Karel MS128 Operating and safety instructions

Karel MS128
Telephone System
Installation
&
Maintenance
Guide
Edition 3.2

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CONTENTS
SECTION PAGE
INTRODUCTION 1
TECHNICAL REFERENCE
I. SYSTEM 3
I.1. PARTS LIST 4
I.2. BACKPLANE OF THE SYSTEM – BPL128 6
I.3. POWER TO THE SYSTEM 7
I.3.A. POWER SUPPLY MODULE – SPS128 7
I.3.B. POWER FAILURE TRANSFER STATIONS 9
I.4. CENTRAL PROCESSING MODULE – CPU128 &
CPU CONNECTION CARD - MS128 CPUKON 9
I.5. EXPANSION MODULES - MS128 EX1 / MS128 EX2 12
I.6. EXTERNAL MUSIC CONNECTOR 15
I.7. EXTERNAL RELAY 15
II. ACCESSORIES 17
II.1. CONSOLES, FEATURE PHONES, DIRECT STATION SELECT
MODULES - OP48(-H), LT48(-H), DSS80, DSS40 18
II.1.A. OP48(-H) CONSOLE 18
II.1.B. LT48(-H) FEATURE PHONE 20
II.1.C. DSS80 DIRECT STATION SELECT MODULE 20
II.1.D. DSS40 DIRECT STATION SELECT MODULE 21
II.2. MINI PRINTER - KY16 22
II.3. SERIAL INTERFACE – CM128, PK128, CM128+PK128, SERIAL
PRINTER INTERFACE
24
II.3.A. CM128 CALL RECORD LISTING INTERFACE AND/OR
PK128 PC-CONSOLE INTERFACE 24
II.3.B. SERIAL PRINTER INTERFACE 27
II.4. DOORPHONE – DY01 28
II.5. EXTERNAL ANNOUNCEMENT SYSTEM 28
II.6. AUTO ATTENDANT & VOICE MAIL – EVM128 28
II.7. ISDN ADAPTOR – IA12, EXP-IA12 30
II.8. LOCAL PAGER – PG100 32
II.9. STANDARD TELEPHONE SETS 33
II.10. FILTER & PROTECTION UNIT – FPBASE, FPEXP 34
III. SOFTWARE 37
IV. TECHNICAL SPECIFICATIONS 39

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SECTION PAGE
INSTALLATION
I. PRELIMINARY NOTICE 41
I.1. DELIVERY CHECK 41
I.2. INSPECTION 41
I.3. ENVIRONMENTAL REQUIREMENTS 41
II. SYSTEM INSTALLATION 43
II.1. GROUNDING 44
II.2. POWER SUPPLY MODULE 45
II.3. CENTRAL PROCESSING MODULE 46
II.4. EXPANSION MODULES 48
III. ACCESSORY INSTALLATION 51
III.1. CONSOLES, FEATURE PHONES, DIRECT STATION SELECT
MODULES
51
III.2. MINI PRINTER 55
III.3. SERIAL INTERFACE 59
III.3.A. PC INTERFACE 59
III.3.B. SERIAL PRINTER INTERFACE 60
III.4. DOORPHONE 61
III.5. EXTERNAL ANNOUNCEMENT SYSTEM 63
III.6. ISDN ADAPTOR 64
III.7. AUTO-ATTENDANT & VOICE MAIL 67
III.8. LOCAL PAGER 68
III.9. STANDARD TELEPHONE SETS, EXTERNAL LINES, POWER
FAILURE TRANSFER STATIONS
72
III.10. FILTER & PROTECTION UNIT 73
III.11. EXTERNAL MUSIC SOURCE 75
III.12. EXTERNAL RELAY 75
MAINTENANCE
I. MAINTAINING THE SYSTEM 77

INTRODUCTION
This Installation and Maintenance Guide provides an overall technical
reference on the KAREL MS128 system and its accessories and
includes descriptions, structures and capabilities as well as the
installation and maintenance information.
This guide is formed up of three main chapters:
1) Technical Reference: The system outline is given and all the
accessories are described. Brief information about the software
structure of the system is presented and finally the technical
specifications of the system are listed.
2) Installation Guide: The basic system installation and wiring
instructions are presented. Following the system installation part,
the installation and wiring of the accessories are explained.
3) Maintenance Guide: The basic steps to solve the problems faced
after the installation of the system are given.

