Union Switch & Signal Microlok II Operating and installation instructions

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2004 Union Switch & Signal India. All Rights Reserved. July 2005
PRINTED IN INDIA Revision Number: 1.3
UM-6800A
FUNCTIONAL DESCRIPTION
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USSI Microlok II Functional description
UM-6800A Rev1.3 July 2005 Page 1 of 27
DOCUMENT APPROVAL RECORD
This Issue Authored By: A.Muruganantham Date: 19 July 2004
Title of Author: Design Engineer
This Issue Approved By: G.Perumalsamy Date: 19 July 2004
Title of Approver: Design Manager
DOCUMENT CHANGE RECORD
Issue No: Reason For Change: Date of Revision
1.0 Draft for review 27 July 2004
1.1 Internal review comments 04 October 2004
1.2 Initial Issue to SECR 12 October 2004
1.3 Board Diagrams added 04 July 2005

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MANUAL CONTENTS
1.1. INTRODUCTION _____________________________________________________________ 4
2.1. SYSTEM OVERVIEW__________________________________________________________ 4
3.1. SYSTEM DESCRIPTION _______________________________________________________ 5
4.1. MICROLOK II HARDWARE_____________________________________________________ 5
4.1.1. ENVIRONMENTAL __________________________________________________________ 6
4.1.2. PHYSICAL ________________________________________________________________ 6
4.1.3. CARDFILE ________________________________________________________________ 6
4.1.4. CPU BOARD_______________________________________________________________ 6
4.1.5. POWER SUPPLY BOARD ____________________________________________________ 9
4.1.6. PHYSICAL I/O_____________________________________________________________ 10
4.1.7. VITAL CUT-OFF RELAY ____________________________________________________ 16
4.1.8. ADDRESS SELECT PCB ____________________________________________________ 16
4.1.9. KEYING PLUG ____________________________________________________________ 17
5.1. SERIAL I / O________________________________________________________________ 17
5.1.1. MICROLOK PROTOCOL ____________________________________________________ 18
5.1.2. GENISYS PROTOCOL ______________________________________________________ 19
6.1. MICROLOK II SOFTWARE ____________________________________________________ 19
6.1.1. EXECUTIVE SOFTWARE ___________________________________________________ 19
6.1.2. APPLICATION SOFTWARE__________________________________________________ 20
7.1. MICROLOK II VITAL DIAGNOSTICS ____________________________________________ 20
8.1. SYSTEM OPERATING MODES ________________________________________________ 21
8.1.1. NORMAL MODE ___________________________________________________________ 21
8.1.2. SELECTIVE SHUTDOWN MODE _____________________________________________ 21
8.1.3. USER SELECTIVE SHUTDOWN MODE ________________________________________ 21
8.1.4. COMPLETE SHUTDOWN MODE _____________________________________________ 21
8.1.5. RESET MENU MODE_______________________________________________________ 22
8.1.6. CONFIGURATION MODE ___________________________________________________ 22
8.1.7. BOOT MODE _____________________________________________________________ 22
9.1. LOGIC PROCESSING ________________________________________________________ 22

USSI Microlok II Functional description
UM-6800A Rev1.3 July 2005 Page 3 of 27
10.1. SYSTEM LOGS ___________________________________________________________ 22
10.1.1. SYSTEM EVENT LOG ______________________________________________________ 23
10.1.2. SYSTEM ERROR LOG______________________________________________________ 23
10.1.3. SYSTEM USER DATA LOG __________________________________________________ 23
10.1.4. SYSTEM MERGED EVENT LOG______________________________________________ 23
11.1. SYSTEM SPECIFICATION __________________________________________________ 24

USSI Microlok II Functional description
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1.1. INTRODUCTION
This manual provides the following information about the Microlok II system.
• System level application and operational descriptions
• System component specifications
This manual is to be referred in conjunction with the Microlok II service
manual SM6800A.
2.1. SYSTEM OVERVIEW
The Microlok II system operation is controlled by proprietary executive
software running on the system hardware. The user application logic is
written in a proprietary Microlok II programming language and is compiled by
a proprietary compiler into a set of data tables which are interpreted by the
executive software during run-time.
The high-level block diagram of the Microlok II system is shown below. The
system uses diversity and self-checking concepts in which critical operations
are performed in diverse ways, using diverse software operations and critical
system hardware is tested with self-checking operations. Permissive outputs
are allowed only if the results of diverse logic operations correspond and the
self-checks reveal no failures. It uses a combination of vital and non-vital
hardware, and an executive software performing critical operations on the
site-specific application logic tables using dual-path processing and double
storage techniques along with continuous monitoring of the hardware
through the use of extensive built-in diagnostics. Any failure in any critical
portion of the equipment will result in the controlled system returning to a
safe state.

