6300 e

Service Manual 6300E
645 Russell Street

Batesburg, SC 29006
GENISYS
HARDWARE & MAINTENANCE
TRAINING MANUAL
January, 1998
1998, Union Switch & Signal Inc.
Printed in the U.S.A.
An ANSALDO Affiliated Company
Table of Contents
Contents
GENISYS Hardware Descriptions
General System Limits.................................................................................................. 1-1
Card File Specifications................................................................................................ 1-2
GENISYS PC Boards................................................................................................. 1-3
9.5 to 35 Volt DC Power Supply Limits....................................................................... 1-3
Controller Board ........................................................................................................... 1-4
Controller Board Switch Selectable Options ................................................................ 1-5
Output Board Constant Delivery ............................................................................. 1-12
Input Board High Threshold.................................................................................... 1-15
Interface Wiring Specification and Diagrams
Constant Delivery Relay-Output PCBs ........................................................................ 2-1
Optical-Input PCBs ...................................................................................................... 2-2
Controller PCB ............................................................................................................. 2-3
DC/DC Power Supply Converter PCB ......................................................................... 2-4
Maintenance and Troubleshooting
General Information...................................................................................................... 3-1
Utilization and Application............................................................................... 3-1
Introduction ...................................................................................................... 3-1
Equipment......................................................................................................... 3-2
I.
Working and Non-Working Systems................................................................ 3-4
II.
Power Supply Converter Board ........................................................................ 3-7
III.
System Reset Checkout Procedure ................................................................... 3-9
IV.
Local Interface Problems ................................................................................ 3-12
V.
Serial Interface Problems................................................................................ 3-17
Tables and Figures

Figure 1-1
Cardfile ................................................................................................. 1-1
Table 1-1
Controller Board LED Indicators.......................................................... 1-5
Table 1-2
Controller Board Slave Baud Rate (SW1) ............................................ 1-6
Table 1-3
Controller Board Control Delivery Time (SW2) .................................. 1-6
Table 1-4
Controller Board Carrier Mode Switch (SW3) ..................................... 1-7
SM6300E (1/98)
Page i
Table of Contents
Table 1-5
Controller Board Slave Address Switch (SW5).................................... 1-7
Table 1-6
Controller Board Key On/Off Delay Switch (SW6)............................. 1-8
Table 1-7
Controller Board Serial Port Test and Data Byte Format (SW7).......... 1-9
Table 1-8
Controller Board System Reset (SW8) ................................................. 1-9
Table 1-9
Controller Board Communication Jumpers .......................................... 1-9
Figure 1-2
Controller Board ................................................................................. 1-10
Figure 1-3
Controller Board Switch Options........................................................ 1-11
Table 1-10
Constant Delivery Output Board LED Indicators............................... 1-13
Figure 1-4
Output Board -Constant Delivery - with LEDs (N451441-7101) ...... 1-14
Table 1-11
High Threshold Input Board Input Limits .......................................... 1-15
Table 1-12
High Threshold Input Board LED Indicators ..................................... 1-16
Figure 1-5
High Threshold Input Board (N451441-7202) ................................... 1-17
Figure 2-1
Typical DC Input Power Circuit........................................................... 2-4
Figure 2-2
Typical Control Delivery or Constant Delivery PCB Output

Circuit Type I........................................................................................ 2-5
Figure 2-3
Typical Control Delivery or Constant Delivery PCB Output

Circuit - Type II .................................................................................... 2-5
Figure 2-4
Typical Input PCB Circuit - Type I ...................................................... 2-6
Figure 2-5
Typical Input PCB Circuit - Type II..................................................... 2-6
Figure 2-6
Typical Master Port to Modem Slave Port to Master Port

Communication Circuit - EIA............................................................... 2-7
Figure 2-7
Typical Master Port to Modem and Multiple Slave Port

