Microlok II Full Box Cardfile - Hitachi Rail · 2019. 3. 25. · The MicroLok II HB2X cardfile has twenty slots (fourteen configurable) and can be wall or shelf mounted. Two PCB motherboards

SM 1D2.0009 1000 Technology Drive, Pittsburgh, PA 15219

645 Russell Street, Batesburg, SC 29006

MicroLok® II HB2X Cardfile

STS USA Part Nos. N18005201 N18005301

Installation

Operation


Copyright 2019 SM 1D2.0009 Rev. 4, March 2019


Copyright 2019 SM-1D2.0009, Rev. 4, March 2019 i

Proprietary Notice This document and the information contained therein are confidential – the disclosure or other communication, copying, reproduction and any use whatsoever is forbidden without the written authorization of Hitachi Rail STS USA, Inc.

Important Notice STS USA constantly strives to improve our products and keep our customers apprised of changes in technology. Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability. The data contained herein purports solely to describe the product, and does not create any warranties.

Within the scope of the attached manual, it is impossible to take into account every eventuality that may arise with technical equipment in service. Please consult an STS USA local sales representative in the event of any irregularities with our product.

STS USA expressly disclaims liability resulting from any improper handling or use of our equipment, even if these instructions contain no specific indication in this respect. We strongly recommend that only approved STS USA spare parts are used as replacements.

© Property of Hitachi Rail STS USA, Inc., 2019 all rights reserved 1000 Technology Drive, Pittsburgh, PA USA 15219-3120

645 Russell Street, Batesburg, SC 29006 sts.hitachirail.com


Copyright 2019 SM-1D2.0009, Rev. 4, March 2019 ii

Revision History

REV. DATE NATURE OF REVISION

1 April 2010 Initial release

2 August 2011 Added information for LCP PCB: Section 3.4, Figure 3-11, Figure 3-12, Section 4.6, and Figure 4-9.

3 September 2014

Added Figure 3-9, Figure 3-8, and information for auxiliary power to Section 3.1. Added Section 3.2, Figure 3-10, Section 4.3, Section 4.4, Figure 4-3 through Figure 4-6, and Section 4.7. Revised Section 3.2, Section 4.3, and Section 4.4. Added PCB information to Section 3.2. Revised Section 3, Section 3.2, Section 4.3. Added new Figure 3-2, Figure 3-4, Figure 3-6, and Figure 4-10. Added Caution statement to Section 3.2.

4 March 2019 Hitachi Rail STS Branding


Copyright 2019 SM-1D2.0009, Rev. 4, March 2019 iii

Table of Contents 1. GENERAL INFORMATION ............................................................................................................... 1-1

1.1. Abbreviations and Acronyms .................................................................................................... 1-1 1.2. Specifications ............................................................................................................................ 1-1

2. GENERAL DESCRIPTION ................................................................................................................ 2-1 2.1. Product Functions ..................................................................................................................... 2-1

3. FUNCTIONAL DESCRIPTION .......................................................................................................... 3-1 3.1. WAGO Connectors ................................................................................................................. 3-15 3.2. Cardfile Address Select Jumpers (where applicable) ............................................................. 3-17 3.3. Communications Ports ............................................................................................................ 3-19

3.3.1. Communication Port 1 ................................................................................................ 3-19 3.3.2. Communication Port 2 ................................................................................................ 3-19 3.3.3. Communication Port 3 ................................................................................................ 3-19 3.3.4. Communication Port 4 ................................................................................................ 3-19 3.3.5. Optional Ethernet PCB ............................................................................................... 3-20

3.4. Optional Local Control Panel PCB ......................................................................................... 3-21 4. INSTALLATION AND CONFIGURATION ........................................................................................ 4-1

4.1. Keying ....................................................................................................................................... 4-1 4.2. Cable Connection ..................................................................................................................... 4-2 4.3. Cardfile Address Select Jumpers (where applicable) ............................................................... 4-3 4.4. Cardfile Instruction and Caution Labels (where applicable) ..................................................... 4-3 4.5. Installation of optional Ethernet PCB ........................................................................................ 4-6 4.6. Installation of optional Local Control panel PCB ...................................................................... 4-8 4.7. Noise Protection ..................................................................................................................... 4-13

5. RAIL TEAM AND TECHNICAL SUPPORT ...................................................................................... 5-1