TECHNICAL REFERENCE

Karel MS128 Installation & Maintenance Guide
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I. SYSTEM
MS128 system has a capacity of 4 to 20 lines and 12 to 124 extensions.
At minimum capacity, the MS128 system consists of the following parts :
• CBN128 Cabinet made of metal, including a metal rack and some plastic parts,
• SPS128 Power Supply Module including a metal power rack, a power card, a
ring transformer and a cable for BPL128 Bacplane connection,
• BPL128 Backplane,
• CPU128 Central Processing Module,
• MS128 EX1 (4/12) Expansion Module that can support the minimum capacity
of 4/12.
The MS128 system has 8 slots for MS128 EX1 (4/12) and MS128 EX2 (0/16)
Expansion Modules, and the maximum capacities that can be reached when all
slots are occupied are 4/124 and 20/108.
See the following figures to have a general idea about the outlook of the system
and the structure of the system cabinet.
Figure A-1

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Figure A-2
The CBN128 metal cabinet provides a strong shell and a natural electromagnetic
shield for the system.
I.1. PARTS LIST
In order to make the reader familiar with the cabinet which has a complex structure,
the parts list for the cabinet is given below with respect to the references in the
following figure.

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Figure A-3
1. Top Cover 2. Side Cover
3. Front Cover 4. Bottom Cover
5. Rack Bottom Plate 6. Rack Top Plate
7. Rack Rear Plate 8. Card Slot
9. KN1 / KN2 Connection Card Holders 10. Front and Top Cover Holders - Female
Parts
11. Front and Top Cover Holders - Male
Parts 12. Pear Holes (to hang the system on the wall)
13. CPU-FC / EX-FC Flat Cable Holes 14. Line / Extension Cable Holes
15. BPL128 Backplane 16. SPS128 Connector
17. CPU128 Connector 18. MS128 EX1 / MS128 EX2 Connector
19. Ventilation Holes 20. Bottom Cover Slot

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I.2. BACKPLANE OF THE SYSTEM – BPL128
The backbone of MS128 system is the BPL128 Backplane. All the modules, which
are SPS128, CPU128, MS128 EX1 and MS128 EX2, are linked through the
backplane.
BPL128 has the following connectors, from left to right (see Figure A-4):
• One 10-pin male connector for SPS128 Power Supply,
• One 64-pin female connector for CPU128 Central Processing Board,
• Eight 64-pin female connectors for the common use of MS128 EX1 and
MS128 EX2 Expansion Modules.
Figure A-4
BPL128 is mounted inside the system cabinet as fixed to the rack rear plate. The
connectors on BPL128 match the card slots on the metal cabinet to ease the
attachment of the modules.
The dimensions of BPL128 are 31 cm x 11.5 cm and the weight is 0.3 kg.

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I.3. POWER TO THE SYSTEM
MS128 system receives 220 VAC from the mains. Inside the mains fuse slot on
SPS128 Power Supply Module, there exist two T-type fuses for mains - one on
phase and the other on neutral - of 2 A / 250 VAC for the first step protection (see
Figure A-5).
The system can operate for the mains input of 180 - 260 VAC 50/60 Hz, which is
processed by the SPS128 Power Supply Module.
I.3.A. POWER SUPPLY MODULE – SPS128
The front view of SPS128 Power Supply Module is illustrated in the following figure.
Figure A-5
SPS128 Power Supply Module is attached to the 10-pin power connector on the
BPL128 Backplane (see Figure A-4) via a cable coming with the module itself and
fixed to the metal rack with two screws.

