AnsaldoSTS Microlok II Guide

1000 TECHNOLOGY DRIVE
PITTSBURGH, PA 15219-3120 SM-6800C
Microlok II System Startup,
Troubleshooting, and Maintenance
Microlok II
Integrated Vital Interlocking, Coded Track
Circuit, and Non-vital Code Line Controller
COPYRIGHT © 2000 Union Switch & Signal Inc. All Rights Reserved.
PRINTED IN USA
September 2000
Revision Number: 2.5
UNION SWITCH & SIGNA
L
THIS DOCUMENT AND ITS CONTENTS ARE THE PROPERTY OF UNION SWITCH & SIGNAL INC.
(HEREINAFTER US&S®) FURNISHED TO YOU ON THE FOLLOWING CONDITIONS: NO RIGHT
OR LICENSE IN RESPECT TO THIS DOCUMENT OR ITS CONTENTS IS GIVEN OR WAIVED IN
SUPPLYING THE DOCUMENT TO YOU. THIS DOCUMENT OR ITS CONTENTS ARE NOT TO BE
USED OR TREATED IN ANY MANNER INCONSISTENT WITH THE RIGHTS OF US&S AND ARE
NOT TO BE COPIED, REPRODUCED, DISCLOSED TO OTHERS OR DISPOSED OF EXCEPT WITH
THE PRIOR WRITTEN CONSENT OF US&S.

NOTE
This manual displays the most recent revision number for its information.
Manuals distributed with revision number of 2.1 or less (or without a revision number)
do not contain the most up-to-date Microlok II information.

REVISION INDEX
Revised pages of this manual are listed by page number and date of revision. On the revised
page, a vertical bar in the margin denotes revised material.
Page Number Revision Date Page Number Revision Date
2-11 09-00 4-42 09-00
3-13 09-00 4-53 09-00
3-19 09-00 4-54 09-00
3-20 09-00 4-55 09-00
3-23 09-00 4-56 09-00
3-24 09-00 4-57 09-00
3-26 09-00 5-2 09-00
3-27 09-00 5-3 09-00
4-2 09-00 6-5 09-00
4-3 09-00 6-6 09-00
4-5 09-00 6-15 09-00
4-6 09-00 6-16 09-00
4-8 09-00 6-17 09-00
4-14 09-00 7-2 09-00
4-15 09-00 7-3 09-00
4-16 09-00 7-4 09-00
4-21 09-00 7-5 09-00
4-22 09-00 7-6 09-00
4-23 09-00 7-7 09-00
4-38 09-00 A-1 09-00
4-40 09-00 A-2 09-00
4-41 09-00 A-7 09-00
3-19 01-04

Microlok II System Startup, Troubleshooting, and Maintenance UNION SWITCH & SIGNAL
SM-6800C Rev. 2.5 September 2000 i
MANUAL CONTENTS
Chapter 1 Introduction.................................................................................................1-1
Chapter 2 System Cardfile Controls and Indications...................................................2-1
Chapter 3 Microlok II CPU Board Front Panel Operations.........................................3-1
Chapter 4 Using the Microlok II Maintenance Tools Program ...................................4-1
Chapter 5 System Startup ............................................................................................5-1
Chapter 6 System Configuration and Testing..............................................................6-1
Chapter 7 System Troubleshooting and Recovery.......................................................7-1
Chapter 8 System Maintenance ...................................................................................8-1
Appendix A CPU Board Error/Event Codes
This manual provides a separate table of contents for each chapter and appendix.

UNION SWITCH & SIGNAL Microlok II System Startup, Troubleshooting, and Maintenance
ii September 2000 SM-6800C Rev. 2.5

Microlok II System Startup, Troubleshooting, and Maintenance UNION SWITCH & SIGNAL
SM-6800C Rev. 2.5 September 2000 1-i
CHAPTER 1 CONTENTS
1. INTRODUCTION................................................................................................... 1-1
1.1 OVERVIEW OF THE MANUAL............................................................................................................ 1-1
1.2 R.A.I.L. TEAM AND TECHNICAL SUPPORT.................................................................................... 1-2

UNION SWITCH & SIGNAL Microlok II System Startup, Troubleshooting, and Maintenance
1-ii September 2000 SM-6800C Rev. 2.5

