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Union Switch & Signal Inc., an Ansaldo Signal company 1000 Technology Drive, Pittsburgh, PA 15219 645 Russell Street, Batesburg, SC 29006

SM 6800B

MICROLOK II
Integrated Vital Interlocking, Coded Track Circuit, and Non-Vital Code Line Controller Hardware Installation

Installation Maintenance

Copyright 2005 Union Switch & Signal Inc.

SM 6800B, December 2005 Rev. 3

Proprietary Notice
This document and its contents are the property of Union Switch & Signal Inc. hereinafter US&S). This document has been furnished to you on the following conditions: no right or license under any patents or any other proprietary right in respect of this document or its content is given or waived in supplying this document. This document and its content are not to be used or treated in any manner inconsistent with the rights of US&S, or to its detriment, and are not to be copied, reproduced, disclosed to others, or disposed of except with the prior written consent of US&S.

Important Notice
US&S constantly strives to improve our products and keep our customers apprised of changes in technology. Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability. The data contained herein purports solely to describe the product, and does not create any warranties. Within the scope of the attached manual, it is impossible to take into account every eventuality that may arise with technical equipment in service. Please consult your local US&S sales representative in the event of any irregularities with our product. We expressly disclaim liability resulting from any improper handling or use of our equipment, even if these instructions contain no specific indication in this respect. We strongly recommend that only approved US&S spare parts be used as replacements.

SM 6800B, Rev. 3, December 2005

Revision History

Revision History
Rev.
3

Date
December 2005

Nature of Revision
Incorporate ECO 140125-1; Corrected voltage levels for Part No. N17061002 for the Vital Input PCBs.

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SM 6800B, Rev. 3, December 2005

Appendix I

Table of Contents
1 1.1 1.2 1.3 1.3.1 1.3.2 1.4 2 2.1 2.1.1 2.1.2 2.1.3 2.1.3.1 2.1.3.2 2.1.4 2.2 2.2.1 2.2.2 2.2.3 2.2.3.1 2.2.3.2 2.2.3.3 2.2.3.4 2.2.3.5 2.2.4 2.3 2.3.1 2.3.2 2.3.3 2.4 2.4.1 2.4.2 2.4.3 2.4.3.1 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9 2.4.10 2.4.11 2.4.12 2.4.13 General Information................................................................................................................................................... 1-1 Introduction ........................................................................................................................................... 1-1 Rail Team and Technical Support ........................................................................................................ 1-1 Hardware General Description ............................................................................................................. 1-1 System Components...................................................................................................................... 1-2 Cardfile and Plug-In Components.................................................................................................. 1-2 Installing a Microlok II System .............................................................................................................. 1-4 Cardfile and Circuit Board Installation ................................................................................................................... 2-1 Installing the Cardfile ............................................................................................................................ 2-1 Mounting and Environment ............................................................................................................ 2-1 General Wiring Practices ............................................................................................................... 2-1 Power Input .................................................................................................................................... 2-2 Source ....................................................................................................................................... 2-2 Wiring and Surge Protection ..................................................................................................... 2-2 Cardfile Grounding ......................................................................................................................... 2-5 Installing the Microlok II Cardfile Plug-ins............................................................................................. 2-5 Circuit Board Installation Rules ...................................................................................................... 2-5 Keying Plug Installation.................................................................................................................. 2-8 Printed Circuit Board Jumper and Firmware Configurations ....................................................... 2-10 Configuring the CPU Board..................................................................................................... 2-10 Configuring the Code System Interface PCB.......................................................................... 2-14 Configuring the Cab Amplifier PCB......................................................................................... 2-18 Configuring the Coder Output PCB (Code Rate Selection) .................................................... 2-20 Configuring the OS Track Circuit PCB .................................................................................... 2-21 Installing Microlok II Circuit Boards and a Local Control Panel ................................................... 2-23 PCB Connector Assembly and Cardfile Address Setting ................................................................... 2-24 General......................................................................................................................................... 2-24 Connector/Cable Assembly Construction Notes.......................................................................... 2-24 Shelf Mounting Assembly Notes .................................................................................................. 2-28 Circuit Board Connections to External Circuits................................................................................... 2-29 CPU Board ................................................................................................................................... 2-29 Vital Input PCBs ........................................................................................................................... 2-31 Standard Vital Output PCBs......................................................................................................... 2-33 Noise Protection ...................................................................................................................... 2-33 Bi-polar Output PCB..................................................................................................................... 2-36 Vital Lamp Driver PCB ................................................................................................................. 2-38 Mixed Vital I/O Boards ................................................................................................................. 2-40 Non-Vital I/O PCBs ...................................................................................................................... 2-42 Code System Interface PCB ........................................................................................................ 2-48 Coded Track Circuit PCBs ........................................................................................................... 2-51 OS Track Circuit PCB .................................................................................................................. 2-53 Cab Signal Coder PCBs and Cab Amplifier PCBs....................................................................... 2-55 Address Select Jumper Settings .................................................................................................. 2-57 AC Lamp Drive ............................................................................................................................. 2-59 iii

SM 6800B, Rev. 3, December 2005

Appendix I
3 Installing Microlok II System Peripheral Devices ................................................................................................. 3-1

3.1 3.1.1 3.1.2 3.1.3 3.1.3.1 3.1.3.2 3.1.3.3 3.1.3.4 3.1.4 3.1.5 3.1.5.1 3.1.5.2 3.2 3.3 3.4 3.5 3.5.1 3.5.2 3.5.3 3.5.3.1 3.5.3.2 3.5.3.3 3.5.4 3.5.5 3.5.6 3.5.6.1

INSTALLING CODED TRACK AND CAB SIGNAL INTERFACE PANELS ......................................... 3-1 Coded Track and Cab Signal Panel Selection............................................................................... 3-1 Mounting the Panels ...................................................................................................................... 3-1 Coded Track Interface Panel Wiring, Grounding, and Surge Protection ....................................... 3-2 Track Leads and Surge Protection............................................................................................ 3-2 Grounding.................................................................................................................................. 3-3 Track Polarity ............................................................................................................................ 3-3 Installing a Termination Capacitor PCB .................................................................................... 3-5 Quick Shunt Module Application and Installation........................................................................... 3-6 Cab Signal Interface Panel Wiring, Grounding and Surge Protection ........................................... 3-6 Single-Cab Signal Configuration Wiring.................................................................................... 3-6 Dual-Cab Signal Configuration Wiring ...................................................................................... 3-6 VITAL CUT-OFF RELAY (VCOR) INSTALLATION AND WIRING....................................................... 3-8 POWER-OFF RELAY INSTALLATION AND WIRING ....................................................................... 3-10 ISOLATION MODULE INSTALLATION AND WIRING ...................................................................... 3-11 CONNECTING MICROLOK II TO EXTERNAL SERIAL DEVICES ................................................... 3-15 Connecting MICROLOK and GENISYS Protocol Serial Ports Using Modems ........................... 3-16 Connecting GENISYS Protocol Serial Ports Using Modems....................................................... 3-16 Connecting MICROLOK Protocol Serial Ports Using Modems.................................................... 3-17 Connecting to RS-485 Serial Ports (Refer to Figure 3-10) ..................................................... 3-17 Connecting to RS-423 Serial Ports (Refer to Figure 3-11) ..................................................... 3-18 Connecting to RS-232 Serial Ports ......................................................................................... 3-19 Isolation of Serial Port Signal Common ....................................................................................... 3-19 Physical Connections to Serial Ports ........................................................................................... 3-19 Configuring MICROLOK II Serial Ports........................................................................................ 3-20 Serial Port Configuration for Operation on a Direct Wire, Point-to-Point, Communication Circuit ................................................................................................................................................. 3-20 3.5.6.2 GENISYS Protocol Serial Port Configuration.......................................................................... 3-20 3.5.6.3 MICROLOK Protocol Serial Port Configuration ...................................................................... 3-22 3.5.7 Configuring MICROLOK II CPU Serial Communication Jumpers................................................ 3-23 3.5.8 Panel Installation and Power Input .............................................................................................. 3-23 3.5.9 Interface Wiring ............................................................................................................................ 3-24 3.6 SERIAL INTERFACE SCHEMATIC DIAGRAMS ............................................................................... 3-26 4 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.4 Installation Parts List................................................................................................................................................. 4-1 MAJOR SYSTEM ASSEMBLIES.......................................................................................................... 4-1 MAJOR CARDFILE COMPONENTS.................................................................................................... 4-1 Plug-in Printed Circuit Boards and Front Panels ........................................................................... 4-1 Code System Interface PCB Executive EPROMs ......................................................................... 4-3 PCB Interface Cable Assembly Components and Tools*.................................................................... Misc. Cardfile Installation Parts...................................................................................................... 4-4 POWER/SIGNAL CONDITIONING AND PROTECTION EQUIPMENT .............................................. 4-4 MISCELLANEOUS UNIT INSTALLATION HARDWARE ..................................................................... 4-5

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Appendix I

List of Figures
Figure Page Figure 2-1 - Cardfile Installation Dimensions .................................................................................................... 2-1 Figure 2-2 - Cardfile Power Input Wiring and Protection .................................................................................. 2-4 Figure 2-3 - Cardfile PCB and Panel Installation Guidelines ............................................................................ 2-7 Figure 2-4 - Cardfile Slot Keying Plug Installation............................................................................................. 2-8 Figure 2-5 - CPU Board Jumper and Jumper Position Checks ...................................................................... 2-11 Figure 2-6 - Code System PCB EPROM Installation and Jumper Positions .................................................. 2-16 Figure 2-7 - Cab Amplifier PCB Frequency-Select and Current-Limiting Jumpers......................................... 2-19 Figure 2-8 - Coder Output PCB Jumper Setting for Cab Signal ..................................................................... 2-20 Figure 2-9 - OS Track Circuit PCB Shunting Voltage Adjustment (Jumper)................................................... 2-22 Figure 2-10 - PCB Wiring Connector Mounting and Integral Address Switch Board...................................... 2-27 Figure 2-11 - Shelf-Mounting Kit ..................................................................................................................... 2-28 Figure 2-12 - CPU PCB - Basic Interface Wiring ............................................................................................ 2-30 Figure 2-13 - Vital Input PCB - Basic Interface Wiring.................................................................................... 2-32 Figure 2-14 - Standard Vital Output PCB - Basic Interface Wiring ................................................................. 2-35 Figure 2-15 - Non-vital Bi-polar Output PCB - Basic Interface Wiring and Correspondence with Front Panel LEDs................................................................................. 2-37 Figure 2-16 - Vital Lamp Driver PCB - Basic Interface Wiring ........................................................................ 2-39 Figure 2-17 - Mixed Vital I/O PCB - Basic Interface Wiring ............................................................................ 2-41 Figure 2-18 - Non-Vital I/O PCB, LCP Version - Basic Interface Wiring......................................................... 2-43 Figure 2-19 - Non-vital I/O PCB, 32/32 Version - Basic Interface Wiring ....................................................... 2-44 Figure 2-20 - Non-Vital, Isolated NV.OUT32 PCB Basic Interface Wiring................................................... 2-45 Figure 2-21 - Non-Vital, Isolated NV.IN32 PCB Basic Interface Wiring....................................................... 2-47 Figure 2-22 - Coded Track Circuit PCBs Basic Interface Wiring ................................................................. 2-48 Figure 2-23 - Code System Interface PCB - Basic Interface Wiring ............................................................... 2-50 Figure 2-24 - Coded Track Circuit PCBs - Basic Interface Wiring .................................................................. 2-52 Figure 2-25 - OS Track Circuit PCB - Basic Interface Wiring ......................................................................... 2-54 Figure 2-26 - Coder Output and Cab Amplifier PCBs - Basic Interface Wiring............................................... 2-56 Figure-3-1 - Mounting Dimensions for Coded Track/Cab Signal Interface Panels and Quick Shunt Module . 3-2 Figure 3-2 - Coded Track Interface Panels - Basic Track Wiring...................................................................... 3-4 Figure 3-3 - Termination Capacitor PCB Installation on Coded Track Interface Panels................................... 3-5 Figure 3-4 - Cab Signal Interface Panel Basic Wiring - Single Cab Configuration ........................................... 3-7 Figure 3-5 - VCOR Relay Wiring...................................................................................................................... 3-9 Figure 3-6 - Power-off Relay Design and Interface Wiring ............................................................................. 3-10 Figure 3-7 - Isolation Module Mechanical Design ........................................................................................... 3-13 Figure 3-8 - Isolation Module Typical Wiring................................................................................................... 3-14 Figure 3-9 - Typical Adapter Panel Application - Master and Slave Microlok II Systems ............................... 3-25 Figure 3-10 - Typical Microlok II Master To Microlok II Slave RS-485 Direct Wire Serial Interface Units Powered By Same Battery (Microlok Protocol Or Half-Duplex Genisys Protocol)................................. 3-26 Figure 3-11 - Typical Microlok II Master To Microlok II Slave RS-423 Direct Wire Serial Interface Units Powered By Same Battery (Microlok Protocol Or Half-Duplex Genisys Protocol)................................. 3-27 Figure 3-12 - Typical Microlok II Master or Slave to RFL Modem Serial Interface RS-232 Port 4 with Serial Isolator (Microlok or Genisys Protocol) ................................................................................... 3-28 Figure 3-13 - Typical Microlok II Master or Slave to RFL Modem Serial Interface RS-423 Port 3 with Serial Isolator (Microlok or Genisys Protocol) ................................................................................... 3-29 Figure 3-14 - Typical Microlok II Master to Microlok Slave Serial Interface RS-232 Port 4 with Serial Isolator (Microlok or Genisys Protocol) ................................................................................................ 3-30 Figure 3-15 - Typical Microlok Master to Microlok II Slave Serial Interface RS-423 Port 3 with Serial Isolator (Microlok Protocol) .................................................................................................................. 3-31 Figure 3-16 - Typical Microlok II Master to Microlok Combo Track Slave Serial Interface RS-423 Direct Wire Interface (Microlok Protocol) Units Powered By Same Battery............................................... 3-31 Figure 3-17 - Typical Microlok II Master to Microtrax EOS Slave RS-423 Direct Wire Serial Interface (Microlok Protocol) Units Powered By Same Battery ............................................................................. 3-32

SM 6800B, Rev. 3, December 2005

Appendix I
Figure 3-18 - Typical Code System PCB Interface to Serial Line Carrier....................................................... 3-33 Figure 3-19 - Typical GENISYS 2000 Master To Microlok II Slave RS-232 Direct Wire Serial Interface Units Powered By Same Battery (Genisys Protocol) ....................................................................... 3-34 Figure 3-20 - Typical GENISYS Master To Microlok II Slave RS-232 Direct Wire Serial Interface Units Powered By Same Battery (GENISYS Protocol).................................................................................... 3-34

List of Tables
Table Table 1-1 Table 1-2 Table 2-1 Table 2-2 Table 2-3 Table 2-4 Table 3-1 Page Microlok II System Major System Components.............................................................................. 1-2 Microlok II Cardfile Plug-In Components ........................................................................................ 1-3 Cardfile Motherboard Keying Plug Locations ................................................................................. 2-9 CPU Board Jumper Positions ....................................................................................................... 2-12 Microlok II PC Board Connector Components and Tools............................................................. 2-25 Microlok II PC Shelf Mounting Kit ................................................................................................. 2-28 Coded Track and Cab Signal Interface Panel Applications............................................................ 3-1

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SM 6800B, Rev. 3, December 2005

General Information

1
1.1

General Information
Introduction

This manual provides the basic information necessary to install the Microlok II system and its peripheral equipment (subject to completion of training by a US&S-approved source). Topics covered include equipment preparation, configuration and mounting, connection of operating power, installation of plug-in boards, and typical printed circuit board external circuit interfaces. For reference, related Microlok II system manuals include: SM-6800A - Microlok II System Description SM-6800C - Microlok II System Startup, Troubleshooting, and Maintenance SM-6800D - Microlok II System Application Logic Programming Other manuals that provide information on related US&S systems include: SM-6700A - GENISYS-2000 Multi-Purpose Non-vital Control/Communications System (Application Logic Programming) SM-6470A - MicroTrax Coded Track Circuit System Application Logic Programming SM-6470B - MicroTrax Coded Track Circuit System Hardware Installation and Configuration SM-6700B - GENISYS-2000 Multi-Purpose Non-vital Control/Communications System Hardware Installation and Configuration US&S provides no shop maintenance procedures for the Microlok II system circuit boards. These boards are not repairable in the field.

1.2

Rail Team and Technical Support

The Rapid Action Information Link (RAIL) team was created in 1996 to serve the technical needs of current and potential US&S customers. Convenient 24-hour access and a rapid resolution to customer problems are the trademarks of this organization. The RAIL team, which is staffed primarily by US&S product and application engineers, is ready to assist and resolve any technical issues concerning the Microlok II system or any other US&S product. Any questions regarding the contents of this service manual should be directed to the RAIL team by telephone at 1-800-652-7276 or through Internet E-mail at railteam@switch.com.

1.3

Hardware General Description

The Microlok II system consists of modular cardfile-mounted equipment and external peripheral devices that are used to interface the cardfile circuitry to the tracks and to other associated interlocking control systems. SM 6800B, Rev. 3, December 2005
1-1

General Information
Sections 1.3.1 and 1.3.2 that follow provide an overview of the hardware available for use in the Microlok II system.

1.3.1 System Components


The Microlok II interlocking control system is a multi-purpose monitoring and control system designed for railroad and rail mass transit wayside interlocking functions such as switch machine and signal lamp control, track circuit occupancy monitoring, and non-vital code line communications. Table 1-1 lists the major components of the Microlok II system that are covered in this manual:

Table 1-1 - Microlok II System Major System Components


Name
Microlok II cardfile VCOR relay

US&S Part No.


N16902101 N322500-701 (US&S PN-150B) J726153-0283 N17001101 (12V) N17001102 (50V) N17001103 (24V) N451835-0101 N451835-0102 N451835-0103 N451835-0104 N451835-0801 N451835-0802 N451052-4601 N17002201

Basic Function(s)
Houses all plug-in printed circuit boards and an optional local control panel. Switches power to all cardfile vital output circuits under the control of the Microlok II CPU board. Detects the failure of commercial power. Provides the equivalent of double-break output circuit isolation (for line circuits or relays in a separate house). Also enables bi-polar operation of standard vital outputs. Interfaces the Microlok II system to mainline coded track circuits in non-cab signal territory applications. Interfaces the Microlok II system to mainline coded track circuits in cab signal territory applications. Provides reduced coded track circuit shunt response time in heavy traffic areas. Interfaces the code system interface circuit board (cardfile) to a Glenaire modem or MCP in ARES and serial line carrier code systems. Interfaces the code system interface circuit board (cardfile) to ATCS systems. Converts vital EIA serial link signals to 20mA current loop signals. Protects serial communications between different houses/cases. Optional built-in LCP.

power-off relay isolation module

coded track interface panels

cab signal interface panels

quick shunt module Type A serial link isolator unit

Type B serial link isolator unit serial communications adapter panel

(to be determined) N451460-3001

local control panel

N16901301

1.3.2 Cardfile and Plug-In Components


The Microlok II cardfile is designed to house standard 6UX220 Eurocard plug-in printed circuit boards. Most Microlok II printed circuit boards are equipped with integral controls and indications on the boards front panel. Some Microlok II circuit boards, however, (the OS track circuit PCB and one version of the power supply
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SM 6800B, Rev. 3, December 2005

General Information
board, for example) do not have any controls or indications. These boards are mounted behind blank front panels. In some applications, the cardfile may be equipped with a local control panel (LCP) that takes up several cardfile slots. The LCP is interfaced to the cardfile circuitry and to the external I/O through a dedicated nonvital I/O printed circuit board that occupies a cardfile slot directly behind the LCP. Unused cardfile slots are covered with blank shield panels. These panels come in single slot and multi-slot widths. Each circuit board/panel is attached to the cardfile frame with two slotted-head machine screws. Two extraction levers are provided on each board to make board removal easier. The Microlok II cardfile can be wall or shelf mounted, and can be easily installed in a standard 19 equipment rack. External wiring is connected to each circuit board through a 48-pin or 96-pin connector. Each connector attaches directly to the boards upper edge connector at the rear of the card file. Certain connector housings incorporate jumpers that are used to set the electrical address for the associated circuit board. The CPU connector housing has an internal EEPROM that is used to store site-specific configuration data. Even if the CPU board is replaced, the configuration data remains intact within the CPU connectors EEPROM. The Microlok II cardfile plug-in components covered in this manual are listed in Table 1-2. See service manual SM-6800A for a detailed description of each circuit board type.