Communication Circuit - EIA............................................................... 2-7
Figure 2-8
Typical Slave Port to Modem Communication Circuit - TTL .............. 2-7
Figure 2-9
Typical Master Port to Modem Communication Circuit - TTL............ 2-7
Figure 2-10
Typical Slave Port to Modem Communication - EIA........................... 2-8
Figure 2-11
Typical Master Port to Modem Communication - EIA......................... 2-8
Table 3-1
Basic Tools for GENISYS Installation ................................................. 3-3
Figure 3-1
GENISYS LEDs (Representative Configuration)................................. 3-4
Figure 3-2
Half-Duplex Carrier Control Mode (SW3)......................................... 3-19
Figure 3-3
Full-Duplex Carrier Control Mode .................................................... 3-19
Figure 3-4
Carrier-Duplex Mode.......................................................................... 3-19
Page ii
SM6300E(1/98)
GENISYS
HARDWARE
DESCRIPTIONS
SM6300E(1/98)

General System Limits
INPUT/OUTPUT LIMITS
There is a limit of 256 output or input bits per card file.
A card file can have all output boards, all input boards or a combination of output and input
boards.
LOGIC LIMITS
A GENISYS unit can emulate approximately 1450 Relays, with each relay having an
unlimited number of contacts.
COMMUNICATION LIMITS
There are two communication ports available to pass serial data between units.
Figure 1-1
SM6300E (1/98)
Page 1-1

Card File Specifications
US&S Part Number N085718-1009
19-inch rack mounting.
14-inches vertical rack space.
10.5 inches rack depth.
Removable front cover with fasteners.
Card file has 18 PCB positions.
Position J1 power supply only.
Position J2 Controller Only.
Position J3 to J18 output or input (user defined).
Each card file position has two (2) connection points.
"A" Connector
A 44-Pin double keyed connector.
Handles all external connections.
This connector is externally mounted to the card file with mechanical latches.
"B" Connector
A 44-pin single keyed connector.
Handles all internal connections.
This connector is mounted on an internal mother board.
Page 1-2
SM6300E (1/98)

GENISYS PC Boards: 9.5 to 35 Volt DC Power Supply Limits
Input Limits
9.5 to 35 Volt DC with less than 5% ripple.
Maximum input power is 52 watts.
Nominal input power is 15 watts.
Output Limits
+5 Volts +/- 2% at 3 Amps
+12 Volts +/- 2% at 1 Amp
-12 Volts +/- 2% at 1 Amp
Ripple 10 millivolts.
Noise < 75 millivolts.
Input To Output Isolation

500 Volts
Efficiency
75%
Operating Temperature Range

-40 to +70C
Indicators
LED 1 + 5 Volts On.
LED 2 + 12 Volts On.
LED 3 - 12 Volts On.
LED 4 input power On.
SM6300E (1/98)
Page 1-3

GENISYS PC Boards: Controller Board
Input Requirements
Input current requirement without external load.
+5 Volts at less than 800 milliamperes.
+12 Volts at less than 100 milliamperes.
-12 Volts at less than 100 milliamperes.

-40 to +70c
Communication Options
Two serial ports one master and one slave
Each port supports TTL or EIA RS-423/232
Logic Options
IC24 can be used to house a pre-programmed EPROM.
That will emulate a field code unit but will not do non-vital logic;
or
IC24 to IC28 can be used to house user programmed application EPROMS that can emulate a
code system or emulate non-vital logic or do both code systems and non-vital logic functions.
Each EPROM is the 2764 type and has 8K bytes of memory.
The part number for a blank EPROM is J715029-0409.
This device has been qualified to operate at 40C.
Off-the-shelf EPROMS are not acceptable for in service use.
Page 1-4
SM6300E (1/98)