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SPS128 Power Supply Module consists of a metal power rack, to which the
SPS128CR Power Card and the ring transformer are fastened. The mains
transformer is located on the SPS128CR Power Card. The module also has a 10-
pin cable for connection to the BPL128 Backplane.
SPS128 is a Switched Mode Power Supply (SMPS) operating at mains voltage.
Receiving 220 VAC over the mains, SPS128CR generates 5 VDC, -5 VDC, +12
VDC and -24 VDC for the system operation, for the accessories and for the ring
transformer. The ring transformer generates the 64 Vrms ring signal. Through the
10-pin power connector, the outputs of SPS128CR and ring transformer are
passed to the BPL128 Backplane, which carries them to the system modules. The
pin-out of the SPS128 – BPL128 connector on the backplane is as follows:
SPS128 – BPL128 Connector
Pin Signal Pin Signal
1 - 24 VDC 6 GND
2 GND 7 - 5 VDC
3 GND 8 GND
4 + 12 VDC 9 + 5 VDC
5 + 5 VDC 10 64 Vrms (Ring)
MS128 system can be backed up with a battery of 24 VDC in order to provide the
continuity of the operation in case of mains failure. Hence, SPS128CR has
necessary circuitries for battery backup. It is strongly recommended to use a dry
battery for proper operation of the system. Also a 24 V - 15 Ah battery is
recommended for a full capacity system with an average traffic of 35%.
There exists one F-type fuse of 8 A / 24 VDC for battery. The battery input is also
controlled by the battery ON/OFF switch, which enables the user to put the battery
out of service when necessary.
SPS128CR is also capable of charging the battery while the system power is on
and the system is running under low traffic. Besides, there exists a low voltage
battery cut-off circuitry, which turns itself off when the battery voltage goes below
17 VDC and does not start until the battery voltage is above 23 VDC. So,
preventing full discharge of the battery SPS128 makes the lifetime of the battery
longer.
The Power Status LEDs on the front panel of the SPS128 Power Supply Module
help to identify the power source in use on time. There are three LEDs. One is for
220 VAC and the others are for -24 VDC and +5 VDC. Normally when the system is
fed from the mains all three LEDs are on. The 220 VAC LED turns off when the
mains power is off. In this case - 24 VDC and + 5 VDC LEDs stay on, if battery
backup is available for the system.
The dimensions of the SPS128 are 9 cm x 26 cm x 23 cm and the weight is 2.2 kg
(including SPS128CR).
The dimensions of the SPS128CR are 5.5 cm x 18 cm x 20 cm and the weight is
0.9 kg.

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I.3.B. POWER FAILURE TRANSFER STATIONS
In case of a power failure, the stand-by battery backup allows the system resume
operation without any interrupt. However if there is no battery connected to the
system, then any four lines can be automatically connected to any four extensions
of the system. The power failure transfer stations are handled by four relays
placed on the MS128 CPUKON card.
I.4. CENTRAL PROCESSING MODULE – CPU128 &
CPU CONNECTION CARD - MS128 CPUKON
CPU128 Central Processing Module is located on the leftmost card slot inside the
cabinet. The board is attached to the CPU connector on the BPL128 Backplane
(see Figure A-4) and fixed to the rack top plate via the the latch on the plastic card
cover.
MS128 CPUKON CPU Connection Card resides on the rack top plate below the top
cover of CBN128 Cabinet (see Figure A-3). It is fixed to the rack by a brass card
holder with its screw and two plastic card holders. The MS128 CPUKON card is
connected to the CPU128 board by a 20-pin flat cable, called MS128 CPU-FC. See
the following figure for the outlook of MS128 CPUKON card.
Figure A-6
CPU128 is the brain of the system consisting of the microprocessor, utility,
switching and DTMF circuitries. See Figure A-8 for the location of these circuitries
and Figure A-7 for the operational flow diagram of CPU128.
MS128 CPUKON is the interface between the accessories and the system, it
includes the connectors used to attach the accessories to the system.
CPU128 generates the address and data signals for the MS128 EX1 and MS128
EX2 Expansion Modules and gives them to the BPL128 Backplane, via the 64-pin
connector on BPL128. Then, the signals travel through the BPL128 Backplane to
the MS128 EX1 and MS128 EX2 Expansion Modules. The pin-out of the CPU128
– BPL128 connector on BPL128 Backplane is as follows:

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CPU128 – BPL128 Connector
Pin Signal Pin Signal Pin Signal Pin Signal
1 + 1 VDC 17 X13 33 + 12 VDC 49 X7
2 - 5 VDC 18 X12 34 - 5 VDC 50 X8
3 CS1 19 GNDCPU 35 A0 51 GNDCPU
4 CS2 20 X11 36 A1 52 X16
5 CONT1 21 X9 37 A2 53 X10
6 CS6 22 X17 38 CONT3 54 X14
7 CONT2 23 X15 39 DATA 55 X5
8 B 24 X0 40 RD 56 X22
9 DA1 25 X1 41 WR 57 X21
10 DA2 26 X2 42 CS3 58 X20
11 A 27 X18 43 DA0 59 X19
12 C 28 X3 44 D 60 X23
13 CS4 29 + 5 VDC 45 CS5 61 + 5 VDC
14 VAG 30 CS7 46 VAG 62 CS8
15 X4 31 GND 47 X6 63 GND
16 + 5 VDC 32 - 24 VDC 48 + 5 VDC 64 - 24 VDC
The data signals for the accessories are generated on CPU128, and then
transmitted to MS128 CPUKON via MS128 CPU-FC. The following table illustrates
the pin-out of the MS128 CPU-FC Flat Cable.
MS128 CPU-FC Cable
Pin Signal Pin Signal Pin Signal Pin Signal
1(red) XREL2 6 GNDCPU 11 OUT1 16 EMBT
2 XREL1 7 + 5 VDC 12 OUT2 17 RMF12
3 MUS1 8 DIAINP 13 - 24 VDC 18 GNDCPU
4 VAG 9 INP2 14 EMBR 19 BUSY
5 DIA 10 INP1 15 SERDATA 20 + 12 VDC
There is a LED on the front panel of CPU128. During normal operation it blinks
continuously. During a Reset or a Parameter Download it remains on. So, the state
of the system can be monitored by way of this LED.

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Figure A-7
Figure A-8

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The dimensions of CPU128 are 26 cm x 21 cm and the weight is 0.3 kg.
The dimensions of MS128 CPUKON are 13 cm x 4.5 cm and the weight is 0.2 kg.
I.5. EXPANSION MODULES - MS128 EX1 / MS128 EX2
MS128 EX1 and MS128 EX2 modules are used to increase the system capacity.
MS128 EX1 Expansion Module has a capacity of 4/12 whereas MS128 EX2
Expansion Module has a capacity of 0/16.
The system should have at least one MS128 EX1 module to support the minimum
capacity of 4/12. At maximum capacity, the system can have 124 extensions or 20
lines. Hence, by means of the 8 general purpose slots for MS128 EX1 and MS128
EX2 modules, the maximum system capacity may be configured as 4/124 or
20/108, when all slots are occupied.
MS128 has a default numbering plan for extensions from 111 to 234 (max.) and
lines from 01 to 20 (max.). When all the cards are installed and the system is
powered on, the system checks and recognizes all the cards automatically and
arranges the numbering plan accordingly.
MS128 EX1 consists of MS128 EX1B and KN1 cards together with the EX-FC flat
cable. Similarly, MS128 EX2 includes MS128 EX2B and KN2 cards together with
the EX-FC flat cable. MS128 EX1B and MS128 EX2B are the capacity expansion
boards, having extension circuitries as well as bus receiver circuitries. MS128
EX1B cards employ line circuitries as well. See Figure A-8 for the location of these
circuitries as well as Figures A-9 and A-10 for the operational flow diagrams of
MS128 EX1 and EX2 Expansion Boards, respectively.
KN1 and KN2 Connection Cards are the interface boards between the extension
telephones / external lines and the MS128 EX1B and EX2B cards, respectively.
KN1 and KN2 have the extension / line connectors as well as some protection and
filter elements.
KN1 lays on the rack top plate below the top cover of CBN128 cabinet (see Figure
A-3). It is fixed to the rack by a brass card holder with its screw and two plastic
card holders. The KN1 card is connected to MS128 EX1B by a 34-pin flat cable,
called EX-FC. The same also applies to the connection of KN2 and MS128 EX2B.
The pin-outs of the KN1 – MS128 EX1B and KN2 – MS128 EX2B connectors are
illustrated in the following tables.

