM-6300B, sections 2.2.2 through 2.2.9, pages 2-1 through 2-6.

NOTE

Section 2.2.7: The EIA RS-423 mode is required when Controller PCB is interfaced with the vital section Code System port of the same MICROLOK PLUS unit.

2.5.4 Non-Vital I/0 PCBs

None of the MICROLOK PLUS non-vital section optical-input or relay-output PCBs require any adjustments prior to installation.

2.6 PCB INSTALLATION

Install the MICROLOK PLUS vital and non-vital PCBs as required by the the application and according to the guidelines in section 1.2.2.1 and Figure 1-4.

CAUTION

DO NOT INSTALL OR REMOVE ANY MICROLOK PLUS PLUG-IN PCBS WITH POWER TURNED ON, OTHERWISE FAULTY SYSTEM OPERATION AND/OR COMPONENT DAMAGE MAY RESULT.

For testing of the MICROLOK PLUS vital section PCBs prior to installation, refer to the following:


Equipment Retesting Guidelines SM-6400C, section 3.4, page 3-108

2.7 ECHO ENABLE JUMPERS (VITAL I/0)

Each vital I/0 card slot location that contains a PCB must be equipped with a blue Echo Enable Jumper on the cardfile back panel. These are installed at the factory per the application, but should be checked prior to putting the MICROLOK PLUS unit into service. As shown in Figure 2-4, place each jumper in the "INw position when a Standard Input board is installed in the corresponding card slot. Place the jumper in the "OUT" position when the card slot contains a standard Relay Driver, Voltage-Limited Relay Driver, Bipolar Relay Driver or DC Lamp Driver PCB.

6500, p. 2-8

M10 M9 MS M7 M6 MS M4 M3 M2 Ml

r:-:, r:-:, r:-:, r:-:, r:-:, r:-:, r:-:, r:-:, r:-:, r:-:,

CARDFILE MOTHERBOARD

REAR VIEW {COVER REMOVED)

VITAL 1/0 SECTION

J10: J9 : JS: J7 : J6 : JS : J4: J3 : J2: J1

IN :

OUT §1 IN :

OUT §1 IN 8: IN :

OUT §1 IN :

OUT §1 IN :

OUT §1 IN :

OUT §1 IN :

OUT §i IN :

OUT §i IN :

OUT ~i OUT C;

L_J L-...J L_J L_J L_J L_J L_J L-...J L-...J

it ECHO ENABLE IN INPUT PCB IN OUTPUT PCB JUMPER FOR I IN THIS SLOT I IN THIS SLOT . ADJACENT CARD OUT OUT

SLOT

Figure 2-4. Echo Enable Jumper Position Check

2.8 VITAL SECTION LOCAL INTERFACES

MICROLOK PLUS uses the same vital I/0 PCBs as MICROLOK. For interfacing of these PCBs, refer to the following:

Subject

Vital I/0 Interfacing

Cross Reference

SM-6400B, sections 2.8.2 through 2.8.4, pages 2-21 through 2-43

NOTES

SM-6400B only lists the vital I/0 boards without individual I/0 line LEDs. However, the boards that are equipped with these LEDs (refer to section 1.3.2.3) are handled in the same manner.

Figure 2-11: This figure shows slot numbers Jl through J7 for the MICROLOK system. In the MICROLOK PLUS system, these slots are identified as letters E through K.

Section 2.8.4.4, part D: The l.3K ohm resistor is not required on Bipolar Relay Driver PCB N451441-8701 (same PCB as N451441-6601, but with I/0 line LEDs added).

6500, p. 2-9

L_J

2.9 VITAL SECTION SERIAL INTERFACES

2.9.1 Serial Ports (See Figure 2-5)

When the vital section of MICROLOK PLUS is configured for serial communications with another vital control system (another MICROLOK PLUS or MICROLOK), cable connections are made on either or both of the two 37-pin "D" connectors (female) on the right hand side (rear view) of the cardfile. This can include EIA signal cables that go directly to another system or modem, or EIA cables that go to an external serial communications Adapter Panel for conversion to 20 mA current loop mode.

When the vital section of MICROLOK PLUS is also configured for non-vital serial communications with the non-vital section or an external GENISYS system, the external cable connection is made on the single 25-pin "D" connector located between the two 37-pin "D" connectors. The 25-pin connector is the external interface for the Code System PCB, and is hardwired to only support EIA communications.

When the unit's vital section is linked to the non-vital section, a serial data cable is run between the vital section 25-pin "D" connector and the 44-pin PCB edge connector on the non-vital Controller PCB. This particular link can only be configured for EIA communications, even though the Controller PCB has jumpers that also allow TTL communications.

2.9.2 Cabling General Notes

US&S provides standard cables for the following serial data interfaces from the MICROLOK PLUS vital section:

Link Type Mode

MICROLOK PLUS-to-MICROLOK PLUS Vital EIA*** MICRO LOK PLUS-to-MICRO LOK Vital EIA*** MICROLOK PLUS-to-MICROLOK PLUS* Non-Vital EIA only MICRO LOK PLUS-to-GEN I SYS Non-Vital EIA only MICROLOK PLUS Internal** Non-Vital EIA only

* From Code System port (vital section) of one MICROLOK PLUS to Controller PCB Port (non-vital section) of other MICROLOK PLUS.

** Vital section (Code System Interface PCB) to non-vital section (Controller PCB).

*** Can be converted to 20 mA current loop communications via Serial Communications Adapter Panel.

Two basic types of EIA cables are available; those that allow direct connection of two or more units, and those which interface MICROLOK PLUS to a serial data modem. US&S recommends these cables be used for all vital and non-vital serial links from the MICROLOK PLUS vital section.

6500, p. 2-10

NON-VITAL SATELLITE PORT TO: NON-VITAL MASTER PORT TO: VITAL MASTER PORT TO: NON-VITAL SATELLITE TO:

(1) EXTERNAL MJCROLOK PLUS (1) EXTERNAL MICROLOK PLUS (T) EXTERNAb MICROLO~ PLUS (1) EXTERNAL MICROLOK PLUS

• NON-VITAL SECTION • VITAL SECTION • VITAL SECTION • NON-VITAL SECTION

• SLOT O (CONTROLLER PCB) • CODE SYSTEM EIA PORT • VITAL SATELLITE PORT • SLOT O (CONTROLLER PCB)

• EIA RS-423 OR TIL (25-PIN D) (37-PIN D) • EIA RS-423 ONLY

(2) GENISYS • EIA RS-423 ONLY • EIA RS-423 ONLY (21 GENISYS

• SLOT J2 (CONTROLLER PCB) (2) MICROLOK (2) MICROLOK • SLOT J2 (CONTROLLER PCB)

• EIA RS-423 OR TIL • CPU CARDFILE • CPU CARDFILE • EIA RS-423 ONLY

• CODE SYSTEM PCB PORT • 110 BUS INTERFACE PCB SLOT (3) OFFICE COMPUTER (3) OFFICE COMPUTER

(37-PIN DJ (37·PIN D)

• CODE SYSTEM PORT EIA RS-423 OR TIL EIA RS-423 ONLY • CODE SYSTEM PORT

• • EIA RS-423 ONLY • EIA RS-423 OR TIL •

MICROLOK PLUS NON·VIT AL SEC.

CONTROLLER PCB PORT, 44-WAY

MICROLOK PLUS NON-VITAL SEC.

CONTROLLER PCB

PORT, 44·WAY

MICROLOK PLUS NON·VITAL SEC.

CONTROLLER PCB PORT, 44·WAY

MICROLOK PLUS

NON·VIT AL SEC.

CONTROLLER PCB

PORT, 44-WAY

NOTE "SATELLITE" IS THE SAME AS "SLAVE".

MICROLDK PLUS INTERNAL

SERIAL INTERFACE:

• MASTER: NON·VIT AL SECTION

• EIA RS-423 ONLY

VITAL SATELLITE TO:

(1) EXTERNAL MICROLOK PLUS

• VITAL SECTION • VITAL MASTER PORT (37-PIN D) • EIA RS-423 ONLY

(2) MICROLOK

• • •

CPU CARDFILE PERIPHERAL PCB SLOT (37-PIN D) EIA RS-423 ONLY

MICROLOK PLUS CARDFILE {REAR VIEW)

I a SATELLITE: VITAL SECTION

~·=,===========1=1 =====~'--~----v-11~~~-'

,..---. r---, I I I I

,,..., ,,..., r' .., r' .., I A II I I II I II I II

II II II II II II II II II

I II I II I II I I II I II I I II I II I II I z I 22 I

L, ,.J L, ,.J ... _/ ... _/

,----. ,..---, D I I I I

""--"" L.--.J

O INTERNAL CABLE 2'~ 0 +-- EIA: 50 FT. MAX. ~

MICROLOK PLUS VITAL SECTION

CODE SYS. PORT, 25·PIN D

EIA: 50 FT. MAX. TIL: 5 FT. MAX.