GENISYS PC Boards: Controller Board Switch Selectable Options
Indicators
(See Figure 1-2.)
LED No.
Name
Function
MTXD
Master Port Transmit Data
MRTS
Master Port Request to Send
MRXD
Master Port Receive Data
MDCD
Master Port Data Carrier Detect
STXD
Slave Port Transmit Data
SRTS
Slave Port Request to Send
SRXD
Slave Port Receive Data
SDCD
Slave Port Data Carrier Detect
WATCHDOG
Microprocessor Monitor
10
DELIVER
Data Output to Output Boards

Table 1-1
SM6300E (1/98)
Page 1-5

GENISYS PC Boards: Controller Board (Continued)
Hardware Switches And Jumpers
Slave Baud Rate **
(See Figure 1-3.)
SW 1 Position
Function
Slave Port Baud Rate of 150
Not Used
Table 1-2
Control Delivery Time **

(See Figure 1-3.)
SW 2 Position
Function
Delivery Time of 10 mSEC.
Delivery Time of 1 SEC.

Table 1-3
** Indicates function can be set in application EPROM.
Page 1-6
SM6300E (1/98)

Carrier Mode Switch
SW 3 Position
Function
Operate
Master Port Carrier goes On-Off
Carrier
Master Port Carrier always On

Table 1-4
Slave Address Switch **

(See Figure 1-3.)
SW 5 Position
Function - Open = 1
Slave Address Binary Weight 1

Table 1-5
** Indicates function can be set in application EPROM.
SM6300E (1/98)
Page 1-7

Key On/Off Delay Switch
(See Figure 1-3.)
SW 6 Position
Function - Open = 1
Key-On Delay - Bit Time Weight 4
Key-Off Delay - Bit Time Weight 4

Table 1-6
Page 1-8
SM6300E (1/98)

Serial Port Test And Data Byte Format
(See Figure 1-3.)
SW 7 Position
Function - Open = 1
Selects Slave Port for Test
Selects Master Port for Test
Selects 50% Duty Cycle Test
Selects Default Space Test
Not Used
Select Even/Odd Parity
Select Parity Enabled
Selects 1 or 2 Stop Bits

Table 1-7
System Reset
(See Figure 1-2.)
SW 8 Position
Function
In
Unit Reset
Table 1-8
Communication Jumpers
Jumper
Position
Function
J1 J5
AB
Slave Port = RS-423/RS232
J1 J5
BC
Slave Port = TTL
J6 J10
AB
Master Port = RS-423/RS232
J6 J10
BC
Master Port = TTL

Table 1-9
SM6300E (1/98)
Page 1-9
Figure 1-2 - Controller Board
Page 1-10
SM6300E (1/98)
Figure 1-3
SM6300E (1/98)
Page 1-11

Constant Delivery Output Board
Output Type
Sixteen (16) PCB mounted Mercury Wetted Reed Relays
Contact Output Limits

Maximum Resistive Switching Load

2 Amps or
500 Volts or
100 Volt Amps
Life Expectancy
20 billion operations.

1000 Volts RMS

-38 to +70c
Page 1-12
SM6300E (1/98)

Indicators
LED No.
Function
LED No.
Function
3-1
Output No. 0
5-9
Output No. 8
3-2
Output No. 1
5-10
Output No. 9
3-3
Output No. 2
5-11
Output No. 10
3-4
Output No. 3
5-12
Output No. 11
4-5
Output No. 4
6-13
Output No. 12
4-6
Output No. 5
6-14
Output No. 13
4-7
Output No. 6
6-15
Output No. 14
4-8
Output No. 7
6-16
Output No. 15
Delivery
Address
Table 1-10
Input Requirements
Normal Load
+12 volts at less than 2 milliamperes.
Normal Load Plus LEDs On
Normal Load Plus LEDs On and

Relay Delivery Circuit Active
SM6300E (1/98)
Page 1-13
Figure 1-4
Page 1-14
SM6300E (1/98)

