MICROLOK –II

Hardware Structure

Suresh Helchel
Instructor Signal (IES/5)
IRISET/SC
 E I MICROLOK –II
1.Hardware Section MLKII
o Configuration of MLK II Electronic Interlocking.
o System Configuration of MLK II .
2.Racks Used in Electronic Interlocking.
o Basic Hardware like MLK Rack(EI Rack).
o Relay Rack arrangement and connectors used.
3.Power Supply Arrangement
o Power Supply Boards
o Conditional Power Supply and fail Safety.
4.Card files and various cards used in MLKII EI.
5.Communication boards used in MLK II
 CONFIGURATION OF MLK II
ELECTRONIC INTERLOKING

Single hardware with Diversified software

(Software Redundant)
Processor

I/P Executive SW

SW_1 SW-2

0 0 0
0 1 0
1 0 0
Output
1 1 1
OVERVIEW OF OPERATING SOFTWARE :
Executive software:

o The executive software is standard for all

Microlok II systems (US&S developed) and is
responsible for the overall vital monitoring and
control of the system.
o Interlocking vital input monitoring, decision
making and commands.
o Monitoring of all vital input and output channels
for intended on/off states.
o Continuous internal and external diagnostics.
o Recording and playback of user-specified events.
o Management of the serial data ports.
o Execution of the application software.
 4

1 3
2

5
 OUT PUT DRIVE

T1

Terminals

A1 A2
Cardfile
Cardfile

Relay Rack CTR

Terminals

R
E
L
A
V
Y
11OVDC/110VAC
 Input Flow

T1

Terminals

A1 A2
Cardfile
Cardfile

Relay Rack CTR

Terminals
V
24VDC
R
E
L
A
Y
 Input/Output with command

T1

Terminals

A1 A2
Cardfile
Cardfile

Relay Rack CTR

Terminals
V
24VDC
R R
E E
L
A
L
A
V
Y Y
11OVDC/110VAC
 Hardware's and Rack Used in MLKII
1. Microlok Rack M1,M2,……..
2. Relay Rack and Accessories used

MLK II Racks Consist of following

Hardware's….
•Card file
•CPU PCB
• Sync and Comm. Board
•Power Supply PCB
•Vital Output PCB
•Vital Input PCB
•Non-vital Input/output PCB
•VCOR – Vital Cut Off Relay
•Wiring hardware
 Basic Hardware
Study of EI and Relay Rack

MLK Rack:

A VCOR VCOR Diode Terminal Vital Out

A B
Put(2 IN 1 Terminal)

B Card File “A”

C Card File “B”

Diode
D/E Terminals

F/G FMS

Power
H
Distribution
 Basic Hardware
Study of EI and Relay Rack

MLK Rack:
H Block
Power Supply Terminals(B 24 or 12)
 Basic Hardware
Study of EI and Relay Rack

MLK Rack: Front View VCOR: Vital Cut Off Relay

 Basic Hardware
Study of EI and Relay Rack

MLK Rack: Front View

Power Supply Section:

o DC -DC Convertors 12 V DC (Redundant
Pair)
o DC-DC Convertor 24 V DC (Redundant Pair)
Relay Rack
 Input Interface:
V
I A
A Vital Input Terminals
P
B Non Vital Input Terminals
V
HECR I B
C Data logger Terminals
P
D Bus bar(+) Sig,Point,LC v
E Bus bar(-) Sig,Point,LC v
F Relay Space (20-6=14) One IN Two out type terminals are used for
G Relay Space (20-6=14)
connecting Input to Input Cards of two
H card file boards.
I
J
K
L

One Rack = 84 Relays

Out Put Drive: B-24
Relay Rack MLK Rack

VCOR VCOR

Out
P C
D Bus bar(+) Sig,Point,LC Put S 250Hz P
Card U
V
E Bus bar(-) Sig,Point,LC VCOR

V Out
HR Put
VCOR Card
V
V
 POWER
VITAL OUTPUT PCBs (12 V) SUPPLY SINGLE WIDTH
NON-VITAL
PCB BLANK PANEL
Cardfile with MLK II PCBs OUTPUT PCBS

OUTPUTS OUTPUTS INPUTS INPUTS

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

17 18 17 18 17 18 17 18
OUT OUT 19 20 19 20 19 20 19 20
21 22 21 22 21 22 21 22
OUT OUT 23 24 23 24 23 24 23 24
OUT OUT 25 26 25 26 25 26 25 26
27 28 27 28 27 28 27 28
29 30 29 30 29 30 29 30
31 32 31 32 31 32 31 32
OUT OUT