Microlok II System Startup, Troubleshooting, and Maintenance UNION SWITCH & SIGNAL
SM-6800C Rev. 2.5 September 2000 1-1
1. INTRODUCTION
1.1 OVERVIEW OF THE MANUAL
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 written specifically for field personnel who are responsible for the startup and
configuration of the Microlok II system. This manual also contains detailed information on
troubleshooting system malfunctions and for maintaining the system in a safe and operable state.
The manual is organized as follows:
• Chapter 2 provides information concerning the Microlok II printed circuit board front panel
controls and indications. The description for each board includes a front view of the circuit
board, a discussion of the function of each front panel control, and the information provided
by each front panel indication.
• Chapter 3 provides procedures for using the front panel controls on the Microlok II system
CPU board. This section also discusses the menu structures associated with the CPU board
and the methods used to interpret the data provided by the CPU board front panel indications.
• Chapter 4 provides procedures for using the Microlok II Maintenance Tools software
package. This software is loaded onto a laptop personal computer that is connected through a
serial cable to the diagnostic port on the Microlok II CPU board. Using this versatile
software, field personnel can download upgrades to the system application and executive
software, configure the Microlok II system, and perform extensive system diagnostics using
the Tools program logging capabilities.
• Chapter 5 provides the procedures for powering up the Microlok II system, checking the
initial operation of the system following power-up, and for downloading the system
application software.
• Chapter 6 provides procedures for adjusting the configurable parameters of the Microlok II
system and for testing the operation of the various system functions.
• Chapter 7 details the resources that are available and the procedures that can be used to
troubleshoot Microlok II system malfunctions.

UNION SWITCH & SIGNAL Microlok II System Startup, Troubleshooting, and Maintenance
1-2 September 2000 SM-6800C Rev. 2.5
• Chapter 8 provides schedules and procedures for performing inspections and preventive
maintenance procedures on the Microlok II system. These procedures are designed to
maintain the system equipment in peak operating condition and to provide a means of
detecting early signs of equipment degradation. This section also contains corrective
maintenance procedures for the Microlok II system. These procedures describe how to
replace modular components of the system following troubleshooting operations.
For reference, related Microlok II system manuals include:
• SM-6800A - Microlok II System Description
• SM-6800B - Microlok II System Hardware Installation
• 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
This manual is divided into chapters, each of which stands alone in the presentation of the
subject matter. Thus, any chapter can be used as a quick reference to the information indicated
by the section title. However, the chapters also organized to provide a logical learning sequence.
To gain an overall understanding of the Microlok II system, read the chapters in the order
presented.
1.2 R.A.I.L. TEAM AND TECHNICAL SUPPORT
The Rapid Action Information Link (R.A.I.L.) 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
R.A.I.L. 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 R.A.I.L. Team by telephone at 1-800-652-7276 or
through Internet E-mail at [e-mail].

Microlok II System Startup, Troubleshooting, and Maintenance UNION SWITCH & SIGNAL
SM-6800C Rev. 2.5 September 2000 2-i
CHAPTER 2 CONTENTS
2. SYSTEM CARDFILE CONTROLS AND INDICATIONS....................................... 2-1
2.1 CPU PRINTED CIRCUIT BOARD (Figure 2-1) ................................................................................... 2-1
2.2 VITAL INPUT PRINTED CIRCUIT BOARD (Figure 2-2) ................................................................. 2-3
2.3 STANDARD VITAL OUTPUT PRINTED CIRCUIT BOARDS (Figure 2-2) .................................... 2-3
2.4 MIXED VITAL I/O PRINTED CIRCUIT BOARDS (Figure 2-3) ....................................................... 2-5
2.5 NON-VITAL I/O PRINTED CIRCUIT BOARD (Figure 2-3).............................................................. 2-5
2.6 NON-VITAL ISOLATED INPUT AND OUTPUT PCBs (Figure 2-4)................................................. 2-5
2.7 Non-vital isolated I/O pcb with lcp panel (Figure 2-5)........................................................................... 2-5
2.8 LAMP DRIVER PRINTED CIRCUIT BOARD (Figure 2-6)............................................................... 2-9
2.9 NON-VITAL I/O PRINTED CIRCUIT BOARD N17061501 (Figure 2-7) .......................................... 2-9
2.10 CODE SYSTEM INTERFACE PCB (Figure 2-7)........................................................................... 2-11
2.11 CODED TRACK CIRCUIT PRINTED CIRCUIT BOARDS (Figure 2-8)................................... 2-13
2.12 75/120/180 CODER OUTPUT PRINTED CIRCUIT BOARDS (Figure 2-9) ............................... 2-15
2.13 AUXILIARY CODER/OUTPUT PCB (Figure 2-9) ........................................................................ 2-15
2.14 60/100 HZ CAB AMPLIFIER PRINTED CIRCUIT BOARD (Figure 2-10)................................ 2-17
2.15 40/50 HZ CAB AMPLIFIER PRINTED CIRCUIT BOARD (Figure 2-10).................................. 2-17
2.16 POWER SUPPLY PRINTED CIRCUIT BOARD N16660301 (Figure 2-11) ............................... 2-19
2.17 LOCAL CONTROL PANEL AND POWER SUPPLY N16600301 (Figure 2-12) ....................... 2-21