High Threshold Input Board
Input Type
Sixteen (16) PCB Mounted Optical Isolators
Input Limits
8.0 To 32 Volts DC
Guaranteed Turn-On
5.7 To 24 Volts AC RMS
Guaranteed Turn-On
5.0 Volts DC
Minimum Turn-On
3.8 Volts AC RMS
Minimum Turn-On
Less Than 4.5 Volts DC
Guaranteed Turn-Off
Less Than 3.4 Volts AC RMS
Guaranteed Turn-Off
Table 1-11
Input Impedance
1800 OHMS
Input Requirements

2500 Volts RMS

-40 to +70C
SM6300E (1/98)
Page 1-15

Indicators
LED No.
Function
LED No.
Function
3-1
Input No. 0
5-9
Input No. 8
3-2
Input No. 1
5-10
Input No. 9
3-3
Input No. 2
5-11
Input No. 10
3-4
Input No. 3
5-12
Input No. 11
4-5
Input No. 4
6-13
Input No. 12
4-6
Input No. 5
6-14
Input No. 13
4-7
Input No. 6
6-15
Input No. 14
4-8
Input No. 7
6-16
Input No. 15
Address Low Byte
Address High Byte
Table 1-12
Page 1-16
SM6300E (1/98)
Figure 1-5
SM6300E (1/98)
Page 1-17
INTERFACE WIRING SPECIFICATION

AND DIAGRAMS
SM6300E (1/98)
Interface Wiring Specifications

and Diagrams
Constant Delivery Relay-Output PCBs
Applicable PCBs:
Constant Delivery: N451441-7101
Cardfile Location(s):
J3 to J18 as required by the application
Keying Plugs:
Between positions 6/7 and 14/15
Label:
OUTPUT
Circuits:
Typical Constant Delivery PCB Output Circuit Type I:

Figure 2-2.
All active circuits wired
Typical Constant Delivery PCB Output Circuit Type II:

Figure 2-3.
SM6300E (1/98)
All active front circuits wired
Common jumper
Single cable
Page 2-1

and Diagrams
Optical-Input PCBs
Applicable PCBs:
Optical-Input (High Threshold): N451441-7202
J3 to J18 as required by the application
Keying Plugs:
Label:
INPUT
Circuits:
Typical Input Circuit Type I:

Figure 2-4.
All active circuits wired
Typical Input Circuit Type II:

Figure 2-5.
Page 2-2
Plus input wired
Negative input jumpered
Single cable
SM6300E (1/98)

and Diagrams
Controller PCB
Applicable PCB:
Controller: N451441-5602
J2 (always)
Keying Plugs:
Label:
COMMUNICATION
Circuits:
Typical Master Port to Modem and Slave Port to Master Port

Communication Circuit EIA
Figure 2-6.
Typical Master Port to Modem and Multiple Slave Port
Communication Circuit EIA
Figure 2-7.
Typical Slave Port to Modem Communication Circuit TTL
Figure 2-8.
Typical Master Port to Modem Communication Circuit TTL
Figure 2-9.
Typical Slave Port to Modem Communication Circuit EIA
Figure 2-10.
Typical Master Port to Modem Communication Circuit EIA
Figure 2-11.
SM6300E (1/98)
Page 2-3

and Diagrams
DC/DC Power Supply Converter PCB
Applicable PCB:
DC/DC Power Supply Converter PCB: N451441-7601
J1 (always)
Keying Plugs:
Label:
POWER
Circuit:
Typical DC Input Power Circuit

Figure 2-1.
Figure 2-1
Page 2-4
SM6300E (1/98)

and Diagrams
Figure 2-2
Figure 2-3
(See Circuits on Figure 1-4.)
SM6300E (1/98)
Page 2-5

and Diagrams
Figure 2-4. Typical Input PCB Circuit - Type I - Figure 2-5. Typical Input PCB Circuit - Type II
(See Circuits on Figure 1-18.)
Page 2-6
SM6300E (1/98)

and Diagrams
SM6300E (1/98)
Page 2-7

and Diagrams
Page 2-8
SM6300E (1/98)
MAINTENANCE AND TROUBLESHOOTING
SM6300E (1/98)