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Figure-1
3.1. SYSTEM DESCRIPTION
The Microlok II interlocking system is a multi-purpose monitoring and
control system, which performs the following.
• Drive Signal, Point, Crank Handle, LC Gate and Siding control relays
• Monitoring of Point position, track circuits occupancy and other field
inputs
• Vital CPU for overall system monitoring, control, diagnostics and data
recording
• Executive and application logic for vital interlocking functions
• Executive and application logic for non-vital control Panel & Operator
VDU functions
• Serial I/O channels for communicating with MLK II to MLK II, MLK II to
CAB/ Other Non-Vital application, Maintenance and Diagnostic function
4.1. MICROLOK II HARDWARE
The Microlok II system consists of modular card file-mounted equipment and
external peripheral devices that are used to interface the card file circuitry to
the field gears and other associated control systems. The following sections
provide an overview of the hardware.
Block Diagram of MICROLOK II System
Vital Conditional
Power Circuit
Microprocessor-
based Computer
System with vital
Software
Vital
Clock
Signal
Vital Input
Monitor
Vital
Inputs
Control
Signal
Output
Device
Control Vital Outputs
Vital Output
Monitor
Vital Output Power
Monitor

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4.1.1. ENVIRONMENTAL
• The Microlok II product will operate in a standard railway environment
• The system operates in ambient temperature ranges of –40 to +70 degrees
centigrade. This refers to the temperature outside the card file but inside
the relevant building enclosure
• The system operates from 0 to 95% non-condensing humidity
• The system meets the required EMI specification
• The system meets the required vibration specification
4.1.2. PHYSICAL
• The card file is 16.75” wide and it can be mounted in a standard 19” rack
• Boards in the card file include a faceplate where status information will be
displayed. A blank panel will be available to cover empty slots
• The system will accept power from an external battery in the range of 9.8V
DC to 16.2V DC for an internal conversion to the required voltages
• The internal power converter will have a start-up voltage requirement of
11.5V DC to inhibit start-up when the battery voltage is low
• Nominal 24V input/output boards will have an input/output supply in
the range of 19.6V DC to 32.4V DC
4.1.3. CARDFILE
The Microlok II card file is a G64/96 bus based card file that holds the CPU,
Power Supply & Variety of I/O boards. The card file will be a user
configurable. The Microlok II card file is designed to house standard 6UX220
Euro card plug-in printed circuit boards. The card file will have twenty slots.
• Slots No. 1 to 15 & 20 are used to accommodate Non-Vital or Vital I/O
boards.
• Slot No. 16 & 17 are reserved for Power Supply board.
• Slot No. 18 & 19 are reserved for CPU board.
4.1.4. CPU BOARD
The CPU board is controlled by a Motorola 68332 microprocessor, which
operates at a speed of 21 MHz, and includes 2K bytes of internal fast
termination RAM. Most internal operations are 32 bits wide, while all outside
bus cycles are 16 or 8 bits wide. The executive and application software is
stored in four flash EPROMs that provide up to 8MB of memory. Flash
EPROMs permit direct handling of the executive and application software
using a PC connected to the CPU board front panel serial port connector.
Jumpers are provided on the board to enable or disable the flash EPROMs for

USSI Microlok II Functional description
UM-6800A Rev1.3 July 2005 Page 7 of 27
programming and to select the required programming voltage. The CPU board
contains the central controlling logic and diagnostic monitoring for the
Microlok II system, and provides five serial data ports. 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 connector’s EEPROM.
• Ports 1 and 2 support an RS-485 hardware interface
• Port 3 supports an RS-423 & RS 232 interface
• Port 4 & 5 supports an RS-232 interface
Figure – 2
ADJUST
UP
DOWN
REJECT
ACTION
ACCEPT
RESET
DOWN
UP
L R
M
E
N
68332
CPU
ON-LINE
VPP ON
RESET
E
D
C
B
A
2
4
5
3
1
7
8
6
1234
CAB D
DTE
RS-232
13
12
11
8
4
1
10
9
7
6
5
3
2
U

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CPU Function
• Monitoring external inputs from vital input boards and non-vital input
boards
• Processing vital external inputs and executing logic defined in the
application software
• Driving vital output boards as required by the application program
• Monitoring and controlling serial communication ports (links to other
controllers)
• Testing individual vital input and output channels for faults (in parallel
with control of these channels) and responding to detected faults
• Monitoring system internal operation for faults and responding to detected
faults
• Controlling power to vital outputs through the card file power supply and
an external VCOR (fail-safe function)
• Recording system faults and routine events in user-accessible memory
Fig. 2 Ref Label Device Purpose
1, 2 (None) 4-character alpha-
numeric displays On-site configuration programming menus and options.
3 A, B, C, D, E Yellow LEDs Reserved for serial link status.
4 1, 2, 3, 4, 5, 6, 7, 8 Red LEDs User-defined in application software.
5 ON LINE Green LED When lit, indicates normal system operation
(successful diagnostics).
6 VPP ON Yellow LED When lit, indicates FLASH +5V or +12V
programming voltage enabled (via board
jumper).
7 RESET Green LED When lit, indicates that the system is in reset
mode.
8 RESET Momentary pushbutton When pressed, resets the CPU. Also used to
place the CPU in the reset mode.
9 MENU 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.
13
RS-232 DTE
Diagnostic Link
Connector
DB9, RS-232 Connector
(DTE) Used for connection to Maintenance PC for System monitoring diagnosis.