MICROLOK CPU CARDFILE

CODE SYS. PORT 37-PIN D

MICROLOK PLUS O NON-VITAL SEC. OR GENISYS

CONTROLLER PCB ---+ PORT, 44·WAY

"~.,,. (

CODE VITAL SYSTEM

MASTER (EIA}

20 14

0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0

0 0 0 0 0 0

0 0 0

0 0 0 0 0 0

0 0 0

0 0 0 0

0 0

0 13 25 0 0 0

0 0 SEE FIGURE

2·6 FOR

PIN·OUTS

19 37

MICROLOK PLUS OR MICROLOK VITAL MASTER PORT, 37-PIN D

MICROLOK OR MICROLOK PLUS VITAL MASTER PORT, 37-PIN D

VCOR DRIVE ONLY REQ'D FOR MICROLOK

EIA: 50

FT. MAX.

SATELLITE

EIA: 50 FT. MAX.

Figure 2-5. Serial Data Ports and Cables

6500, p. 2-11

VITAL SLAVE

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

19

EIA: 50

FT. MAX.

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

20

37

MICROLOK PLUS OR MICROLOK

VITAL SATELLITE

PORT, 37-PIN D

MICROLOK OR MICROLOK PLUS VITAL SATELLITE PORT, 37-PIN D

Direct-link EIA cables are available from US&S in various lengths up to 45 feet. Fifty feet is the US&S recommended maximum cable separation between two units in EIA communications. At greater lengths, line resistance and transient signals may cause interference with serial communications. A modem should be used when EIA cable length exceeds 50 feet, and/or the communications line leaves the equipment house containing the MICROLOK PLUS unit. MICROLOK PLUS-to-EIA modem cables are available in 20 foot lengths to allow cutting to the desired length.

2.9.3 Modem Recommendations

Consult US&S for recommendations on the modem used with MICROLOK PLUS vital and non-vital sections serial ports.

2.9.4 Vital Master and Satellite EIA Interfaces

For serial interfacing of the MICROLOK PLUS vital CPU, refer to the following:

Subject

Vital CPU Serial Interfacing

Cross Reference


NOTES

MICROLOK PLUS does not utilize redundant CPU serial interfaces. Ignore sections 2.9.4.2, 2.9.4.4, and 2.9.4.6 of SM-6400B.

Section 2.9.4.1, part A: In a MICROLOK PLUS/MICROLOK interface, the cable assembly contains two separate wires available at the connector housing. These wires are provided for the MICROLOK Satellite unit (I/0 Bus Interface PCB) to supply the VCOR drive+ and - wires. For MICROLOK PLUS, the VCOR wires may be connected from this cable assembly also, or from the Faston terminals (RLY (+), RLY (-)) on the motherboard.

6500, p. 2-12

This page intentionally left blank.

6500, p. 2-13

2.9.5 Vital Section - Code System Interface

A. Design

NOTE

In this section, the term "non-vital controller" refers to an:

External GENISYS unit Non-vital section of an external MICROLOK PLUS unit Non-vital section of the same MICROLOK PLUS unit.

Figure 2-6 shows the standard interface between the non-vital port of the MICROLOK vital section, and a non-vital controller. In this interface, the MICROLOK PLUS vital section functions as a Satellite to the non-vital controller. The left-hand pin-outs are on the 25-pin "D" connector of the MICROLOK PLUS unit. The right-hand pin-outs are on the 44-pin connector of the non-vital controller.

Note that the shielded cable is grounded at the non-vital controller end of the interface. The MICROLOK PLUS end does not require shield grounding. Note also that various carrier control lines on the MICROLOK PLUS end are jumpered on the MICROLOK PLUS motherboard. Therefore, jumpers are not required within the 25-pin "D" connector.

The non-vital interface can only be configured for EIA communications, even though a TTL option is available on the non-vital Controller PCB.

B. Ordering References

The following tabulation lists the standard US&S connector/cable assemblies available for this interface. The 2 ft., 6 in. cable is intended for the direct interface between the vital section (Code System Interface) and non-vital section of the same MICROLOK PLUS unit.

Length US&S Part No.

2 ft. 6 in. N451458-9801 5 ft. N451458-9802

10 ft. N451458-9803 15 ft. N451458-9804 20 ft. N451458-9805

6500, p. 2-14

MICROLOK PLUS: • VITAL SECTION • "CODE SYSTEM (EIA)" PORT • 25-PIN "D"

INTERFACE CABLE

·~ ·~ RXD (75, 78) 1, 14 ... BU

.ii 1 TXD

.... ,...,

TXD (79, 82) 3, 16 ... BR .ii

4 RXD ' .... ' ....

DCD (57, 60) 5, 18 ... y .ii

2 RTS

" .... ' ....

RTS (73, 76) 13, 25 ... 0 ... 5 DCD

'~ -~ RX COM (83, 86) 7 ... G ... J COM (OV)

SIG

~

/_ ~

GND (OV) (49-52, 54) 20 ... BK k·~

6 CTS ....

CTS (69, 72) 11,23 / ... R

.ii 7 DSR

, .... ' ....

~' ~' CTS u +12V - k·~

DSR (61, 64) ... 19 ov ' .....

(RXD} (74)

i (RXD) (68, 70) MICROLOK PLUS:

• NON-VITAL SECTION

• CONTROLLER PCB, SLOT O

• 44-WA Y PCB EDGE

(DCD} (59) GENISYS:

JUMPERS • CONTROLLER PCB, SLOT J2

INTERNAL TO • 44-WA Y PCB EDGE

(DCD} (53, 55) MICRLOK PLUS MOTHERBOARD

(CTS) (71) 25-PIN D PIN NO .

(CTS) (65, 67) • (XX) X

t (

(DSR) (62) PCB TOP EDGE (A) CONTACT

(DSR) (56,58) ~ 44-WAY

Figure 2-6. Standard MICROLOK PLUS Vital section/Non-Vital Interface

6500, p. 2-15

2.9.6 current Loop Interface

MICROLOK PLUS uses the same Current Loop Interface option as MICROLOK. For utilization of this interface, refer to:

Cross Reference

Current Loop Interface, Typical Application


NOTES

MICROLOK manual SM-6400B shows the current loop interface used for vital communications. This interface can also be used for non-vital communications.

The MICROLOK PLUS power supply cannot be used to power the Current Loop Adapter Panel. A separate external supply is required.

2.10 NON-VITAL SECTION LOCAL INTERFACES

The non-vital I/0 PCBs of MICROLOK PLUS use the same local interfaces as the GENISYS I/0 PCBs. For interfacing of these boards, refer to:


Non-Vital I/0 PCBs Interfacing SM-6300B, section 2.5.2, page 2-9 Connector/Cable Assembly

Control Delivery N451441-3601 and SM-6300B, section 2.5.3.1, page 2-12 Constant Delivery N451441-7101 PCBs Interfacing

Control and Delivery PCB SM-6300B, section 2.5.3.2, page 2-14 N451441-4701 Interfacing

Optical Input PCBs N451441-7202 SM-6300B, section 2.5.3.3, page 2-16 and N451441-5802 Interfacing

Misc. Interfacing Recommendations SM-6300B, section 2.5.4.13, page 2-29/30

Non-Vital I/0 PCB Electrical SM-6300B, sections 2.5.4.5 through Specifications 2.5.4.9 of SM-6300B, pages 2-23

through 2-26

6500, p. 2-16

2.11 NON-VITAL SECTION SERIAL INTERFACE SPECIFICATIONS

NOTE

See Figure 2-5 for physical arrangement of all MICROLOK PLUS serial data ports and cables.