General Information
A. Utilization and Application
In order to use this Guide, you should have a basic knowledge of general electronic
equipment and the product GENISYS. You should be able to perform resistance and voltage
readings with a multimeter or oscilloscope, be familiar with the various boards (Power
Supply, Controller & I/O) that comprise a GENISYS Cardfile and have a basic understanding
of each boards function.
The Field Service Guide was prepared to provide a systematic approach to identifying,
repairing and eliminating problems related to GENISYS installations. It was meant to
address those types of problems that occur most often and should not be regarded as a
complete definition of all possible problems and solutions. If a GENISYS problem is
encountered, please use the Guide in trying to eliminate common problems while installing,
maintaining and repairing these systems. If situations are encountered beyond this
documents scope, please record the problem symptoms and any steps that may have been
taken to attempt to correct it. Have as much necessary data regarding the specific installation
and its configuration readily available before contacting a US&S product specialist for
assistance.
B. Introduction
The best way to avoid problems when installing GENISYS units is to take time when first
designing a system to determine what effect the value of software and hardware switch
settings will have on the entire system operation. This Guide, Sections I V, deal with field
installation and should be used to help identify areas that are most likely to cause operational
problems. If consideration is given to these issues prior to actual field installation, many
problems can be prevented.
Before any attempt is made to get a GENISYS unit working, the application logic should be
compiled and simulated to remove the majority, if not all, of application logic errors. A
cardfile must have the correct boards installed to agree with application logic plus proper
voltage inputs to the power supply.
If serial links are defined in the application logic, a unit on the other end of the link should
be connected and operational. If the unit at the other end of a serial link is non-operational,
be sure the validation option is turned off on the unit where you are working, until all other
problems have been resolved or the link is eventually connected.
Insert the application PROM(s) in the correct socket(s) on the GENISYS controller board.
Make sure all boards are in the correct slots and firmly seated in the cardfile. Place physical
inputs in the positions you wish them to be to start your testing and turn on the GENISYS
power supply. If the correct outputs are displayed on the output boards, continue to test logic.
If any logic problems are found, correct them and continue testing.
SM6300E (1/98)
Page 3-1

If a GENISYS unit is functioning improperly, the problem may be the result of various
causes. There are numerous ways to approach troubleshooting a GENISYS system,
depending on the kind of problems experienced. For that reason, this guide has been divided
into categorized sections. Section I deals with proper operation of a working system. It
should be used to help narrow down the area of a system where you may be having trouble.
Section II is a guide on power supply problems. Section III is a guide for non-operational
systems in which a Controller Board is resetting. Once a system is at least partially
operational, Section IV can be used to eliminate Local I/O and interface problems. Serial
interface problems are handled in Section V.
WARNING:
Please remember to turn off power when installing or removing any board in a cardfile.
This is not always explicitly stated in different steps performed throughout this guide,
but it should always be done before handling boards. For Controller and/or I/O
Boards, it is only necessary to turn off the Power Supply Converter. If a Power Supply
Board is being removed or installed, input power to a Power Supply Converter should
be turned off or disconnected, if possible. Removing or inserting boards while power is
applied to them can cause damage to a board or a system.
C. Equipment
When attempting to locate and correct problems with a GENISYS installation, several basic
tools will be required. These items should be part of a standard field troubleshooting kit.
Items such as screwdrivers, pliers, extra wire, etc. should also be available. Some of these
may not be needed for locating and/or correcting problems with existing installations, but
each item is marked to define its importance for various service levels. Some items are
designated with more than one letter. They fall in between the categories and may or may not
be necessary, depending on the scope of the operation.
R for Required
Items needed to attempt installation, maintenance or repair operations
S for Suggested
should be taken if work other than simple board swapping is to be

performed.
O for Optional
will only be used for installation or major repair efforts.
Page 3-2
SM6300E (1/98)