Copyright 2019 SM-1D2.0009, Rev. 4, March 2019 iv

List of Figures Figure 3-1. N18005201 Cardfile Front View for Revisions 02 and Lower .......................................... 3-3 Figure 3-2. N18005201 Cardfile Front View for Revisions 03 and Higher ......................................... 3-5 Figure 3-3. N18005301 Cardfile Front View for Revisions 02 and Lower .......................................... 3-7 Figure 3-4. N18005301 Cardfile Front View for Revisions 03 and Higher ......................................... 3-9 Figure 3-5. N18005201 Cardfile with Power Supply and CPUs Installed for Revisions 02 and Lower3-11 Figure 3-6. N18005201 Cardfile with Power Supply and CPUs Installed for Revisions 03 and Higher3-13 Figure 3-7. Upper Motherboard WAGO Connector Wiring .............................................................. 3-15 Figure 3-8. Lower Motherboard WAGO Connector Wiring .............................................................. 3-16 Figure 3-9. Access Panel ................................................................................................................. 3-17 Figure 3-10. Address Select Jumpers ................................................................................................ 3-19 Figure 3-11. LCP PCB with Toggle Switches ..................................................................................... 3-22 Figure 3-12. LCP PCB with Pushbuttons ........................................................................................... 3-23 Figure 4-1. Keying Plug Installation .................................................................................................... 4-2 Figure 4-2. Cable Connection............................................................................................................. 4-3 Figure 4-3. Instruction label for HB2X (N18005201) 48-way connectors ........................................... 4-4 Figure 4-4. Instruction label for HB2X (N18005301) 48-Way and 96-way connectors ..................... 4-4 Figure 4-5. Caution Label (same for all 3 cardfiles) ........................................................................... 4-4 Figure 4-6. Label Locations ................................................................................................................ 4-5 Figure 4-7. Location of Rear Cover Retaining Screws ....................................................................... 4-6 Figure 4-8. Ethernet PCB Location .................................................................................................... 4-7 Figure 4-9. N18005201 Cardfile with LCP Installed for Revisions 02 and Lower .............................. 4-9 Figure 4-10. N18005201 Cardfile with LCP Installed for Revisions 03 and Higher ........................... 4-11

List of Tables Table 1-1. Operating Specifications .................................................................................................. 1-1 Table 1-2. Mechanical Specifications ................................................................................................ 1-2 Table 3-1. Pinout of Serial Link Com Ports 3 .................................................................................. 3-20 Table 3-2. Pinout of Serial Link Com Port 4 (Front of Motherboard) .............................................. 3-21 Table 3-3. Pinout of Serial Link Com Port 4 (Rear of Motherboard) ............................................... 3-21


Copyright 2019 SM-1D2.0009, Rev. 4, March 2019 1-1

1. GENERAL INFORMATION

1.1. Abbreviations and Acronyms

The following are abbreviations and acronyms used in this manual along with their associated meanings.

STS USA STS USA (formerly known as Union Switch & Signal)

DB D-subminiature (a common type of computer connector)

DCD Data Carrier Detect

LCP Local Control Panel

RS-232 Recommended Standard 232

RX Receive

RXD Receive Data

RTS Request to Send

SEC Serial-to-Ethernet Converter

TX Transmit

TXD Transmit data

VDC Volts Direct Current 1.2. Specifications

The operating specifications for the HB2X Cardfile are given in Table 1-1X.

Table 1-1. Operating Specifications

PARAMETER VALUE

System Power Source Voltage +9.8 to +16.2VDC, Fuse Protected (10A) Minimum voltage required for system start is 11.2VDC.

Power Connection Six position WAGO connector on upper right panel of cardfile

Temperature Range -40° C to +70°C Humidity 0% to 95% non-condensing



The mechanical specifications for the HB2X Cardfile are shown in Table 1-2X.

Table 1-2. Mechanical Specifications

PARAMETER VALUE

Height 17.19 in. (43.7 cm) Width 19.0 in. (48.26 cm) Depth 11.0 in. (27.9 cm) Material Stainless steel Weight 22.25 lb. (10.09 kg) for the assembled unit.

Mounting Wall or Shelf Mount, cardfile is equipped with mounting ears on the rear and bottom sides.



2. GENERAL DESCRIPTION

The MicroLok II® HB2X is a cardfile that can be configured as a multi-purpose vital and/or non-vital monitoring and control system for railroad and rail mass transit wayside interlocking equipment. The MicroLok II HB2X cardfile has twenty slots (fourteen configurable) and can be wall or shelf mounted. Two PCB motherboards interconnect the MicroLok II CPUs, Power Supply, and up to fourteen I/O PCBs to the I/O field connectors at the top of the cardfile motherboard.

The cardfile is available in two versions. Part number N18005201 contains 48-pin upper connectors in all slots. Part number N18005301 contains 96-pin upper connectors in slots 1 thru 3 (to accommodate the 32 I/O boards) and 48-pin connectors in slots 4 thru 14.

2.1. Product Functions

Basic applications and uses of the MicroLok II HB2X include:

• Direct control of wayside signals (color light signal lamps, LED signal, and searchlight signal mechanisms)

• Switch machine control and switch point position monitoring

• Switch lock position monitoring

• Monitoring of mainline track circuits for track occupancy indications and track circuit problems such as faulty insulated joint or broken rail (Microtrax or Ecode)

• Through-the-rails communications to adjacent wayside control systems: Microtrax or Ecode.

• Monitors interlocking OS track circuits

• Cab signal carrier/code generation

• Line wire communications interface

• Local manual control of wayside signals and switch machines for maintenance and contingency operations

• Vital serial communications to other compatible interlocking control and coded track circuit systems. Protocol is a function of the CPU software

• Non-vital controller logic

• Non-vital (code line) communications to remote office

• PTC signal and switch status

MicroLok is a registered trademark of Hitachi Rail STS USA, Inc.