Table 1-2 - Microlok II Cardfile Plug-In Components


Name
CPU PCB

US&S Part No.


N17061301

Basic Functions
Provides system vital controlling logic, vital I/O management, external serial communications, application logic execution, internal and external diagnostics, event logging, and a user programming and diagnostics interface. Regulates and protects external power input, conditions and converts the battery input voltage to the various voltage levels required for cardfile circuitry operation, provides an isolated source for external contact sensing, and energizes the VCOR relay under the control of the CPU board. * Without front panel (mounted behind LCP) ** With front panel (no LCP installed in cardfile)

power supply PCB

N16600301* N16660301**

standard vital output PCBs

N17060501 (12V) N17060502 (24V) N17061801

Controls standard +/- vital outputs (switch machine relay coil or Microlok II isolation module, for example). Controls bi-polar outputs (to searchlight signal positioning mechanism, for example). Controls signal lamps in color lights and searchlight signals.

Bi-polar non-vital output PCB (12 bi-polar outputs) vital lamp driver PCB (16 lamps)

N17060101

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1-3

General Information
Name
vital Input PCBs (16 inputs)

US&S Part No.


N17061001 (12V) N17061002 (24V) N17061003 (50V)

Basic Functions
Receives standard +/- or bi-polar vital inputs (search light mechanism position check, switch machine correspondence, or OS track circuit occupancy, for example). Low and high minimum threshold versions available. Provides same I/O functions as standard vital output PCB and vital input PCB on one board. Low voltage (12V) and high voltage (50V in, 24V out) versions are available. Interfaces vital CPU with non-GENISYS 2000 external code system. LCP version interfaces cardfile LCP non-vital I/O with CPU. 32/32 version used for connection to external I/O. LCP version. 16 separate inputs for connection to external inputs. 32 outputs for connection to external outputs. 32 inputs for connection to external inputs. Provides train detection in mainline coded track circuits. Versions for non-cab applications and cab applications at various frequencies. Provides OS track circuit train detection in endof-siding applications. Generates standard 75, 120 and 180 CPM cab signal codes Generates two 50 CPM cab signal codes Generates 60 or 100 Hz cab signal carrier Generates 40 or 50 Hz cab signal carrier

mixed vital I/O PCBs (eight inputs and eight outputs)

N17061601 (12V) N17061602 (24V) N17061603 (Input 50V, output 24V))

code system interface PCB non-vital I/O PCB

N17061401 N17000601 (LCP) N17061501 (32/32) N17002801 (9.535V) N17062701 (9.535V) N17063701 (9.535V) N451910-0701 N451910-7601 N451910-7602 N451910-7603 N451810-6701 N451910-5801 N451910-7001 N451910-6401 N451910-6901

non-vital isolated PCB non-vital isolated PCB non-vital isolated PCB coded track circuit PCBs

OS track circuit PCB coder output PCB auxiliary coder output PCB 60/100 Hz cab amplifier PCB 40/50 Hz Cab amplifier PCB

1.4

Installing a Microlok II System


WARNING Failure to obtain approved training, and to act in accordance with the procedures and warnings outlined in these manuals, may result in serious personal injury and/or property damage.

This manual is generic in nature and is intended to cover the installation of the Microlok II system cardfile and its external support equipment for all possible applications of the system. The extent and complexity of each installation depends on the application, the equipment ordered for the application, and the as-shipped configuration of the equipment when it leaves the US&S factory.

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General Information
In some cases, the entire compliment of equipment may be pre-configured and assembled at the factory. In other cases, board configuration and installation may be done at the installation site. All of these factors are determined mainly by customer preference. Thus, the installation process will differ somewhat from job to job. Regardless of the specific configuration, there are five basic steps involved in the installation of a Microlok II system. These are:

1. Install the Microlok II cardfile. 2. Install the Microlok II printed circuit boards and make the necessary wiring connections for each specific
board.

3. Install the necessary Microlok II peripheral devices and make the necessary wiring connections between the
cardfile and the rails/interlocking equipment.

4. Make the necessary communications connections between the Microlok II cardfile and other remote train
control equipment.

5. Power up, configure, and test the Microlok II system.


Steps 1 through 4 are detailed in this manual. Note that it may not be necessary to perform all of these steps for all Microlok II applications. Step 5 actually includes a number of system checks and configuration procedures. This information is contained in service manual SM-6800C - Microlok II System Startup, Troubleshooting, and Maintenance.

SM 6800B, Rev. 3, December 2005

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General Information

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation

2
2.1

Cardfile and Circuit Board Installation


Installing the Cardfile

2.1.1 Mounting and Environment


The Microlok II cardfile may be mounted in a standard 19-inch equipment rack, or on a wall or shelf using the fiberglass mounting brackets supplied with the unit.* Keep the cardfile away from sources of excessive heat or battery vapors. Positive ventilation is not required. Cardfile operating temperature limits are -40o to +70oC. Cardfile mounting dimensions (including rear connectors) are shown in Figure 2-1. * The fiberglass mounting bracket should be used to isolate the cardfile from earth ground.

19.25

9.5 12.19

3 3 3 11.5

Fiberglass Mounting Brackets

PCB Interface Connector Housing

Figure 2-1 - Cardfile Installation Dimensions 2.1.2 General Wiring Practices


Microlok II installations that are wired in the field should be configured to minimize cross talk between wires. Dirty wiring (connections to external equipment) should be separated as much as possible from wires carrying electronic data signals. Cables and wires in general should be kept as short as possible to minimize induced line noise. (The input and output wires should be twisted in pairs.) Case/house wiring layouts should also be arranged to minimize noise. Switch heater wire runs, track leads, switch machine power wiring and any other noisy wiring should be separated as much as possible from Microlok II wiring, both in the case or house and in outside cable runs. Battery leads should be as short as possible and must be isolated as much as possible from noisy wiring.

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2-1

Cardfile and Circuit Board Installation 2.1.3 Power Input 2.1.3.1 Source

The Microlok II cardfile requires a single, 12 Vdc (nominal) battery for operating power. The requirements for the dc input voltage are as follows:
Voltage: Range Nominal Min. Startup Ripple 0.5 VP-P 9.8 to 16.2 Vdc 12.0 Vdc 11.5 Vdc

Current draw on the battery is determined by the application configuration, (number of signal lamps, cab signal carrier frequency, etc.). A constant voltage type charger is recommended for the battery. Note that the battery must be capable of providing a minimum voltage of 11.5 Vdc at system start-up. (This means that anytime the OFF/On switch is operated, battery voltage must be at least 11.5 V. or the unit will not start.)

2.1.3.2

Wiring and Surge Protection

Input power wiring to the Microlok II cardfile is connected through the 48-pin connector attached to the back of the power supply PCB (N16600301 or N16660301). Figure 2-2 shows the typical installation for the battery input to the Microlok II cardfile. Refer to section 2.1.6 for connector wiring data. Internal system power (+5V, +/-12V) may also be supplied by an externally mounted power supply instead of the plug-in PCB (N16600301 or N16660301). In this case the system VCOR must be controlled by the plug-in CPS Board N451910-7501. The second drawing in Figure 2-2 shows the typical wiring for this board.

CAUTION The surge suppression devices described below must be installed for all Microlok II applications. Failure to install these devices may result in damage to the power supply or the Microlok II system circuitry due to voltage transients. restrictions are not followed, damage to equipment could result.
Observe the following guidelines when connecting battery power to the cardfile: 1. To minimize noise, keep the battery leads as short as possible. Whenever possible, the battery leads should be located entirely within the case or house. 2. Lightning arrestors should not be used on the wiring between the battery and the cardfile. 3. Install 40 mm or 60 mm line-to-line and line-to-ground MOVs as follows: a) If the feed is 110 Vac, use a Siemens B40K130 or B60K130, or a GE V131DA40 or V131BA60 (J582324).
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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


b) If an isolation transformer is used, also install a block type MOV on the transformer secondary line-toline. 4. Secondary surge suppression (US&S USSP units) and common mode filtering are not required on the battery wiring to the cardfile.
250 Hz INPUT FROM CPU SYSTEM POWER SUPPLY A2 N166003-01 C2 B12 IN A12 A14 C12 C14 E12 E14 N12 IN A16 A18 C16 C18 E16 E18 AUX SHUTDOWN (+ 5) C6 A22 C22 E22 A24 C24 E24 A26 C26 E26 -12 + 12 USE ONLY TO POWER O. S. TRK BD +5 A6 -12V USE FOR INPUTS OUTSIDE THIS CASE MAX = 20MA.

E6

(+ ) (-)

ISOLATED OUTPUT 12 @ 20MA. VCOR (-) (+ )

N12

CPS ONLY BOARD N451910-7501


250 Hz INPUT O C FROM EXTERNAL SYSTEM POWER SUPPLY + 5V E6 A6

VCOR (-) (+ N12

A22 C22 E22

+ 12 N12

E24 A28 C28 E28 A30 C30 E30

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2-3

Cardfile and Circuit Board Installation

To cardfile power supply PCB or external power supply converter N12 (BATT-) 9.8V to 16.2V Battery 0.5V P-P Ripple B12 (BATT+)

Transient Voltage Suppressor 5KP16A or 6KZ16A (US&S J792736-0030)

MOVs for use in 110V system: US&S J582324, G.E. V131DA40, or Siemens B40K130

Prime Ground Bus

Constant Voltage Charger

1 110V Commercial 110 Vac

Figure 2-2 - Cardfile Power Input Wiring and Protection

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation 2.1.4 Cardfile Grounding


All Microlok II circuitry is isolated from the Microlok II cardfile chassis. This allows the cardfile to be connected to earth ground for shielding purposes if desired. For CE-compliant installations, cardfiles must be grounded via the metal cardfile-mounting brackets supplied with all Microlok II units beginning in late-1999. For other installations, optional fiberglass mounting brackets are available from US&S to electrically insulate the cardfile from its mounting structure if desired. The part numbers for these fiberglass brackets are: Right Left M4518114501 M4518114502

2.2

Installing the Microlok II Cardfile Plug-ins

Installing the Microlok II system cardfile plug-ins is a four-step process. Each of the following steps must be performed for each circuit board to be installed: Selecting the appropriate cardfile slot for each circuit board (section 2.2.1). Configuring the cardfile keying plugs for each circuit board (section 2.2.2). Configuring the circuit board jumpers and firmware just prior to installation (section 2.2.3). Install the circuit boards (section 2.2.4)

2.2.1 Circuit Board Installation Rules


Observe the following arrangement rules when installing Microlok II printed circuit boards and a local control panel (when applicable) into the card file: A. Refer to Figure 2-3. With the following exceptions, any plug-in PCB may be installed in any cardfile slot: Slot 19 cannot be used because there is no corresponding buss connector. The code system interface PCB should be installed in slot 20 at the far right hand side of the cardfile. This slot accommodates the special width (1.1 inches) of this board. Power supply PCB N16660301, which has a two slot wide front panel, should be used when a local control panel is not being used for the application. Power supply PCB N16600301 (no front panel) should only be used when a local control panel is to be installed. If the cardfile is to be equipped with a local control panel: Non-vital I/O PCB N17000601 must be positioned behind the local control panel so that the rear 48-pin connector on the panel engages the front connector of the I/O board. For example, if the LCP covers slots 1 through 7, the non-vital I/O board must be installed in slot 5.

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2-5

Cardfile and Circuit Board Installation


Power supply board N16600301 (without front panel) must be positioned behind the LCP so that its LEDs are visible in the holes provided on the panel. For example, if the LCP covers slots 1 through 7, the power supply board must be installed in slot 6. The OS track circuit PCB is typically mounted behind the LCP in any open slot. US&S recommends that the CPU board be installed in slot 18 because it is a double-width module that covers the unusable space of slot 19.

B.

If needed, two useable cardfile board slots can be gained by not installing a power supply board. In this case, the cardfile must be powered from an external power supply that meets the applicable rating requirements (see section 3.1 of service manual SM-6800A). Refer to section 2.1.3 in this manual for the recommended power supply wiring scheme. Any two boards can be installed adjacent to one another without concern for EMI or RF effects between the boards. Typically, the boards are grouped according to general function (I/O with I/O and coded track with coded track, for example). All unused slots and slots must be fitted with a blank shield panel so that the entire front face of the cardfile is covered. Available blank panels include: Single slot shield panel: N451850-2902 Double slot shield panel: N451850-2901 Blank LCP replacement panel: N451850-1101

C.

D.

E.

Once the full set of PCBs is defined for the application, keying plugs must be installed in the lower motherboard connectors. These plugs prevent insertion of the wrong replacement board for a given slot. Refer to section 2.2.2 for keying plug installation procedures.

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


Code System Interface PCB (N17061401)

Standard Location for Code System Interface PCB (N17061401)

Cardfile Slot No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Non-vital I/O PCB (N17000601)

Power Supply PCB (N16600301) (without front panel)

Local Control Panel (N16901301) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Sample Locations for LCP, Non-vital I/O PCB (N17000601) and Power Supply PCB (N16600301)

Typical PCB Installation


Slot No. 1-7 7 8 9 10 11 12 14, 15 16, 17 18, 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PCB or Panel Local Control Panel Bi-Polar Output PCB Blank Panel Vital Input PCB Mixed Vital I/O PCB Vital Lamp Driver PCB Blank Panel Coded Track PCB Coded Track PCB CPU PCB Code System Interface PCB d

Figure 2-3 - Cardfile PCB and Panel Installation Guidelines

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2-7

Cardfile and Circuit Board Installation

2.2.2 Keying Plug Installation


Each of the Microlok II cardfile slots includes a 12-way female keying guide next to the 96-pin connector. The guide is used to ensure installation of the proper circuit board in each cardfile slot after the complete cardfile board configuration has been determined. Each board is equipped with a corresponding 12-way male keying guide; individual keying tabs are removed at the factory in a specific pattern for the board part number. Prior to installing a board, insert keying plugs (part number J709146-0473) into the corresponding cardfile motherboard keying guide as shown in Figure 2-4 and as listed in Table 2-1. If it becomes necessary to change the type of board installed in a given slot, the previously installed keying plugs can be removed using a knife or a pair of needle nose pliers.
96-pin (Female) Connector on Cardfile Motherboard Keying Plug No.

96-pin (Male) Connector on PCB

Insert Keying Plug J709146-0473 Per Table 2-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .

1 2 3 4 5 6 7 8 9 10 11 12 Printed Circuit Board

Adjacent Keying Plug Connector (Female)

Adjacent Keying Plug Connector (Male)

PCB Keying Tabs Set at Factory

Figure 2-4 - Cardfile Slot Keying Plug Installation


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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation Table 2-1 - Cardfile Motherboard Keying Plug Locations
Keying Plug Location (Figure 2-4) Printed Circuit Board
CPU power supply (without panel) power supply (with panel) standard vital output (12V) standard vital output (24V) non-vital bi-polar output vital lamp driver vital input (12V) vital input (24V) vital input (50V) mixed vital I/O (12V) mixed vital I/O (24V) mixed vital I/O (50V) Serial Link Relay PCB code system interface non-vital I/O non-vital I/O non-vital, isolated non-vital, isolated non-vital, isolated coded track circuit coded track circuit coded track circuit coded track circuit OS track circuit coder output auxiliary coder output

Part No. 1
N17061301 N16600301 N16660301 N17060501 N17060502 N17061801 N17060101 n17061001 n17061002 N17061003 N17061601 N17061602 N17061603 N17062301 n17061401 N17000601 N17061501 N17002801 n17062701 N17063701 n451910-0701 n451910-7601 n451910-7602 n451910-7603 N451810-6701 N451910-5801 N451910-7001
                          

2
                          

5


6


7


9


1 0

1 1

1 2

                                           

  

             

 

     

  

 

           

           

  

SM 6800B, Rev. 3, December 2005

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Cardfile and Circuit Board Installation


Keying Plug Location (Figure 2-4) Printed Circuit Board
60/100 Hz cab amplifier 40/50 Hz cab amplifier CPS only power supply no front panel CPS only power supply with front panel

Part No. 1
N451910-6401 N451910-6901 N451810-7501 N451910-7501
 

2
 

3
 

6
 

9
 

1 0

1 1
 

1 2

No keying plugs No keying plugs

2.2.3 Printed Circuit Board Jumper and Firmware Configurations


There are five types of Microlok II printed circuit boards that contain jumpers and firmware that must be configured before each board is installed. These boards are the CPU board, the code system interface PCB, the cab amplifier PCB, the coder output PCB, and the OS Track Circuit PCB.

2.2.3.1 Configuring the CPU Board


2.1.2.3.1 Jumper Settings (See Figure 2-5)

Prior to installing the CPU board in the Microlok II cardfile, the following jumpers (Table 2-2) should be checked to make certain they are in their proper positions per the system application logic software or factory requirements.

NOTE Bold face letters indicate basic operation with the 21mHz system clock.

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


Currently, only Rocker 1 is used. Rocker 1 is used to determine the front panel serial port baud rate during boot mode operations. OPEN=57600 BAUD CLOSED=19200 BAUD BOT 1
J
M

1 O P E N 2 3 4

L 3
J
M

TOP 4
J
M

F 6
J
M

COM 7
J
M

R 8 9
J
M

2
J
M

5
J
M

10
J
M

P 1

o o o

P 2

o o o

P 3

o o o

P 4

o o o

P 5

o o o

P 6

o o o

P 7

o o o

J
M

P 8

o o o

P 9

o o o

P 1 0

o o o

JMP25

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J
M

o o o L S 1 o o 2 3 o o 4

P 2 6

JMP27 SW1

o o o N HZ

...

.. ..

... . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

JMP29=Bottom JMP28=Top 1-2 = Lock 2-3 = Program

J
M

P 2 8

o o o

o o o

J
M

P 2 9

. . . . . .

. . . . . . . . .

....
J
M

P 2 4

o o o o o o o o o

B O O T

P 1 1

o o o 11

J
M

P 1 2

o o o 12

J
M

P 1 3

o o o 13

J
M

P 1 4

o o o 14

J
M

P 1 5

o o o 15 o o o

J
M

P 1 6

o o o 16

J
M

P 1 7

o o o 17

J
M

P 1 8

o o o 18

Jumpers 20-24: Position 1-2 = Lock Position 2-3 = Program

o o o o o o

F1 F2 J J P 2 1 F3 J
M M M

J
M

P 2 2

F4 J
M

P 3 1

JMP30

P 2 0

P 2 3

1-2=OFF 2-3 = +5V 3-4 = +12V

oooo 1 2 3 4

Figure 2-5 - CPU Board Jumper and Jumper Position Checks

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2-11

Cardfile and Circuit Board Installation Table 2-2 - CPU Board Jumper Positions
Jumper ID
JMP1 JMP2 JMP3 JMP4 JMP5 JMP6 JMP7 JMP8 JMP9 JMP10 JMP11 JMP12 JMP13 JMP14 JMP15 JMP16 JMP17 JMP18 JMP19 JMP20 JMP21 JMP22 JMP23 JMP24 JMP25 FLASH 1 Wait State Enable COM4 RXD Enable COM4 DCD Disable Backplane CPU Reset COM1 TX.CLK is an Output COM3 Voltage Drive Levels COM3 Voltage Drive Levels COM3 TX.CLK is an Output COM3 TX.CLK is an Output COM4 RX.CLK=9.83Mhz COM3 RX.CLK=9.83Mhz COM2 RX.CLK=9.83Mhz COM1 RX.CLK=9.83Mhz Not Available FLASH 3 Programming Language (Application space) FLASH 1 Programming Language (Executive space) FLASH 2 Programming Language (Executive space) FLASH 4 Programming Language (Application space) FLASH 1 Boot Block (Boot space) Speaker Volume Locked Program Locked Program Locked Program Locked Program Locked Program Soft Loud Off JMP26 JMP27 JMP28 IRQ7 Off 68332 Normal Top PCMCIA Programming Voltage Locked Program 2-12 RS-232 RS-423 RS-232 RS-423 On-Board RAM 1 Wait State Top PCMCIA 2 Wait States

Description
Bottom PCMCIA 2 Wait States

Position
Position 2-3 Not installed Position 2-3 Position 2-3 Not installed Position 2-3 Position 1-2 Position 1-2 Position 1-2 Position 2-3 Position 1-2 Position 2-3 Position 1-2 Position 2-3 Position 2-3 Position 1-2 Position 1-2 Position 1-2 Position 1-2 Position 1-2 N/A Position 1-2 Position 2-3 Position 1-2 Position 2-3 Position 1-2 Position 2-3 Position 1-2 Position 2-3 Position 1-2 Position 2-3 Position 2-3 Position 1-2 Not Installed Position 2-4 Position 1-2 Position 1-2 Position 2-3 1 2 2 2 2 2 2 1 1

Notes

SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


Jumper ID
JMP29 JMP30

Description
Bottom PCMCIA Programming Voltage FLASH Programming Voltage Locked Program Off 5V 12V

Position
Position 1-2 Position 2-3 Position 1-2 Position 2-3 Position 3-4 Position 1-2 1 2 2

Notes

JMP31 Notes: 1. 2.

