Union Switch & Signal GENISYS II Manual
1000 TECHNOLOGYDRIVE
PITTSBURGH, PA15219-3120 SM-6900B
Hardware Installation
GENISYS
II
Non-Vital Logic Emulator
And Remote Control Interface
COPYRIGHT 1999 Union Switch & Signal Inc. All Rights Reserved.
PRINTED IN USA August 1999
UNION SWITCH & SIGNAL
THISDOCUMENT AND ITSCONTENTSARE THE PROPERTY OFUNION SWITCH & SIGNALINC.
(HEREINAFTER US&S®)FURNISHED TO YOU ON THE FOLLOWING CONDITIONS: NO RIGHT OR
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THE DOCUMENT TOYOU. THISDOCUMENT OR ITSCONTENTSARE NOT TO BE USED OR
TREATED INANY MANNER INCONSISTENT WITH THE RIGHTSOFUS&SAND ARE NOT TO BE
COPIED, REPRODUCED, DISCLOSED TO OTHERSOR DISPOSED OFEXCEPT WITH THE PRIOR
WRITTEN CONSENT OFUS&S.
'-----'~
REVISION INDEX
Revised pages of this manual are listed by page number and date of revision. On the affected
pages, a vertical bar in the margin denotes revised material.
Page Number Revision Date
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
SM-6900B Rev. 0.0 July 1999 1-i
MANUAL CONTENTS
Chapter 1 General Information................................................................................... 1-1
Chapter 2 Cardfile and Circuit Board Installation...................................................... 2-1
Chapter 3 Installing GENISYS II System Peripheral Devices................................... 3-1
Chapter 4 Installation Parts List................................................................................. 4-1
This manual provides a separate table of contents for each chapter.
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
SM-6900B Rev. 0.0 August 1999 1-1
CHAPTER 1 CONTENTS
1. GENERAL INFORMATION..................................................................................1-3
1.1 INTRODUCTION........................................................................................................................................1-3
1.2 R.A.I.L TEAM AND TECHNICAL SUPPORT.......................................................................................1-3
1.3 HARDWARE GENERAL DESCRIPTION..............................................................................................1-3
1.3.1 System Components.............................................................................................................................1-4
1.3.2 Cardfile and Plug-In Components........................................................................................................1-4
1.3.3 Installation Cables................................................................................................................................1-5
1.4 INSTALLING A GENISYS II SYSTEM...................................................................................................1-5
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
1-2 August 1999 SM-6900B Rev. 0.0
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
SM-6900B Rev. 0.0 August 1999 1-3
1. GENERAL INFORMATION
1.1 INTRODUCTION
This manual provides the basic information necessary to install the GENISYS
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 GENISYS II system manuals include:
SM-6900A - GENISYS II System Description
SM-6900C - GENISYS II System Startup, Troubleshooting, and Maintenance
SM-6900D - GENISYS II System Application Logic Programming
US&S
provides no shop maintenance procedures for the GENISYS II system circuit boards.
These boards are not repairable in the field.
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 rapid resolutions 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 GENISYS 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 e-mail at railteam@switch.com.
1.3 HARDWARE GENERAL DESCRIPTION
The GENISYS II system consists of modular cardfile-mounted equipment and external peripheral
devices that are used to interface the cardfile circuitry to other associated interlocking control
systems. Sections 1.3.1 and 1.3.2 provide an overview of the hardware available for use in the
GENISYS II system.
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
1-4 August 1999 SM-6900B Rev. 0.0
1.3.1 System Components
The GENISYS II control system is a non-vital logic emulator and remote control interface for
railroad and rail mass transit wayside interlocking installations. Table 1-1 lists the major
components of the GENISYS II system that are covered in this manual:
TABLE 1-1. GENISYS II SYSTEM MAJOR SYSTEM COMPONENTS
Name US&S Part No. Basic Function(s)
GENISYS II Cardfile N16902101 Houses all plug-in printed circuit boards and an optional local
control panel.
Power-Off Relay J726153-0283 Detects the failure of commercial power.
Serial Link Isolator Unit N16401101 Provides an “isolated common” interface between RS-232
compatible asynchronous serial communication ports on the
GENISYS II controller board and external communication
equipment.
Local Control Panel N17062901, N17062902 Optional built-in local control panels.
Installation Cables Contact US&S Eliminate the need for special wiring tools.
1.3.2 Cardfile and Plug-In Components
The GENISYS II cardfile is designed to house standard 6UX220 Eurocard plug-in printed circuit
boards. Most GENISYS II printed circuit boards are equipped with integral status indicator LEDs
on the board’s front panel.