The MicroLok II HB2X implements these functions in any combination, from basic to complex through the use of application-specific hardware configurations. The modular design of MicroLok II system enables each customer to configure a system that will meet the specific control and interface requirements for their application. The operational configuration of the MicroLok II system is primarily defined within the Application logic software, which is custom-developed using the MicroLok II programming tools.



3. FUNCTIONAL DESCRIPTION

The MicroLok II HB2X cardfile accommodates standard MicroLok II plug-in PCBs (see Figure 3-1 and Figure 3-3). The cardfile is twenty slots wide. Three double-width PCB slots are reserved for the Power Supply PCB in Slots 15 and 16, the vital CPU PCB (MicroLok II) in Slots 17 and 18, and the non-vital CPU PCB (Genisys II) in Slots 19 and 20. The remaining fourteen slots can accommodate any standard MicroLok II I/O PCBs except the Code System Interface PCB (CSIB) (N17061401), On Switch (OS) Track Circuit PCB (N451810-6701, Cab Amplifier PCB (451910-6401, N451910-6402, and N451910-6901), and a Central Processor Unit (CPU) PCB outside the assigned cardfile slots for CPUs (N176061301, N17061302, N17066701, and N17067602). The 32 I/O PCB can only be installed in slots 1, 2, and 3 of cardfile part number N18005301.

The cardfile has an upper and a lower motherboard. The cable connectors for external cables are mounted on the front of the upper motherboard. The lower motherboard contains keying strips for the lower connectors to prevent insertion of an improper board type.

Address select jumpers are located on the upper motherboard of Revisions 03 and higher of the HB2X cardfile.

The motherboard uses nominal 12 volt battery power (9.8V to 16.2V) as the system operating power.





1A1.

0184

.00

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

TOP VIEW

J18

GNDGND+5V+5V-12V+12V

I/OSLOT 1

I/OSLOT 2

I/OSLOT 3

I/OSLOT 4

I/OSLOT 5

I/OSLOT 6

I/OSLOT 7

I/OSLOT 8

I/OSLOT 9

I/OSLOT 10

I/OSLOT 11

I/OSLOT 12

I/OSLOT 13

I/OSLOT 14

J2 J4 J6 J8 J10 J12 J16 J18 J20 J22 J24 J26 J28 J40 J41 J42

1 2 3 4J30

+ _

TRANSZORB5KP16A

FUSE10A

POWERON

OFF654321 BAT (+)

BAT (-)VCOR (+)VCOR (-)SHUTDOWNBAT(-)

J33

VITALCOM PORTS

NON-VITALCOM PORTS

COM3

COM4

COM3

COM4

COM2COM2

1J3

613

1425

1J3

85

69

15

J34

69

15

J39

69

15

J35

69

J37

113

1425

AUXILIARY POWERCONNECTOR

J29

OPTIONAL ETHERNET CONNECTOR

UPPERMOTHERBOARD

LOWERMOTHERBOARD

NON-VITAL COMMUNICATION PORTS

VITAL COMMUNICATION PORTS

GND +5V +12V

GND +5V +12V

Figure 3-1. N18005201 Cardfile Front View for Revisions 02 and Lower





1A1.

0184

.02

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

TOP VIEW

J18


I/OSLOT 1

I/OSLOT 2

I/OSLOT 3

I/OSLOT 4

I/OSLOT 5

I/OSLOT 6

I/OSLOT 7

I/OSLOT 8

I/OSLOT 9

I/OSLOT 10

I/OSLOT 11

I/OSLOT 12

I/OSLOT 13

I/OSLOT 14


1 2 3 4J30

+ _

TRANSZORB5KP16A

FUSE10A

POWERON

OFF654321 BAT (+)


J33

VITALCOM PORTS

NON-VITALCOM PORTS

COM3

COM4

COM3

COM4

COM2COM2

1J3

613

1425

1J3

85

69

15

J34

69

15

J39

69

15

J35

69

J37

113

1425


J29

OPTIONAL ETHERNET CONNECTOR

UPPERMOTHERBOARD

LOWERMOTHERBOARD



GND +5V +12V

GND +5V +12V

SET THE BOARD ADDRESS SELECT USING THE 6 BLUE JUMPERS JUST TO T HE RIGHT OF THE 48WAY CONNECTOR INSIDE THE CARD FILE. T HE 6 ADDRESS SELECT JUMPERS IN THE CABLEASSEMBLY ARE NOT USED - PINS ACE28, ACE30 AND ACE32 IN THE CABL E ASSEMBLY DO NOTCONNECT TO THE48 WAY CONNECTOR INSIDE THE CARD FILE.

1

0

123

PLACE THE BLUE JUMPER BETWEEN 1 AND 2 FOR A “1”PLACE THE BLUE JUMPER BETWEEN 2 AND 3 FOR A “0”.

EXAMPLE OF JUMPERINSIDE THE CARD FILE

Figure 3-2. N18005201 Cardfile Front View for Revisions 03 and Higher





1A1.