The following table summarizes the interface options available to the non-vital section Controller PCB:

Interface To

External MICROLOK PLUS

External MICROLOK PLUS

External MICROLOK

External GENISYS

Office Computer

Same MICROLOK PLUS

Remote Port Modem Options

Controller PCB (Non-Vital Section) EIA or TTL (Master and Satellite ports)

Code System PCB (Vital Section) EIA Only

Code System PCB EIA or TTL

Controller PCB EIA or TTL (Master and Satellite ports)

EIA or TTL

Code System PCB (Vital Section) EIA Only

The non-vital Controller PCB of MICROLOK PLUS use the same serial interfaces as the GENISYS Controller PCB. For interfacing of this board, refer to:


Master/Satellite System Configua- SM-6300B, section 2.4, page 2-7 tion Guidelines

Non-Vital Controller PCB (N451441-5602) Connector/Cable Assembly

Non-Vital Controller PCB (N451441-5602) Interfacing

Non-Vital Controller PCB (N451441-5602) Electrical Specifications


SM-6300B, section 2.5.3.4, page 2-18

SM-6300B, section 2.5.4.4, page 2-22

6500, p. 2-17/18

SECTION III FUNCTIONAL DESCRIPTION

3.1 VITAL SECTION

The MICROLOK PLUS vital section utilizes the same operating principles as the MICROLOK system. For functional descriptions, refer to:

Subject

Basic Vital Operating Principles

Non-Vital Serial Communications

Cross Reference

SM-6400A, sections 2.1 through 2.3, pages 2-1 through 2-11

SM-6400A, section 2.5, pages 2-14 through 2-17/18

NOTES

Section 2.4: This section describes the redundant CPU function of MICROLOK. Since MICROLOK PLUS cannot be equipped with redundant CPUs, section 2.4 is not applicable.

Figure 3-1 on the following page is MICROLOK PLUS equivalent of Figure 2-3, page 2-15, of MICROLOK manual SM-6400A.

3.2 NON-VITAL SECTION

The MICROLOK PLUS non-vital section utilizes the same operating principles as the GENISYS system. For functional descriptions, refer to:

Subject

Serial Port Operation Data and Control Lines LEDs carrier Control Modes

Controller PCB (N451441-5602) Functions

Relay-Output PCBs (N451441-3601) and N451441-7101 Functions

Relay-Output PCB (N451441-4701) Functions

Optical Input PCBs (N451441-7202) and N451441-5802 Functions

Cross Reference

SM-6300B, section III, pages 3-1 through 3-7/8

SM-6300C, section 2.1, pages 2-1 through 2-9

SM-6300C, section 2.2.1, pages 2-10 through 2-13/14

SM-6300C, section 2.2.2, pages 2-16 through 2-17/18

SM-6300C, section 2.3, pages 2-20 through 2-23/24

6500, p. 3-1

--- EXTERNAL MICROLOK PLUS OR GENISYS UNIT

CONTROLLER PCB

MASTER SERIAL PORT

~--+-----• TO EXTERNAL CONTROL SYSTEM (I.E. OFFICE

COMPUTER)

MICROLOK PLUS UNIT

SA TEL. SERIAL PORT


DATA AND CONTROL

LINES

CODE SYSTEM PCB

CODE SYS. ~ MICRO-

PORT PROCESSOR CONTROL

,Ir

CODE SYSJ ~ ... VITAL CPU

PORT

-i t .. MICROLOK/ CODE SYSJ

GENISYS VITAL CPU

TO EXTERNAL CONTROL SYSTEM (I.E. OFFICE

COMPUTER)

VITAL CPU

,. MASTER SERIAL PORT

VITAL MICRO-

PROCESSOR

a

PORT

~

~

,, SLAVE SERIAL PORT

~}.-~ NON-VITAL PORT CONTROL CONTROLLER PCB

DATA AND CONTROL LINES

PORT

VITAL CPU BUS

t I

Figure 3-1. Vital Section Serial Link to Non-Vital Controller

NOTE

The above figure is the MICROLOK PLUS equivalent of Figure 2-3, page 2-15 of MICROLOK manual SM-6400A.

6500, p. 3-2

SECTION IV APPLICATION PROGRAMMING

4.1 VITAL SECTION

The MICROLOK PLUS vital section uses the same application logic as the MICROLOK system. For programming procedures and guidelines, refer to:


Programming Formats, Guidelines SM-6400A, sections 3.1 through 3.6, pages 3-1 through 3-28

MICROLOK Development System Introduction


Files Compiler Simulator EPROM Programmer Scan Time Estimates

Supplemental Data Application Logic Compiler Switches Status Byte Allocation in Non-Vital Controller Compiler Error Messages

SM-6400A, section IV, pages 4-1 through 4-12

NOTES

The MICROLOK Development System compiler permits up to 15 I/0 PCBs to be defined. However, the MICROLOK PLUS vital section only allows 10 vital I/0 PCBs. This aspect of MICROLOK PLUS programming should be noted in the following sections of SM-6400A:

Section

3.3.1.3, part B 3.5, step 4

3-10 3-24

Section 4.3.3, page 4-11 of SM-6400A: Semantic Error Code number 10 will be displayed when more than 15 local I/0 boards are specified. However, no error will be displayed if 11 to 15 local I/0 boards are specified for MICROLOK PLUS.

Figures 4-1 and 4-2 on the following pages show a sample symbol table and source listings for a MICROLOK PLUS vital section application program. Refer to these listings in place of of the listings on pages 3-34 and 3-35 of SM-6400A.

6500, p. 4-1

MICROLOK SOURCE LISTING ( VERSION 4.00) 18-APR-1989 COPYRIGHT 1985, REVISED 1989 UNION SWITCH & SIGNAL INC.

1 %$D+ DEBUG ON' 2 % THIS IS A SAMPLE PROGRAM\ 3 4 %$Ll 1 MINUTE RESET OUTPUT INHIBIT TIME'\ 5 6 MICROLOK PROGRAM EXAMPLEl; 7 8 INTERFACE 9 LOCAL

10 OUTPUT DC.STANDARD WORD: 01,02,03; 11 OUTPUT DC.LAMP WORD: Ll,L2,L3; 12 LAMPOUT: L01,L02,L03; 13 INPUT DC.STANDARD WORD: Il, I2, I3, I4, IS, I6; 14 15 VAR 16 Vl; 17

TIMER Vl 01 03

SET=lOO:MSEC SET=56 0 :MSEC SET=O:MSEC

CODED OUTPUT TOGGLE L2 AT 10:CPM

20:CPM

BEGIN ASSIGN Il ASSIGN Il AND I2 ASSIGN I3 XOR I2 ASSIGN I6

IF IF

CLEAR=lOO:MSEC; CLEAR=SO:MSEC; CLEAR=SO:MSEC;

I3; I4;

TO 01; TO 02; TO 03, Vl; TO L3;

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

ASSIGN L2 AND (I3 or I4) TO Ll; END

ERRORS DETECTED : 0 UNASSIGNED INTERNAL/OUTPUT BITS 3

PAGE:

Figure 4-1. Sample Source Listing for MICROLOK PLUS Vital Section Application Program

6500, p. 4-2

1

'-.:! ..... <Q s;::: rs Cl)

""' I 1-J .

:i:,, Cl)

:g !!J 1--''0 ..... I-' n Cl) QJ rt Cl) ..... '< 0 :I ::s tr

0 'i:::t I-' rs 0 8

<Q QJ O'I rs tr l11 QJ I-' 0 :I Cl) 0 .. I:"' .....

'Cl rn . rt" ..... ""' ::s I <Q w

111 0 rs :;:: H ()

~ I:"'

~ 'i:::t

8 Cl)

<: ..... rt QJ I-'

Cl) Cl) n rt ..... 0 ::s

MlCROL.OK Symbol Table Listing [ Vers i ,:,n 4.00

Bit Bit Bit Equations Using Nurnbet· Name Type Front Back

01 OUTPUT 2 02 OUTPUT 3 0:3 OUTPUT 4 L1 OUTPlJT 5 L';> OUTPUT 1 0 6 L:3 OUTPUT 7 L01 SYSTEM BIT 8 L02 SYSTEM BIT 9 UJ::::: SYSTEM BIT

10 11 INPUT 2 0 11 I·" '- INPUT 2 0 12 1·-:> •J INPUT 2 0 1:3 14 INPUT 1 (I

14 15 INPUT 15 16 INPUT 1 0 11.::, V1 INTERNAL 17 KILL *UNASSIGNED 18 RESET *UNASSIGNED 19 SYSERR.CLEAR *UNASSIGNED 20 SYSERR SYSTEM BIT 21 SYSERR.1 SYSTEM BIT ·":--":-"-"- SYSERR.2 SYSTEM BIT 23 SYSERR.3 SYSTEM BIT 24 SYSERR.4 SYSTEM BIT :2:5 SYSERR.5 SYSTEM BIT 26 SYSERR.6 SYSTEM BIT 27 SYSERR.7 SYSTEM BIT 28 SYSERR.8 SYSTEM BIT 29 SYSERR.9 SYSTEM BIT :30 SYSERR.10 SYSTEM BIT