In most applications, the cardfile will 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 inputs
through a dedicated non-vital I/O printed circuit board that occupies a cardfile slot directly
behind the LCP. Any unused slots in the cardfile 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 slotted-head machine screws. Two extraction levers are provided on each
board to make board removal easier. The GENISYS 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 board’s upper-edge connector at the rear of the card file.
Connector housings for I/O circuit boards incorporate a DIP switch that is 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 connector’s EEPROM.
The GENISYS II cardfile plug-in components covered in this manual are listed in Table 1-2. See
Service Manual SM-6900A for a detailed description of each circuit board type.
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
SM-6900B Rev. 0.0 August 1999 1-5
1.3.3 Installation Cables
Installation cabling may be field-fabricated as described in Sections 2.3 and 2.4 or standard
factory-fabricated cable and terminal assemblies may be used. Prefabricated cable and terminal
assemblies consist of Harting connectors, 6-foot cables and Wago connectors pre-mounted on
19” rack-mountable DIN rails. They allow a GENISYS II unit to be installed in a 19” rack
without the use of special wiring tools. Standard installation cable assemblies are available for a
number of GENISYS II configurations. Contact US&S Customer Service (1-800-652-7276) for
details and part numbers.
TABLE 1-2. GENISYS II CARDFILE PLUG-IN COMPONENTS
Name US&S Part No. Basic Functions
CPU PCB N17061310
Provides system controlling logic, I/O management,
external serial communications, application logic
execution, internal diagnostics, event logging, and a user
programming and diagnostics interface.
Power Supply PCB N17063001 Conditions and converts the battery input voltage to the
various regulated voltage levels required for cardfile
circuitry operation.
Non-Vital I/O PCB N17061501 Provides 32-level inputs and 32-level outputs for interface
with external circuits.
Local Control Panel Driver / Input PCB N17002801 Drives GENISYS II local control panel and provides 16
isolated external inputs.
Non-Vital Output PCB N17062701 Provides 32 isolated external outputs
1.4 INSTALLING A GENISYS II SYSTEM
This manual is generic in nature and is intended to cover the installation of the GENISYS 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.
In some cases, the entire complement 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
GENISYS II system. These are:
1. Install the GENISYS II cardfile.
2. Install the required GENISYS II printed circuit boards and make the necessary wiring
connections for each specific board.
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
1-6 August 1999 SM-6900B Rev. 0.0
3. Install the necessary GENISYS II peripheral devices and make the necessary wiring
connections between the cardfile and external equipment.
4. Make the necessary communications connections between the GENISYS II cardfile and other
remote train control equipment.
5. Power up, configure, and test the GENISYS 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 GENISYS II applications. Step 5 actually includes a number of system checks
and configuration procedures. This information is contained in Service Manual SM-6900C -
GENISYS II System Startup, Troubleshooting, and Maintenance.
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
SM-6900B Rev. 0.0 August 1999 2-i
CHAPTER 2 CONTENTS
2. CARDFILE AND CIRCUIT BOARD INSTALLATION ..........................................2-1
2.1 Installing the Cardfile .................................................................................................................................2-1
2.1.1 Mounting and Environment .................................................................................................................2-1
2.1.2 General Wiring Practices .....................................................................................................................2-1
2.1.3 Power Input..........................................................................................................................................2-2
2.1.4 Cardfile Grounding ..............................................................................................................................2-5
2.2 Installing the GENISYS II Cardfile Plug-ins............................................................................................2-5
2.2.1 Circuit Board Installation Rules...........................................................................................................2-5
2.2.2 Keying Plug Installation.......................................................................................................................2-7
2.2.3 Printed Circuit Board Jumper and Firmware Configurations ..............................................................2-8
2.2.4 Installing GENISYS II Circuit Boards and a Local Control Panel ....................................................2-12
2.3 PCB Connector Assembly and Cardfile Address Setting......................................................................2-13
2.3.1 General...............................................................................................................................................2-13
2.3.2 Connector/Cable Assembly Construction Notes................................................................................2-13
2.3.3 Shelf Mounting Assembly Notes........................................................................................................2-16
2.4 Circuit Board Connections to External Circuits....................................................................................2-17
2.4.1 CPU Board.........................................................................................................................................2-17
2.4.2 Non-Vital I/O PCBs........................................................................................................................... 2-19
2.4.3 Non-vital 32-Bit Output PCBs...........................................................................................................2-21
2.4.4 Local Control Panel Driver / External Input PCBs............................................................................2-21
2.4.5 Cable Jumper Settings ........................................................................................................................2-24
UNION SWITCH & SIGNAL GENISYS II System Hardware Installation
2-ii August 1999 SM-6900B Rev. 0.0
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
SM-6900B Rev. 0.0 August 1999 2-1
2. CARDFILE AND CIRCUIT BOARD INSTALLATION
2.1 INSTALLING THE CARDFILE
2.1.1 Mounting and Environment
The GENISYS 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 -40oto +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”
3”
3”
3”
11.5”
12.19”
9.5”
Fiberglass Mounting Brackets PCB Interface Connector Housing
FIGURE 2-1. CARDFILE INSTALLATION DIMENSIONS
2.1.2 General Wiring Practices
GENISYS 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
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UNION SWITCH & SIGNAL GENISYS II System Hardware Installation
2-2 August 1999 SM-6900B Rev. 0.0
be separated as much as possible from GENISYS 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.