0186

.00

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

TOP VIEWOPTIONAL ETHERNET CONNECTOR

J18


I/OSLOT 1

I/OSLOT 2

I/OSLOT 3

I/OSLOT 4

I/OSLOT 5

I/OSLOT 6

I/OSLOT 7

I/OSLOT 8

I/OSLOT 9

I/OSLOT 10

I/OSLOT 11

I/OSLOT 12

I/OSLOT 13

I/OSLOT 14


1 2 3 4J30

+ _

TRANSZORB5KP16A

FUSE10A

POWERON

OFF654321 BAT (+)


J33

VITALCOM PORTS

NON-VITALCOM PORTS

COM3

COM4

COM3

COM4

COM2COM2

1J3

613

1425

1J3

85

69

15

J34

69

15

J39

69

15

J35

69

J37

113

1425


J29

PCB CONNECTORS

UPPERMOTHERBOARD

LOWERMOTHERBOARD



GND +5V +12V

GND +5V +12V

Figure 3-3. N18005301 Cardfile Front View for Revisions 02 and Lower





1A1.

0186

.01

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

TOP VIEWOPTIONAL ETHERNET CONNECTOR

J18


I/OSLOT 1

I/OSLOT 2

I/OSLOT 3

I/OSLOT 4

I/OSLOT 5

I/OSLOT 6

I/OSLOT 7

I/OSLOT 8

I/OSLOT 9

I/OSLOT 10

I/OSLOT 11

I/OSLOT 12

I/OSLOT 13

I/OSLOT 14


1 2 3 4J30

+ _

TRANSZORB5KP16A

FUSE10A

POWERON

OFF654321 BAT (+)


J33

VITALCOM PORTS

NON-VITALCOM PORTS

COM3

COM4

COM3

COM4

COM2COM2

1J3

613

1425

1J3

85

69

15

J34

69

15

J39

69

15

J35

69

J37

113

1425


J29

PCB CONNECTORS

UPPERMOTHERBOARD

LOWERMOTHERBOARD



GND +5V +12V

GND +5V +12V

SET THE BOARD ADDRESS SELECT USING THE 6BLUE JUMPERS JUST TO THERIGHT OF THE48OR 96 WAY CONNECTORSINSIDE THECARD FILE. THE6 ADDRESSSELECT JUMPERS IN THECABLE ASSEMBLY ARE NOT USED - PINS ACE28, ACE30 AND ACE32 OR ABC30, ABC31 AND ABC32IN THECABLE ASSEMBLYDO NOT CONNECT TO THE48 OR 96 WAYCONNECTORS INSIDETHECARD FILE.

1

0

123

PLACETHE BLUE JUMPER BETWEEN 1 AND 2 FOR A “1”PLACETHE BLUE JUMPER BETWEEN 2 AND 3 FOR A “0”.

EXAMPLEOF JUMPERINSIDE THECARD FILE

Figure 3-4. N18005301 Cardfile Front View for Revisions 03 and Higher





1A1.

0190

.00

J18


I/OSLOT 1

I/OSLOT 2

I/OSLOT 3

I/OSLOT 4

I/OSLOT 5

I/OSLOT 6

I/OSLOT 7

I/OSLOT 8

I/OSLOT 9

I/OSLOT 10

I/OSLOT 11

I/OSLOT 12

I/OSLOT 13

I/OSLOT 14


1 2 3 4J30

+ _

TRANSZORB5KP16A

FUSE10A

POWERON

OFF654321 BAT (+)


J33

VITALCOM PORTS

NON-VITALCOM PORTS

COM3

COM4

COM3

COM4

COM2COM2

1J3

613

1425

1J3

85

69

15

J34

69

15

J39

69

15

J35

69

J37

113

1425

J29

Figure 3-5. N18005201 Cardfile with Power Supply and CPUs Installed for Revisions 02 and Lower





1A1.

0296

.00

J18


I/OSLOT 1

I/OSLOT 2

I/OSLOT 3

I/OSLOT 4

I/OSLOT 5

I/OSLOT 6

I/OSLOT 7

I/OSLOT 8

I/OSLOT 9

I/OSLOT 10

I/OSLOT 11

I/OSLOT 12

I/OSLOT 13

I/OSLOT 14


1 2 3 4J30

+ _

TRANSZORB5KP16A

FUSE10A

POWERON

OFF654321 BAT (+)


J33

VITALCOM PORTS

NON-VITALCOM PORTS

COM3

COM4

COM3

COM4

COM2COM2

1J3

613

1425

1J3

85

69

15

J34

69

15

J39

69

15

J35

69

J37

113

1425

J29

Figure 3-6. N18005201 Cardfile with Power Supply and CPUs Installed for Revisions 03 and Higher





3.1. WAGO Connectors

A six-connection, removable WAGO power connector (J33) is mounted on the front of the upper motherboard (see Figure 3-1). This connector is used for the battery input and VCOR coil wiring. The pinout for the connector is as follows:

• Pin 1 B12 input

• Pin 2 N12 input

• Pin 3 VCOR positive terminal (1A) connection

• Pin 4 VCOR negative terminal (1C) connection

• Pin 5 Shutdown

• Pin 6 N12 input

Pins 2, 3, & 6 of J33 are connected internally to bring N12 to the VCOR relay coil as well as the negative return of the shutdown. Pin 5 of J33 is connected internally to the shutdown function of the Power Supply PCB. The shutdown function allows the user to shut down the system using an external power supply. Figure 3-7 shows the connector wiring.