UNION SWITCH & SIGNAL Microlok II System Startup, Troubleshooting, and Maintenance
2-ii September 2000 SM-6800C Rev. 2.5

Microlok II System Startup, Troubleshooting, and Maintenance UNION SWITCH & SIGNAL
SM-6800C Rev. 2.5 September 2000 2-1
2. SYSTEM CARDFILE CONTROLS AND INDICATIONS
Before you can set up and configure the Microlok II system, you should become familiar with the
front panel controls and indications associated with the Microlok II system printed circuit boards.
Sections 2.1 through 2.15 that follow provide an introduction to the functions associated with
each control and the information provided by each indicator on the Microlok II circuit boards.
2.1 CPU PRINTED CIRCUIT BOARD (FIGURE 2-1)
Fig. 2-1 Ref Label Device Purpose
1, 2 (none) 4-character alpha-
numeric displays
On-site configuration programming menus
and options
3A, B, C, D, E yellow LEDs Reserved for serial link status
41, 2, 3, 4, 5, 6, 7, 8 red LEDs User-defined in application software
5ON LINE green LED When lit, indicates normal system operation
(successful diagnostics)
6VPP ON yellow LED When lit, indicates FLASH +5V or +12V
programming voltage enabled (via board
jumper).
7RESET green LED When lit, indicates that the system is in
reset mode.
8RESET Momentary pushbutton When pressed, resets the CPU. Also used
to place the CPU in the reset mode.
9MENU L-R 3-position (return-to-
center) toggle switch
Used to search main program menu items
shown on displays.
10 MENU UP-DOWN 3-position (return-to-
center) toggle switch
Used to select main program menu items
shown on displays.
11 ADJUST UP-DOWN 3-position (return-to-
center) toggle switch
Used to cycle through configuration values
to be selected with ACTION switch.
12 ACTION ACCEPT-
REJECT
3-position (return-to-
center) toggle switch
Executes or cancels configuration value
selected with ADJUST switch.

UNION SWITCH & SIGNAL Microlok II System Startup, Troubleshooting, and Maintenance
2-2 September 2000 SM-6800C Rev. 2.5
68332
CPU
ABCD
1 2 3 4
RS-232
DTE
UP
DOWN
M
E
N
U
ACCEPT
REJECT
ACTION
UP
DOWN
ADJUST
LR
RESET
1
2
3
4
5
6
7
8
ON-LINE
VPP ON
RESET
A
B
C
D
E
1
2
3
4
5
6
7
8
9
10
11
12
13
Figure 2-1. CPU PCB Front Panel Layout

Microlok II System Startup, Troubleshooting, and Maintenance UNION SWITCH & SIGNAL
SM-6800C Rev. 2.5 September 2000 2-3
2.2 VITAL INPUT PRINTED CIRCUIT BOARD (Figure 2-2)
Fig. 2-2 Ref Label Device Purpose
1IN1 - IN8 green LEDs Monitor state of vital inputs 1 through 8. When lit, indicates
respective input is turned on.
2IN9 - IN16 green LEDs Monitor state of vital inputs 9 through 16. When lit,
indicates respective input is turned on.
2.3 STANDARD VITAL OUTPUT PRINTED CIRCUIT BOARDS (Figure 2-2)
Fig. 2-2 Ref Label Device Purpose
3OUT1 - OUT8 yellow LEDs Monitor state of vital outputs 1 through 8. When lit,
indicates respective output is turned on.
4OUT9 - OUT16 yellow LEDs Monitor state of vital outputs 8 through 16. When lit,
indicates respective output is turned on.