OUT OUT

OUT OUT

OUT OUT

OUT OUT

OUT OUT

OUT OUT

OUT OUT

UP

LAMP 16 NV.OUT32 NV.OUT32 NV.IN32 NV.IN32

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

VITAL INPUT PCBs NON-VITAL

SINGLE WIDTH INPUT PCBS CPU PCB
17
BLANK PANEL TMP 205_02; related to PRC 001
MLK II Cardfile Rare view
Motherboard 96-Pin Keying Guide PCB Slot
Support Connector Guides
Motherboard

J20-External
Power Input
(on rear)

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

18
TMP 205_02; related to PRC 001
Card Interfaces

MOTHER BOARD

Mother Board Consist of Keying plugs

,prevents wrong insertion of cards
Cards Connector
Backplane Connector Keying Guide External
Connector
•48 Pin Address select PCB and Connector assembly
for Vital Input cards.
 Address Select PCB

Main Purpose of Address Sect PCB

o Application determines the board address
by the order in which each board is
defined in Application SW.
o Provide safe guard to ensure correct
application SW.
o If an address is wrong MLK II will NOT
come online.
 Address Select PCB

o Each Address select PCB has 6

jumper settings SW1 to SW6
o SW1 & SW6 is used for power supply
connection
o SW2 to SW5 is used as address
selects bits for CPU addressing.
 Cards Used in MLK II
1 Power Supply Board

o Power Supply board serves a vital role

in the fail-safe design.
o PSB is basically DC-DC Convertor.
o Placed on 16th and 17th Slot of card file.
o Out put +12 V and +5 V to System Card
files.
o Supplies energy to the VCOR Relay
Coil under the control of CPU Card.
 Power Supply Distribution

110V/12V Cardfile
12V DC +12V DC
DC-DC
Converter -12V DC
PSB +5V DC
O
U
250Hz T
IPS CPU P
U
Signal
T
OUTPUT RELAY
+12 DC
-12V P
VCOR C
B
VCOR 24VDC
I
110V/24V N
DC-DC P
Converter INPUT RELAY U
T
24VDC
P
C
B
System Operating Power
 Cards Used in MLK II
VCOR Relay

o MLK II Used VCOR Relay to control

power to all Vital Outputs.
o This relay is energized by the
conditional output from the power
supply PCB in the system card file.
o The CPU boards controls this fail
safe function.
o 400 Ω Coil resistance and 6F/B
Interface Diagram of VCOR
Power Flow Diagram and Fail Safety of System

110V/12V 12V DC
DC-DC Cardfile
POWER
Converter 12V DC
SUPPLY
-12V DC
PSB 5V DC
250Hz

IPS -12V DC
CPU O
Signal U
T
OUTPUT RELAY
P
VCOR U
T
Vita Input PCB
VCOR P
24VDC
C
B
110V/24V
Signal DC-DC
N 24VDC I
Converter N
INPUT RELAY P
U
NV
T
24VDC
O
P
U
24VDC C
T
B

I
P
N
C
B
 Cards Used in MLK II

CPU Card : Central Processing Unit

Alphanumeric
(CPU) serves as Logic processor.
Display
o It consists of microprocessor,
o RAM – Random accessible memory,
Various
Indication ROM – Read only memory and
EPROM – Erasable Programmable
LEDs

Reset
Button
read only Memory.
Adjust
Button
Menu
Button

RS232
Port
 CPU

o EEPROM PCB The EEPROM PCB is

placed on the 48 Pin connector assembly
of the CPU PCB. The purpose of
EEPROM PCB is to store Site specific
configuration data.
o Even if the CPU is replaced, the
Configuration data remains intact within
the CPU connector’s EEPROM PCB.
Interface CPU and EPROM PCB
OVERVIEW OF OPERATING SOFTWARE :

Microlok II system card file can contain up to

two different software elements.
o All Microlok II systems contain vital executive
and application software on the CPU board.
o In addition, an EEPROM, located on the CPU
board edge connector housing, is
programmed with site-specific configuration
data that is unique to the card file of that
station.
OVERVIEW OF OPERATING SOFTWARE :
Executive software:

o The executive software is standard for all

Microlok II systems (US&S developed) and is
responsible for the overall vital monitoring and
control of the system.
o Interlocking vital input monitoring, decision
making and commands.
o Monitoring of all vital input and output channels
for intended on/off states.
o Continuous internal and external diagnostics.
o Recording and playback of user-specified events.
o Management of the serial data ports.
o Execution of the application software.
OVERVIEW OF OPERATING SOFTWARE :
Application software:

o The vital application software contains the

application-specific logic (user-developed)
appropriate for the overall Microlok II system
configuration.
o Generally, the user develops this software
using the same US&S programming tools
used for executive software version upgrades.
o Site-specific configuration data stored in the
CPU board edge connector housing EEPROM
 CPU Card Communications Ports