MICROLOK Symbol Table Listing Version 4.00 J

Bit Number

Bit Name

SWITCH Settings

Debus Initial Output Delay MIP Sum No Response Time MASTER

Time Out Baud Rate f<ey On Key Off

SLAVE Time Out Baud Rate f<ey On Key Off

Bit Type

ON 1 MIN 1.0 SEC 116 MSEC

4.0 SEC 1200 BPS O MSEC O MSEC

4.0 SEC 1200 BPS O MSEC O MSEC

Equations Using Front Back

Program: "E}(AMPLE1

Intet·face Inf,)nnat ion Type Station Position

LOCAL 1 0 LOCAL 1 1 LOCAL 1 2 LOCAL 2 0 LOCAL 2 1 LOCAL 2 2

LOCAL 3 0 LOCAL 3 1 LOCAL 3 2 LOCAL 3 3 LOCAL 3 4 LOCAL 3 5

Program: "EXAMPLE1

Interface Information Type Station Position

Bit Attribute

TIMER BIT

TIMER BIT

CODED OUTPUT

TIMER BIT

II

Bit Attribute

Page: SYM-1

Time Delay Set Clear

560:MSEC 50:MSEC

O:MSEC 50:MSEC

100:MSEC 100:MSEC

Page: SYM-2

Time Delay Set Clear


The MICROLOK PLUS non-vital section uses the same application logic as the GENISYS system. For programming procedures and guidelines, refer to:

Subject

Programming Formats, Guidelines

GENISYS Development System Introduction Files Compiler Simulator EPROM Size Estimates Program EPROM Programmer

Program Design Notes Logic and Timing Overflows Timing Elements Validation Option Logic Queuing and Execution

Misc. Application Information Local I/0 serial communications Timing

Serial Communications Protocols Introduction to Formats Detailed Descriptions

Error/Warning Messages Token and Parsing Semantic

Cross Reference

SM-6300A, sections 2.1 and 2.2, pages 2-1 through 2-23


SM-6300A, section III, pages 3-1 through 3-7/8

SM-6300A, section IV, pages 4-1 and 4-2

SM-6300A, section V, pages 5-1 through 5-10

SM-6300A, sections 6.1 and 6.2, pages 6-1 through 6-4.

NOTES

The GENISYS Development System compiler permits up to 16 I/0 PCBs to be defined. However, the MICROLOK PLUS non-vital section only allows two I/0 PCBs. This aspect of MICROLOK PLUS programming should be noted in the following sections of SM-6300A:

Section

2.2.3.1 2 • 7 • 1 , " NI OB " 2.7.2, "How many local I/0 boards?"

2-8 2-50 2-51

Section 6.2, page 6-21 of SM-6300A: Semantic Error Code number 1 will be displayed when more than 16 local I/0 boards are specified. However, no error will be displayed if 3 to 16 local I/0 boards are specified for MICROLOK PLUS.

6500A, p. 4-4

NOTES (Cont'd)

Figures 4-3 and 4-4 on the following pages show sample symbol table and source listings for a MICROLOK PLUS non-vital section application program. Refer to these listings in place of of the listings on pages 2-30 and 2-31 of SM-6300A.

In the Symbol Table Listing, note that the I/0 slots are numbered 3 and 4. These are the first two slot numbers used in the GENISYS compiler. In MICROLOK PLUS these slots are numbered P and Q.

6500, p. 4-5

GENISYS SOURCE LISTING VERSION 2.06 20-MAR-1989

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

COPYRIGHT 1984 - 1988, UNION SWITCH & SIGNAL, INC.

%

\

THIS IS AN EXAMPLE OF A BASIC GENISYS PROGRAM.

%$D+ %$Q+

DEBUG ON\ TWO QUEUE OPTION\

PROGRAM NBR3; INTERFACE

LOCAL OUTPUT WORD: OUT.I, OUT.2, OUT.3,

SPARE, SPARE, SPARE, SPARE, SPARE, OUT.4, OUT.5, OUT.6, OUT.7, OUT.8;

INPUT WORD: IN.A, IN.B, IN.C, IN.D;

VAR STICK, Tl;

TIMER Tl: OUT.7 OUT.8

BEGIN

SET=l:SEC SET=l:SEC SET=O:SEC

ASSIGN IN.A AND IN.B ASSIGN IN.A XOR IN.B ASSIGN IN.A OR IN.B ASSIGN NOT IN.A

CLEAR=l:SEC; CLEAR =l:SEC; CLEAR =500:MSEC;

ASSIGN IN.C OR (STICK AND NOT IN.D) ASSIGN STICK

TO OUT. l; TO OUT.2; TO OUT.3; TO OUT.4; TO STICK; TO OUT.6; TO Tl; ASSIGN NOT Tl

ASSIGN Tl ASSIGN NOT Tl

END

TO OUT.7; TO OUT.8;

WARNINGS DETECTED: 0 ERRORS DETECTED: 0

Figure 4-3. Sample source Listing for MICROLOK PLUS Non-Vital Section Application Program

6500, p. 4-6

PAGE 1

BIT SYMBOL TABLE FOR "NRB3"

IDENTIFIER BIT NUMBER & TYPE

LOCAL I/0 BOARDS OUTPUT - SLOT 3

OUT.l 1 OUTPUT OUT.2 2 OUTPUT OUT.3 3 OUTPUT SPARE 4 SPARE 5 SPARE 6 SPARE 7 SPARE 8 OUT.4 9 OUTPUT OUT.5 10 UNASSIGNED OUT.6 11 OUTPUT OUT.7 12 OUTPUT OUT.8 13 OUTPUT

INPUT - SLOT 4 IN.A 14 INPUT IN.B 15 INPUT IN.C 16 INPUT IN.D 17 INPUT

LOCAL VARS STICK 18 INTERNAL Tl 19 INTERNAL

SWITCH SETTINGS

SLAVE BAUD RATE MASTER BAUD RATE POLLING TIME OUT CONTROL DELIVERY TIME SECURITY DEBUG SYMBOL TABLE LISTING VALIDITY CHECK TWO QUEUE OPTION

HARDWARE SWITCH 1200 BPS 1000 MSEC HARDWARE SWITCH AUTOMATIC ON ON ON ON

20-MAR-1989. PAGE SYM- 1

TIMER SET

1.0: SEC 0.0: MSEC

1.0: SEC

CLEAR

1. 0: SEC 400.0: MSEC

1. 0: SEC

Notes: "OUTPUT - SLOT 3" is slot "P" in MICROLOK PLUS cardfile. "INPUT - SLOT 4" is slot "Q" in MICROLOK PLUS cardfile.

Figure 4-4. Sample Symbol Table for MICROLOK PLUS Non-Vital Section Application Program

6500, p. 4-7/8

5.1 VITAL SECTION

5.1.1 General Requirements

SECTION V FIELD MAINTENANCE

The MICROLOK PLUS unit is subject to the same general maintenance requirements as the MICROLOK system. For these requirements, refer to:


Gene·-·al Maintenance Requirement SM-6400C, section 3.1, page 3-1

NOTE

The MICROLOK PLUS power supply drawer is subject to the same maintenance requirements as the MICROLOK CPU and I/0 power supplies. No attempt should be made to shop repair the drawer in the field. The drawer should be returned to US&S for repair or

eplacement.

5.1.2 Periodic Inspection

For periodic inspection of the MICROLOK PLUS unit, refer to:


Periodic Inspection SM-6400C, section 3.2, page 3-2

5.1.1 Troubleshooting Guide

5.1.3.l Required Test Equipment and Materials

The M!CROLOK PLUS unit uses the same test equipment and materials as the MICROLOK system. For a listing of these items, refer to:

Subject

Required Test Equipment and Materials

Cross Reference

SM-6400C, section 3.3.1, page 3-3

6500, p. 5-1

5.1.3.2 Power-Off Checks

The power-off checks of the MICROLOK PLUS unit are the same as those for the MICROLOK system. For these checks, refer to:


Power-Off Checks SM-6400C, section 3.3.2, pages 3-4 and 3-5

NOTES

Step 1: Unlike the MICROLOK system, the order of the vital CPU boards in MICROLOK PLUS is fixed.

Step 4: This step only lists the vital I/0 boards without individual I/0 line LEDs. The equivalent boards with I/0 line LEDs are as follows:


US&S Part No. N451441-

w/o LEDs w/LEDs

-6501 -8601 -7401 -8501 -6601 -8701 -6402 -8802 -6403 -8803

Step 5: The Echo Enable jumpers on MICROLOK PLUS are labelled differently than the MICROLOK CPU cardfile. Refer to section 2.7 of this manual when performing the jumper position check.