CPS Drive Normal

If header posts are not installed in these locations, no jumper is required. Settings shown in boldface are the normal jumper positions, which lock the FLASH devices and prevent their contents from being modified. Refer to the FLASH Programming Instructions for further information.

2.1.2.3.2

DIP Switch SW1

This is an unused input; the rockers may be left in any position without affecting normal system operation. 2.1.2.3.3 PCMCIA Cards

The CPU board is designed to incorporate a PCMCIA memory card module to provide additional logging capability for the User Data Log. Installation The PC Card can be installed in the top or bottom slot on the Microlok II controller board. The following jumpers must be set correctly: ID
JMP28 JMP29 JMP30

Description
Top PCMCIA Prog Volt Program Bottom PCMCIA Prog Volt Program FLASH Prog Volt 5V or 12 V

Position
2-3 2-3 2 - 3 or 3 - 4

Use of the PC Card The PC Card is used to expand the User Data Log logging capability. Currently only one type of FLASH card will be recognized by the executive software: INTEL 28F008S5. This chip has an Intelligent Identifier of 89A6h. Any SRAM card may be used in the system. Current restrictions of the hardware limit the size of the PC Card to a maximum of 6Mb. A 4Mb FLASH Card (J703105-0107) is available from US&S. Information stored on the PC Card includes:

Executive and Application CRCs First and last numeric ID numbers All ID Names for application variables User Data Log information

If no PC Card is installed, then the User Data Log is stored in internal RAM.

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Cardfile and Circuit Board Installation


At reset, the card is detected and checked for correct CRCs and IDNames. IF the CRCs or IDNames do not match the ones present in the executive and application software, the PC Card will be erased and started as a new card. If these items are valid, the executive software finds the starting and ending location for any data stored on the card. If the software cannot find a starting/ending location, or finds an invalid record on the card, it will be erased. Suggested Application Code Display PC Card's Health on a front panel
NV.ASSIGN ((PCMCIA.INSTALLED & BATTERY.HEALTH) & (LOG.OK | flasher)) TO LED.X;

PCMCIA.INSTALLED - System Bit BATTERY.HEALTH - System Bit LOG.OK - System Bit flasher - Toggling 0.5 secs ON / 0.5 secs OFF X - 1 through 8 for front panel LED

The LED will be ON steady whenever the PC Card is installed and logging information. It will be dark if no PC Card is installed. It will be flashing if a PC Card is installed but write-protected.

2.2.3.2
2.2.2.3.1

Configuring the Code System Interface PCB


EPROM Installation (see Figure 2-6)

CAUTION When handling any Microlok II circuit board or board component, observe all electrostatic discharge (ESD) precautions. Improper handling of boards or components may result in damage to static sensitive circuitry.
The Microlok II code system interface PCB is shipped without executive or application software EPROMs. Four EPROMs are required for system operation. This includes two executive EPROMs and two application EPROMs. The sockets for these chips are marked as follows: EXEC EVEN - socket U7 EXEC ODD - socket U6 APPL EVEN - socket U5 APPL ODD - socket U4

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


Install the executive and application software EPROMs according to their labels, with the Even EPROMs inserted in the EVEN sockets, and the Odd EPROMs inserted in the ODD sockets. When installing an EPROM, make certain the chip has the proper pin orientation and is fully inserted. Executive EPROMs must be selected according to the type of code system emulation. Check the label on the chip to make certain the proper EPROM is installed for the code application. Refer to the following tabulation for application EPROM part numbers. Application
ATC/PTS US&S GENISYS Harmon MCS-1 WB&S S2 Allen Bradley DF1 ARES GRS Datatrain II GRS Datatrain VIII US&S GENISYS Dual Slave US&S GENISYS Dual Ind. Slave

US&S Part No.


N451800-0201 N451800-0202 N451800-0204 N451800-0206 N451800-0207 N451800-0208 N451800-0210 N451800-0211 N451800-0212 N451800-0213

Refer to Service Manual SM-6700A for EPROM programming procedures.

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Cardfile and Circuit Board Installation


A o o C o A o o C o

A o A o A o o o o C o C o C o
J P 4 J P 2 J P 3

J P 1

J P 5

U4

A P P L

U6

E X E C

O D D

. . . . . . . . .

U5

U7

E V E N

. . . . . .

. . . . . . . . .
A o o C o A o o C o
J P 6

J P 7

A o o C o

J P 8

Figure 2-6 - Code System PCB EPROM Installation and Jumper Positions

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


2.2.2.3.2 Genisys 2000 CSIB Controller Board Jumpers

GENISYS 2000 CSIB Controller Board Jumpers


JUMPER
JP1 JP2 Slave port 2 synchronous transmit clock Slave port 1 synchronous transmit clock Slave port 2 JP3 asynchronous clock; synchronous receive clock Slave port 1 JP4 asynchronous clock; synchronous receive clock Slave port 2 synchronous transmit clock Watchdog function

FUNCTION

POSITION
AB BC* AB BC* AB BC* (1) AB BC* (1) AB* BC AB BC* (2) AB* (3) BC OPEN AB* BC

EFFECT
External Internal External Internal External Internal External Internal Internal External Disabled Enabled 1200 ms. 150 ms. 600 ms. Disabled Enabled

JP5 JP6

JP7

Watchdog time-out

JP8 * 1. 2. 3.

Bus enable Indicates factory configuration.

For asynchronous serial port operation, asynchronous clock must be set to internal. External position is used for synchronous communication only. Watchdog MUST be enabled for all normal operation. Disabled position is for factory test only. Factory watchdog setting should not be changed. Lowering watchdog time-out could affect controller reliability.

2.2.2.3.3

Jumper Settings for GENISYS / 5XX, S2, and MCS-1 Slave Applications

Jumper Settings for GENISYS / 5XX, S2, and MCS-1 Slave Applications
Jumper
JP1 JP2 JP3 JP4 BC BC BC BC

Position

Jumper
JP5 JP6 JP7 JP8 BC BC AB AB

Position

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Cardfile and Circuit Board Installation

2.2.2.3.4

Jumper Settings for ATCS Communication Application

Jumper Settings for ATCS Communication Application


Jumper
JP1 JP2 JP3 JP4 BC BC AB AB

Position
JP5 JP6 JP7 JP8

Jumper
AB BC AB AB

Position

2.2.2.3.5

Jumper Settings for ARES Communication Application

Jumper Settings for ARES Communication Application


Jumper
JP1 JP2 JP3 JP4 AB AB AB AB

Position
JP5 JP6 JP7 JP8

Jumper
BC BC AB AB

Position

2.2.3.3

Configuring the Cab Amplifier PCB

For Microlok II installations that are configured for cab signal generation, the appropriate carrier frequency must be jumper-selected on the cab amplifier PCB. Set jumper JMP-2 as shown in Figure 2-7 to select 60 Hz or 100 Hz operation on PCB 6401, or 40 Hz or 50 Hz operation on PCB -6901. Also, position jumper JMP-1 to the HIGH position as shown in Figure 2-7. The position of this jumper may be changed during system configuration after the cab signal current levels have been set. Section 6.2.11 of service manual SM-6800C covers this procedure.

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation

60/100 Hz Cab Amplifier PCB or 40/50 Hz Cab Amplifier PCB

Current Limiter Jumper: LOW Position: Short Track Circuits. Set when using taps 1 and/or 2 on cab interface panel. HIGH Position: Long Track Circuits. Set when using taps 3 and/or 4 on cab interface panel.

Frequency Select Jumper: 60 or 100 Hz (40 or 50 Hz)*

JMP1 HIGH

o o o

LOW

60 Hz

o o o
JMP2

100 Hz

*NOTE: On the 40/50 Hz Cab Amplifier PCB, these jumper positions are labeled 40 Hz and 50 Hz.

Figure 2-7 - Cab Amplifier PCB Frequency-Select and Current-Limiting Jumpers

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Cardfile and Circuit Board Installation

2.2.3.4

Configuring the Coder Output PCB (Code Rate Selection)

The coder output PCB is equipped with a single jumper for setting the number of different code rates used by the Microlok II system. Set this jumper to the 3-CODE position when the system is to be set up for the three standard code rates of 75, 120 and 180 CPM. When the system incorporates additional code rates from the auxiliary coder PCB, set this jumper to the 6-CODE position. Figure 2-8 shows the jumper position on the board.

JP1 6-CODE

o o o

3-CODE

Number Of Cab Signal Code Rates: 3-CODE Position: 75, 120, 180 CPM 6-CODE Position: 75, 120, 180 CPM Plus Additional Codes from Auxiliary Coder PCB

Coder Output PCB

Figure 2-8 - Coder Output PCB Jumper Setting for Cab Signal

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Cardfile and Circuit Board Installation

2.2.3.5

Configuring the OS Track Circuit PCB

As shown in Figure 2-9, a jumper is provided on the OS Track Circuit PCB (N451810-6701) for the purpose of selecting one of the four possible positions. JP1 represents the lowest power setting and JP4 represents the highest.

1. Connect voltmeters across the MICROTRAX inputs. 2. Select the lowest power setting that results in at least 12V dc on both inputs. 3. Verify this setting by playing a 0.06 ohm track shunt across each leg of the OS circuit, one leg at a time.
Each shunt must result in at least one of the two input voltages dropping below 3V dc.

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Cardfile and Circuit Board Installation

1 2 3 4

JP1 JP2 JP3 JP4

O.S. TRACK CIRCUIT PCB N451810-6701

O.S. TRACK SHUNTING VOLTAGE ADJUSTMENT MOVE ONE JUMPER BETWEEN JP1 AND JP4 TO ADJUST SHUNTING VOLTAGE

OS Receiver 1

OS Transmitter

OS Receiver 2

To MICROTRAX Vital Inputs

22 21

20 19

18 17

16 15

MICROTRAX RIGHT CONNECTOR

Figure 2-9 - OS Track Circuit PCB Shunting Voltage Adjustment (Jumper)

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation 2.2.4 Installing Microlok II Circuit Boards and a Local Control Panel
US&S recommends that power is removed from the cardfile before removing or installing circuit boards. Use the following the procedure to install the Microlok II plug-in circuit boards:

1. US&S provides stickers with each Microlok II system that are used to identify the type of circuit board
installed in each cardfile slot. Obtain the proper sticker for the board to be installed. Attach the sticker to the inside bottom surface of the cardfile. Make certain that the arrow on the sticker points toward the appropriate card slot.

2. Hold the circuit board to be installed vertically in front of the cardfile. 3. Insert the board upper and lower edges into the plastic card guides inside the cardfile. CAUTION When installing any Microlok II circuit board into the card file, do not attempt to force the board into the slot. Damage to the circuit board and motherboard 96-pin connectors may result. If resistance is encountered when installing a board, gently rock the board to engage the male and female connectors. If the board still cannot be fully inserted into the card slot, remove the board from the cardfile and attempt to determine the source of the resistance. 4. Gently push the board into the cardfile until the board and cardfile 96-pin connectors are fully engaged. If
the board has an integral front panel, make certain that the rear face of the front panel is flush against the front of the cardfile.

5. If the board has an integral front panel, secure the board into position using the two retaining screws
attached to the front panel. Use the following procedure to install a local control panel:

1. Position the LCP over the front of the cardfile. 2. Align the connector on the rear of the LCP with the connector on the front of the non-vital I/O board
(N17000601) in cardfile slot 4.

3. Gently press the LCP onto the front face of the cardfile. Make certain that the rear of the LCP is flush with
the front face of the cardfile. Also, ensure that the two LEDs on the power supply board (installed behind the LCP) are properly aligned with the associated holes in the LCP.

4. Secure the LCP in position using the four retaining screws that are attached to the LCP front panel.

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Cardfile and Circuit Board Installation

2.3

PCB Connector Assembly and Cardfile Address Setting


NOTE Refer to Section 3 for Microlok II printed circuit board interfaces to external circuits.

2.3.1 General

Individual Microlok II circuit boards are interfaced (as applicable) to external circuits using connector/cable assemblies with a 48-pin or 96-pin female connector housing that attaches directly to the matching connector on the applicable circuit board. All boards except the 96-pin non-vital I/O PCB (N17000601) use the 48-pin connector. Each connector housing is secured to the cardfile backplane with four small machine screws (see Figure 2-10). The complete connector/cable assemblies may be assembled to order by US&S, or assembled by the user. The connector cable assemblies provide discrete wiring for all available I/O points on each PCB. As shown in Figure 2-9, wire bundles are routed through a protective sleeve on one of the two wiring openings of the connector housing. For most applications, the cable assemblies utilize only one cable opening on the connector housing. However, non-vital I/O PCB N17001501 may need to use both openings to accommodate the full set of 32 input and 32 output wires. For some Microlok II circuit boards, the connector housing also includes an Address Select PCB with six twoposition jumpers used to set the cardfile electrical address of the associated board. These addresses are defined in the Microlok II vital application logic (refer to section 2.4.12). The jumper settings must exactly match the values set in the application program to ensure normal system operation. The following circuit boards do not require a cardfile bus address and do not have jumpers included with the connector housing: CPU board code system interface power supply OS track circuit cab amplifier auxiliary coder output

US&S provides stickers with each Microlok II system that depict individual connector jumpers. After each jumper has been attached to the associated cardfile connector, affix a sticker to the cardfile frame directly below the connector. Use a pen or indelible marker to mark each jumper position on the sticker. An EEPROM is included within the special connector housing used for the CPU board. This chip holds sitespecific configuration data and allows the CPU to be changed while keeping the chip programming intact.

2.3.2 Connector/Cable Assembly Construction Notes


User assembly of the Microlok II connector/cable requires the parts and tools shown in Table 2-3:

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation Table 2-3 - Microlok II PC Board Connector Components and Tools
Figure 2-9 Item Description
connector housing assembly 1 48-pin 96-pin connector receptacle 2 48-pin 96-pin 3 receptacle mounting screw guide 4 48-pin 96-pin wire crimp contact 5 48-pin, #16 to #20 wire 48-pin, #20 to #26 wire 96-pin, #20 to #28 wire crimp tool, for: -48-pin, #16 to #20 wire 48-pin, #20 to #26 wire 96-pin, #20 to #28 wire extraction tool, for: -48-pin, #16 to #20 wire 48-pin, #20 to #26 wire 96-pin, #20 to #28 wire insertion tool, for: -48-pin, #16 to #20 wire 48-pin, #20 to #26 wire 96-pin, #20 to #28 wire locator tool, for: -48-pin, #16 to #20 wire 48-pin, #20 to #26 wire 96-pin, #20 to #28 wire Address Select PCB 48-pin housing 6 96-pin housing n17003101 n17003301 -Harting tool 09-99-000-0086 (Contact US&S) Harting tool 09-99-000-0099 Used to set cardfile slot address on selected PCBs. N17003101 replaces N17002002 N17003301 replaces N17002101 -(Contact US&S) (Contact US&S) Harting tool 09-99-000-0100 -Harting tool 09-99-000-0087 (Contact US&S) Harting tool 09-99-000-0101 j709146-0453 j709146-0853 j709146-0921 -Harting tool 09-99-000-0077 Harting tool 09-00-000-0076 Harting tool 09-00-000-0075 Harting 09-06-000-8482 Harting 09-06-000-8481 Harting 09-06-000-8484 J709146-1106 J709146-1107 J709146-0452 J709146-0922 J525400-0001 Mounts both 48-pin or 96-pin receptacle. --J709146-1105 J709146-1104 Used with most PCBs. Used with non-vital I/O PCB N17001501.

US&S Part No.

Comments/Vendor Part No.

SM 6800B, Rev. 3, December 2005

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Cardfile and Circuit Board Installation

Fig. 2-10 Item


48-pin 96-pin

Description
connector housing assembly

US&S Part No.

Comments/Vendor Part No.

J709146-1105 J709146-1104

Used with most PCBs. Used with non-vital I/O PCB N17061501. --

connector receptacle 2 48-pin 96-pin J709146-0452 J709146-0922

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


Narrow (96-pin) Connector Per View A C1 B1 A1 Wide (48-pin) Connector per View A E1 C1 A1

QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ QQQ

]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]] ]]]

2 6

5 3
SW1 SW2 SW3 SW4 SW5 SW6 Address Select PCB

0 0 0 0 0 0

1 1 1 1 1 1

C32 B32 A32 Narrow 96-pin Connector: For Non-Vital I/O PCB N17061501 Only

E32 C32 A32 Wide 48-pin Connector: For All Other PCBs

Housing Cover Housing Assembly Screws

Figure 2-10 - PCB Wiring Connector Mounting and Integral Address Switch Board

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Cardfile and Circuit Board Installation 2.3.3 Shelf Mounting Assembly Notes
Shelf mounting requires the use of the kit shown in Table 2-4:

Table 2-4 - Microlok II PC Shelf Mounting Kit


Figure 2-11 Item
1

Description
Shelf mounting kit

US&S Part No.


X16903906

Comments/Vendor Part No.


--

Installation standoffs included - in Shelf Mounting Kit using existing hardware from front-mounting angles.

Figure 2-11 - Shelf-Mounting Kit

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Cardfile and Circuit Board Installation

2.4

Circuit Board Connections to External Circuits

The configuration of the external wiring to each Microlok II printed circuit board depends entirely on the board type and the selected application. Sections 2.4.1 through 2.4.11 that follow, detail the specific connection requirements for each type of Microlok II circuit board.

2.4.1 CPU Board


The CPU board contains the central controlling logic and diagnostic monitoring for the Microlok II system, and provides serial five data ports. Four of these ports are used for communication with external systems (see Figure 2-25). The fifth port enables the connection of a laptop PC for software maintenance, diagnostics, and data log downloading. This diagnostic port is terminated at the 9-pin connector on the CPU board front panel The four general purpose ports can be used for vital serial communications with another Microlok II system, a Microlok system, or one of the MicroTrax systems (coded track, end-of-siding or cab signal controller). For installations where the Microlok II system is communicating with another vital system in the same house or case, the maximum serial cable length is 50 ft. A modem is required for cables longer than 50 ft. For locations where the Microlok II system and the remote vital system are located in different cases or houses, US&S recommends the use of a serial communications adapter panel (N451460-3001). This device converts EIA-level signals to 20mA current loop signals, and is designed to protect signal lines from transient line noise. Serial communications adapter panels are required at both the Microlok II location and the remote location. Refer to section 3.6 for panel installation and wiring. The four configurable ports can also be used as a non-vital channel to interface the Microlok II system to an external GENISYS-2000 non-vital code system. In this configuration, the non-vital application logic resides in the CPU board along with the vital application logic. Alternately, the code system interface PCB can be used to interface the Microlok II system to an external GENISYS-2000 system. In this application, the non-vital application logic resides on the code system interface PCB. Refer to section 2.4.8 for external connections to the code system interface PCB.

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Cardfile and Circuit Board Installation

Figure 2-12 - CPU PCB - Basic Interface Wiring

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Cardfile and Circuit Board Installation 2.4.2 Vital Input PCBs


Each of the vital input PCBs can accept up to 16 isolated inputs. The specifications for these boards are as follows: US&S Part No.
N17061001 N17061002 N17061003

Nom. Input Voltage


12V 24V 50V

Min. Voltage to Ensure ON State


9.5V 17.0V 35.0V

Voltage to Ensure OFF State


7.0V or less 9.0V or less 15.0V

Max. Sustained Input Voltage


34V 62V 72V

There are no power connections required through the upper connector. When wiring a vital input PCB to a relay contact circuit contained in the same house as the Microlok II cardfile, the signal battery may be used as the energy source to activate the inputs. Terminals designated (-) may be connected to battery N12 and B12 switched over relay contacts. When wiring a vital input PCB to a relay contact circuit outside the Microlok II house, use the isolated source that is part of the power supply. This is consistent with the practice of confining signal battery to the case in which the Microlok II unit is housed. External wiring should be protected with equalizer lightning arrestors from line-to-line (US&S part number N451552-0101) and with high voltage arrestors from line-to-ground (US&S part number N451552-0201). As shown in Figure 2-13, inputs can also be wired in a bi-polar configuration. Note in the Figure 2-12 example that input 7 is on and input 8 is off for the polarity indicated. For the reverse polarity, input 7 is off and input 8 is on. Noise Protection

1. US&S recommends the use of twisted pair wiring (2-3 turns per foot) for all input to minimize possible
noise.

2. US&S recommends the separation of clean and dirty wiring. Ideally, all inputs are gathered in a
bundle, all outputs are gathered in a bundle, and power wiring is gathered in a bundle. Each of these bundles is physically separated from other house wiring. It is particularly important to maintain this physical separation from high-current dirty wiring.