UNION SWITCH & SIGNAL Microlok II System Startup, Troubleshooting, and Maintenance
2-4 September 2000 SM-6800C Rev. 2.5
IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN 7
IN 8
IN 9
IN 10
IN 11
IN 12
IN 13
IN 14
IN 15
IN 16
1
2
IN16 OUT16
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 7
OUT 8
3
4
OUT 9
OUT10
OUT11
OUT12
OUT13
OUT14
OUT15
OUT16
Figure 2-2. Vital Input and Standard Vital Output PCBs - Front Panel Layouts

Microlok II System Startup, Troubleshooting, and Maintenance UNION SWITCH & SIGNAL
SM-6800C Rev. 2.5 September 2000 2-5
2.4 MIXED VITAL I/O PRINTED CIRCUIT BOARDS (Figure 2-3)
Fig. 2-3 Ref Label Device Purpose
1IN1 - IN8 green LEDs Monitor state of vital inputs 1 through 8. When lit,
indicates respective input is turned on.
2OUT1 - OUT8 yellow LEDs Monitor state of vital outputs 1 through 8. When lit,
indicates respective output is turned on.
2.5 NON-VITAL I/O PRINTED CIRCUIT BOARD (Figure 2-3)
Fig. 2-3 Ref Label Device Purpose
31, 2, 3, 4 yellow LEDs/
green LEDs
Monitor state of bi-polar outputs 1 through 4. When yellow
LED is lit, output has positive polarity. When green LED is
lit, output has negative polarity. When neither LED is lit,
output is off.
45, 6, 7, 8 yellow LEDs/
green LEDs
Monitor state of bi-polar outputs 5 through 8. When yellow
LED is lit, output has positive polarity. When green LED is
lit, output has negative polarity. When neither LED is lit,
output is off.
59, 10, 11, 12 yellow LEDs/
green LEDs
Monitor state of bi-polar outputs 9 through 12. When
yellow LED is lit, output has positive polarity. When green
LED is lit, output has negative polarity. When neither LED
is lit, output is off.
2.6 NON-VITAL ISOLATED INPUT AND OUTPUT PCBs (Figure 2-4)
Fig. 2-4 Ref Label Device Purpose
1, 2, 3, 4 1, 2, 3…32
NV.OUT32
yellow LEDs Monitor state of non-vital outputs 1 through 32. When lit,
indicates respective output is turned on.
5, 6, 7, 8 1, 2, 3…32
NV.IN32
green LEDs Monitor state of non-vital inputs 1 through 32. When lit,
indicates respective input is turned on.
2.7 NON-VITAL ISOLATED I/O PCB WITH LCP PANEL (Figure 2-5)
Fig. 2-5 Ref Label Device Purpose
11, 2, 3…16
NV.IN32.OUT16
green LEDs Monitor state of external non-vital, isolated inputs 1
through 16. When lit, indicates respective input or output
is turned on.
216 outputs red LEDs Indicates state of software directed outputs. When lit,
indicates respective input or output is turned on.
316 inputs Pushbuttons Selects 16 software directed inputs.

UNION SWITCH & SIGNAL Microlok II System Startup, Troubleshooting, and Maintenance
2-6 September 2000 SM-6800C Rev. 2.5
IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN 7
IN 8
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 7
OUT 8
1
2
IN8
.OUT8
NVB
.0UT12
1
2
3
4
5
6
7
8
9
10
11
12
3
4
5
OUTPUTS
Figure 2-3. Mixed Vital I/O and Non-vital Bi-Polar Output PCBs - Front Panel Layouts

Microlok II System Startup, Troubleshooting, and Maintenance UNION SWITCH & SIGNAL
SM-6800C Rev. 2.5 September 2000 2-7
Figure 2-4. Non-vital, isolated Input and Output PCBs
12
34
56
78
910
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
INPUTS
NV.IN32
12
34
56
78
910
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
OUTPUTS
NV.OUT32
15
26
37
48

UNION SWITCH & SIGNAL Microlok II System Startup, Troubleshooting, and Maintenance
2-8 September 2000 SM-6800C Rev. 2.5
N17002901 w/key N17002902 w/o key
Figure 2-5. LCP panels for non-vital, isolated NV.IN32.OUT16 PCB
2
4
6
8
10
12
14
16
EXTERNAL
INPUTS
1
3
5
7
9
11
13
15
UNION SWITCH & SIGNAL
MADE IN USA
13 14
15 16
UNION SWITCH & SIGNAL
MADE IN USA
REMOTE L
O
C
A
L
EXTERNAL
INPUTS
12
34
56
78
910
11 12
1
2
3