1

1A1C

2

3

5

4

6

J16

POWER / VCOR CONNECTOR

BATTERY INPUT9.8V – 16.2V

+_

+ -

VCOR EXTERNAL RELAY

BAT(+)

BAT

BAT

(

(

-

-

)

)

VCOR (+)

VCOR (-)

1A1.

0185

.00

WAGO CONNECTOR

SHUTDOWN

PINS 2, 3 AND 6 ARECONNECTED INTERNALLY

TO MOTHERBOARD

BATTERY

BATTERY INPUT9.8V - 16.2V-

-

-

+

+

SHUTDOWN

VCOR RELAYCOIL4

3

2

1

5

6

Figure 3-7. Upper Motherboard WAGO Connector Wiring



Input Battery power (12V) from the WAGO connector is routed through the power switch and a 10 amp fuse to the power supply PCB. Surge protection across the battery is provided by a 5 watt, 16 volt, Trans Zorb (Vishay-General Semi part number 5KP16A-E3/4 5KP16A) mounted on screw terminals. The Trans Zorb assembly with ring terminals (STS USA part number N50770002) is field replaceable.

The lower motherboard is equipped with a 6-pin WAGO connector (J18) to provide auxiliary (external power supply) power to the MicroLok II HB2X in lieu of the MicroLok II II Power Supply PCB (see Figure 3-1 or Figure 3-2). Pins 1 and 2 are for common, pins 3 and 4 are for +5 volts, pin 5 is for -12 volts, and pin 6 is for +12 volts. Figure 3-8 shows the connector wiring. The connector is located at the lower right of the motherboard. Proceed as follows to install the external power cable:

1. Remove the two screws that secure the access panel to the cardfile (see Figure 3-9).

2. Route the external power cable through the opening.

3. Insert the connector of the external power supply cable into the 6-pin WAGO connector located on the lower right side of the motherboard.

1

2

3

5

4

6

J18

AUXILIARY POWER CONNECTOR

COMMON

COMMON

COMMON

COMMON

+12V

+12V

+5V

+5V

+5V

+5V

1A1.

0191

.00

4

3

2

1

WAGO CONNECTOR

-12V

-12V5

6

Figure 3-8. Lower Motherboard WAGO Connector Wiring



Figure 3-9. Access Panel When using auxiliary power, the Conditional Power Supply PCB (N4519107501) is used in place of the nominal Power Supply PCB (N16660301 or N16661203). The lower motherboard transfers the required voltage (+12V, +5V, & GND) to the upper motherboard Slot 15 connector to satisfy the voltage requirements of the Conditional Power Supply. In this configuration, J33 must be used in conjunction with the auxiliary power so that there is a connection to the VCOR and shutdown function. An external fuse and surge protection are recommended when using auxiliary power. The values of the protection will depend on the auxiliary power source.

3.2. Cardfile Address Select Jumpers (where applicable)

Revisions 03 and higher of the HB2X cardfile have six blue address select jumpers mounted inside the cardfile on the upper motherboard, just to the right of the upper 48 and 96 pin connectors (see Figure 3-2 or Figure 3-4 or Figure 3-6). The six blue address select jumpers on the motherboard are used to identify the printed circuit board to the central processing unit (CPU). The address select jumpers on the cable assembly are inactive when used on Revision 03 and higher of the HB2X cardfile. The address select jumpers in the cable assembly are not connected to pins ACE28, ACE30, and ACE32 on the PCB.

CAUTION



Use caution when inserting PCBs into the cardfile. Avoid contact with the motherboard address select jumpers. Otherwise, equipment damage may result.

NOTE

The following PCBs will not work in the HB2X cardfiles that have the blue address select jumpers mounted inside the cardfile (Revision 03 or higher):

● Code System Interface Board (CSIB) – N17061401.

● On Switch (OS) Track Circuit – N451810-6701.

● Cab Amplifier – N451910-6401, N451910-6402, and N451910-6901.

● Any third or more CPU.



Figure 3-10. Address Select Jumpers 3.3. Communications Ports

The MicroLok II HB2X cardfile contains three vital and/or three non-vital communications ports for external communications. An additional port is used for internal communications between the non-vital and vital CPU PCBs.

3.3.1. Communication Port 1

The upper motherboard contains RS-485 serial ports that are connected internally from com port 1 of the vital CPU board to com port 1 of the non-vital CPU.