Refer to Figure 1-4 of this manual in place of Figure 3-1 of SM-6400C.

5.1.3.3 Power-On Checks

The power-on checks of the MICROLOK PLUS unit are the same as those for the MICROLOK system. For these checks, refer to:

Subject

Power-On Checks

Cross Reference

SM-6400C, section 3.3.3, pages 3-7 and 3-8

6500, p. 5-2

NOTES

Section 3.3.3, page 3-7: The power-on checks given in this section are applicable to MICROLOK PLUS. This includes all voltage specifications. However, note that MICROLOK PLUS is equipped with a single power supply drawer, rather than the separate CPU and I/0 power supply panels of MICROLOK.

The MICROLOK PLUS 12 volt output for an RFL modem should also be checked. Specifications for these outputs are 270 mA on +12 Vdc, -135mA on -12 Vdc.

5.1.3.4 Power-On System Tests

The power-on checks of the MICROLOK PLUS unit are the same as those for the MICROLOK system. For these checks, refer to:

Subject

Power-On System Tests

Cross Reference

SM-6400C, section 3.3.4, pages 3-9 through 3-11

NOTES

Section 3.3.4.1: When the MICROLOK PLUS unit is turned on, all LEDs on the power supply drawer front panel should light.

See Figure 5-1 on the following page for the configuration of the vital section CPU and I/0 LEDs. Refer to this figure in place of Figure 3-2 on page 3-11 of SM-6400C.

5.1.3.5 Displaying and Clearing Error Codes

Displaying and clearing of error codes from the MICROLOK PLUS unit is handled in the same manner as the MICROLOK system. For procedures, refer to:

Subject

Displaying and Clearing of Error Codes

Cross Reference

SM-6400C, section 3.3.5, page 3-12

NOTE

Section 3.3.5.2: This section of SM-6400C is not applicable to the MICROLOK PLUS system (no redundant CPUs).

6500, p. 5-3

',;l ..... t.Q s::: l"'I <D

U1 I ~ . : n 0 ::, HI

°' .....

u, t.Q 0 s::: 0 l"'I'

... ~ 'U

..... 0 ::,

u, I 0

"'" HI

~ ..... rt DI 1--'

Cl)

<D (')

rt ..... 0 ::,

t"' t>l t:, en

RED

LED

NO.

t

ORANGE

LED

NO.

+

YELLOW WHITE BLUE

DLED NO. .. !

LED

NO.

t 7 (RTS)

8 (WTCHDG)

1 (DCD}

2 (DIAG.)

3 (DIAG.)

4 (DIAG)

5 (DIAG.)

6 (DIAG.)

7 (WTCHDG)

6 (NOT USED}

5 (NOT USED}

LED

NO.

! 4 (SYS. STAT.) NO.

3 (SYS. STAT.) + 2 (SYS. STAT.)

BLUE PINK PINK AQUA AQUA VIOLET GREEN GREEN

D D D D D D D 9 (INRUSH 1)

8 (VOLT. 1)

7 (INRUSH 2)

6 (VOLT. 2)

5 (INRUSH 3)

4 (VOLT. 3)

LED LED

II II I~ 3 (INRUSH 4} NO. NO. 2 (VOLT. 4)

+ t 2 (INPUT 1)

2 (OUTPUT 1) 2 (OUTPUT 1) 2 (OUT IN} 3 (INPUT 2)

3 (OUTPUT 2) 3 (OUTPUT 2) 3 (OUT IR 4 (INPUT 3)

4 (OUTPUT 3) 4 (OUTPUT 3) 4 (OUT 2N} 5 (INPUT 4)

5 (OUT 2R) LED LED 5 (OUTPUT 4) 5 (OUTPUT 4) NO. NO. 6 (INPUT 5)

6 (OUTPUT 5) 6 (OUTPUT 5) 6 (OUT 3N)

+ + 7 (INOUT 6)

7 (OUTPUT 6) 7 (OUTPUT 6) 7 (OUT 3R) 8 (INPUT 7)

1 (BD. ADR.) 1 (BD. ADR.) 9 (INPUT 8)

NO. NO. NO. NO. NO. NO.

1 (CLOCK) 1(0N·LINE)

l= 1 (SYS. STAT.) 1 (BD. ADR.}

l"" ~ (BD. ADR.}

l"" ~ (BD. ADR.)

l "" ~ (SD. ADR.)

l "" ~ (BD. ADR.)

l"" ~ (BD. ADR.)

l"" ~ (BD. ADR.}

PROCESSOR 1/0 BUS CODE SYS. PERIPHERAL STANDARD STANDARD VOL T.-LIMIT. VOLT.-LIMIT. Bl-POLAR Bl-POLAR DC LAMP STANDARD STANDARD N451441- INTERFACE INTERFACE N451441- RELAY RELAY RELAY RELAY RELAY RELAY DRIVER INPUT INPUT

5701 N451441- N451441- 5502 DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER N451441· N451441- N451441-6001 5302 N451441- N451441- N451441- N451441- N451441- N451441- 6702, 6703, 6402, 6403, 8802, 8803

6501 8601 7401 8501 6601 8701 7301

SLOT A SLOT B SLOT C SLOT D SLOTS E-N SLOTS E-N SLOTS E-N SLOTS E-N SLOTS E-N SLOTS E-N SLOTS E-N SLOTS E-N SLOTS E-N

r VITAL CPU VITAL 1/0 ~, SEE FIG. 5-3 FOR NON-VITAL PCB LEDS

5.1.3.6 Reading Error Codes Error Code Descriptions and Troubleshooting

The MICROLOK PLUS vital section error codes are interpreted in the same manner as the MICROLOK system. For error code descriptions and recommended troubleshooting, refer to:

Subject

Error Code Reading

Cross Reference


Error Code Descriptions, Troubleshooting Suggestions


NOTES

There are no specific error codes generated by the MICROLOK system diagnostics to indicate that too many I/0 boards are defined for the smaller MICROLOK PLUS unit. Make certain the application logic specifies no more than 10 I/0 boards.

The MICROLOK PLUS unit is not equipped with the 37-wire I/0 cable of the MICROLOK system. All references to this cable should be ignored.

Figure 5-2 on the interpret typical LOK PLUS system. of Figure 3-5 of

following page shows how to long error codes from the MICRORefer to this figure in place

SM-6400C.

Section 3.3.7.2, page 3-26: Long error code lE is not applicable to the MICROLOK PLUS system, but may appear if there is a failure of the failover hardware during diagnostics.

Section 3.3.7.2, page 3-31, Error 27x: Section 3.3.7.2, page 3-51, Error 97x: All MICROLOK PLUS systems are equipped with Executive Software revision #7 and higher.

6500, p. 5-5

• 0 -, I

0 • l r-1'. >4-9

eY • ' I

• o-.J

1/0 BUS ERROR

0

LED ON

A B I C I D I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

• LED OFF

I

TYPICAL LONG ERROR CODES

• • 181 -, I

erl\,.Orl\,.l8I \2-7-x oYoYl!!! r

I

e O 181-.J

MONITOR ERROR

EXAMPLE OF COMPLETE LED DISPLAY CYCLE: 984

HEX CODE~ 9

0

0

• 8

0

0 4 0

• • • .• r-1'. • r-1'. • r-1'. • r-1'. 0 r-1'. • eYeYeYeYeYe

0 • • • • 9 8 4: DC LAMP DRIVER PCB DETECTED

BURNED OUT OR MISSING LAMP IN VITAL 1/0 SECTION 4TH SLOT (H).

VITAL 1/0 SECTION l

•

0 0 !SI -, I

•¢•¢181 l '• 9 - 8 - x • • 181 ,~ I

0 • !SI _.J

DC LAMP DRIVER PCB DETECTED BURNED-OUT OR MISSING LAMP

E F G H K L M N o P o .__ CARD SLOT ID

2 3 4 5

2 3 4 5

6 7 8 9 10 4.,1-+--+---t---

6 7 8 9 A -, I I

:1 !SI

LED ON OR OFF. HEX CODE DETERMINED BY BOARD LOCATION "n" OF FAULT IN VITAL 1/0 SECTION.