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Cardfile and Circuit Board Installation


48-pin Connector
SEL+
SW1 SW2 SW3 SW4 SW5 SW6

Pin No. E32 E30 C30 A30 E28 C28 A28 A26 E2 E4 C2 C4 A2 A4 E6 E8 C6 C8 A6 A8 E12 E14 C12 C14 A12 A14 E16 E18 C16 C18 A16 A18 E22 E24 C22 C24 A22 A24 E26 C26

Address Select PCB

GND

White Brown Red Orange Yellow Green Blue Black


+ + + + + + + + + + + + + + + + -

To Board Addressing Circuits

Input#1 Input#2 Input#3 Input#4 Input#5 Input#6 Input#7 Input#8 Input#9 Input#10 Input#11 Input#12 Input#13 Input#14 Input#15 Input#16

Bi-Polar Input Detection Example: For Indicated Polarity, Input 7 ON, Input 8 OFF For Reverse Polarity, Input 7 OFF, Input 8 ON

Vital Input PCB N17061001 N17061002

Figure 2-13 - Vital Input PCB - Basic Interface Wiring

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation 2.4.3 Standard Vital Output PCBs
Each of the standard vital output PCBs provides up to 16 outputs. The specifications for these boards are as follows: US&S Part No.
N17060501 N17060502

Voltage VBATT Range


12V 24V

Load Resistance Range


50 - 100 -

Max. OFF Voltage


0.75V 1.5V

Min. ON Voltage
VBATT - 1V VBATT - 1V

Outputs are controlled by high side software-controlled switches. Loads should be connected from outputs to battery negative. The high side switch is used to connect battery (+) to the output. Each output is protected with a polyswitch, which acts like a circuit breaker. When the overcurrent trip point is reached (approximately 0.75A), the polyswitch switches to a high impedance. The switch resets to its normal low impedance when the additional load or short is removed. A short to battery (-) will trip the polyswitch and cause the VCOR relay to drop, but will not cause any damage. A short to battery (+) will not cause any damage, but since this condition is equivalent to a false output, the Microlok II CPU will cause the VCOR relay to drop. Figure 2-13 shows the suggested wiring connections for the standard vital output PCBs. There are multiple connecting points available for both the B12 and N12 connections. A single contact can handle up to 3 amps of load current. If the anticipated load current exceeds 3 amps, use additional connecting points for the B12 and N12 feeds (one point for each additional 3 amps).

2.4.3.1

Noise Protection

Relay Coil Snub


Relay snubs are intended to dissipate large electromagnetic surges from the coil inductance and to prevent these surges from interfering with normal operation of the Microlok system. It is recommended that all relays being driven by Microlok be snubbed to prevent unwanted monitor errors. This is particularly true where the coil load to the Microlok relay driver is being broken by a series contact. Relay snubs can also be installed on other relays that are not directly controlled by Microlok outputs, but may be contributing to possible noise due to their close proximity to the Microlok wiring. US&S recommends the use of transorbs (J792736-0002) for relay snubbing. They will have minimal effect on relay timing. Resistors are also suitable relay snubs. When using a resistor loading of the Microlok output an effect on timing (relay drop away) must be considered. Diodes can also be used as snubs but:

1. They will definitely increase relay drop time. They may cause contact burning in some circuits.

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Cardfile and Circuit Board Installation

WARNING Do not use diodes or any devices that could function as a diode in ac or dc electrified territory; otherwise, voltage induced by the device could cause a relay to remain falsely energized.

Twisted Wire
US&S recommends the use of twisted pair wiring (2 to 3 turns per foot) for all relay loads to minimize possible noise. This should be done wherever possible on all I/O wiring.

Wire Separation
US&S recommends the physical separation of clean and dirty wiring. Ideally, all outputs are gathered in a bundle, inputs are gathered in a bundle, and power wiring is gathered in a bundle. Each of these bundles is physically separated from each other (6 preferred) and all bundles are physically separated from other house wiring. It is particularly important to maintain this physical separation from high-current dirty wiring.

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Cardfile and Circuit Board Installation


48-pin Connector
SEL+
SW1 SW2 SW3 SW4 SW5 SW6

Pin No. E32 E30 C30 A30 E28 C28 A28 A26 A16 C16 E16 E2 C2 Output#1 Output#2 Output#3 Output#4 Output#5 Output#6 Output#7 Output#8 Output#9 Output#10 Output#11 Output#12 Output#13 Output#14 Output#15 Output#16 E12
White Brown Red Orange Yellow Green Blue Black

To Board Addressing Circuits

VCOR Relay B12

Address Select PCB

GND

24 Vdc Required for High Voltage Version of PCB (N17060502)

+ +

A2 + E4 + C4 + A4 + E6 + C6 + A6 + E8 + C8 + A8 + E10 + C10 + A10 + + E22 C22 A22 N12

A24, C24, E24, A26, C26, and E26 are also common connection

Standard Vital Output PCBs N17060501 and N17060502

Figure 2-14 - Standard Vital Output PCB - Basic Interface Wiring

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Cardfile and Circuit Board Installation 2.4.4 Bi-polar Output PCB


The bi-polar output PCB provides 12 outputs and is typically used to drive searchlight signal positioning mechanisms. The specifications for this board are as follows: Voltage VBATT Range
12V

Load Resistance Range


250 -

The 12 physical outputs change polarity under the control of 24 paired virtual outputs (VO). Alternate assertion of a virtual pair changes the polarity of the physical output. Each output circuit has two LEDs (one green and one yellow) on the board front panel that indicate the on/off state and the polarity of the output. If either VO associated with a bi-polar output is asserted, the associated LED, green or yellow, will be illuminated. If neither element of the pair is asserted, the output is off and the corresponding LEDs are both off.
Example:

Physical output #1 is connected to terminals E2 and E4 and is controlled by virtual outputs VO1 and VO2. If VO1 is asserted, B12 is routed to E2, N12 is routed to E4, and the yellow LED will be illuminated. If VO2 is asserted, B12 is routed to E4, N12 is routed to E23, and the green LED will be illuminated. Figure 2-14 shows the relationships of the remaining virtual outputs, physical outputs, and front panel LEDs. Outputs on the non-vital bi-polar output PCB are protected from short circuits and inadvertent connection to either B12 or N12. If both virtual outputs of a pair are asserted, a warning will be logged on the CPU board and the output will default to an off state.

NOTE These outputs are non-vital. When used with searchlight mechanisms, vitality is ensured by feedback of the mechanism contacts to Microlok II or a vital input. The status of the call is compared in the application software. If a vital bi-polar output is required, the isolation module should be used. (See section 3.4 in this manual.)

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


48-pin Connector
SEL+
SW1 SW2 SW3 SW4 SW5 SW6

Pin No.

E32 White E30 Brown C30 Red A30 Orange E28 Yellow C28 Green A28 Blue To Board Addressing Circuits

Non-vital Bi-polar Output PCB N17061801

Address Select PCB

GND

A24 Black
A22 C22 E22 E2 E4

B12 VCOR Relay

Front Panel LEDS


Yellow Green

Out #1
2

Paired

C2

Yellow Green

1 ON E2+, E42 ON E2-, E4+

C4

Out #2
4

Paired

A2

Yellow Green

3 ON C2+, C44 ON C2-, C4+

A4

Out #3
6

Paired

E6

Yellow Green

5 ON A2+, A46 ON A2-, A4+

E8

Out #4
8

Paired

Outputs 1 2 3 4 5 6 7 8
9 10 11 12
Yellow Green Yellow Green 7 ON E6+, E88 ON E6-, E8+

C6 C8

Out #5
10

Paired

A6

11

Yellow Green

9 ON C6+, C810 ON C6-, C8+

A8

Out #6
12

Paired

E12

13

Yellow Green

11 ON A6+, A812 ON A6-, A8+

E14 Out #7 14 C12 15

Paired

Yellow Green

13 ON E12+, E1414 ON E12-, E14+

C14 Out #8 16 A12 17

Paired

Yellow LEDS
Yellow Green

15 ON C12+, C1416 ON C12-, C14+

A14 Out #9 18 E16 19

Paired

Green LEDS

17 ON A12+, A1418 ON A12-, A14+

E18 Out #10 20 C16 21

Paired

Non-vital Bi-polar Output PCB Front Panel

Yellow Green

19 ON E16+, E1820 ON E16-, E18+

C18 Out #11 22 A16 23

Yellow Green

21 ON C16+, C1822 ON C16-, C18+

A18 Out #12 24 A26 C26 E26

Paired Paired

N12
23 ON A16+, A1824 ON A16-, A18+

Figure 2-15 - Non-vital Bi-polar Output PCB - Basic Interface Wiring and Correspondence with Front Panel LEDs

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Cardfile and Circuit Board Installation

2.4.5 Vital Lamp Driver PCB


Depending on the lamp power ratings, the vital lamp driver PCB can operate up to 8, 12, or 16 signal lamps. The specifications for this board are as follows: Signal Lamp Volt. Range
10V - 12V

Signal Lamp Watt. Range


16W - 36W

Max. Activated Load


300W

Max. No. of 25W Lamps


12

Max. No. of Max. No. of 18W Lamps 36W Lamps


16 8

Outputs from this board are controlled by low side software switches, thus lamps must be connected from the output through a front contact of the VCOR relay to battery (+). A short from an output to N12 or B12 will not cause damage, but the system will detect an error and shut down due to the false lighting of a lamp. A variable dropping resistor should be installed in the common return for each signal head to provide a means of adjusting lamp voltage. This resistor limits current in the event of a short circuit outside the house or case. This arrangement protects vital lamp driver circuitry from damage. To accommodate unusually long signal lamp leads, battery voltage on the lamp driver PCB can be increased to 18 Vdc. Figure 2-15 shows the typical wiring of the vital lamp driver PCB. Note in the lower part of the figure that for each pair of lamps that can be lit at the same time, one return to N12 should be used. For the example shown in the figure, five lamps can be turned on at the same time, thus three N12 return connections are required.

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Cardfile and Circuit Board Installation


48-pin Connector
SEL+
SW1 SW2 SW3

Pin No. E32 White E30 C30 A30 E28 C28 A28 E26
Brown Red Orange Yellow Green Blue Black

one of the lamps sharing *Only a common adjusting resistor can be on at any one time .

SW4 SW5 SW6

To Board Addressing Circuits

VCOR Relay B12

Address Select PCB

GND

E18 E20 BATT+ E2 L.Drive #1 C2 L. Drive #2 E4 L. Drive #3 C4 L. Drive #4 E6 L. Drive #5 C6 L. Drive #6 C10 L. Drive #7 E10 L. Drive #8 A16 L. Drive #9

Software Controlled Switches

VCOR Relay B12

A18 L. Drive #10 A20 L. Drive #11 E22 L. Drive #12 C22 L. Drive #13 C24 L. Drive #14 E24 L. Drive #15 A24 L. Drive #16 A2 A4 A6 A8 A10 A12 A14 C8 C12 C14 Vital Lamp Driver PCB N17060101

NOTE For each pair of lamps that can be simultaneously lit, use one return to N12. For this case, five lamps can be on simultaneously. Therefore, use three return connections.

N12

Figure 2-16 - Vital Lamp Driver PCB - Basic Interface Wiring

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Cardfile and Circuit Board Installation 2.4.6 Mixed Vital I/O Boards
The mixed vital I/O boards provide up to 8 isolated inputs and 8 non-isolated outputs. This board type is used for smaller applications that do not require full vital input or standard vital output boards. The specifications for the mixed vital I/O boards are as follows: Output Specifications US&S Part No.
N17061601 N17061602 N17061603

Voltage VBATT Range


12V 24V 24V

Load Resistance Range


50 - 100 - 100 -

Max. OFF Voltage


0.75V 1.5V 1.5V

Min. ON Voltage
VBATT - 1V VBATT - 1V VBATT - 1V

Input Specifications US&S Part No. Nom. Input Voltage Min. Voltage to Ensure ON State
9.5V 16.0V 35.0V

Voltage to Ensure OFF State


7.0V or less 12.0V or less 15.0V

Max. Sustained Input Voltage


34V 62V 72V

N17061601 N17061602 N17061603

12V 24V 50V

Inputs can be wired in a bi-polar configuration. Note in the Figure 2-16 example that input 7 is on and input 8 is off for the polarity indicated. For the reverse polarity, input 7 is off and input 8 is on.

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


48-pin Connector
SEL+
SW1

Pin No.

E32

White Brown Red Orange Yellow Addressing Green Circuits Blue Black

E30 C30 A30 E28 C28 A28


GND

SW2 SW3 SW4 SW5 SW6

To Board

Address Select PCB

A26
E2 E4 C2 C4 A2 A4 E6 E8 C6 C8 A6 A8 E12 E14 C12 C14

+ + + + + + + + -

Input#1 Input#2 Input#3 Input#4 Input#5 Input#6 Input#7 Input#8

Bi-polar Input Detection Example: For Indicated Polarity, Input 7 ON, Input 8 OFF For Reverse Polarity, Input 7 OFF, Input 8 ON

+ -

Mixed Vital I/O PCB N17061601 N17061602

* VCOR
B12

A24 C24 E18


Output#1

C18
+

Output#2

A18
+

Output#3

E20
+

Output#4

C20
+

Output#5

A20
+

Output#6

E22
+

Output#7

C22
+

Output#8

E24 E26

N12

Figure 2-17 - Mixed Vital I/O PCB - Basic Interface Wiring


* Note: Even if you are using only inputs on this board, you must connect B12 to A24 and/or C24. This may or may not be through the VCOR.

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Cardfile and Circuit Board Installation

2.4.7 Non-Vital I/O PCBs


Two versions of the non-vital NV.IN32.OUT32, I/O PCBs are available. The LCP version (N17000601) is designed for use with the optional Microlok II Local Control Panel (LCP) N16901301. This version of the board is fitted with a 48-pin connector on the front and back. The front connector engages the LCP. The remaining I/O (16 inputs and 8 outputs) are available on the rear connector. The other version of the NV.IN32.OUT32 board (N17061501) connects each of its 32 inputs and outputs to a 96-pin connector mounted on the rear of the board. Both boards are treated as the same type of board in the Microlok II application software. Non-vital, optically isolated I/O PCBs are available as NV.OUT32 (N17062701), NV.IN32 (N17063701), and NV.IN32.OUT16 (N17002801). See Figures 2-19A, B, and C for basic interface wiring diagrams. The NV.OUT32 PCB provides 32 isolated, outputs for control of external devices such as indicators and relays. The outputs are divided into two groups of 8 outputs and one group of 16 outputs, each group having a separate bussed common (negative DC) reference output. Isolation allows switching power from sources isolated from the Microlok II power supply battery. Outputs are designed to operate at battery voltages between 9.5 and 35VDC. Outputs switch positive battery and are capable of supplying up to .5AMPS. Nominal voltage drop per output is load dependent and usually less than 2.5volts. The NV.IN32 PCB provides 32 isolated external inputs. The 32 inputs are divided into two groups of 8 inputs and one group of 16 inputs, each group having a separate bussed common (negative DC) reference input. External input voltages between 6 and 35VDC represent logical 1. The NV.IN32.OUT16 PCB provides 16 isolated external inputs. These external inputs each have separate (+) and (-) connections and present a logical 1 when the applied voltage is 6 to 35VDC. This board also utilizes a Local Control Panel (LCP) N1700290X connected via a 96-pin connector to the front edge of the PCB. The LCP controls and monitors local non-vital circuits and devices through 16 inputs from the PCB and 16 outputs from the LCP to the PCB. Sixteen of the inputs are selectable by the front panel LCP pushbuttons. The 16 PCB outputs feed the LED indicators on the LCP. Specifications for the non-vital I/O PCBs are as follows: Non-Vital I/O Printed Circuit Boards US&S Part No.
N170006101

Input and Output Voltage Range


6.0 to 30.0VDC

Externally Available Inputs


16

Externally Available Outputs


8

Current Rating On Outputs


Outputs 25-30: 0.5A fuse Outputs 31, 32: 5.0A fuse* Outputs 1-30: 0.25A (polyswitch-protected) Outputs 31, 32: 5.0A fuse* Outputs 1-32: 0.5AMPS

N17061501 N17062701 N17002801 N17063701 N17061801

6.0 to 30.0VDC 9.5 to 35VDC 6.0 to 35VDC 6.0 to 35VDC 9.8 to 16.2VDC

32 0 16** 32 0

32 32 0 0 12 bi-polar outputs

250 min load

*Suitable for lighting lamp up to 25W. **Other 16 inputs and outputs are used by LCP panel. 2-42

SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


Figure 2-18 and Figure 2-7 show the generic interface wiring for both versions of the board.
48-pin Rear Connector
SEL+
SW1 SW2 SW3 SW4 SW5 SW6 Address Select PCB

Pin No.
E32 White E30 Brown C30 Red A30 Orange E28 Yellow C28 Green A28 Blue

To Board Addressing Circuits

48-Pin Front Connector


A2 A4 A6 A8 A10 A12 A14 A16 A22 A20 A18 A24 A26 A28 A30 A32 E2 E4 E6 E28 E30 E32 C6 C4 C2 C8 C10 C12 C14 C16 E14 E12 E10 E18 E16 E20 E22 E24 C22 C20 C18 C24 C26 C28 C30 C32

GND

A22 Black A2 A4 A6 A8 A10 A12 A14 A16 C2 C4 C6 C8 C10 C12 Input 17 Input 18 Input 19 Input 20 Input 21 Input 22 Input 23 Input 24 Input 25 Input 26 Input 27 Input 28 Input 29 Input 30 Input 31 Input 32

Pin No.
Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8 Input 9 Input 10 Input 11 Input 12 Input 13 Input 14 Input 15 Input 16 +5V +5V +5V N12 N12 N12

Connect Loads as Shown Below B12

C14 C16

Non-Vital I/O PCB N17000601

E2 E4 E8 E12 E16 E18

Output 25 Output 26 Output 27 Output 28 Output 29 Output 30 Output 31 Output 32

Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Output 9 Output 10 Output 11 Output 12 Output 13 Output 14 Output 15 Output 16 Output 17 Output 18 Output 19 Output 20 Output 21 Output 22 Output 23 Output 24

LCP

Protected with 5A Fuses

E20 E22 A24 A26 C24 C26

N12

E24 E26

Figure 2-18 - Non-Vital I/O PCB, LCP Version - Basic Interface Wiring

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Cardfile and Circuit Board Installation

96-pin Connector
SEL+ o o o o o o o o o o o o o o o o o o
SW6 SW5 SW4 SW3 SW2 SW1

Address Select PCB

GND

C32 White C31 Brown B31 Red A31 Orange To Board Addressing C30 Yellow Circuits B30 Green A30 Blue B13 Black A1 Input 1 B1 Input 2 C1 Input 3 A2 Input 4 B2 Input 5 C2 Input 6 A3 Input 7 B3 Input 8 A4 Input 9 B4 Input 10 C4 Input 11 A5 Input 12 B5 Input 13 C5 Input 14 A6 Input 15 B6 Input 16 A7 Input 17 B7 Input 18 C7 Input 19 A8 Input 20 B8 Input 21 C8 Input 22 A9 Input 23 B9 Input 24 A10 Input 25 B10 Input 26 C10 Input 27 A11 Input 28 B11 Input 29 C11 Input 30 A12 Input 31 B12 Input 32 Non-vital Output PCB N17061501

B12
Connect Load as Shown Above

Protected with 5Amp Fuses

N12

This connector continued at right

Figure 2-19 - Non-vital I/O PCB, 32/32 Version - Basic Interface Wiring
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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation


48-pin connector
Outputs E2 Output 1 C2 Output 2 A2 Output 3 C4 Output 4 A4 Output 5 C6 Output 6 N17062701 A6 Outut 7 E8 Output 8 NV.OUT32 E4 Output Gnd 1-8 E6 Output Battery + 1-8 C8 Output 9 non-vital A8 Output 10 isolated C10 Output 11 A10 Output 12 Output C12 Output 13 PCB A12 Output 14 Output 15 E14 C14 Output 16 E10 Output Gnd 9-16 E12 Output Battery + 9-16 A14 Output 17 E16 Output 18 C16 Output 19 A16 Output 20 E18 Output 21 C18 Output 22 A18 Output 23 C20 Output 24 A20 Output 25 C22 Output 26 A22 Output 27 E24 Output 28 C24 Output 29 A24 Output 30 E26 Output 31 C26 Output 32 E20 Output Gnd 17-32 E22 Output Battery + 17-32 A32 C32 E32 E30 C30 CONNECTIONS A30 TO PCB ADDRESS SELECT CIRCUITS E28 C28 A28 A26

SEL+
SW1 SW2 SW3 SW4 SW5 SW6

Address Select PCB

GND

Figure 2-20 - Non-Vital, Isolated NV.OUT32 PCB Basic Interface Wiring

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Cardfile and Circuit Board Installation

NOTE In Figure 2-18, , pins A13 C29 are common connector pins. The number of required common returns depends on the number of outputs activated. The general guidelines are: . a. Outputs 31 and 32 are intended for high current; add a return for each used. b. For each of the other outputs, add one return for every 8 outputs used.