MLK II CPU board has five serial ports

Ports 1 to 4 contained within the 48-pin
connector
Port 5 is located on the front panel.
The five serial ports support three
different serial interface standards
Ports 1 and 2 support RS-485 Used for
communication with other MLK.
Port 3 supports RS-423/RS-232 NV
code VDU.
Ports 4 RS-232 VDU
Port 5 RS 232 Maintenance Terminal
39
 Communications Ports

Status of the Communications Ports is displayed via 5 LEDs

on the front panel, labeled A through E.

A LED flashes when the serial port is transmitting data to the

device at the opposite end of the connection.
Indication
LEDs
B LED flashes when the serial port is receiving data from the
device at the opposite end of the connection.

C LED indicates that a good address has been received from

the device at the opposite end of the connection. This LED
is normally on.

D LED indicates DCD detected. This LED is normally flashing.

E LED indicates that a serial receive error has been detected.

This LED is normally off.
40
A

D
E

CPU

ON LINE WHEN LITS INDICATES NORMAL SYSTEM OPERATION

VPP WHEN LITS INDIACTES +5 V & +12 V

PROGRAMMING VOLTAGES IS ENABLED.

RESET WHEN LITS INDICATES THAT SYSTEM IS IN RE-SET MODE.

 Vital Output PCB

o Vital output boards enable the Microlok II system to

control the field gears like signals, point machines,
LX, CH etc.
o Drive up to 16 vital output interface relays
o Each output is also protected with a poly switch. A
poly switch functions like a circuit breaker.
o Tranzorb is provided across all output relay coils to
nullify the back emf
o Vital output PCB receives VCOR controlled 24VDC
to energize Vital output relays
o The vital output functions are read back as inputs to
the system for the purpose of ensuring integrity of
the vital output commands generated by CPU.
 Poly Switch

Tri State logic switch provided in the out put

circuit.
o It has three position close. Open &
Impedance
o Main function is to protect the circuit under
abnormal condition.
o For Vital out put 750 mA.
o Advantages : If one of the out put is short,
its current goes more than 750MA Poly
Switch goes to high Impedance mode ,as a
result CPU withdraws its control and VCOR
Relay drops.

Read back inputs : the vital output functions are read back as inputs to the
system for the purpose of ensuring integrity of the vital output commands
generated by CPU.
Out Put Drive: B-24
Relay Rack MLK Rack

VCOR VCOR

Out
P CP
D Bus bar(+) Sig,Point,LC Put S 250Hz U
Card
V
E Bus bar(-) Sig,Point,LC VCOR

V Out
HR Put
VCOR Card
V
V
 Vital Input PCBs:

o Vital input boards enable the Microlok II system to

monitor the field gear status like signal aspect,
point detection, track status, LX status, CH status
etc.
o To each vital input board 16 isolated inputs are
connected through a 48-pin connector mounted on
the rear side of the card file.
o External wiring is achieved using 48-pin connector
and “one-in-two-out” terminals. • All inputs require a
“double cut” wiring using twisted pair cables
o Interfaces external relay contacts to CPU vital
inputs
 Non Vital PCB
Non-Vital I/O PCBs: The non-vital I/O PCB s enables the Microlok II
system to generate and monitor the status of non-vital discrete inputs and
outputs. Examples of non-vital I/O include controlled outputs to light remote
indicator lamps, and the I/O associated with the switches and indicators on
the local control panel (if installed). I/O board part number N17061501 is
used for external I/O circuits only, and provides 32 inputs and 32 outputs
through its rear 96-pin connector. This board employs polyswitches to
protect the output circuitry. Outputs on board are protected by 5.0A fuse.
Outputs are designed to operate at battery voltages between 9.5 and
35VDC. Outputs switch positive battery and are capable of supplying up to
0.5AMPS. Nominal voltage drop per output is load dependent and usually
less than 2.5volts.
 Input Interface:
V
I A
A Vital Input Terminals
P
B Non Vital Input Terminals
V
HECR I B
C Data logger Terminals
P
D Bus bar(+) Sig,Point,LC v
E Bus bar(-) Sig,Point,LC v
F Relay Space (20-6=14) One IN Two out type terminals are used for
G Relay Space (20-6=14)
connecting Input to Input Cards of two
H card file boards.
I
J
K
L