Communication Port 2 incorporates two RS-485 serial ports that use standard DB-9 male connectors, DIP switches, and terminating resistors (see Figure 3-1). The connectors are labeled "J34, COM 2" and "J35, COM 2" on the motherboard. The ports are connected internally to com port 2 on the vital and non-vital CPU PCBs. The DIP switches switch the terminating resistors in or out. DIP switch SW1 connects terminating resistors to the non-vital com port 2. DIP switch SW2 connects terminating resistors to the vital com port 2. When the DIP switches are in the closed position, the terminating resistors are connected into the circuit. Terminating resistors are used to reduce reflections on a multi-drop line. Terminating resistors should be implemented if the cardfile is at the two furthest ends of the line.

NOTE

The four switches of SW1 or SW2 must be set to the same position, either all open or all closed.


The upper motherboard contains two RS-232 serial ports that use standard DB-25 connectors (J36 & J37). J36 is connected to com port 3 of the vital CPU. J37 is connected to com port 3 of the non-vital CPU.


The upper motherboard contains two RS-232 serial ports (J38 & J39) using standard DB-9 connectors. These connectors are connected internally to the com Port 4 of the CPU boards (vital and non-vital). The signals associated with the connector J38 are shared with the rear mounted DB-9 connector with sockets (J29) for the Serial to Ethernet Converter (SEC) board. DIP switch SW3 transfers the TXD, RXD, RTS, and DCD signals from the vital CPU board between the two connectors J29 and J38.



Switch SW3 ensures that only one connector of com port 4 is active at a given time. When all four switches of SW3 are set to the "FRONT" position, the signals are routed to connector J38. When all four switches of SW3 are set to the "REAR" position, the signals are routed to connector J29.

NOTE

All four switches of SW3 must be set to the same position, either all FRONT or all REAR.

3.3.5. Optional Ethernet PCB

An Ethernet PCB (STS USA part number N17006202) can be plugged onto the rear of the upper motherboard. The Ethernet port is on top of the cardfile when the Ethernet PCB is installed. The 12 volt power for the Ethernet PCB comes through connector J30 (on the rear of the cardfile) and the serial communications signals come through connector J29, "COM 4". See Section 4.5 for installation instructions.

Refer to SM-6800O, for configuration of the Ethernet PCB. Service Manual SM-6800O describes the Serial to Ethernet Converter (SEC). The SEC (STS USA part number N16920401) is different in physical appearance from the optional Ethernet PCB. However, the configuration procedures are the same for both units.

When using the optional Ethernet PCB, Switch SW3 must be set to the "REAR" position.

The signals and pin numbers for the com ports are shown in Table 3-1 through Table 3-3.

Table 3-1. Pinout of Serial Link Com Ports 3 PIN NUMBER SIGNAL COM 3

1 Not Connected 2 TXD (Transmit Data) 3 RXD (Receive Data) 4 RTS (Request to Send) 5 CTS (Clear to Send) 6 Not Connected 7 COMMON (N12) 8 DCD (Data Carrier Detect) 9 Not Connected 10 Not Connected 11 Not Connected 12 Not Connected 13 Not Connected 14 Not Connected 15 TXCLK (Transmit Clock) 16 Not Connected 17 RXCLK (Receive Clock) 18 -12V 19 Not Connected



20 Not Connected 21 +12V 22 Not Connected 23 Not Connected 24 Not Connected 25 Not Connected

Table 3-2. Pinout of Serial Link Com Port 4 (Front of Motherboard)

PIN NUMBER SIGNAL COM 4 FRONT 1 DCD (Data Carrier Detect) 2 RXD (Receive Data) 3 TXD (Transmit Data) 4 Not Connected 5 COMMON (N12) 6 Not Connected 7 RTS (Request to Send) 8 Not Connected 9 Not Connected

Table 3-3. Pinout of Serial Link Com Port 4 (Rear of Motherboard) PIN NUMBER SIGNAL COM 4 REAR

1 COMMON (N12) 2 Not Connected 3 RXD (Receive Data) 4 TXD (Transmit Data) 5 DCD (Data Carrier Detect) 6 Not Connected 7 Not Connected 8 RTS (Request to Send) 9 Not Connected

3.4. Optional Local Control Panel PCB

A Local Control Panel (LCP) PCB can be plugged into the front of the 96-pin cardfile (part number N18005301). The LCP is available with toggle switches or with pushbuttons installed in the uppermost row of controls. Figure 3-11 shows the front panel of the LCP PCB with toggle switches (part number N16926001). Figure 3-12 shows the front panel of the LCP with pushbuttons (part number N16926002). A relay driver PCB (part number N4518104801) is also required when using the LCP PCB. See Section 4.6 for the installation instructions.



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Figure 3-11. LCP PCB with Toggle Switches



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Figure 3-12. LCP PCB with Pushbuttons





4. INSTALLATION AND CONFIGURATION

The cardfile can be either wall or shelf mounted. One inch flanges are located along each side with four slotted mounting holes for wall mounting. One inch flanges are located along the bottom sides with five holes in each side for shelf mounting. Screws or bolts can be used to secure the cardfile to the wall or shelf.

WARNING

When replacing a power supply PCB, make certain of the board type. An old model PCB (N16660301) can be replaced with a new model PCB (N16661203), but not a new with an old (due to current rating).