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48-pin connector
Inputs E2 Input 1 C2 Input 2 A2 Input 3 C4 Input 4 A4 Input 5 C6 Input 6 N17063701 A6 Input 7 E8 Input 8 NV.IN32 E4 Input Gnd 1-8 C8 Input 9 A8 Input 10 non-vital C10 Input 11 isolated A10 Input 12 Input 13 C12 Input A12 Input 14 PCB E14 Input 15 Input 16 C14 E10 Input Gnd 9-16 A14 Input 17 E16 Input 18 C16 Input 19 A16 Input 20 E18 Input 21 C18 Input 22 A18 Input 23 C20 Input 24 A20 Input 25 C22 Input 26 A22 Input 27 E24 Input 28 C24 Input 29 A24 Input 30 E26 Input 31 C26 Input 32 E20 Input Gnd 17-32 E6 E12 E22 A32 C32 E32 E30 C30 CONNECTIONS A30 TO PCB ADDRESS SELECT CIRCUITS E28 C28 A28 A26

SEL+
SW1 SW2 SW3 SW4 SW5 SW6

Address Select PCB

GND

Figure 2-21 - Non-Vital, Isolated NV.IN32 PCB Basic Interface Wiring

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Cardfile and Circuit Board Installation


48-pin connector 96-pin connector

Inputs E2 + Input 1 E4 C2 + Input 2 C4 A2 + Input 3 A4 N17002801 E6 + Input 4 E8 NV.IN32. C6 + Input 5 C8 OUT16 A6 + Input 6 A8 non-vital E12 + Input 7 E14 isolated C12 + Input 8 I/O C14 PCB A12 + Input 9 A14 E16 + Input 10 E18 C16 + Input 11 C18 A16 + Input 12 A18 E22 + Input 13 E24 C22 + Input 14 C24 A22 + Input 15 A24 E26 + Input 16 C26 E26 C26 E20 E6 E12 E22 A32 C32 E32 E30 C30 CONNECTIONS A30 TO PCB ADDRESS SELECT CIRCUITS E28 C28 A28 A26

Outputs
Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Output 9 Output 10 Output 11 Output 12 Output 13 Output 14 Output 15 Output 16

+ 5V + 5V + 5V GND GND GND Input 17 Input 18 Input 19 Input 20 Input 21 Input 22 Input 23 Input 24 Input 25 Input 26 Input 27 Input 28 Input 29 Input 30 Input 31 Input 32

+ 5V + 5V + 5V GND GND GND IN 1 LED IN 2 LED IN 3 LED IN 4 LED IN 5 LED IN 6 LED IN 7 LED IN 8 LED IN 9 LED IN 10 LED IN 11 LED IN 12 LED IN 13 LED IN 14 LED IN 15 LED IN 16 LED

SEL+
SW1 SW2 SW3 SW4 SW5 SW6

Address Select PCB

GND

+ 5V + 5V + 5V GND GND GND

B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 A32 A31 A30 A29 A28 A27 A26 A25 A24 A23 A22 A21 A20 A19 A18 A17 A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 C32 C31 C30 C29 C28 C27 C26 C25 C24 C23 C22 C21 C20 C19 C18 C17 C16 C15 C14 C13 C12 C11 C10 C9 C8 C7 C6 C5 C4 C3 C2 C1

LCP
PANEL
N1700290X

Figure 2-22 - Coded Track Circuit PCBs Basic Interface Wiring

2.4.8 Code System Interface PCB


The code system interface PCB interfaces the Microlok II system to various types of non-vital code lines. Basic functions include conversion of the particular code line protocol to a format compatible with the Microlok II system (and vice-versa) and operation as a non-vital logic controller. This board is electrically identical to the
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Cardfile and Circuit Board Installation


enhanced controller PCB used in the US&S GENISYS-2000 systems, and uses executive and application software that is identical to that used on the enhanced controller board. The GENISYS-2000 hardware is modified to make the board mechanically compatible with the Microlok II cardfile. The basic interfacing rules for the code system interface PCB are as follows: A. This board must be used when interfacing the Microlok II system to all types of non-vital code systems except GENISYS. Either the code system interface PCB or the Microlok II CPU board (refer to section 2.4.1) can be used for the GENISYS interface. B. When interfacing the Microlok II system to a DC code line, an external GENISYS unit must be included to provide the electrical interface to the code line. The Microlok II system does not include an equivalent to the GENISYS code line interface PCB. C. Microlok II serial link isolator units should be included in the interface to the code line to protect circuits on both ends of the interface from potentially damaging voltage transients. These units are different from the GENISYS surge suppression/serial interface panels. The latter cannot be used as a substitute. Serial link isolator unit specifications are as follows: Unit Type
Type A serial link isolator unit

US&S Part No.


N17002201

Unit Specifications
Interfaces the code system PCB (cardfile) to a Glenaire modem or MCP in ARES and serial line carrier code systems. Input Power: 9.5 to 16.2 Vdc Modem Power Outputs: +12 Vdc and 12 Vdc

Type B serial link isolator unit

(Contact US&S)

Interfaces the code system interface board to ATCS systems. Signal compatibility: Balanced RS-485 and unbalanced RS-423 ports

Figure 2-20 shows the standard interface wiring pin-outs for the code system interface PCB.

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Cardfile and Circuit Board Installation


48-pin Connector Pin No.
C2 C4 C6 C8 C10 A10 C14 C16 C18 A2 A4 A6 A8 E2 E4 E6 E8 E10 E12 E14 E16 E18 E20 E22 E32 C12 C20 C22 C28 C32 A20 A22 A24 A28 A30 A32 A12 A14 A16 A18 E24 C24 C26 A26 E26 E28 E30 C30 Slave Receive Data - (S1RXD-) Slave Receive Data + (S1RXD+) Slave Receive Clock - (S1RXC-) Slave Receive Clock + (S1RXC+) Slave Transmit Clock - (S1TXC-) Slave Transmit Clock + (S1TXC+) Slave 2 Receive Clock (S2RXC) Slave Data Carrier Detect (S2DCD) Slave Receive Data - (S2RXD-) Slave Clear To Send - (S1CTS-) Slave Clear To Send + (S1CTS+) Slave Data Carrier Detect - (S1DCD-) Slave Data Carrier Detect + (S1DCD+) Slave Transmit Data (S1TXD) Slave Transmit Clock (S1TXC) (Output) Slave Request To Send (S1RTS) Slave Data Terminal Ready (S1DTR) 0 Volts Slave 2 Common (0 Volts) Slave Transmit Data (S2TXD) (In / Out) Slave Transmit Clock (S2TXC) Slave Request To Send (S2RTS) Slave Data Terminal Ready (S2DTR) + 5 Volts 0 Volts 0 Volts + 12 Volts + 5 Volts - 12 Volts 0 Volts + 12 Volts Master Receive Data (MRXD) Master Data Carrier Detect (MDCD) - 12 Volts 0 Volts Master Common - 0 Volts Slave Common - 0 Volts (S1COM) Master Transmit Data (MTXD) Master Request To Send (MRTS) Master Data Terminal Ready (MDTR) Parallel Output 1 (POUT1) Parallel Output 2 (POUT2) Parallel Output 3 (POUT3) Parallel Output 4 (POUT4) Parallel Input 1 (PIN1) Parallel Input 2 (PIN2) Parallel Input 3 (PIN3) Parallel Input 4 (PIN4)

To Serial or ATCS-compliant Code System via Serial Link Isolator Unit See Section 3.5 for Isolator Unit Installation See Section 3.7 for Typical Code System Interface Diagrams

To dc Code Lines (US&S 500 Series or GRS K Series) Refer to SM-6700B for Application Data

S1 Slave Port: RS-423 (RS-422 Compatible) S2 Slave Port: RS-232D Compatible

Code System Interface PCB N17061401

Figure 2-23 - Code System Interface PCB - Basic Interface Wiring

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Cardfile and Circuit Board Installation 2.4.9 Coded Track Circuit PCBs
The coded track circuit PCBs interface the Microlok II system to the mainline coded track circuits (with and without cab signals). The specifications for these boards are as follows: US&S Part No.
N451910-0701 N451910-7601 N451910-7602 N451910-7603

Track Circuit Application


General non-cab and 100 Hz cab signal Required for 40 Hz cab signal Required for 50 Hz cab signal Required for 60 Hz cab signal

Track Circuit Operating Power


9.8 to 16.2 Vdc 9.8 to 16.2 Vdc 9.8 to 16.2 Vdc 9.8 to 16.2 Vdc

The Microlok II system can accommodate up to four coded track circuit printed circuit boards in the same cardfile. Refer to Section 3.1.3 for coded track interface panel wiring to the rails.

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Cardfile and Circuit Board Installation


48-pin Connector
SEL+
SW1 SW2 SW3 SW4 SW5 SW6

Pin No. E32 E30 C30 A30 E28 C28 A28 A26 A2
White Brown Red Orange Yellow Green Blue Black

To Board Addressing Circuits

L+ Master Side Coded Track Interface Panel (See Fig. 3-2 for Track Wiring) L-

Address Select PCB

GND

A OUT+

A4

A OUT-

L+ Slave Side Coded Track Interface Panel (See Fig. 3-2 for Track Wiring) L-

A8

B OUT+

A10

B OUTCoded Track Circuit PCBs N451910-0701 N451910-7601 N451910-7602 N451910-7603 Wake-up (Sleep Mode)

B12 N12

C22 A24 A12

Figure 2-24 - Coded Track Circuit PCBs - Basic Interface Wiring

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Cardfile and Circuit Board Installation 2.4.10 OS Track Circuit PCB

The OS track circuit PCB interfaces the Microlok II system to the OS track circuit in interlocking applications requiring one OS transmitter and two OS receivers (end-of-siding). Specifications for this board are as follows: Transmitter/Receiver Frequency
400 Hz

Receiver Output Voltage


12 Vdc to 20 Vdc 15 Vdc (nominal)

Track Circuit Length


1000 ft. @ 5/1000 ft. Ballast

Track Lead Resistance


0.5 (max.)

It is not necessary to connect both receivers if it is not required by the application. In many cases the transmitter is connected at the heel block and the two receivers provide independent train detection on the interlocking through and turnout tracks. Transmitter output power is insufficient to drive a relay. Figure 2-22 shows the basic wiring of the OS track circuit PCB. Outputs OUT1 and OUT2 must be wired to one of the inputs on the vital input PCB to provide the train detection input to the CPU board. OUT1 and OUT2 should each be wired to a + input on the vital input PCB, with N12 connected to each negative input. See Figure 2-11 for vital input PCB wiring pin-outs. Separate B12/N12 and +5V connections are also required to power the OS track circuit PCB transmitters and board circuitry. Also note the installation of primary surge protection on the wiring.

CAUTION Lightning arrestors (shown in Figure 2-20) must be used in all Microlok II OS track installations, otherwise the system could be damaged from lightning surges or operate improperly as the result of transient signals.
Refer to service manual SM-6800C for procedures to adjust the OS track circuit PCB power output for various track circuit lengths.

CAUTION The OS track circuit provides a transmitter and 2 receivers. at an end of siding type location this puts either a transmitter or receiver at each end of the OS circuit. All OS track circuits operate at the same frequency. If multiple OS circuits are used at a double-crossover type location, a defective joint potentially could cause a falsely energized track output.

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Cardfile and Circuit Board Installation

OS

Maximum OS Track Lead Resistance = 0.5 Ohms

OS

OS

Line-to-Line Arrester USGA Blue N451552-0101 Line-to-Ground Arrester USGA Red N451552-0201
2 1

Pin No.
A2

48-pin Connector

Transmit

A4

A8

Receive 1

A10

A18

Receive 2

A20

+OUT 1 +OUT 2

A14

+ DC + Logic Output* N12 N12 B12 N12 +5V from Power Supply PCB + -

INPUT X INPUT Y

A24

A28

A32 OS Track Circuit PCB N451810-6701

Vital Input PCB N17061001 or N17061002 (See Fig. 2-7 for Complete Wiring)

A30

*Track Occupancy Indication to Vital Input PCB

Figure 2-25 - OS Track Circuit PCB - Basic Interface Wiring

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SM 6800B, Rev. 3, December 2005

Cardfile and Circuit Board Installation 2.4.11 Cab Signal Coder PCBs and Cab Amplifier PCBs
The coder output and cab amplifier printed circuit boards are used to generate cab signal carrier frequencies and code rates, and output these signals to the rails through cab signal interface panels. Each Microlok II cab signal application requires one coder output board and one or two cab amplifier boards installed in the following combinations: Amplifier PCB
N451910-6401 N451910-6901

Coder PCB(s)
N451910-5801 N451910-5801, N451910-7001

Application
For 60 or 100 Hz carrier, 75/120/180 code rates For 40 or 50 Hz carrier, 50/75/120/180 code rates

The -5801 coder output PCB (75/120/180 CPM) is controlled by the Microlok II CPU board and requires an Address Select PCB with six two-position jumpers in the connector housing to set its cardfile bus address. When the additional 50 CPM code rate is required, it is produced by the -7001 board, which feeds the rate to the cab amplifier board through the -5801 coder output board. (A jumper must be set on the -5801 board for this configuration; refer to service manual SM-6800C). The -7001 coder output PCB does not communicate over the Microlok II cardfile bus and is only connected to the -5801 coder output board through the upper wiring connector. Code rates produced by the single -5801 board or combination -5801/-7001 boards are delivered to the cab amplifier PCB through the upper wiring connectors, not the cardfile bus. The cab amplifier PCB also operates separately from the CPU board (no cardfile bus communications). The cab amplifier PCB output is wired to the cab signal interface panel for final connection to the rails. Figure 2-23 shows the standard wiring options for the four Microlok II cab signal boards. Cab amplifier output connections to cab panel transformer primary are doubled to carry the extra current load. The East and West direction relays on the panel are energized through three additional wire connections. A jumper is required between pin-outs E14 and E16 on coder output PCB. This jumper provides the east/west direction input from output #4 on the coder output PCB.

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Cardfile and Circuit Board Installation


Pin No. A10 A8 C10 C8 E2 E4 A2 A4 22-way Terminal Strip 22 E 21 20 13 19 18 10 17 9 16 8 7 15 Direction Control Relays 1 Code Output E20 C6 A6 E6 C24 E2 Output 3 Code Input Output 4 E12 C22 E14 E16 E32 E30 To Board Address Circuits C30 A30 E28 C28 A28 A26
GND SEL+ o oo ooo ooo ooo ooo ooo Address Select PCB
SW6 SW5 SW4 SW3 SW2 SW1

48-pin Connector B12

See Figure 3-4 for Cab Signal Panel-to-Track Wiring


N12 AAR Terminals

Cab Amplifier PCB N451910-6401 (60/100 Hz) N451910-6901 (40/50 Hz)

A14 C14 E14 E10 A18 C18 E18 A16 A22 C22 E22 C20 A26 C26 E26 E24 E32

E1 East Track Feed

14 6 12 11 E E2

W1 West Track Feed

W2

Code Input

East West

2 3

Coder Output PCB (75/120/180) N451910-5801

B12 N12 VCOR Relay Direction Input +12 East, 0 West

Cab Signal Interface Panels: For 100 Hz Cab: N451835-0802 For 60 Hz Cab: N451835-0801 For 50 Hz Cab: N451835-1101 For 40 Hz Cab: N451835-1101

Group 1 Group 2

Code Turn-On Code Output Code Turn-On E10 Code Output E22 A10 N12

Auxiliary Coder Output PCB (50/50) N451910-7001

Figure 2-26 - Coder Output and Cab Amplifier PCBs - Basic Interface Wiring

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Cardfile and Circuit Board Installation 2.4.12 Address Select Jumper Settings
On the PCBs that use them, the address select jumpers are used for board addressing. The jumper settings are automatically determined by the compiler when the application program is written. This information is clearly defined and available to the user in the list file (.mll), which is one product of compiling an application text file (.ml2). If this file is unavailable, the user can determine the jumper settings by following the instructions below. By far the best way to determine the jumper settings, however, is to use the list file. The jumper settings for each board are determined by the order in which the boards are defined in the application. The jumper settings do not depend on the order the boards happen to appear in the cardfile. If the application program and list file are both unavailable, then the order can also be found by looking at the configuration menu in the Microlok II Maintenance Tool. (See Section 6.2 in the 6800C manual.) The buttons for the board listing in the configuration window are in the same order, from left to right, as they are in the application. There are two types of boards: 8-bit and 16-bit. Lamp boards are 16-bit boards, and all other boards are 8-bit boards. So, for this purpose, there are lamp boards and non-lamp boards. The following table shows how to set the jumpers for each type of board (lamp and non-lamp). Each type must be counted separately to determine the order and, therefore, the proper jumper setting. Note: Each jumper may be set to either a "0" or "1" position.

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Board Order 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Non-Lamp Board Jumpers 2 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 3 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 4 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 5 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Lamp Board Jumpers 3 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 4 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 5 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

For example, for the first non-lamp board, jumpers 1 through 5 are set to "0", while jumper 6 is set to "1". The second non-lamp board will have jumpers 2 and 6 set to "1" with the rest at "0", and so on. The first lamp board listed will have all jumpers set to "0". The fifth lamp board listed will have jumper 4 set to "1", and the rest set to "0".

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Cardfile and Circuit Board Installation


As an example, the following list was formed using the table above: Settings:

Non-Lamp Boards
1. TheIN8_OUT8 2. TheNV_IN32_OUT32 3. TheIN16 4. TheOUT16 5. TheNVB.OUT12 6. TheCODEROUT 7. TheTrxTrack 0 0 0 0 0 0 0

1
0 1 0 1 0 1 0

2
0 0 1 1 0 0 1

3
0 0 0 0 1 1 1

4
0 0 0 0 0 0 0

5
1 1 1 1 1 1 1

Lamp Boards
TheLAMP16 0

Settings:

1
0

2
0

3
0

4
0

5
0

It is assumed that the application software defines the boards as they are shown above, i.e., Board #1 is an NV.IN32.OUT16 board, etc. It is the order in which they are defined in the application program that determines the board number, not the relative position in the cardfile.

2.4.13 AC Lamp Drive


With some additional hardware, Microlok II can provide AC lighting of nominal 12V signal lamps. The required hardware includes: 12V Vital Input Board 12V Vital Output Board AC Lamp Driver Module AC Lamp Hot Filament Checker Part numbers and wiring details are contained in US&S service manual SM-8525.

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Installing Microlok II System Peripheral Devices

3
3.1

Installing Microlok II System Peripheral Devices


INSTALLING CODED TRACK AND CAB SIGNAL INTERFACE PANELS

3.1.1 Coded Track and Cab Signal Panel Selection


Four coded track interface panels and three cab signal interface panels are available for use in Microlok II systems. Make certain to use the unit appropriate to the application:

Table 3-1 - Coded Track and Cab Signal Interface Panel Applications
Description
Coded track interface panel with 10 mH inductor Coded track interface panel with 15 mH inductors Coded track interface panel with 20 mH inductors Coded track interface panel with 40 mH inductors Cab signal interface panel Cab signal interface panel

Application
General applications without cab signal Non-cab territories with 86 Hz crossing predictors.

US&S Part No.


N451835-0101 N451835-0102

Cab signal territories with 100 Hz carriers. Use with cab signal interface panel N451835-0802. Cab signal territories with 60 Hz carriers. Use with cab signal interface panels N451835-0801 and N451835-1101. Cab signal territories with 60 Hz carriers. Use with coded track interface panel N451835-0104. Cab signal territories with 100 Hz carriers. Use with coded track interface panel N4518350103. Cab signal territories with 40 Hz carriers. Use with coded track interface panel N4518350104.