One Rack = 84 Relays

SYNC COMM 16 &17 18 &19 20
Synchronization PCB(Hot Standby)

o The Synchronization PCB allows two

Microlok II units to connect to each other in
order to form a synchronized pair for a
seamless redundant application.
o Each Microlok II unit monitors the state of
the other Microlok II unit via the
synchronization Ethernet link and the
physical I/O on the Synchronization PCB.
Synchronization PCB(Hot Standby)

o Both units deliver synchronized

physical outputs so that if one unit is
disabled (due to a system reset, power
down or other error condition), the
internal and output states remain
unchanged and control will transfer to
and seamlessly continue with the
second unit.
Synchronization PCB(Hot Standby)

o The Synchronization PCB has two Ethernet

ports on the rear side.

o The Sync PCB of system A card files is

connected with the Sync PCB of system B
card files through one of these two Ethernet
ports The front panel of Sync PCB contains
one DB9 connector, a reset button, fourteen
LEDs, and two toggle switches.
oThe DB9 connector is used for factory
diagnostic testing.
oThe reset button resets the Synchronization
PCB.
oThe quarantine toggle switch – toggles this
MICROLOK II unit to Quarantine mode (YES)
or not in Quarantine mode (NO).
oThe Power-Up delay toggle switch – sets a
power-up delay to either a slow powerup or a
fast power-up.
Synchronization PCB
SYNC I/O board
Self Partner
Online
Partner VCOR Online
Partner VCOR
UP
Quarantine Down
Quarantine
Yes No
Quarantine toggle
switch
Sync self Sync partner
OK OK

Factory diagnostic
testing
Reset the SYNC Flashes when there
PCB is activity on
Flashes
Ethernetwhen
port there
1
Flashes when the
is activity on
executive has
Ethernet port 2
successfully booted

Power Up Delay (PUD)

toggle switch

58
 Communication PCB

o MLKII System has 5 Ports for its connectivity

with other devices.
 Port 1 & 2 RS 485 / RS 422
Port 3 & 4 RS 232 / RS 423
Port 5 RS 232 (debug)
For smaller installations these serial ports are
sufficient to have connectivity between different
components
In bigger EI installations and for distributed EI
systems we need to connect multiple MLK card
files for which these 4 serial ports are not
 Communication PCB

o Each Microlok II card file contains a

Communication PCB.
o The Communication PCB allows a
Microlok II system to connect directly to
an Ethernet network by means of two
Ethernet ports.
o Microlok II card file linking the Microlok II
CPU Board to external equipment via two
Ethernet ports.
o The Communication PCB contains its
own microprocessor.
MLK II DISTRIBUTED EI SYSTEM WITH RUGGEDCOM
 MLKII EI Distributed System Configuration

Ethernet switch 1 at central Relay room

E1 E1 E1 E1

A1 A2 A3 A4
E2 E2 E2 E2

Ethernet switch 2 at central Relay room

Ethernet switch 1 Ethernet switch 1

E/Cabin W/Cabin

Ethernet Ethernet switch

switch 2 2 W/Cabin
E/Cabin
 Single MLK II connected in an network (redundant) using Comms board
MLK II - MLK II –
A1 E1 P
Network -P E1 A2
1 Packet
P
1 A
COMMS

COMMS
BOARD

BOARD
P Discarded
1
P
1
E2 P
Network - P E2 1
1 B 1

Press ‘Enter’ to simulate the following steps (Two duplicated packet

from
Step COMMS board)
1: One data (packet - p1) delivered by A1 is duplicated at
COMMS board E1 & E2
Step 2: E2 of A2 system receives packet (p1) earlier than
E1 of A2
Step 3: As E1 of A2 is received LATE, that particular packet is discarded
by using sequence number method

63
 Multiple MLKs connected in an network (redundant) using Comms board
MLK II - MLK II –
A1 Packet A2
E1 PP
Network -P E1
(ONLINE
11 A P1 P (ONLINE
Discarded
COMMS

COMMS
BOARD

BOARD
) P 1 )
1 P
1
E2 P
Network - P E2 1
E1
1 B P1 E1

SYNC 1 SYNC

MLK II – E1
MLK II – E1

B1 Packet B2
E1 E1
(OFFLINE) Discarded (OFFLIN

COMMS
COMMS
BOARD

BOARD
E)