A power supply PCB cannot be interchanged with a CPS only PCB.

4.1. Keying

The lower motherboard contains keying guides for the lower connectors to prevent accidental insertion of a printed circuit board into the wrong cardfile slot. Keying plugs are inserted by the customer (during installation) into the motherboard connector keying guide (see Figure 4-1). This guide mates with the keying strip mounted alongside the PCB's lower 96-Pin connector. The PCB's keying strip is equipped with twelve male keying tabs from which six tabs are removed at the factory in a specific pattern for the board part number. Each PCB type has a unique six tab arrangement to distinguish it from other boards.

Prior to installing a board, insert keying plugs (Part Number J709146-0473) into the corresponding cardfile motherboard keying guide (next to the connector). Plugs are installed in all cavities not corresponding to a keying tab location.

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.



96-pin (Female)Connector on

CardfileMotherboard

AdjacentKeying PlugConnector(Female)

KeyingPlugNo.

1

2

3

4

5

6

7

8

9

10

11

12

PrintedCircuitBoard

96-pin (Male)Connector on PCB

AdjacentKeying PlugConnector

(Male)

PCB KeyingTabs Set at

Factory

Insert Keying PlugJ709146-0473

n n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n nn n n

n n nn n nn n n

n n n

Figure 4-1. Keying Plug Installation

4.2. Cable Connection

When connecting a cable to a MicroLok II HB2X, make sure that the notches on the cable connector line up with the tabs on the cardfile connector. The address jumpers may be upside down due to the construction of the cable. See Figure 4-2 for the connector orientation. The connector screws must be tightened to secure the cable connector to the cardfile.

NOTE

The cables must be secured six to twelve inches from the cardfile connector.



Figure 4-2. Cable Connection

4.3. Cardfile Address Select Jumpers (where applicable)

For HB2X cardfile Revisions 03 and higher, the address select jumpers for each PCB are located to the right of the PCB's slot on the upper motherboard in the cardfile. Set the jumpers as defined in the .mll file produced from the compiled application. The address select jumpers on the cable assembly need no modification and can be set to any position. Their settings are not functional. 4.4. Cardfile Instruction and Caution Labels (where applicable)

HB2X cardfiles Revision 03 and higher have an instruction label and a caution label affixed to the top of the cardfile. An instruction label (see Figure 4-3 or Figure 4-4) is located on the top left side of the rear cover (see Figure 4-6). A caution label (see Figure 4-5) is located on the top of the cardfile (see Figure 4-6).



SET THE BOARD ADDRESS SELECT USING THE 6 BLUE JUMPERS JUST TO THE RIGHT OF THE 48 WAY CONNECTOR INSIDE THE CARD FILE. THE 6 ADDRESS SELECT JUMPERS IN THE CABLE ASSEMBLY ARE NOT USED - PINS ACE28, ACE30 AND ACE32 IN THE CABLE ASSEMBLY DO NOT CONNECT TO THE 48 WAY CONNECTOR INSIDE THE CARD FILE.

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0

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EXAMPLE OF JUMPER INSIDE THE CARD FILE

Figure 4-3. Instruction label for HB2X (N18005201) 48-way connectors

SET THE BOARD ADDRESS SELECT USING THE 6 BLUE JUMPERS JUST TO THE RIGHT OF THE 48 OR 96 WAY CONNECTORS INSIDE THE CARD FILE. THE 6 ADDRESS SELECT JUMPERS IN THE CABLE ASSEMBLY ARE NOT USED - PINS ACE28, ACE30 AND ACE32 OR ABC30, ABC31 AND ABC32 IN THE CABLE ASSEMBLY DO NOT CONNECT TO THE 48 OR 96 WAY CONNECTORS INSIDE THE CARD FILE.

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0

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EXAMPLE OF JUMPER INSIDE THE CARD FILE

Figure 4-4. Instruction label for HB2X (N18005301)

48-Way and 96-way connectors

PLEASE USE CAUTION WHEN INSERTING PCBS INTO THE CARDFILE TO AVOID CONTACT WITH THE MOTHERBOARD ADDRESS SELECT JUMPERS.

CAUTION

Figure 4-5. Caution Label (same for all 3 cardfiles)



Figure 4-6. Label Locations



4.5. Installation of optional Ethernet PCB

Proceed as follows to install the Ethernet PCB (STS USA part number N17006202) on the rear of the cardfile motherboard:

1. Remove the HB2X cardfile from the wall or shelf.

2. Remove the three screws that are located on each side of the cardfile toward the back of the cardfile (see Figure 4-7).

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REAR COVERRETAINING SCREWS



COVER PLATE

Figure 4-7. Location of Rear Cover Retaining Screws 3. Remove the five screws from the cardfile that are located at the top of the

motherboard.

4. Remove the rear cover from the cardfile.



5. Remove the nut that secures the cover plate from the inside of the back cover.

6. Slide the cover plate so that the large portion of the hole in the cover plate is over the head of the mounting screw, and lift the cover plate off of the rear cover.