N451835-0103

N451835-0104

N451835-0801 N451835-0802

Cab signal interface panel

N451835-1101

3.1.2 Mounting the Panels


Refer to Figure-3-1. When two coded track interface panels are being mounted in the same location, they must be separated by at least 12 inches to minimize magnetic interference between them. The optional quick shunt module should be mounted close to the coded track interface panel. In Microlok II applications where the system is also used to generate cab signals, the cab signal interface panel should be mounted close to the cardfile. This panel can be mounted on a wall or shelf, and can be installed in a standard 19-inch rack. For this application, the associated track interface panels should be mounted nearby because the track leads are shared with the cab signal interface panel. The temperature limits on these panels are the same as those for the cardfile. See section 3.11 of service manual SM-6800A for environmental limitations on the Microlok II system.

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Installing Microlok II System Peripheral Devices

Coded Track and Cab Signal Interface Panels

Quick Shunt Module 8-3/8

2-3/4

4-5/8

17-3/4

19

4-3/4

7-5/8

Track Panel Dim. A Dim. A Coded Track = 5-1/4 Cab Signal = 5-1/2 7

Figure-3-1 - Mounting Dimensions for Coded Track/Cab Signal Interface Panels and Quick Shunt Module 3.1.3 Coded Track Interface Panel Wiring, Grounding, and Surge Protection 3.1.3.1 Track Leads and Surge Protection

Refer to Figure 3-2. Per standard railroad practice, leads from the coded track interface panel should be equipped with line-to-line and line-to-ground lightning arresters. Special track surge protection or common mode filtering is not required on these leads.

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SM 6800B, Rev. 3, December 2005

Installing Microlok II System Peripheral Devices

CAUTION The track leads to the Microlok II coded track interface panel must be equipped with US&Sspecified lightning arresters. Damage to the Microlok II equipment may result from lightning surges if the arresters are not properly installed.

3.1.3.2

Grounding

Chassis grounds are not required for the coded track interface panels.

3.1.3.3

Track Polarity

Figure 3-2 shows how to connect the coded track interface panels to the rails so that proper polarity is established between adjacent track circuit blocks. Note in the figure that the polarity of the panel terminals (L+, L-, T+, T-) is reversed from one end of the panel to the other. To confirm the proper track circuit polarity, use the procedure in section 7 of service manual SM-6800C. Section 7 also provides procedures for all coded track circuit adjustments that must be made during system startup.

CAUTION Track polarity between adjacent tracks must be reversed to prevent a Microlok II system from communicating through a faulty insulated joint connection.

SM 6800B, Rev. 3, December 2005

3-3

Installing Microlok II System Peripheral Devices


+

+
Insulated Joints

Insulated Joints

+ Insulated Joints

+
Insulated Joints -

2
1

2
1

2
1

2
1

T-

T+

T-

T+

TSee Figure 2-19 for Interface Wiring to Coded Track Circuit PCBs

T+

Coded Track Interface Panels


L+ L-

Coded Track Interface Panels

T-

T+

L+

L-

L+

L-

L+

L-

Microlok II Cardfile

Coded Track Circuit PCBs

To Microlok II Vital Input PCB


B+

To Battery
B-

To Microlok II Vital Input PCB

Quick Shunt Module

3 4 Out 1

7 8 Battery

5 6 Out 2

Line-to-Line Arrester USGA Blue N451552-0101 Line-to-Ground Arrester USGA Red N451552-0201

Track 1 2 2 1

Track 1 1 7

Track 2 4 8

Track 2

REC. XMT. REC. XMT.

REC. XMT. REC. XMT.

To Track

To Track

To Track

T-

T+

T-

T+

L+

L-

L+

L-

To Microlok II Cardfile (See Above)

To Microlok II Cardfile (See Above)

Figure 3-2 - Coded Track Interface Panels - Basic Track Wiring

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SM 6800B, Rev. 3, December 2005

Installing Microlok II System Peripheral Devices 3.1.3.4 Installing a Termination Capacitor PCB
When using coded track interface panels N451835-0103 or -0104, a special termination capacitor PCB (part number N451923-2501) should be mounted on the two panel terminals wired to the Microlok II cardfile. This PCB contains two back-to-back electrolytic capacitors and is designed to prevent the high power output of the Microlok II cab transmitter from interfering with the coded track messages. This board also filters 60 Hz induction interference from power lines. For the 100 Hz cab signal frequency, no other filtering is required. For lower cab signal frequencies, special track printed circuit boards are required (contact US&S). Figure 3-3 shows the termination capacitor PCB installation.

AAR Terminal T-

AAR Terminal T+

Coded Track Interface Panel N451835-0103 N451835-0104 (Cab Signal Compatible)

AAR Terminal L+

AAR Terminal L-

Termination Capacitor PCB N451923-2501

Either Position OK

Figure 3-3 - Termination Capacitor PCB Installation on Coded Track Interface Panels

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3-5

Installing Microlok II System Peripheral Devices

3.1.4 Quick Shunt Module Application and Installation


The optional quick shunt module (N451052-4601) is used in applications where an improved shunt detection time is required. The quick shunt module reduces the detection time to approximately 100 milliseconds and contains circuitry for independent train detection on both sides of the insulated joint. Two 8-way screw-lock connectors are provided for external wiring. The two independent receivers on this device should be connected to the coded track interface panels as shown in Figure 3-2. With this configuration, true shunt mode operation is attained without the need for separate track termination leads. The detection zone is limited to approximately 75 feet. For greater lengths, the transmitted and receiver track terminations must be separated.

3.1.5 Cab Signal Interface Panel Wiring, Grounding and Surge Protection 3.1.5.1
3.1.1.5.1

Single-Cab Signal Configuration Wiring


Track Leads

For Microlok II installations that control one cab signal interface, track leads from the cab signal interface panel are connected to the track terminals of the coded track interface panels, as shown in Figure 3-4. No special line filtering or surge suppression is required on these terminals. 3.1.1.5.2 Cab Interface Panel-to-Cardfile Wiring

Refer to section 2.4.11 and Figure 2-21 for wiring of the cab interface panel to the Microlok II cardfile.

3.1.5.2

Dual-Cab Signal Configuration Wiring

Consult US&S for Microlok II cab signal applications where the system is generating separate cab signal codes to different interlocking tracks (main and siding tracks).

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Installing Microlok II System Peripheral Devices


+ Insulated Joints +

2 1

2 1

T-

T+ Termination Capacitor PCB

T-

T+

Coded Track Interface Panel L+ L-

Coded Track Interface Panel L+ L-

To Microlok II Cardfile Coded Track Circuit PCB


1 2 3 4 5

Cab Signal Interface Panel


7 6 8 9 11 13 15 17 19 21 10 12 14 16 18 20 22

To Microlok II Cardfile Coded Track Circuit PCB

W Direction Control Cab Signal Output

Line-to-Line Arrester USGA Blue N451552-0101 Line-to-Ground Arrester USGA Red N451552-0201 Microlok II Cardfile

See Figure 2-21 for Interface Wiring to Cab Signal PCBs

Coder Output PCB

Cab Amplifier PCB

Figure 3-4 - Cab Signal Interface Panel Basic Wiring - Single Cab Configuration

SM 6800B, Rev. 3, December 2005

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Installing Microlok II System Peripheral Devices

3.2

VITAL CUT-OFF RELAY (VCOR) INSTALLATION AND WIRING

The VCOR controls power to all Microlok II vital outputs under the control of the Microlok II CPU board. Power for the relay coil is supplied by the cardfile power supply PCB. A US&S PN-150B relay (part number N322500-701) is used for all VCOR installations. The components required to rack-mount the relay are listed below. Item
PN-150B relay relay mounting base contact springs for #14 - #16 wire rack mounting bars (2 required) mounting bar clamps (4 required)

US&S Part No.


N322500-701 N451376-0302 M451142-2702 M381333 M381298

Double battery and return paths are wired to the relay to eliminate voltage drops. Use #14 wire for connections between the cardfile and the relay. Also, use parallel contacts of the VCOR where possible. Figure 3-5 shows the wiring between the Microlok II cardfile and the VCOR for the various types of vital output boards.

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Installing Microlok II System Peripheral Devices


Pin No. A6 48-pin Connector VCOR Relay US&S PN-150B 1C 1A

VCOR Switching

N12

Power Supply PCB A16 To Outputs C16 E16

B* *12V for PCB N17060501 *24V for PCB N17060502

Standard Vital Output PCB (See Figure 2-12)

A22 To Outputs C22 E22

B12

Bi-polar Vital Output PCB (See Figure 2-9) To Outputs A22 C22

B12

Mixed Vital I/O PCB (See Figure 2-15) E18 BATT+ E20 B12 Vital Lamp Driver PCB (See Figure 2-14)

Figure 3-5 - VCOR Relay Wiring

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Installing Microlok II System Peripheral Devices

3.3

POWER-OFF RELAY INSTALLATION AND WIRING

The power-off relay is provided for Microlok II installations that require the detection of commercial power failure. A loss of commercial power drops the relay and closes a normally open relay contact. The contact closure makes an input circuit to the non-vital I/O PCB in the Microlok II cardfile. (See Figure 3-6.) The power-off relay is mounted on a plug-in base and secured with a spring clip. This base is designed for attachment to a standard equipment rack DIN rail, or can be secured to a flat surface using a screw hole in the base under the relay. The part numbers are as follows: Item
relay base spring clip
2-1/8
22 21 24

US&S Part No.


J726153-0283 J581782-0026 J680167-0009
5/8
NC
COMM

12 11 14

NO

A2

COIL

A1

A1 A2 14 21 12 Power-off Relay Vital Input or Non-vital I/O PCB Commercial 110/120V Under-voltage Monitor

Figure 3-6 - Power-off Relay Design and Interface Wiring

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Installing Microlok II System Peripheral Devices

3.4

ISOLATION MODULE INSTALLATION AND WIRING

The isolation module is used for Microlok II applications that require the equivalent of a double-break output circuit. When connected to an output of the standard vital output PCB or mixed vital I/O PCB, the isolation module creates an isolated output suitable for connection to line or relay circuits in a different house or case. The module contains two independent circuits that can be interconnected to create a single, isolated bi-polar output when required by the application. Figure 3-7 shows the module mechanical design. The module is typically rack mounted on a DIN rail, but can also be wall mounted. Three versions of the isolation module are available. All three models are controlled by a nominal 12V vital output. Module N17001101 (12V output) provides an output slightly greater than the battery source voltage. Current is limited to 0.4A with voltage fold-back occurring at that point. Module N17001102 (50V output) also provides an output proportional to the battery source voltage, with fold-back occurring at approximately 0.13A. Module N17001103 (24V output) also provides an output proportional to the battery source voltage, with foldback occurring at approximately 0.4A. Outputs are short circuit protected and will withstand a single cross to B12 or N12 without damage. Outputs will also withstand 2000V RMS to battery or to earth ground. Refer to Figure 3-8. Isolation module terminals B12 and N12 designate battery positive and battery negative, respectively. For two independent outputs, with terminal IN1 activated by a nominal +12 voltage relative to N12, output 1 is activated with the indicated polarity (OUT1+ or OUT1-). Output 2 is similarly activated. For bi-polar operation, make the following connections: Jumper between J1A and J2B Jumper between J2A and J1B Load between BP1 and BP2 Polarity will establish BP1 positive relative to BP2 with IN1 activated. Polarity is reversed when IN2 is activated. For bi-polar operation, both inputs should never be activated simultaneously.

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Installing Microlok II System Peripheral Devices


The drawing and table below summarize the operations:

SYS BATT

Output PCB

VCOR

Isolator
CONTROL

OUTPUT

BATT

PART NUMBER 1101 1101 1102 1102 1103 1103

SYS BATT 12 Vdc 12 Vdc 12 Vdc 12 Vdc 12 Vdc 12 Vdc

BATT 9.6 Vdc 16.2 Vdc 14 Vdc 18 Vdc 18 Vdc 35 Vdc

OUTPUT VOLTAGE 10 Vdc 18 Vdc 40 Vdc 55 Vdc 18.2 Vdc 36.8 Vdc

NOTE:

1102 assumes a 500 1103 assumes a 1000

or greater load. or greater load.

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Installing Microlok II System Peripheral Devices


5-1/2

OUT1+ IN1

J1A OUT1-

J2B BP2

B12 N12

OUT2+ IN2

J2A OUT2-

J1B BP1

N12 N12

3-1/2

12 Volt Isolated Output Module

2-5/16
5 6 7 8 5 6 7 8

Bottom View

Position shown for wall mounting.

Bend tab up to move mounting clip. Position shown for DIN rail mounting.

Figure 3-7 - Isolation Module Mechanical Design

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Installing Microlok II System Peripheral Devices


Standard Vital Output PCB N17000501* OUTPUT 1 E2 A26* BATT + 12 Vdc for 1101 and 1102 BATT 24 Vdc for 1103

Pin No.

Isolation Module N1700110X IN1 N12 B12 N12 IN2 OUT2+ OUT2 Isolated Output #2 OUT1+ OUT1 Isolated Output #1

VCOR 12 VDC

OUTPUT 2

C2

48-pin Connector

No Connections for Unipolar Operation: J1A, J1B, J2A, J2B, BP1, BP2

Unipolar Operation

Standard Vital Output PCB N17000501* VCOR 12 VDC Output 1 Output 2 E2

Pin No.

Isolation Module N1700110X IN1

C2 C26* BATT +

IN2 BP1 N12 B12 N12 J1A J2B J2A J1B BP2 Bi-polar Output**

48-pin Connector

12 Vdc

BATT -

Bi-polar Operation
(1101 and 1102 only)

*Other Available Common (N12) Connections:


E26, A24, C24, E24, A22, C22, E22

**Note:
Do not energize output 1 and output 2 at the same time. BP1 will be positive with respect to BP2 when output 1 is energized. The reverse is true when output 2 is energized.

Figure 3-8 - Isolation Module Typical Wiring

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Installing Microlok II System Peripheral Devices

3.5

CONNECTING MICROLOK II TO EXTERNAL SERIAL DEVICES

The MICROLOK II controller board has four independent serial ports. The MICROLOK II application program determines the function of each of these ports. Each port may be designated as a MICROLOK protocol master, a MICROLOK protocol slave, a GENISYS protocol master, or a GENISYS protocol slave. The function of serial ports may be designated in any combination. The four serial ports support three different hardware interface standards. Ports 1 and 2 support an RS-485 hardware interface while port 3 supports an RS-423 interface and port 4 supports an RS-232 interface. These standards (RS-485, RS-423, and RS-232) define only the characteristics of the hardware interface. They define characteristics such as interface voltage levels, whether signals are balanced or unbalanced with respect to signal common, and whether or not outputs can be set to a high impedance state for compatibility with multi-drop communication circuits. They have no bearing on the protocols or data that may be passed through these ports. Any of the four serial ports may be used to pass any of the protocols currently supported by MICROLOK II. The only restriction is that ports must connect to external ports which support a like hardware standard. RS-485 ports can be connected to RS-485 or RS-422 compliant ports, RS-423 ports can be connected to RS-423 compliant ports, and RS-232 ports can be connected to RS-232 compliant ports. RS-232 and RS-423 ports can usually be interconnected. Typically, the RS-485 serial ports are reserved for direct, local connections between two or more RS-485 capable units located in the same equipment facility and powered by the same vital battery power supply. The RS-485 ports utilize balanced signal drivers and receivers that offer a high degree of immunity to ambient electrical noise. In addition, RS-485 serial ports may be connected directly to a multi-drop, hard-wired, serial communication circuit without the use of external signal processing hardware (signal splitters, etc.). The allowable length of the communication circuit is essentially unlimited as long as no part of the circuit leaves the equipment room or signal house where it originates. (MICROLOK II RS-485 circuits cannot be run between signal houses without serial communication circuit isolation hardware.) RS-423 and RS-232 serial ports are most easily connected to common serial devices and commercially available modems. The RS-423 port may be used in simple, short distance, multi-drop applications while the RS-232 port may be used only in short distance point-to-point applications. Short distance, in this case, means less than 50 feet. The RS-423 port should normally be reserved for direct connections to other RS-423 devices such as MICROTRAX EOS when required. The RS-232 port should normally be reserved for use as a GENISYS protocol slave port to be employed as a serial interface to a central control office when such an interface is required. In this case the RS-232 port would normally connect to the master port of the GENISYS 2000 code system interface CPU or directly to an RS-232 modem depending on the specific application. Serial devices are generally identified as DTE (Data line Terminating Equipment) or DCE (Data Carrying Equipment). In DCE equipment, transmit data (TXD) and request to send (RTS) are inputs and receive data (RXD) and data carrier detect (DCD) are outputs. Modems are generally DCE devices. All MICROLOK II serial ports are labeled as DTE or terminal devices. This means that transmit data (TXD) and request to send (RTS) signals are outputs and receive data (RXD), data carrier detect (DCD), and clear to send (CTS) are inputs. When connecting DTE devices to DCE devices (when connecting a MICROLOK II serial port to a modem, for example) it is necessary to connect TXD to TXD, RTS to RTS, RXD to RXD, and DCD to DCD. To establish a useable direct bi-directional connection between two MICROLOK II serial ports (both DTE devices), TXD and RXD signals and signal common (COM) must always be connected. The serial port assigned to this connection on one of the two units must be designated as the master port and the serial port assigned on the other unit must be designated as a slave. (A MICROLOK or GENISYS protocol communication link may have multiple slaves but it may have only one master unit.) The ports assigned to this connection must be set to the same protocol (MICROLOK or GENISYS). The data transmitter (TXD) on the SM 6800B, Rev. 3, December 2005
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Installing Microlok II System Peripheral Devices


master unit must be connected to the data receiver (RXD) on the slave unit(s). Likewise, RXD on the master unit is connected to TXD on the slave unit(s). The signal common (COM) for master and slave units is connected together. This connection is the simplest connection that allows data to be passed in both directions between master and slave units. Protocols such as the MICROLOK protocol require message framing signals that tell the port at the receiving end of the communication circuit where a message starts and ends. This information is passed by crossconnecting RTS and DCD. In other words RTS on the master unit is connected to DCD on the slave unit(s) and DCD on the master unit is connected to RTS on the slave unit(s). This control signal connection coupled with the data signal connection described in the paragraph above is often referred to as a NULL MODEM connection or a connection between serial ports implemented without the use of modems. The RTS signal on the sending unit signals the beginning of the message when it is asserted. This occurs shortly before data transmission begins. The RTS signal is deasserted shortly after the end of data transmission. The NULL MODEM connection may always be used to connect two units located in the same equipment facility, which are to communicate using MICROLOK or GENISYS protocols. Of these two protocols, however, only the MICROLOK protocol actually REQUIRES the connection of RTS and DCD. The GENISYS protocol requires only that TXD, RXD, and COM be connected. The DCD signals may be strapped in the asserted state for any unit supporting the GENISYS protocol or simply left disconnected for MICROLOK II or GENISYS 2000 units. (These units are designed to ignore the DCD signal UNLESS half-duplex or keyed carrier communication is selected.)

3.5.1 Connecting MICROLOK and GENISYS Protocol Serial Ports Using Modems
Whenever it is necessary to connect MICROLOK or GENISYS protocol ports which are not located in the same equipment facility, some type of modem or communication device which provides serial common isolation and secondary transient protection MUST be used. While the operating characteristics of modems vary widely, there are a few requirements that apply to all serial interface applications which employ modems. MICROLOK and GENISYS protocols can only be passed through modems that are capable of passing asynchronous data. Most low speed modems (19,200 bps. or less) and carrier sets have this capability. Neither MICROLOK nor GENISYS protocol implementations support the use of transmit and receive data clocks that are separate from the data signals. Therefore, modems which support only a synchronous serial interface to connected serial equipment, as a general rule, cannot be used. GENISYS protocol requires modems that can process all messages without the use of either hardware or in-band flow control. This means that either the modems must not buffer outbound data or the modems outbound data buffer must be large enough to hold the longest message that is expected to be transmitted on the communication link. This constraint applies to modems only. Simple carrier sets generally are not capable of buffering data. MICROLOK protocol MUST NOT be transported by modems that buffer data in any way. Such modems pose a safety risk when they are used to transport the MICROLOK protocol as it is possible that they may buffer complete MICROLOK protocol messages. Care must be exercised in configuring more sophisticated modems to insure that all of the above requirements are met.