Figure 5-2. Typical Long Error Codes

6500, p. 5-6

NUMERICAL LOCATION

HEXADECIMAL EQUIVALENT

LED DISPLAY CHANGE

5.1.3.7 PCB Descriptions

The circuit and functional descriptions of the MICROLOK PLUS vital section PCBs are the same as those for the MICROLOK system. For these descriptions, refer to:

Subject

Processor PCB (N451441-5701) Description

Peripheral PCB (N451441-5502) Description

Cross Reference

SM-6400C, section 3.3.8.1, pages 3-57 through 3-59

SM-6400c, section 3.3.8.2, pages 3-60 through 3-63

NOTE

Page 3-60: Part B, section b: The failover hardware is present on the Peripheral board used in the MICROLOK PLUS unit, however this hardware is not used by the system.

Figure 3-7, page 3-63: The LOCK ON/AUTO/LOCK OFF switch (SW5) is not used in MICROLOK PLUS. However, always keep this switch in the AUTO position. If the LOCK LED is on, SW5 is not in the required AUTO position.

I/0 Bus Interface PCB (N451441-6001) Description

Code System Interface PCB (N451441-5302) Description



NOTE

The descriptions of the Code System PCB Interface to an external GENISYS unit also apply to an intra-unit interface to the MICROLOK PLUS non-vital section.

6500, p. 5-7


Vital I/0 PCB Descriptions SM-6400C, sections 3.3.8.5 through 3.3.8.8, pages 3-72 through 3-87.

NOTE

SM-6400C only describes the vital I/0 boards without out individual I/0 line LEDs. However, these descriptions are also applicable to the boards that are equipped with the line LEDs. Equivalent boards are as follows:


US&S Part No. N451441-

w/o LEDs w/LEDs

-6501 -8601 -7401 -8501 -6601 -8701 -6402 -8802 -6403 -8803

Each of the "-8000" series boards is equipped with eight output monitoring LEDs. A given LED lights when the respective circuit is energized. See Figure 5-1 for the configurations of these LEDs.

6500, p. 5-8

5.1.3.8 Code System Interface Troubleshooting

The MICROLOK PLUS system uses the same Code System interface troubleshooting procedures as the MICROLOK system.

Subject

Code System Interface Troubleshooting

Cross Reference


NOTES

Section 3.3.9.2, part c, page 3-96: This section is not applicable to the MICROLOK PLUS system. All systems are equipped with Code System Executive Software revision 2 and higher.

The descriptions of the Code System PCB Interface to an external GENISYS unit also apply to an intra-unit interface to the MICROLOK PLUS non-vital section.

5.1.4 Retesting Guidelines

Retesting guidelines for the MICROLOK PLUS hardware and software are basically the same as those for the MICROLOK system. For these guidelines, refer to:

Subject

Hardware and Software Retesting Guidelines

Cross Reference

SM-6400C, section 3.4, pages 3-108 through 3-114

NOTES

Section 3.4.4, page 3-113: The I/0 Bus Interface cable checkout procedure is not applicable to the MICROLOK PLUS system.

Section 3.4.5, page 3-113: The power supply replacement procedure applies to the single MICROLOK PLUS power supply drawer.

Section 3.4.6, page 3-113: The cardfile replacement procedure applies to the single MICROLOK PLUS cardfile.

6500, p. 5-9


5.2.1 Basic Maintenance

Basic field maintenance of the MICROLOK PLUS non-vital section is the same as that for the GENISYS system. For maintenance recommendations, refer to:

Subject

Basic Maintenance of Non-Vital Section

5.2.2 Systematic Troubleshooting

5.2.2.1 Introduction

Cross Reference

SM-6300B, section v, page 5-1/2

The troubleshooting information referenced in this section is intended for new MICROLOK PLUS installations with a non-vital section that is experiencing start-up or initial operating difficulties. However, this section may also be used to troubleshoot problems with in-service MICROLOK PLUS installations.

All plug-in boards in the MICROLOK PLUS non-vital section, except the Controller PCB, may be directly swapped with spares, as long as the correct option is chosen for each type. A spare Controller PCB must contain the same application logic and hardware switch settings as the replaced board to insure proper system operation. Faulty boards may be returned to US&S for repair or replacement.

If repairing boards in the field, refer to SM-6300C (GENISYS) for board-level troubleshooting information.

5.2.2.2 Recommended Test and Repair Equipment

The MICROLOK PLUS non-vital section uses the same test and repair equipment as the GENISYS system. For a list of this equipment, refer to:

Subject

Test and Repair Equipment for Non-Vital Section

Cross Reference

SM-6300B, section 4.2, pages 4-2 through 4-4

6500C, p. 5-10

5.2.2.3 Initial Checks and Diagnostics Via Board LEDs

Initial checks of the MICROLOK PLUS non-vital section are the basically the same as those for the GENISYS system. For these checks, refer to:

Subject

Initial Checks of Non-Vital Section

LED Checks on Operational System

Cross Reference

SM-6300B, section 4.3, page 4-5

SM-6300B, section 4.4, pages 4-6 through 4-27/28

NOTES

Parts of this test procedure are written in accordance with the 15 I/0 slots of the GENISYS cardfile. The MICROLOK PLUS non-vital section has only two I/0 slots. Note this difference when performing the test procedure. For example, the non-vital I/0 section cannot have empty slots between boards.

The non-vital section of the MICROLOK PLUS unit is not equipped with a Power Supply Converter PCB. Board operating power is obtained from the power supply drawer. Where the GENISYS test procedure calls for turn-on and turn-off of the Power Supply Converter PCB, perform this step with the main power switch on the MICROLOK PLUS unit.

Figure 5-3 on the next page shows the configuration of the non-vital section LEDs. Refer to this figure in place of Figure 4-4 of SM-6300B.

Section 4.5, page 4-8: Steps 1 through 4 of this section are not applicable to MICROLOK PLUS. Use the following steps in their place:

1. Check the input voltage from the power source.

a. The input voltage should be in the range of 19.8 to 32.4 Vdc.

b. Make sure the supply current is sufficient and the voltage is steady when a load is placed on the supply.

2. Check the power supply converter module outputs by attaching a digital voltmeter ground to test point TP3 and the meter probe to test points TP4, TP5, TP6 and TP7. See Figure 2-3 on page 2-6 of this manual for locations.

6500, p. 5-11

WHITE

Dr~ D or~ D D or~ 1 (M TXD) 13 (BITS 1-4) 13 (BITS 1-4)

2 (M RTS) 14 (BITS 5-8) 14 (BITS S·B) 3 (M RXD)

4 (M DCD) Is (BITS 9·12) I s (BITS 9-12)

5 (S TXD) 16 (BITS 13·16) 16 (BITS 13·16) 6 (S RTS)

7 (S RXD)

8 (S DCD)

9 (WTCHDG.)

10 (DELIVER)

SEE FIGURE 5-1 FOR VITAL SECTION PCB LEDS.

LED

LED LED NO.

LED LED

NO. NO. t NO. NO.

t t t t 1 (ADDRESS)

2 (DELIVER) 2 (DELIVER) 1 (LO BYTE) 1 (LO BYTE)

2 (DELIVER)

1 (ADDRESS) 1 (ADDRESS) 2 (HI BYTE) 2 (HI BYTE)

CONTROLLER CONTROL CONSTANT CONTROL & INDICATION INDICATION N451441· DELIVERY DELIVERY DELIVERY OPTO OPTO

5602 N451441- N451441- N451441- N451441- N451441· 3601 7101 4701 5802 7202

SLOT O SLOTPORQ SLOTPORQ SLOTPORQ SLOTPORQ SLOT PORQ ,~ NON-VITAL 1/0

Figure 5-3. Configuration of Non-Vital Section LEDs

6500, p. 5-12

a. The power supply should show the following outputs:

TP4 = +5 Vdc, + 0.25 Vdc, -o.o Vdc TP5 = +12 Vdc, + 0.25 Vdc. TP6 = -12 Vdc, ~ o.25 Vdc. TP7 -5 Vdc, ±_ 0.25 Vdc.

b. If the 5 volt output on TP4 is out of specification, it may be adjusted using the procedure in section 2.4.4 of this manual.

c. If the 5 volt output cannot be brought into specification, or if any of the remaining outputs are out of specification, replace the power supply drawer with a good spare and repeat the test. If the readings do not repeat, the original unit is faulty and should be serviced.

5.3 POWER SUPPLY DRAWER

Field troubleshooting of the MICROLOK PLUS power supply drawer consists of making output voltage checks at test points within the drawer. Refer to the preceding section (5.2.2.3) for the test procedure. Do not attempt any field repairs to the supply. If output voltages are not to specification, replace the complete assembly and return the faulty unit to US&S for service.