E2 Packet
E2
Discarded

Press ‘Enter’ to simulate four duplicated packets using

COMMS board

64
 MLK II reset scenario
Panel Processor
(NV I/O and NV logic) Vital I/O and Vital logic
Operator
SYSTEM
S1
Console
S2

A1 P4 P4 A2 C1T 1T 2T 50BT L1T

RESET POINT POSITION

NORMAL REVERSE

Vital Output Relay - HR Field

Pickup

B1 P4 P4 B2
Drop

Press ‘ENTER’, to reset A1 ( single point failure)

Seamless transfer to B1 is seen

65
 Ethernet Communication PCB
• The Communication PCB interfaces through an
external board connector.
• The connector contains address selection
jumpers (SW2, SW3, and SW4) and two RJ45
jacks (ETH1 and ETH2) for the Ethernet ports.
• This allows a standard Ethernet cable to be
plugged directly into the back of the MicroLok
II card file.
• The Communication PCB is to be located
always in the first six slots of the MLKII cardfile
MICROLOK Rack:
Poly Switch as a protected Output Contact:
 Poly Switch:
o It is a tri State logic switch & is always provided in the out put circuit.
o It has three position
i. Close
ii. Open
iii. Impedance.
o Main function is to protect the circuit under abnormal condition.
o For Vital out put 750 mA.
o For Non vital out put 500 mA.
o Advantages : If one of the out put is short, its current goes more than 750mA
poly switch goes to High Impedance mode ,as a result CPU withdraws its
control and VCOR Relay drops.
o Why it is used?
Poly switch is also one kind of hardware, so to check the integrity of this
switch CPU Checks it by + 5 V.

B-24 VCOR

CPU Poly Switch

+5V HR
A

D
E

CPU

ON LINE WHEN LITS INDICATES NORMAL SYSTEM OPERATION

VPP WHEN LITS INDIACTES +5 V & +12 V

PROGRAMMING VOLTAGES IS ENABLED.

RESET WHEN LITS INDICATES THAT SYSTEM IS IN RE-SET MODE.

 MLK-II CPU BOARDHAS FOUR BASIC MODE OF OPERATION
1. ON LINE MODE (NORMAL MODE)
WHEN THE SYSTEM IS WORKING IN NORMAL MODE OF
OPERATION,CPU ACTIVIELY CONTROLLS ALL THE ACTIVITY
OF INTERLOCKING.
A
B
C
D
E
CPU

ONLINE

VPP

RESET
2.CPS MODE
WHENEVER THE PROCESSOR DETECTS THE FAILURE OF AN
INTERNAL DIAGNOSTIC CHECK CPU ASSUMES CPS MODE.
WHEN AN ERROR IS DETECTED CPU CUTT OFF THE 250Hz
SIGNAL TO VCOR RELAY AND VCOR RELAY DROPS AND OUT PUT
TO EACH VITAL RELAY IS CUTT OFF.
CPU CONTINUE TO EXCUTE ALL NON VITAL PROCESS SUCH AS
TRACK MONITORING & NON VITAL INPUT OUT PUT.

WHEN LITS INDICATES CONDITIONAL POWER ON TO

VCOR
VCOR RELAY.
3. CONFIGURATION MODE
WHENEVER MAINTENANCE P.C IS CONNECTED TO DIAGNOSTIC PORT AND
CONFIGURATION SECTION FO THE MAINTENANCE TOOL IS OPENED ,SYSTEM ASSUMES
CONFIGURATION MODE .

WHILE THE SYSTEM IS IN CONFIGURATION MODE

 APPLICATION LOGIC IS NOT PROCESS.
ALL CONTROL FUNCTIONS ARE IN-ACTIVE.

•Single System ~ 300 routes

•1 CPU can replace ~ 4000 relays
 The CPU card holds a number of jumpers and these jumper are required to be verified
before CPU card installation at site.
Jumper J-20 & J-23 are to be placed in program position before loading application
programs
They should be placed in locked position after uploading the application programs.
 Configuration of MLK II
SM Room
OP.
VDU CONTROL PANEL

To Adjacent To Adjacent
Station Station
P1 P1
MLK II OP VDU Link NV MLK II
P4 P4
UNIT - A UNIT - B
P5 P3 P3 P5
Maint. VDU Link NV MAINT.
Diagnostic Link VDU

RELAY RACK - A CT RACK RELAY RACK - B

Relay Room