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KN1 – MS128 EX1B Connector
Pin Signal Pin Signal Pin Signal Pin Signal
1(red) LED2 10 SUB5A 19 SUB9A 28 TRK6B
2 SUB1A 11 SUB5B 20 SUB10B 29 TRK6A
3 SUB1B 12 SUB6A 21 SUB10A 30 TRK7B
4 SUB2A 13 SUB6B 22 SUB11B 31 TRK7A
5 SUB2B 14 SUB7A 23 SUB11A 32 TRK8B
6 SUB3A 15 SUB7B 24 SUB12B 33 TRK8A
7 SUB3B 16 SUB8A 25 SUB12A 34 LED1
8 SUB4A 17 SUB8B 26 TRK5B
9 SUB4B 18 SUB9B 27 TRK5A
KN2 – MS128 EX2B Connector
Pin Signal Pin Signal Pin Signal Pin Signal
1(red) LED2 10 SUB5A 19 SUB9A 28 SUB14B
2 SUB1A 11 SUB5B 20 SUB10B 29 SUB14A
3 SUB1B 12 SUB6A 21 SUB10A 30 SUB15B
4 SUB2A 13 SUB6B 22 SUB11B 31 SUB15A
5 SUB2B 14 SUB7A 23 SUB11A 32 SUB16B
6 SUB3A 15 SUB7B 24 SUB12B 33 SUB16A
7 SUB3B 16 SUB8A 25 SUB12A 34 LED1
8 SUB4A 17 SUB8B 26 SUB13B
9 SUB4B 18 SUB9B 27 SUB13A
MS128 EX1B and MS128 EX2B cards are connected to the BPL128 Backplane
through the 64-pin connectors on BPL128 (see Figure A-4). The pin-out of the
MS128 EX1B/EX2B – BPL128 connector is illustrated in the following table :

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MS128 EX1B/EX2B – BPL128 Connector
Pin Signal Pin Signal Pin Signal Pin Signal
1 + 1 VDC 17 X13 33 + 12 VDC 49 X7
2 - 5 VDC 18 X12 34 - 5 VDC 50 X8
3 CONT3 19 GNDCPU 35 A0 51 GNDCPU
4 - 20 X11 36 A1 52 X16
5 CONT1 21 X9 37 A2 53 X10
6 - 22 X17 38 CS 54 X14
7 CONT2 23 X15 39 DATA 55 X5
8 B 24 X0 40 RD 56 X22
9 DA1 25 X1 41 WR 57 X21
10 DA2 26 X2 42 - 58 X20
11 A 27 X18 43 DA0 59 X19
12 C 28 X3 44 D 60 X23
13 - 29 + 5 VDC 45 - 61 + 5 VDC
14 VAG 30 RING 46 VAG 62 RING
15 X4 31 GND 47 X6 63 GND
16 + 5 VDC 32 - 24 VDC 48 + 5 VDC 64 - 24 VDC
There is a LED on the front panel of MS128 EX1 / MS128 EX2 cards. This LED
turns on when any port on the card is in use. During Reset or Parameter Download
these LEDs remain on.
Figure A-9