6500, p. 5-13/14

6.1 VITAL SECTION PCBS

SECTION VI SHOP MAINTENANCE

US&S recommends against attempting shop repairs on any of the MICROLOK PLUS vital section PCBs. Such repairs might degrade the vital performance qualities of the system after the PCB is returned to service. Any repairs made to any vital CPU or vital I/0 PCBs within the warranty period will invalidate the warranty for the entire system.

6.2 NON-VITAL SECTION PCBS

Shop repairs of the MICROLOK PLUS non-vital section PCBs are the same as those for the GENISYS PCBs. For repair procedures, refer to the following:

Subject

Non-Vital PCBs - Shop Maintenance

6.3 POWER SUPPLY DRAWER

Cross Reference

SM-6300C, sections II and III

US&S recommends against attempting shop repairs on any of the MICROLOK PLUS power supply drawer, other than adjusting the 5 volt output (refer to section 2.4.4 of this manual). Such repairs might affect the performance of the vital section PCBs after the drawer is returned to service. Any repairs made to the power supply drawer within the warranty period will invalidate the warranty for the entire system.

6500, p. 6-1/2

it:CI UNION SWITCH '1\JJ & SIGNAL INC. A member of the ANSALDO Group 5800 Corporate Drive Pittsburgh, PA 15237

SERVICE MANUAL 6500

APPENDIX A

PARTS LIST

MICROLOK PLUS TM


September, 1990 A-09/90-100-2882-1 ID0280F


AN SAL DO Trasporti

A.l CARDFILE N451796-0102 (See Figure A-1)

Item

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Description

Basic Housing Door, Front Motherboard Plate, PCB Shielding (Vital Section) Plate, PCB Shielding (Non-Vital Section) Cover, Back Stiffener Stiffener Extension Rod, Support PCB Guide, Nylon Post, Terminal Nut, 14-24 Hex, Brass Nut, 14-24 Hex, Brass Nameplate Rivet, Pop Screw, 6-32 x 3/8n Panhead, Steel Washer, #6 Lock, Steel Nut, 6-32 Hex, Steel Screw, 6-32 x 3/4n Binding Head Compound, RTV Adhesvive/Sealant (not shown) Washer, #6 Shakeproof Lock Washer, 17/64 x 9/16n CO Washer, 1/4 Shakeproof Lock Clip, Cable Rivet, 1/8 Aluminum, Pop Power Supply Drawer Tie, Cable Power Cable Bundle

6500, p. A-2

US&S Part No.

N4517960-0202 N451795-0502 N451657-4401 N451975-0704 N451795-0702 N451795-0602 M451795-0603 N451795-0608 M451795-0606 J712093 J071936 J480301 J480300 J451665-1901 J490037-0015 J507262 JO 47941 J048148 J507008 J041943 J047713 J047818 J047648 J700590 J490037-0022 N451796-0301 J703300 N451795-1401

0

~

N

cxi

c:::::J

c:::::J c:::::J

c:::::J c::::::J

c::::::J c::::::J

c::::::J c::::::J

c::::::J O

0

0

0

.:iii c:====-;t!Hii

I I I I I I

0 0 0 O I o I I

-----,1

r-----, II I r-----i- --------.'-!, .,, -------1.,11

111 1,1 ,I ~: 1 1 I I 1 1 I I

~: r.: '-t I r' I -L~-----r-~-----------~~ C::J I I I

0

I r-1 LIO I IO I ~I I I ~L'!...

~--~--~ ....... \~~~~--:--------y-,r -

C::J I -rr-----~-~-----------r~ nl ~· 111 111 '-ti L..I

11 I I 11 I I

,JI I I 111 i.1 ,J I I I

I L-----T- ---::i-::i-I 1 1

L------'- --------•-:-i --------JI

I

-llllll1lll

r;; ~I I I ~I 10 I IO ,-1 L-

O O : 0 0

r

l

'° N

"' N

E::::::3 E::::::3 c::::::J c:::::J

c::::::J c::::::J

c::::::J c::::::J

c::::::J c:::::J

c::::::J c:::::J

c:::::J c:::::J

c:::::J c:::::J

c::::::J c::::::J

c:::::J c::::::J

c:::::J c::::::J

c::::::J

c::::::J

c::::::J

c:::::J

J I I I I I I I I I

1-1-

~ I I

f\ I I I I

I'\ ~ I I I I I I I I I

11

Figure A-1. cardfile Assembly

6500, p. A-3

A.2 PLUG-IN PRINTED CIRCUIT BOARDS

Description

Vital Section

Processor PCB I/0 Bus Interface PCB Code System Interface PCB Peripheral PCB

Standard Input Standard Input Standard Input Standard Input

(12 (24 (12 (24

V nominal v nominal v nominal v nominal

input, input, input, input,

( slot A only) (slot B only) ( slot C only) (slot D only)

w/o input line LEDs* w/o input line LEDs* with input line LEDs* with input line LEDs*

Standard Relay Driver (without output LEDs)* Standard Relay Driver (with output LEDs)*

Voltage-Limited Relay Driver (without output LEDs)* Voltage-Limited Relay Driver (with output LEDs)*

Bipolar Relay Driver (without output LEDs)* Bipolar Relay Driver (with output LEDs)*

DC Lamp Driver (18 W lamp)* DC Lamp Driver (25 W lamp)* DC Lamp Driver (36 W lamp)*

Non-Vital Section

Controller ( slot O only)

Control Delivery Constant Delivery Control and Delivery Indication Opto (High Threshold) Indication Opto (Wide Range)

*Slots E through N

(slots (slots (slots (slots (slots

6500, p. A-4

P or Q) P or Q) p or Q) p or Q) p or Q)

US&S Part No.

N451441-5701 N451441-6001 N451441-5302 N451441-5502

N451441-6402 N451441-6403 N451441-8802 N451441-8803

N451441-6501 N451441-8601

N451441-7401 N451441-8501

N451441-6601 N451441-8701

N451441-6702 N451441-6703 N451441-7301

N451441-5602

N451441-3601 N451441-7101 N451441-4701 N451441-7202 N451441-5802

A.3 VITAL SECTION SERIAL LINK CABLE ASSEMBLIES

A.3.1 Complete Assemblies

Description

MICROLOK PLUS Vital Master Port (EIA RS-423) to: External MICROLOK PLUS Satellite Port or, External MICROLOK Satellite Port

MICROLOK PLUS Vital Master Port to Modem (EIA RS-423)

MICROLOK PLUS Vital Satellite Port to Modem (EIA RS-423)

MICROLOK PLUS Code System Port (EIA RS-423) to: External MICROLOK PLUS Non-Vital Controller or, External GENISYS Non-Vital Controller or, Intra-Unit*

Length

10 ft. 15 ft. 25 ft. 35 ft.

2.5 ft. 5 ft.

10 ft. 15 ft. 20 ft.

US&S Part No.

N451458-8201 N451458-8202 N451458-8203 N451458-8204

N451458-8301

N451458-8001

N451458-9801* N451458-9802 N451458-9803 N451458-9804 N451458-9805

*Used for intra-unit connection between vital Code System and non-vital Controller PCBs.

6500, p. A-5

A.3.2 Standard Components

A.3.2.1 37-Pin D Connector/Cable Assemblies (Master/Satellite)

The MICROLOK PLUS vital CPU uses the same serial data cable assemblies as the MICROLOK system, except for the code system interface. For standard parts lists, refer to:

Subject

37-Pin "D" Connector to MICROLOK PLUS Vital Master Port - Parts List

37-Pin "D" Connector to MICROLOK PLUS Vital Satellite Port -Parts List

Cross Reference

SM-64008, section A.2.2.1, page A-5

SM-6400B, section A.2.2.2, page A-6

NOTE

Refer to section 2.9.4 of this manual for application of the VCOR drive wires.

6500, p. A-6

A.3.2.2 N451458-98XX Cable Assemblies: Vital Code System Port to Non-Vital Controller (See Figure A-2)

Item

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20

4

7

Description

Cable, Multi-Conductor, Shielded Tape, 3/4 W Wire, #22 PVC, Black Block, 44-way contact Plug, Keying Spacer Bracket, Strain Relief Spring, Latch Screw, 4-40 x 7/s•, Panhead Steel Washer, #4 Lock, Steel Nut, 4-40 Hex, Steel Tie, Cable Label 25-Pin Plug 25-Pin Backshell Assembly (Not identified in Figure A-2) Crimp Pin Label Screwjack Assembly, Male

---El--

\ 4 7

""' 10

i_ __ 0

2 15 0

Oo Oo Oo Oo Oo Oo Oo Oo Oo Oo Oo Oo

0

US&S Part No.