7. Remove the four screws and washers from the mounting standoffs on the motherboard.

8. Line up the connectors on the Ethernet PCB with the connectors on the back of the motherboard (see Figure 4-8). Make sure the four pins of the power connector engage with the sockets on the motherboard. Make sure the 9-pin D connectors line up. Press the Ethernet PCB down onto the mounting standoffs. Make sure that PCB is positioned completely onto the standoffs and that the connectors are secure.

Figure 4-8. Ethernet PCB Location



9. Install the four screws and washers through the Ethernet PCB into the standoffs.

10. Place the back cover on the cardfile. The tabs on the top of the rear cover must be behind the motherboard.

11. Install the six screws into the sides of the cardfile and rear cover that were removed in Step 2.

12. Install the five screws at the top of the motherboard that were removed in Step 3.

13. Set Switch SW3 to the REAR position.

14. Installation of the Ethernet PCB is complete.

15. Proceed to SM6800O to configure the Ethernet PCB.

4.6. Installation of optional Local Control panel PCB

Figure 4-9 shows the LCP PCB with pushbuttons installed in the HB2X cardfile.

Proceed as follows to install the LCP PCB (part number N16926001 or N16926002) on the front of 96-pin cardfile (N18005301):

1. Remove power from the HB2X cardfile.

2. Remove any existing PCBs that are installed in slots 1 through 5.

3. Line up the connectors on the Relay Driver PCB with the connectors on the back of the LCP PCB.

4. Press the Relay Driver PCB into the LCP PCB. Make sure that the PCBs are securely connected.

5. Align the Relay Driver PCB's edges with the cardfile slot's channels.

6. Slide the LCP and Relay Driver PCB assembly into the cardfile channels and into the motherboard connectors. Make sure that the PCB assembly is securely connected to the motherboard.

7. Tighten the four screws on the front of the LCB PCB.

8. Apply power to the HB2X cardfile.

9. Installation of the LCP PCB is complete.



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I/OSLOT 1

I/OSLOT 2

I/OSLOT 3

I/OSLOT 4

I/OSLOT 5

I/OSLOT 6

I/OSLOT 7

I/OSLOT 8

I/OSLOT 9

I/OSLOT 10

I/OSLOT 11

I/OSLOT 12

I/OSLOT 13

I/OSLOT 14


1 2 3 4J30

+ _

TRANSZORB5KP16A

FUSE10A

POWERON

OFF654321 BAT (+)


J33

VITALCOM PORTS

NON-VITALCOM PORTS

COM3

COM4

COM3

COM4

COM2COM2

1J3

613

1425

1J3

85

69

15

J34

69

15

J39

69

15

J35

69

J37

113

1425

J29

GND +5V +12V

GND +5V +12V

Figure 4-9. N18005201 Cardfile with LCP Installed for Revisions 02 and Lower





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J18


I/OSLOT 1

I/OSLOT 2

I/OSLOT 3

I/OSLOT 4

I/OSLOT 5

I/OSLOT 6

I/OSLOT 7

I/OSLOT 8

I/OSLOT 9

I/OSLOT 10

I/OSLOT 11

I/OSLOT 12

I/OSLOT 13

I/OSLOT 14


1 2 3 4J30

+ _

TRANSZORB5KP16A

FUSE10A

POWERON

OFF654321 BAT (+)


J33

VITALCOM PORTS

NON-VITALCOM PORTS

COM3

COM4

COM3

COM4

COM2COM2

1J3

613

1425

1J3

85

69

15

J34

69

15

J39

69

15

J35

69

J37

113

1425

J29

GND +5V +12V

GND +5V +12V

Figure 4-10. N18005201 Cardfile with LCP Installed for Revisions 03 and Higher





4.7. Noise Protection

Relay coil snubs are intended to dissipate large electromagnetic surges from the coil inductance and to prevent these surges from interfering with normal operation of the MicroLok system. It is recommended that all relays being driven by MicroLok outputs be snubbed to prevent unwanted monitor errors. This is particularly true where the coil load to the MicroLok relay driver is being broken by a series contact.

Relay snubs can also be installed on other relays that are not directly controlled by MicroLok outputs, but may be contributing to possible noise due to their close proximity to the MicroLok wiring.

STS USA recommends the use of TranZorbs (J792736-0002) for relay snubbing. They will have minimal effect on relay timing.

Resistors are also suitable relay snubs. When using a resistor, the loading of the MicroLok output will have an effect on timing (relay drop away) and must be considered.

Diodes can also be used as snubs but:

• They will definitely increase relay drop time.

• They may cause contact burning in some circuits.





5. RAIL TEAM AND TECHNICAL SUPPORT

The Rapid Action Information Link Team (RAIL Team) is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product. Contact the RAIL Team in the United States at 1-800-652-7276 or by e-mail at [email protected].



End of Manual

Documents

Microlok II Full Box Cardfile - Hitachi Rail · 2019. 3. 25. · The MicroLok II HB2X cardfile has twenty slots (fourteen configurable) and can be wall or shelf mounted. Two PCB motherboards