2.1.3 Power Input
2.1.3.1 Source
The GENISYS II cardfile requires a single, 12 Vdc, 16 Vdc, or 24 Vdc (nominal) battery for
operating power. The requirements for the DC input voltage are as follows:
Voltage:
Range:
Nominal:
Min. Startup:
9.0 to 36 Vdc
12 Vdc, 16 Vdc, or 24 Vdc
9.0 Vdc
Ripple: 0.5 VP-P
Current draw on the battery is determined by the application configuration, (number of boards,
etc.). Typically, current draw ranges from 0.1 to 7 AMPS. A constant voltage type charger is
recommended for the battery. Note that the battery must be capable of providing a minimum
voltage of 9.0 Vdc at system start-up. (This means that anytime the OFF/ON switch is operated,
battery voltage must be at least 9.0 V or the unit will not start.)
2.1.3.2 Wiring and Surge Protection
Input power wiring to the GENISYS II cardfile is connected through the 48-pin connector
attached to the back of the power supply PCB (N17063001). Figure 2-2 shows the typical
installation for the battery input to the GENISYS II cardfile. Refer to Section 2.1.6 for connector
wiring data.
CAUTION
THE SURGE SUPPRESSION DEVICES DESCRIBED IN THIS SECTION MUST BE
INSTALLED FOR ALL GENISYS II APPLICATIONS. FAILURE TO INSTALL THESE
DEVICES MAY RESULT IN DAMAGE TO THE POWER SUPPLY OR THE GENISYS
II SYSTEM CIRCUITRY DUE TO VOLTAGE TRANSIENTS.
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
SM-6900B Rev. 0.0 August 1999 2-3
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 line-to-line and line-to-ground MOVs as follows:
a) If the feed is 110 Vac, use a Siemens B40K130 or a GE V131DA40 (J582324).
b) If an isolation transformer is used, also install a block type MOV on the transformer
secondary line-to-line.
4. Secondary surge suppression (US&S USSP units) and common mode filtering are not
required on the battery wiring to the cardfile.
5. Connect FILTER_COM (pin E32) to rack frame or to the nearest earth ground using the
shortest practical length of #16 wire. If connecting to rack frame, verify that rack frame is
properly connected to earth ground.
6. Make NO connection to power supply case A32 or C32.
UNION SWITCH & SIGNAL GENISYS II System Hardware Installation
2-4 August 1999 SM-6900B Rev. 0.0
FIGURE 2-2. CARDFILE POWER INPUT WIRING AND PROTECTION
To
cardfile
power
supply
PCB
or
external
power
supply
converter
(BATT-)
9.0V
to
36
V
Battery
0.5V
P-P
Ripple
(BATT+)
Transient
Voltage
Suppressor
Constant
Voltage
Charger
110V
G)
MO
Vs
for
use
in
11
0V
system:
US&S
J582324,
G.E.
V131DA40,
or
Siemens
B40K130
G)
Prime
Ground
Bus
G)
Commercial
110
Vac
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
SM-6900B Rev. 0.0 August 1999 2-5
2.1.4 Cardfile Grounding
DO NOT ground the GENISYS II cardfile chassis. High ground potential could create undesirable
current paths through the system. The fiberglass mounting brackets electrically insulate the
cardfile from its mounting structure.
2.2 INSTALLING THE GENISYS II CARDFILE PLUG-INS
Installation of the GENISYS 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:
1. Selecting the appropriate cardfile slot for each circuit board (Section 2.2.1).
2. Configuring the cardfile keying plugs for each circuit board (Section 2.2.2).
3. Configuring the circuit board jumpers and firmware just prior to installation (Section 2.2.3).
4. Install the circuit boards (Section 2.2.4)
2.2.1 Circuit Board Installation Rules
Observe the following arrangement rules when installing GENISYS II printed circuit boards and
a local control panel (when applicable) into the cardfile:
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.