3.5.2 Connecting GENISYS Protocol Serial Ports Using Modems


GENISYS protocol may be transported using either half-duplex or full-duplex modems. Half-duplex modems do not support simultaneous transport of data in both directions while full duplex modems do. Half-duplex modems require that both the master and slave end modem interfaces be wired to key the outbound carrier on and off using the RTS signal. Full duplex modems allow the master-end carrier to be strapped permanently in the ON state. Full duplex modems have an advantage in that the master end of the circuit does not have to wait for carrier to stabilize before the transmission of each message as the outbound office carrier is always on.
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Typically, the slave end of the communication circuit always keys its outbound carrier on and off whether a half-duplex or full duplex circuit is used. This is because a GENISYS protocol master usually communicates with more than one slave and the slaves would interfere with each other if they did not turn on their outbound carrier only when responding to the master. However, on a point-to-point full duplex communication circuit (a circuit having only one GENISYS protocol master and slave), both master and slave ends may operate with their carrier strapped continuously in the ON state. In this case, the GENISYS protocol port RTS output signal is not connected to the modem RTS (or KEY ON) input. The modem RTS input is permanently strapped in the active state by applying the appropriate voltage to the modem RTS input or by configuring the modem to transmit continuously. The GENISYS protocol requires only that the DCD input signal be connected to the DCD output of the modem for half duplex modems. For full duplex modems, the DCD input of the GENISYS protocol serial port is either left disconnected or strapped in the active state. In a typical full duplex modem installation, only TXD, RXD, and COM are connected on the master end and RTS, TXD, RXD, and COM are connected on the slave end. In a half duplex modem installation, RTS, TXD, RXD, DCD, and COM are connected on both master and slave ends of the communication circuit. The CTS signal, when it is available, can be used to shorten the required delay between the assertion of RTS and the transmission of the first byte of outbound data. This delay is often called the key-on delay. Typically, when data is to be transmitted via a modem and keying of carrier is required, RTS is asserted and a delay timer is started by the serial port handler to delay the transmission of the first byte of data. This is to allow outbound carrier time to stabilize prior to the beginning of data transmission. This timer is normally set to the worst-case carrier stabilization time for the modem. The CTS output from a modem is asserted when the outbound carrier is ACTUALLY stable and ready to transport data. While the use of CTS is optional, it can improve the efficiency of the communication link by allowing data transmission to begin as soon as outbound carrier is stable and before the worst-case carrier stabilization time has elapsed.

3.5.3 Connecting MICROLOK Protocol Serial Ports Using Modems


MICROLOK protocol may only be transported using full duplex modems. RTS, TXD, RXD, DCD, and COM must always be connected on both master and slave ends of the circuit. The outbound carrier signal must stabilize quickly (within 50 bit times at all supported bit rates) when RTS becomes active and must shutdown quickly (within 50 bit times) when the RTS signal is set inactive. When it is available, the CTS signal may optionally be connected as described above to shorten the average outbound carrier key-on delay. The presence of the carrier signal at the receiver must be accurately reflected in the DCD signal, as the MICROLOK protocol requires that received messages be framed by the DCD signal. (Note that many modern, full duplex modems do not manipulate DCD in a way that is useful in framing MICROLOK protocol messages. These modems cannot be used to transport the MICROLOK protocol.)

3.5.3.1

Connecting to RS-485 Serial Ports (Refer to Figure 3-10 - )

Serial ports 1 and 2 are the RS-485 serial ports. Port 1 supports TXD and RTS output signals and RXD, DCD, and CTS input signals. Data clock signals including transmit clock (TXC) which may be either an input or an output and receive clock (RXC) which is an input are present on port 1 but are not currently not supported by the MICROLOK II executive. These signals should not be connected. These signals may be supported in a future release of the MICROLOK II executive. Port 2 supports TXD and RTS output signals and RXD and DCD input signals. Each RS-485 port signal is transported by a twisted pair of wires labeled as XXX- and XXX+ (TXD- and TXD+, for example). Outputs labeled with a (-) always connect to inputs labeled (-) or (A). Outputs labeled with a (+) always connect to inputs labeled (+) or (B). Differential voltage between (-) and (+) conductors of a pair is typically 1.5 to 5 volts with the (-) conductor negative with respect to the (+) conductor when the signal is SM 6800B, Rev. 3, December 2005
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Installing Microlok II System Peripheral Devices


not asserted. (For data lines TXD and RXD, the quiescent or unasserted state is identified as the MARK state.) In addition, the signal commons (COM) for all ports on an RS-485 communication link must be connected together to equalize potential between signal commons for the connected units. When two MICROLOK II units powered by the same battery are serially connected, the connection of serial commons is made through negative battery and does not have to be made through the serial cable. Note that COM cannot be connected to frame or earth ground as it is directly connected through the MICROLOK II power supply to negative vital battery. RS485 ports should be interconnected using ONLY twisted pair cable with an over-all shield. For best performance, the interconnecting cables should not contain extra, unused pairs. Any unused pairs should be connected together at both ends of the cable and connected to signal common (COM) for best noise immunity. If connected, the shield should be connected to frame ground at one end of the cable only. On the units at each end of the communication circuit, 120 ohm, watt external load resistors should be placed across the TXD and RTS transmitters and across the RXD and DCD receivers. Any units in-between should simply bridge the circuit using a bridging stub which is as short as possible. On a multi-drop communication circuit (a circuit to which more than two units are connected), the DCD input on the master unit should be biased in its unasserted state. This may be done by connecting 470 ohm, watt resistors between the DCD- input and 0V and between the DCD+ input and +5V. The load resistor for the master DCD input should be 240 ohms, watt (rather than 120 ohms) to maintain the required circuit impedance for the biased circuit. If the CTS input on any serial port is available but not used, it should be forced to its unasserted state. To permanently force an unused RS-485 input to its unasserted state, the (+) input should be connected to +5V and the (-) input should be connected to COMMON (0V). To force an RS-485 input to its asserted state the (+) input should be connected to COMMON (0V) and the (-) input should be connected to +5V or +12V.

3.5.3.2

Connecting to RS-423 Serial Ports (Refer to Figure 3-11)

Serial port 3 is the RS-423 serial port. Serial port 3 supports TXD and RTS output signals and RXD, DCD, and CTS input signals. Data clock signals including transmit clock (TXC) which may be either an input or an output and receive clock (RXC) which is an input are present but are not currently supported by the MICROLOK II executive. These signals should not be connected. These signals may be supported in a future release of the MICROLOK II executive. In an RS-423 interface, outputs are referenced to signal common (COM) while inputs have their own independent common, receive common (RXCOM). Signal outputs are connected to signal inputs by a single wire as the are in the RS-232 interface but COM on each end is connected to RXCOM on the other end. As this connection of commons does not equalize potential between the signal commons (COM) of the two connected units, an additional connection must be made between COM terminals on the connected units. The quiescent or inactive state for all signals is between 3.6 and 6 volts. (For data lines TXD and RXD, the quiescent state is the MARK state.). The active state for all signals is between +3.6 and +6 volts. RS-423 ports should be interconnected using only multi-conductor cable with an over-all shield. The cable should not contain any twisted pairs. The serial port commons (COM) should be connected using one of the conductors in the cable (NOT the shield). For best performance, interconnecting cables should not contain extra wires. Extra wires should be connected together and connected to COM at both ends for best noise immunity. Note that COM cannot be connected to frame or earth ground as it is directly connected through the MICROLOK II power supply to negative vital battery. The cable shield should be connected to frame ground at one end of the cable only. If CTS is not used, it must be forced to its unasserted state. To permanently force an input to its unasserted state, the input should be connected to -12V. To force an input to its asserted state, the input should be connected to +12V. RS-423 ports may be connected to RS-232 ports by strapping COM and RXCOM terminals together on the RS423 end and connecting signals as described under the RS-232 connection scheme below.

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Installing Microlok II System Peripheral Devices 3.5.3.3 Connecting to RS-232 Serial Ports

Serial port 4 is the RS-232 serial port. Serial port 4 supports TXD and RTS output signals and RXD and DCD input signals. Each RS-232 signal is transported by a single wire and is referenced to signal common (COM). When any RS-232 signal is not asserted the voltage level for that signal is between 3 and 15 volts. (For data lines TXD and RXD, the quiescent or unasserted state is the MARK state.). The asserted state for all signals is between +3 and +15 volts. RS-232 ports should be interconnected using only multi-conductor cable with an over-all shield. The cable should not contain any twisted pairs. The serial port signal commons (COM) should be interconnected using one of the conductors in the cable (NOT the shield). For best performance, interconnecting cables should not contain extra wires. Extra wires should be connected together and connected to COM at both ends for best noise immunity. If connected, the cable shield should be connected to frame ground at one end of the cable only. The length of interconnecting cables should be limited to 50 feet or less. If it is necessary to permanently force an input to its unasserted state, the input should be connected to -12V. To force an input to its asserted state, the input should be connected to +12V.

3.5.4 Isolation of Serial Port Signal Common


Application engineers should note that the serial commons for all MICROLOK II serial ports are connected directly to negative vital battery AND to each other. This means that anything connected to any serial port signal common IS ALSO CONNECTED TO NEGATIVE VITAL BATTERY. Furthermore, anything connected to the serial common of any equipment that is directly connected to any MICROLOK II serial port is connected to negative vital battery through MICROLOK II. This imposes serious restrictions on the characteristics of the devices that can be DIRECTLY CONNECTED MICROLOK II serial ports. It should be noted, for example, that most commercial data modems connect their serial common to earth ground in some way, either directly or through a low resistance. It should also be noted that most data radios connect their serial common directly to their antenna ground. Both of these conditions create a problem since they introduce a connection between negative vital battery and earth ground. (Vital battery is required to float with respect to ground.) This effectively means that devices like these MUST be connected to MICROLOK II through a serial line isolator which provides a high level of isolation between the signal commons of MICROLOK II and serial devices such as modems and data radios. Isolation between serial signal commons is also necessary when serially connecting MICROLOK II units that are powered by different batteries. As these battery power supplies are considered vital and are required to float with respect to ground, significant potential differences can develop between the battery negatives. These potential differences can wind up being equalized by the connection between serial commons. This situation poses a threat both to communication circuit reliability and the electrical integrity of the connected MICROLOK II units. In addition, interconnection of battery commons by any means is not a recommended practice. This situation, too, can be remedied by introducing a serial line isolator in the serial line between the MICROLOK II units. It is strongly recommended that all MICROLOK II units NOT connected to the same battery power supply be interconnected serially using communication devices that provide serial common isolation. Furthermore, care must be exercised to insure that devices that ARE serially connected directly to a MICROLOK II unit DO NOT have serial connections to devices that might ground serial common.

3.5.5 Physical Connections to Serial Ports


SIGNAL
TXDTXD+ RXDRXD+

PORT 1 RS-485
A2 A4 C6 C8

PORT 2 RS-485
A16 A18 A24 A26

PORT 3 RS-423
E16 E14

PORT 4 RS-232
C20 C22

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Installing Microlok II System Peripheral Devices


PORT 1 RS-485
E2 E4 A10 A12 C10 C12 C2 C4 E6 E8 E18 A32 C24 C26 A32 C24 C26 C18 C24 C26 E22 C24 C26 A8 A28 A30 A6 E10 C16

SIGNAL
RTSRTS+ CTSCTS+ DCDDCD+ TXCTXC+ RXCRXC+ RXREF COM (0V) +12V -12V

PORT 2 RS-485
A20 A22

PORT 3 RS-423
C14 E12

PORT 4 RS-232
A14

3.5.6 Configuring MICROLOK II Serial Ports


All four MICROLOK II serial ports have many configuration options. These are made available to accommodate most requirements that might be encountered in modern communication equipment. Most of the available options are not intended to be used in the typical MICROLOK II installation. In most typical installations, only one port configuration should be used for GENISYS protocol and one for MICROLOK protocol.

3.5.6.1

Serial Port Configuration for Operation on a Direct Wire, Point-to-Point, Communication Circuit

MICROLOK II serial ports 1, 2, and 3 are designed to operate on a direct wire, multi-drop communication circuit. When any of these three ports is designated as either a MICROLOK or GENISYS protocol slave port, the default port configuration is set by the MICROLOK II compiler to accommodate a multi-drop communication circuit. This causes transmit data (TXD) and request to send (RTS) drivers to assume a high impedance state whenever these ports are not actively placing data on the communication circuit. This configuration may not be acceptable for most point-to-point communication circuits as external biasing resistors may be required on inputs to which RTS and TXD are connected to positively hold those inputs in an unasserted state when RTS and TXD drivers go to their high impedance state. This problem can be overcome without the use of external biasing resistors by setting the point-to-point serial port configuration parameter to 1 (POINT.POINT: 1;). This causes RTS and TXD outputs to actively drive the inputs to which they are connected at all times. Note that for ports designated as master ports, this need not be done. The default configuration of all master ports is point-to-point. Note also that serial port 4 is capable only of point-to-point operation regardless of its designated function and the value of the POINT.POINT parameter for port 4.

3.5.6.2

GENISYS Protocol Serial Port Configuration

The standard GENISYS protocol configuration is:


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Installing Microlok II System Peripheral Devices


STOPBITS: PARITY: CARRIER.MODE: SECURE.MODE: MASTER.CHECKBACK: CRC.SIZE: 1; NONE; CONSTANT; ON; OFF; 16; (GENISYS MASTER PORT ONLY) (GENISYS MASTER PORT ONLY)

Some configuration items are intended to vary with the requirements of the installation. The data rate (BAUD:), should be set to accommodate the requirements of the communication system and system responsiveness. When interconnection of units is accomplished by direct wire, a data rate of 19200 BPS should be used to insure good communication response. When modems are used, a data rate appropriate for the selected modems should be used. This can be determined by referring to the application information that accompanies the modem being used. Key-on (KEY.ON.DELAY:) and key-off delays (KEY.OFF.DELAY:) should be set to 0 for direct wire connections. For modem connections, key-on and key-off delays should be set to a value appropriate for the modems being used. This can be determined by referring to the application information that accompanies the modem. When simple, frequency shift modems are used (such as those manufactured by RFL Industries), 8 to 12 bit times is a good value for key-on and key-off delays. More sophisticated modems and more sophisticated communication links (those with regenerative repeaters, for example) may require longer key-on and key-off delays. The approximate required key-on and key-off delays may often be determined empirically by setting the delays to a high value (about 64 bit times) and attempting to establish communication. Once communication is established, the delays can be progressively reduced until communication becomes erratic. About 4 to 8 bit times should be added to the values which produce erratic operation. Master port polling timeout (MASTER.TIMEOUT:) must be set to accommodate the worst-case delay time required for a slave to respond. The default value of 500 milliseconds is usually adequate. However, when a GENISYS protocol master is communicating with many slaves on a communication circuit where all slave units may not always be answering, a shorter timeout may be appropriate to insure minimum communication delays when slaves occasionally fail to respond. In any case, the timeout must always be long enough to allow a slave which is capable of responding sufficient time to respond. This time is approximately equal to twice the worst case end-to-end delay for the communication channel plus the worst case communication channel turnaround delay (relevant only for half-duplex channels) plus the worst case turnaround delay for a MICROLOK II slave port (the time between receiving the last byte of a message and transmitting the first byte of the response). The worst case delays for the communication channel may be determined by referring to application information for the communication equipment being used. The worst case turnaround delay for a MICROLOK II slave port is typically less than 50 milliseconds. The average turnaround delay is less than 20 milliseconds. The master port polling interval parameter (POLLING.INTERVAL:) is provided to adjust communication loading on a MICROLOK II unit which is heavily loaded (many complex logic equations in the application program which execute very frequently). The polling interval is the time inserted between the completion of one message exchange initiated by the master port and the start of the next. Typically, the default value for this parameter should be used. Increasing the value of this parameter decreases the load on the MICROLOK II processor due to communications and increases communication delays because additional time is inserted between messages transmitted by the master. Decreasing the value of this parameter increases the load on the MICROLOK II processor due to communications and decreases communication delays. This parameter should be adjusted only if processor loading problems have been confirmed.

SM 6800B, Rev. 3, December 2005

3-21

Installing Microlok II System Peripheral Devices 3.5.6.3 MICROLOK Protocol Serial Port Configuration

The standard MICROLOK protocol configuration is: STOPBITS: PARITY: 1; NONE;

Some configuration items vary with the requirements of the installation. The data rate (BAUD:), should be set to accommodate the requirements of the communication system and system responsiveness. When interconnection of units is accomplished by direct wire, a data rate of 19200 BPS should be used to insure good communication response. When modems are used, a data rate appropriate for the selected modems should be used. This can be determined by referring to the application information that accompanies the modem. Key-on (KEY.ON.DELAY:) and key-off delays (KEY.OFF.DELAY:) should be set to 12 for direct wire connections except that at a data rate of 19200 BPS., a key-on delay of at least 30 bit times should be used to allow for worst case receiver enable delays. For modem connections, key-on and key-off delays should be set to a value appropriate for the modems being used. This can be determined by referring to the application information that accompanies the modem. When simple, frequency shift modems are used (such as those manufactured by RFL Industries), 12 bit times is a good value for key-on and key-off delays. More sophisticated modems and more sophisticated communication links (those with repeaters, for example) may require longer key-on and key-off delays. For the MICROLOK protocol, key-on delays of less than 12 bit times should never be used. The approximate required key-on and key-off delays may often be determined empirically by setting the delays to a high value (about 64 bit times) and attempting to establish communication. Once communication is established, the delays can be progressively reduced until communication becomes erratic. About 4 to 8 bit times should be added to the values which produce erratic operation. Master port polling timeout (MASTER.TIMEOUT:) must be set to accommodate the worst-case delay time required for a slave to respond. The default value of 500 milliseconds is usually adequate. However, when a MICROLOK protocol master is communicating with many slaves on a communication circuit where all slave units may not always be answering, a shorter timeout may be appropriate to insure minimum communication delays when slaves occasionally fail to respond. In any case, the timeout must always be long enough to allow a slave which is capable of responding sufficient time to respond. This time is approximately equal to twice the worst case end-to-end delay for the communication channel plus the worst case communication channel turnaround delay (relevant only for half-duplex channels) plus the worst case turnaround delay for a MICROLOK II slave port (the time between receiving the last byte of a message and transmitting the first byte of the response). The worst case delays for the communication channel may be determined by referring to application information for the communication equipment being used. The worst case turnaround delay for a MICROLOK II slave port is typically less than 50 milliseconds. The average turnaround delay is less than 20 milliseconds. The master port polling interval parameter (POLLING.INTERVAL:) is provided to adjust communication loading on a MICROLOK II unit which is heavily loaded (many complex logic equations in the application program which execute very frequently). The polling interval is the time inserted between the completion of one message exchange initiated by the master port and the start of the next. Typically, the default value for this parameter should be used. Increasing the value of this parameter decreases the load on the MICROLOK II processor due to communications and increases communication delays because additional time is inserted between messages transmitted by the master. Decreasing the value of this parameter increases the load on the MICROLOK II processor due to communications and decreases communication delays. This parameter should only be adjusted if processor loading problems or communication timing problems have been confirmed.

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SM 6800B, Rev. 3, December 2005

Installing Microlok II System Peripheral Devices 3.5.7 Configuring MICROLOK II CPU Serial Communication Jumpers
The MICROLOK II hardware and executive software current at the time of release of this document REQUIRE that jumpers JMP7, JMP8, JMP10, JMP13, JMP14, JMP15, JMP16, JMP17, and JMP18 be placed in the factory default position. Future releases of the MICROLOK II hardware and executive software may support other jumper settings. Both jumpers JMP11 and JMP12 must be set in the same position but may be set as required by the specific installation. However, the default setting for JMP11 and JMP12 is recommended for ALL installations. The following table shows the function of all serial communication jumpers and their default position:

JUMPER
JMP7 JMP8 JMP10 JMP11 JMP12 JMP13 JMP14 JMP15 JMP16 JMP17 JMP18

FUNCTION
Port 4 receive data input Port 4 data carrier detect input Port 1 synchronous transmitter clock Port 3 output driver low level Port 3 output driver high level Port 3 synchronous transmitter clock Port 3 synchronous transmitter clock Port 4 asynchronous clock input Port 3 asynchronous clock or synchronous receiver clock input Port 2 asynchronous clock input Port 1 asynchronous clock or synchronous receiver clock input

POSITION
1-2* 2-3 1-2* 2-3 1-2 2-3* 1-2* 2-3 1-2* 2-3 1-2 2-3* 1-2* 2-3 1-2* 2-3 1-2* 2-3 1-2* 2-3 1-2* 2-3

EFFECT
ENABLED DISABLED ENABLED DISABLED INPUT OUTPUT RS-232 RS-423 RS-232 RS-423 INPUT OUTPUT OUTPUT INPUT INTERNAL OFF INTERNAL EXTERNAL INTERNAL OFF INTERNAL EXTERNAL

Jumper positions marked with (*) are the factory default.