A434058 J733078 A045662 J713797 J709248 J718271 M451393-0202 M451187-6601 J680190-001 J507297-0114 J047765 J480006 J7 0338 7 M451559-5601 J709146-0101 J709146-0314

J709565 M451460-6007 J507357

3

11

-- -1}---j-~ I"

Figure A-2. Code System/Controller Cable Assembly N451458-980X

6500, p. A-7

A.4 VITAL SECTION LOCAL I/0 CABLE ASSEMBLIES

The MICROLOK PLUS vital I/0 section uses the same connector/cable assemblies as the MICROLOK system. For top assemblies and standard parts lists, refer to:

Subject

Vital I/0 Connectors - Parts Lists

Cross Reference

SM-6400C, section A.2.6, page A-18

NOTE

Add the following connector/cable assembly top part number to the listing in SM-6400C:

Voltage Limited Output Cable - N451458-6702

The tag (item 11) for this assembly is as follows:

Tag, "Voltage-Limited Outputs" - M451640-3906

A.5. NON-VITAL SECTION SERIAL AND LOCAL CABLE ASSEMBLIES

The MICROLOK PLUS non-vital section uses the same connector/cable assembly as the GENISYS system. For standard parts lists, refer to:

Subject

Non-Vital Serial and Local Connector Assembly - Parts List

Cross Reference

SM-6300B, section 2.5.2.2, page 2-11 (Figure 2-2)

A.6 DEVELOPMENT SYSTEM HARDWARE AND SOFTWARE

The MICROLOK PLUS vital CPU uses the same development system equipment as the MICROLOK system. For standard parts lists, refer to:

Subject

MICROLOK Development System, Hardware and Software Part Lists

Cross Reference

SM-6400A, Appendix A, page A-1

The MICROLOK PLUS non-vital Controller uses the same development system equipment as the GENISYS system. For standard parts lists, refer to:

Subject

GENISYS Development System, Hardware and Software Part Lists

Cross Reference

SM-6300A, Appendix A, page A-1

6500, p. A-8

lc::<]UNION SWITCH 1UJ& SIGNAL INC. A· member of the ANSALDO Group 5800 Corporate Drive Pittsburgh, PA 15237

SERVICE MANUAL 6500

APPENDIX B

KEY COMPARISONS OF:

MICROLOK PLUS TM


September, 1990 A-09/90-100-2882-1 100280F

MICROLOK R

VITAL INTERLOCKING CONTROL SYSTEM

GENISYSR NON-VITAL LOGIC EMULATOR


AN SAL DO Trasporti

°' u, 0 0 ... -a . 0, I

f--0

COMPONENT OR FUNCTION MICROLOK PLUS

Cardfile Single cardfile - 17 slots:

card Slot Numbering

PCB Arrangements

P• B-1

Vital CPU: A through D

Vital I/0: E through N

Non-Vital Control: 0 Non-Vital I/0: P and Q

Vital CPU: Fixed Locations 3 or 4 PCBs Code System PCB optional

Vital I/0: - Up to 10 PCBs - Output PCBs left of input

PCBs - No empty slot(s) between

PCBs

Non-Vital Controller: Fixed location

Non-Vital I/0: - 1 or 2 PCBs - Output PCB left of

input PCB

MICROLOK

CPU cardfile - 16 slots I/0 Cardfile - 15 slots

CPU: Jl through Jl6 (JS to Jl2 active)

I/0 Jl through Jl5

----

CPU: - Variable locations - 8 slots active - 1 or 2 CPUs - 3 or 4 PCBs per CPU - Code System PCB optional

I/0: - Up to 15 PCBs - Output PCBs left of input

PCBs - No empty slot(s) between

PCBs

GENISYS

Single cardfile, 18 slots

Controller: J2 I/0: J3 through Jl8

- Power Supply - fixed location

- Controller - fixed location - Up to 16 non-vital I/0 PCBs - Output PCBs left of input

PCBs - Empty slot(s) between PCBs

permitted

°' U1 0 0 ..

'Cl . tel I

[',.)

COMPONENT OR FUNCTION

Plug-In PCB Types

Echo Enable Jumpers

Power Supply:

P• B-2

MICROLOK PLUS

Vital CPU: - Processor - I/0 Bus Interface - Code System Interface - Peripheral

Vital I/0: - standard Relay Driver - Voltage-Limited Relay

Driver - Bipolar Relay Driver - DC Lamp Driver - standard Input

Non-Vital Controller

Non-Vital I/0: - Control Delivery - Constant Delivery - Control and Delivery - Optical-Input (High

Threshold) - Optical-Input (Wide Range)

Cardfile backplane: - IN position: Input PCB - OUT position: Output PCB - No PCB - No jumper

Slide-Out Drawer

MICROLOK

CPU: - Processor - I/0 Bus Interface - Code System Interface - Peripheral

I/0: - Standard Relay Driver - Voltage-Limited Relay

Driver - Bipolar Relay Driver - DC Lamp Driver - Standard Input

CPU cardfile backplane: - OV position: Input PCB - +5 position: Output PCB - No PCB - No jumper

CPU and I/0 Panels

GENISYS

Controller

Control Delivery Constant Delivery Control and Delivery - Optical-Input (High

Threshold) Optical-Input (Wide Range)

Converter PCB

°' (.11

0 0 ..

'O . 0, I w


Power Input

Power for Modem

Vital CPU Failover

VCOR Drive

P• B-3

MICROLOK PLUS

System operating: Single 24 Vdc source

19.8 to 32.4 Vdc, 24 Vdc nominal

Vital I/0 Drive: Single 12 Vdc source through VCOR

270 mA on +12 Vdc 135 mA on -12 Vdc

Circuit present but not functional.

Keep failover switch on Peripheral PCB in AUTO position.

Power connected from+/wires in serial interface to Satellite port, or Faston terminals on power supply.

MICROLOK

System operating: 24 Vdc source for CPU and I/0 supplies

18.0 to 32.0 Vdc, 24 Vdc nominal

Vital I/0 Drive: Single 12 Vdc source through VCOR

-12 Vdc not available.

Circuit present, used with redundant CPUs.

Set failover switch on Peripheral PCB as required by application.

Power obtained exclusively from+/- wires in serial interface to Satellite port.

GENISYS

Single 9.5 to 35 Vdc source for Converter PCB -7601

Single 120 Vac source for Converter PCB -4601

800 mA on +5 Vdc 100 mA on +12 Vdc 100 mA on -12 Vdc

O'\ U1 0 0 .. 'U . ttJ I

""'

COMPONENT OR FUNCTION MICROLOK PLUS

Serial Interfaces Vital CPU, Master and Satellite Ports:

37-pin "D" EIA RS-423 No redundant CPUs

MICROLOK

CPU, Master and Satellite Ports:

37-pin "D" EIA RS-423 Redundant CPU options

Vital CPU, Code System port: CPU, Code System Port: - 25-pin "D" - EIA RS-423 - No redundant CPUs

Non-Vital Controller port: - 44-pin PCB edge connector - EIA RS-423 or sv TTL - No redundant CPUs

Current Loop Communi- Via optional Serial Comm • cations Adapter panel:

P• B-4

- Separate external power supply required.

- Use for vital or nonvital communications.

- 37-pin "D" - EIA RS-423 or sv TTL - Redundant CPU option

Via optional Serial Comm. Adapter panel: - Power can be obtained

from CPU or I/0 power supplies.

GENISYS

Controller PCB Port: - 44-pin PCB edge connector - EIA RS-423 or sv TTL - No redundant CPUs

°' V1 0 0 ...

'? 01 I

V1


Application Logic

Executive Software

P• B-5

MICROLOK PLUS

Vital Section: Uses MICROLOK Development System Maximum I/0 boards specified: 10

Non-Vital Section: Uses GENISYS Development System Maximum I/0 boards specified: 2

Vital CPU: Revision 8 and higher

MICROLOK

CPU: Uses MICROLOK Development System Maximum I/0 boards specified: 15

CPU: Revisions 1 through 8 and higher as determined by delivery date.

Code System: higher

Revision 3 and Code System: Revisions 1 through 3 and higher, as determined by delivery date.

Non-Vital Controller: Revision 9

GENISYS

Controller Uses GENISYS Development system Maximum I/0 boards specified: 16

Controller: Revisions 1 through 9 and higher as determined by delivery date.

Documents

A member of the ANSALDO Group 5800 Corporate Drive ... INTRODUCTION (See Figures 1-1 and 1-2) 1.2.1 General The MICROLOK PLUS Vital and Non-Vital Control Package is a multi-purpose,