Power supply PCB N17063001, which has a two-slot-wide front panel, should be
installed in slot 18.
If the cardfile is to be equipped with a local control panel, non-vital I/O PCB
(N17002801) must be positioned behind the local control panel, so that the rear 96-
pin connector on the local control panel engages the front connector of the I/O board.
For example, if the LCP covers slots 1 through 5, the non-vital I/O board must be
installed in slot 5. Additional LCP sections may be installed as space permits. Any
combination of N17062901 and N17062902 panel sections may be installed.
US&S recommends that the CPU board should be installed in slot 16, beside the
power supply board.
B. 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.
UNION SWITCH & SIGNAL GENISYS II System Hardware Installation
2-6 August 1999 SM-6900B Rev. 0.0
C. All unused 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
D. 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.
FIGURE 2-3. CARDFILE PCB AND PANEL INSTALLATION GUIDELINES
LCP
Drivers
(N
1
?00
2801
)7 Power Supply PCB
(N17063001)1
..
,.-
.....
---··
......
..-·
__,,///~
.........
1~111
I I I I I I I I I I
~
I
Sample
Locations for
LCP, Non-vital
1/0 PCB
(N17002801)
and
Local
Control
Panel
(N16901301)
--
~
-·
.............
II
~
I I I I Ij
~I~
I I I I I
II~
I I
~
Power Supply
PCB
(N17063001)
/
1 2 3
_4,_5-·t
7 8 9
10
11
12 13 14 15 16 17 18 19
al
......
---..-·-
--
....
-·
Typical PCB Installation
Slot
No.
PCB or Panel
1 - 5 Local Control Panel
6 - 10 Optional LCP
11
32-Bit Output Board
12,
13
Blank Panel
14,
15
Blank Panel
16,
17
CPU PCB
18,
19
Power Supply
20 Blank Panel
1 2 3 4 5 6 7 8 9
10
11
12 13 14 15 16
17
18 19
al
GENISYS II System Hardware Installation UNION SWITCH & SIGNAL
SM-6900B Rev. 0.0 August 1999 2-7
2.2.2 Keying Plug Installation
Each of the GENISYS II cardfile slots includes a 12-way female keying guide next to the 96-pin
buss 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 (P/N:
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.
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
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. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
96-pin (Female)
Connector on
Cardfile
Motherboard
Adjacent
Keying Plug
Connector
(Female)
Keying
Plug
No.
1
2
3
4
5
6
7
8
9
10
11
12
Printed
Circuit
Board
96-pin (Male)
Connector on PCB
Adjacent
Keying Plug
Connector
(Male)
PCB Keying
Tabs Set at
Factory
Insert Keying
Plug J709146-0473
Per Table 2-1
FIGURE 2-4. CARDFILE SLOT KEYING PLUG INSTALLATION
I !
--+
--+
--+
-·-·1::::::.
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--+
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.,_,_,;
--+
--1.::::::;
UNION SWITCH & SIGNAL GENISYS II System Hardware Installation
2-8 August 1999 SM-6900B Rev. 0.0
TABLE 2-1. CARDFILE MOTHERBOARD KEYING PLUG LOCATIONS
Keying Plug Location (Figure 2-4)
PrintedCircuitBoard PartNo. 123456789101112
CPU N17061310
Power supply N17063001
non-vital output N17062701
non-vital input / LCP driver N17002801
non-vital I/O (32/32) N17061501
2.2.3 Printed Circuit Board Jumper and Firmware Configurations
Two types of GENISYS II printed circuit boards contain jumpers and firmware that must be
configured before each board is installed. These boards are the CPU board and the power supply
board.
2.2.3.1 Configuring the CPU Board
2.2.3.1.1 Jumper Settings (See Figure 2-5)
Prior to installing the CPU board in the GENISYS II cardfile, the following jumpers 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 21 MHZ
SYSTEM CLOCK.
TABLE 2-2. CPU BOARD JUMPER POSITIONS
Jumper
ID Description Position Notes
JMP1 Bottom PCMCIA 2 Wait States Position 2-3
JMP2 Not installed
JMP3 On-Board RAM 1 Wait State Position 2-3 1
JMP4 Top PCMCIA 2 Wait States Position 2-3
JMP5 Not installed
JMP6 FLASH 1 Wait State Position 2-3 1
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