3.5.8 Panel Installation and Power Input


The serial communications adapter panel (N451460-3001) is provided for Microlok II vital serial communications links that run between separate houses or cases. This device consists of a 5-1/4 inch by 19-inch panel with a circuit board mounted on standoffs. The panel is typically mounted in a standard 19-inch equipment rack. The following hardware is required to mount the panel:

SM 6800B, Rev. 3, December 2005

3-23

Installing Microlok II System Peripheral Devices


Item
Nut screw, #12-24 x 1/2 pan head washer, #12 shakeproof lock

US&S Part No.


J480203 J507261 J047750

The panel requires two power sources: a +5 Vdc source that powers the electronics and a 12 Vdc source that powers the interface signals. Fasten terminals are provided on the panel for power connections.

3.5.9 Interface Wiring Figure 3-9 - shows a typical 20 mA current loop interface between master and slave Microlok II systems using the serial communications adapter panel. Transmit Data, Request-to-Send, Data Carrier Detect, and Receive Data are each placed in a twisted pair with a separate ground wire. This is done to improve noise immunity from external sources and eliminate possible cross talk between lines. The current loop cable assembly is cut to length per the application and fitted with connectors. The cable specifications are as follows:
Maximum Cable Length
5,000 ft.

Maximum Total Cable Path Length


10,000 ft.

Nominal Cable Wire Gauge/Type


#19 AWG twisted pair

Minimum Cable Wire Gauge/Type


#24 AWG twisted pair

Wire Capacitance
0.09 mF/1000 ft.

Wire Resistance
30 ohms/mile

The 20 mA current loop cable should be run below ground where it runs outside of the equipment house or case to minimize possible lightning damage. The shield wire at the end of the cable should be grounded using one of the 25-pin D connector attachment screws on the interface panel. Also, a rack ground wire should be run from the panels EARTH GROUND dual Fasten terminal to the equipment rack prime ground bus. Keep this wire as short as possible and minimize the number of bends. Make certain that both ends of the serial link have both shield and rack ground connections as shown in Figure 3-10. The current loop cable should also be provided strain relief by securing it to the rack frame with wire tie straps.

3-24

SM 6800B, Rev. 3, December 2005

48-pin Connector 37-pin Connector Current Loop Cable


J2

37-pin Connector

48-pin Connector

J1

Twisted Pair Wires


J2 J1

5 RTS (IN) DCD (OUT) RXD COM TXD COM RTS (OUT) RTS COM DCD (IN) DCD COM 21 23 DCD (IN) 14 TXD (IN) RXD (OUT) SIG COM TXD (OUT) 10 12 RTS COM 24 11 RTS (OUT) 22 9 DCD COM 16 1 11 24 9 22 23 12 RXD (IN) TXD (OUT) 21 10 13

SM 6800B, Rev. 3, December 2005


RTS (IN) 5 DCD (OUT) 13 TXD IN) 14 RXD (OUT) 16 SIG COM 1 See Figure 2-11 for Pin-outs

Microlok II System (Master) Serial Communications Adapter Panel Equipment House/Case

CPU
Equipment House/Case

Serial Port 3 or 4

See Figure 2-11 for Pin-outs

RXD (IN) RXD COM


Serial Communications Adapter Panel

TXD COM

Microlok II System (Slave) CPU Serial Port 3 or 4

Figure 3-9 - Typical Adapter Panel Application - Master and Slave Microlok II Systems
(Adapter Panel may be used with Microlok II serial ports 3 or 4 only)

Installing Microlok II System Peripheral Devices

3-25

Installing Microlok II System Peripheral Devices

3.6

SERIAL INTERFACE SCHEMATIC DIAGRAMS


MASTER MICROLOK II CPU CONN. A PORT 2 A20 PORT 1 E2 RTSL RTS+ L DCD+ CONNECTION TO ADDITIONAL SLAVES DCDSLAVE MICROLOK II CPU CONN. A PORT 1 C10 PORT 2 A28

A22

E4

C12

A30

A16

A2

TXDL TXD+ L

RXDRXD+

C6

A24

A18

A4

C8 A2

A26

A24

C6

RXDL RXD+ L

TXD-

A16

A26

C8

TXD+

A4

A18

A28

C10

DCDLM DCD+ L

RTS-

E2

A20

A30 _

C12

RTS+

E4

A22 _

A10

CTS-

CTS-

A10

A12

CTS+

CTS+

A12

E20

E20

5V

5V

E20

E20

A32

A32

0V

0V

A32

A32

Figure 3-10 - Typical Microlok II Master To Microlok II Slave RS-485 Direct Wire Serial Interface Units Powered By Same Battery (Microlok Protocol Or Half-Duplex Genisys Protocol) 1. Resistors (R) are 470 Ohm, watt. 2. For full duplex Genisys Protocol RTS and DCD need not be connected. 3. Serial commons are interconnected through a battery that powers Microlok II units. 4. Load resistors (L) are 120 Ohm, 1/2 watt and are to be installed externally on the master and on the most
distant slave on the circuit only. Load resistor (Lm) is 240 Ohm, watt and is installed on master DCD only, as shown.

5. Do not connect COMMUNICATION COMMON to ground.


3-26

SM 6800B, Rev. 3, December 2005

Installing Microlok II System Peripheral Devices


CONNECTION TO ADDITIONAL MICROLOK II SLAVES RTS

MASTER MICROLOK II CPU CONN. A PORT 3 C14

SLAVE MICROLOK II CPU CONN. A PORT 3 DCD E10

E16

TXD

RXD

E14

E14

RXD

TXD

E16

E10

DCD R

RTS

C14

C26

-12V

-12V

C26

E12

CTS

CTS

E12

E18

RXREF

COM RXCOM

C18

C18

COM

E18

Figure 3-11 - Typical Microlok II Master To Microlok II Slave RS-423 Direct Wire Serial Interface Units Powered By Same Battery (Microlok Protocol Or Half-Duplex Genisys Protocol) 1. Resistor (R) is 10K, watt. 2. For full duplex Genisys protocol connection, RTS and DCD need not be connected. 3. Serial commons are interconnected through battery which powers units.

SM 6800B, Rev. 3, December 2005

3-27

Installing Microlok II System Peripheral Devices


MASTER OR SLAVE MICROLOK II CPU CONN. A PORT 4 A14 RTS 24 24

TO MICROLOK II BATTERY N12 B12

RFL CARRIER SET

REQUEST TO SEND OR KEY ON

C20

TXD

25

25

DATA OUT

C22

RXD DCD

12

12

DATA IN

C16

23

23

DATA CARRIER DETECT OR SQUELCH

E22

COM

10

10

SIGNAL COMMON

SERIAL COMMUNICATION CIRCUIT ISOLATION UNIT N16401101

Figure 3-12 - Typical Microlok II Master or Slave to RFL Modem Serial Interface RS232 Port 4 with Serial Isolator (Microlok or Genisys Protocol)

DCD need not be connected for Genisys protocol on a full-duplex communication link.

3-28

SM 6800B, Rev. 3, December 2005

Installing Microlok II System Peripheral Devices


MASTER OR SLAVE MICROLOK II CPU CONN. A PORT 3 C14 RTS 24 24

TO MICROLOK II BATTERY N12 B12

RFL CARRIER SET

REQUEST TO SEND OR KEY ON

E16

TXD

25

25

DATA OUT

E14

RXD DCD

12

12

DATA IN

E10

23

23

DATA CARRIER DETECT OR SQUELCH

C18

COM

10

10

SIGNAL COMMON

E18 E12

RXREF

CTS -12V

SERIAL COMMUNICATION CIRCUIT ISOLATION UNIT N16401101

C26

Figure 3-13 - Typical Microlok II Master or Slave to RFL Modem Serial Interface RS423 Port 3 with Serial Isolator (Microlok or Genisys Protocol)
DCD need not be connected for Genisys protocol on a full-duplex communication link.

SM 6800B, Rev. 3, December 2005

3-29

Installing Microlok II System Peripheral Devices

MASTER MICROLOK II CPU CONN. A PORT 4 A14 RTS

TO MASTER MICROLOK II BATTERY N12 B12

SLAVE MICROLOK I CONN 1

24

24

DCD

C20

TXD

25

25

RXD

14

C22

RXD DCD

12

12

TXD

16

C16

23

23

RTS

13

E22

COM

10

10

SIGCOM RXCOM

SERIAL COMMUNICATION CIRCUIT ISOLATION UNIT N16401101

18

SIGCOM

19

RTS

32 11

CTS

Figure 3-14 - Typical Microlok II Master to Microlok Slave Serial Interface RS-232 Port 4 with Serial Isolator (Microlok or Genisys Protocol)

3-30

SM 6800B, Rev. 3, December 2005

Installing Microlok II System Peripheral Devices


MASTER MICROLOK I CONN. 3 TO SLAVE MICROLOK II BATTERY N12 B12 SLAVE MICROLOK II CPU CONN. A PORT 3 13 RTS 24 24 DCD E10

16

TXD

25

25

RXD

E14

14

RXD DCD

12

12

TXD

E16

23

23

RTS

C14

1 18

SIGCOM

10

10

COM RXREF

C18

RXCOM SIGCOM

SERIAL COMMUNICATION CIRCUIT ISOLATION UNIT N16401101

E18

19

CTS -12V

E12

32 11

RTS CTS

C26

Figure 3-15 - Typical Microlok Master to Microlok II Slave Serial Interface RS-423 Port 3 with Serial Isolator (Microlok Protocol)
MASTER MICROLOK II CPU CONN. A PORT 3 C14 RTS DCD

MICROTRAX CODED TRACK PORT A OR B 23

E16

TXD

RXD

12

E14

RXD

TXD

25

E10

DCD R

RTS

24

C26

-12V

E12

CTS

E18

RXREF

C18

COM

COM

10

Figure 3-16 - Typical Microlok II Master to Microlok Combo Track Slave Serial Interface RS-423 Direct Wire Interface (Microlok Protocol) Units Powered By Same Battery
SM 6800B, Rev. 3, December 2005
3-31

Installing Microlok II System Peripheral Devices

MASTER MICROLOK II CPU CONN. A PORT 3 C14 RTS

CONNECTION TO ADDITIONAL MICROTRAX EOS SLAVES

MICROTRAX EOS SLAVE CONNECTOR

DCD

19

E16

TXD

RXD

E14

RXD

TXD

21

E10

DCD R

RTS

20

C26

-12V

CTS

E12

CTS

E18

RXREF

COM

10

C18

COM

RXCOM

Figure 3-17 - Typical Microlok II Master to Microtrax EOS Slave RS-423 Direct Wire Serial Interface (Microlok Protocol) Units Powered By Same Battery

3-32

SM 6800B, Rev. 3, December 2005

Installing Microlok II System Peripheral Devices

B12 N12 48-p in Conn. E2 C2 E6 C4 C12 A8 A6 23 23 Ca rrier D t t Ea rth GND Seria l Line Ca rrier o r M d 25 12 24 10 25 12 24 10 Da ta In Da ta O t Key-On Sig na l C

Cod e System Interfa c e PCB S1TXD S1RXD S1RTS Sla ve Port S1RXD+ S1COM S1DCD+ S1DCD-

Seria l Link Isola tor Unit N16401101 A14 A22 A16

MTXD Ma ster Port MRXD MRTS

MDCD A24

RTS Co m m . DCD Port 4 (RS-232) TXD RXD CPU PCB

A14 C16 C20 C22

Figure 3-18 - Typical Code System PCB Interface to Serial Line Carrier

SM 6800B, Rev. 3, December 2005

3-33

Installing Microlok II System Peripheral Devices

GENISYS 2000 CPU CONN. A MASTER PORT 18 MTXD RXD

MICROLOK II CPU CONN. A PORT 4 C22

21

MRXD

TXD

C20

MCOM

COM

E22

DCD

C16

-12V

C26

Figure 3-19 - Typical GENISYS 2000 Master To Microlok II Slave RS-232 Direct Wire Serial Interface Units Powered By Same Battery (Genisys Protocol)

GENISYS CPU CONN. A MASTER PORT 2 MRTS

MICROLOK II CPU CONN. A PORT 4 DCD C16

MTXD

RXD

C22

MRXD

TXD

C20

MDCD

RTS

A14

MCOM

COM

E22

MDSR

+ 12V

MCTS

Figure 3-20 - Typical GENISYS Master To Microlok II Slave RS-232 Direct Wire Serial Interface Units Powered By Same Battery (GENISYS Protocol)

3-34

SM 6800B, Rev. 3, December 2005

Installation Parts List

4
4.1

Installation Parts List


MAJOR SYSTEM ASSEMBLIES
Item/Description
system cardfile

US&S Part No.


N16902101

Comments
Empty enclosure without field-replaceable components (PCBs and panels). Reference section 4.2 for components. US&S PN-150B. Reference section 4.4 for installation parts. 12V model 50V model 24V model Reference section 3.4 for applications. General non-cab applications Non-cab with 86 Hz crossing predictors. Compatible with 100 Hz cab signal. Compatible with 60 Hz cab signal. Reference section 3.1 for applications. Reference section 3.1.4 for applications. Compatible with 60 Hz cab signal. Compatible with 100 Hz cab signal. Compatible with 40 Hz cab signal. Reference section 3.1 for applications. Genisys and Microlok protocols. Reference section 4.4 for installation hardware. Reference section 3.6 for applications.

VCOR relay isolation module

N322500-701 N17001101 N17001102 N17001103

coded track interface panels

N451835-0101 N451835-0102 N451835-0103 N451835-0104

quick shunt module cab signal interface panels

N451052-4601 N451835-0801 N451835-0802 N451835-1101

serial link isolator units serial communications adapter panel

N16401101 N451460-3001

4.2

MAJOR CARDFILE COMPONENTS

4.2.1 Plug-in Printed Circuit Boards and Front Panels


Item/Description
CPU PCB power supply PCBs standard vital output PCBs vital lamp driver PCB non-vital bi-polar output

US&S Part No.


N17061301 N16600301 N16660301 N17060501 N17060502 N17060101 N17061801 --

Comments

Without cardfile front panel With cardfile front panel 16 outputs at 12V 16 outputs at 24V 16 lamp outputs 12 bi-polar outputs

SM 6800B, Rev. 3, December 2005

4-1

Installation Parts List


US&S Part No.
N17061001 N17061002 N17061003 mixed vital I/O PCBs N17061601 N17061602 N17061603 code system interface PCB non-vital I/O PCBs non-vital, isolated Output PCB non-vital, isolated Input PCB non-vital isolated I/O PCB w/LCP coded track circuit PCBs N17061401 N17000601 N17061501 N17062701 N17063701 N17002801 N451910-0701 N451910-7601 N451910-7602 N451910-7603 OS track circuit PCB coder output PCB auxiliary coder output PCB 60/100 Hz cab amplifier PCB 40/50 Hz cab amplifier PCB local control panel local control panel (w/key) local control panel (w/o key) 1-wide blank front panel 2-wide blank front panel CPS CPS N451810-6701 N451910-5801 N451910-7001 N451910-6401 N451910-6901 N16901301 N17002901 N17002902 N451850-2902 N451859-2901 N451910-7501 N451810-7501 16 inputs at 12V 16 inputs at 24V 16 inputs at 50V 8 inputs at 12V, 8 outputs at 12V 8 inputs at 24V, 8 outputs at 24V 8 inputs at 50V, 8 outputs at 24V Without executive EPROMs. Reference section 4.2.2 for EPROMs. IN32.OUT32 w/LCP version IN32.OUT32 w/o LCP version 32 isolated outputs 32 isolated inputs 16 isolated inputs, 16 in and 16 out LCP lines General non-cab and 100 Hz cab-compatible 40 Hz cab-compatible 50 Hz cab-compatible 60 Hz cab-compatible -75, 120, 180 CPM Two 50 CPM cab codes 60 or 100 Hz cab signal 40 or 50 Hz cab signal Use with N17000601 Use with N17002801 Use with N17002801 --With front plate Without front plate

Item/Description
vital input PCBs

Comments

4-2

SM 6800B, Rev. 3, December 2005

Installation Parts List 4.2.2 Code System Interface PCB Executive EPROMs
US&S Part No.
N451800-0201 N451800-0202 N451800-0204 N451800-0206 N451800-0207 N451800-0208 N451800-0210 N451800-0211 N451800-0212 N451800-0213 ATC/PTS US&S GENISYS Harmon MCS-1 WB&S S2 Allen Bradley DF1 ARES GRS Datatrain II GRS Datatrain VIII US&S GENISYS Dual Slave US&S GENISYS Dual Ind. Slave

Comments

4.2.3 PCB Interface Cable Assembly Components and Tools*


Item/Description
48-pin connector assembly 96-pin connector assembly 48-pin connector receptacle 96-pin connector receptacle receptacle mounting screw 48-pin guide 96-pin guide wire crimp contacts

US&S Part No.


J709146-1105 J709146-1104 J709146-0452 J709146-0922 J525400-0001 J709146-1106 J709146-1107 j709146-0453 j709146-0853 j709146-0921

Comments*
Used with all PCBs except N17061501. Used with non-vital I/O PCB N17061501. --48-pin or 96-pin receptacle --48-pin, #16-#20, (Harting # 09-06-000-8482) 48-pin, #20-#26 (Harting # 09-06-000-8481) 96-pin, #20-#28 (Harting # 09-06-000-8484) 48-pin housing (replaces N17002002) 96-pin housing (replaces N17002101) CPU PCB connector assembly only. 48-pin, #16-#20 (Harting # 09-99-000-0077) 48-pin, #20-#26 (Harting # 09-00-000-0076) 96-pin, #20-#28 (Harting # 09-00-000-0075) 48-pin, #16-#20 (Harting # 09-99-000-0087) 48-pin, #20-#26 Wire 4-3

Address Select PCB EEPROM PCB crimp tools

n17003101 n17003301 n17002001 ----

extraction tools

-Contact US&S

SM 6800B, Rev. 3, December 2005

Installation Parts List


US&S Part No.
-insertion tools Contact US&S Contact US&S -locator tools -Contact US&S Contact US&S 48-pin, #16-#20 48-pin, #20-#26 96-pin, #20-#28 (Harting # 09-99-000-0100) 48-pin, #16-#20 (Harting tool 09-99-000-0086) 48-pin, #20-#26 96-pin, #20-#28 (Harting tool 09-99-000-0099)

Item/Description

Comments*
96-pin, #20-#28 (Harting # 09-99-000-0101)

* Reference section 2.1.6.2 and Figure 2.5 for parts locations.

4.2.4 Misc. Cardfile Installation Parts


Item/Description
PCB keying plug L.H. cardfile mounting bracket R.H. cardfile mounting bracket

US&S Part No.


J709146-0473 M451811-4501 M451811-4502

Comments
Reference section 2.1.5.2 for installation. Included with cardfile. Included with cardfile.

4.3

POWER/SIGNAL CONDITIONING AND PROTECTION EQUIPMENT


Item/Description
termination capacitor PCB USGA blue lightning arrester

US&S Part No.


N451923-2501 N451552-0101 Applications:

Comments
Reference section 3.1.3.4 for application. Coded track circuit Reference section 3.1.3 and Figure 2-19 OS track circuit Reference section 2.2.10 and Figure 2-16

USGA red lightning arrester metal oxide varistor

n451552-0201 J582324

Applications: Same as above. Application: Cardfile system power input Reference section 2.1.3.2 and Figure 2-2. Equivalent: GE V131DA40 or Siemens B40K130.

transient voltage suppressor

J792736-

Application: Cardfile system power input Reference section 2.1.3.2 and Figure 2-2. Equivalent: 5KP16A or 16KZ16A.

4-4

SM 6800B, Rev. 3, December 2005

Installation Parts List

4.4

MISCELLANEOUS UNIT INSTALLATION HARDWARE


Item/Description
VCOR relay mounting parts PN-150B relay relay mounting base contact springs
rack mounting bars

US&S Part No.


N322500-701 N451376-0302 M451142-2702
M381333

Comments
Reference section 3.2. --#14 - #16 wire
2 required

mounting bar clamps power-off relay relay base spring clip serial communication adapter panel nut screw, #12-24 x 1/2 P-head washer, #12 lock 4MB FLASH PCMCIA Card

M381298 J726153-0283 J581782-0026 J680167-0009

4 required Reference section 3.3. ---Reference section 3.6.

J480203 J507261 J047750 J703105-0107

---Reference section 2.2.3.1.3

SM 6800B, Rev. 3, December 2005

4-5

Installation Parts List

4-6

SM 6800B, Rev. 3, December 2005