Item
Used For
GENISYS Manual SM6300 series Reference
GENISYS location fact sheet
Reference
Spare boards
(min. of 1 of each type used)
Replacement parts
R/S
I/O configuration listing
Reference
R/S
Circuit plans for I/O
Reference
R/S
Isolated Oscilloscope
Checking noise levels
R/S
Multimeter
Accurate voltage readings and continuity

checks
Soldering iron & solder
Fixing broken connections
Crimp pin extraction tool
Removing connections
Crimp pins
Replacement parts
Crimp tools
Fixing connections
Clip leads
Miscellaneous measurements and

connections
Card mountable switch panel
Checking input boards
Card mountable LED panel
Checking output boards
GENISYS extender card
Checking controller board
Spare cardfile
Replacement parts
GENISYS development system
Changing application logic
Application logic program
Changing application logic
Datascope
Troubleshooting serial links

Table 2-1
SM6300E (1/98)
Page 3-3
I. Working and Non-Working Systems

To effectively troubleshoot a GENISYS system, you must first determine what kind of
problems the system is experiencing. To accomplish this, normal conditions of a correctly
operating system should be known, so check your system in the following prescribed order.
If a problem is encountered, correct it before continuing on.
A.
Working Systems Perform a visual inspection of a normally operating system,

which should appear as follows: See Figure 3-1, which shows a representation of all
GENISYS LEDs.
Step 1. Power Supply Board
a.
Switch is turned on
b.
All LEDs are on
Step 2. Controller Board LEDs on this board may show signs of functional
problems other than power.
a.
Page 3-4
LED 9 Watchdog Indicator

1)
When system is normal, LED should always be dark.
2)
If LED is flashing, system is going through reset.
SM6300E (1/98)

b.
c.
d.
LEDs 1 to 4 Master Serial Port

1)
If no MASTER port is defined in the application logic

interface section, there should be no connections to the
MASTER transmit and receive lines on the Controller Board
top edge connector. In this case, LEDs 1, 2 and 4 should be
dark; LED 3, when unconnected, is a floating input. It will
likely be on but could also be dark and not cause problems.
2)
If there is a MASTER port defined in the interface section of

the application logic, these LEDs will tell the serial
communications status. LEDs monitor status of the four main
communication lines. See details on serial communications in
Section V.
LEDs 5 to 8 Slave Serial Port

1)
If no slave port is defined in the application logic interface

section, there should be no connections to the SLAVE transmit
and receive lines on the Controller Board top edge connector.
In this case, LEDs 5, 6 and 8 should be dark; LED 7, when
unconnected, is a floating input. It will likely be on but could
also be dark and not cause problems.
2)
If a slave port is defined in the interface section of the

application logic, these LEDs will tell the serial
communications status. LEDs monitor status of the four main
communication lines. See details on serial communications in
Section V.
LED 10 Deliver Line

1)
LED 10 is normally dark when the system is stable and no

physical outputs are being delivered. If no location outputs are
defined, this LED will always be dark.
2)
When the executive delivers a change to output boards, LED

10 will be on for the duration of the deliver pulse. This time
will vary, depending on the selected control delivery time.
Step 3. Output Boards

a.
SM6300E (1/98)
Address LEDs * Two LEDs are on the Output Boards that indicate
a board is being addressed. They are dark normally, except when the
executive is delivering data to that particular board. These LEDs
should correspond with the deliver LED on the Controller Board. The
Address LED on the Output Board should come on shortly before the
Page 3-5

Deliver LED on the Controller as the executive sends data to the
board. The Deliver LED on the Output Board and the Deliver LED
on the Controller Board should come on at the same time. All three
LEDs should stay on for the duration of the control deliver pulse.
There should never be a case when LEDs on more than one Output
Board are lit at the same time.
b.
Output Status LEDs On the new version of the Constant Control

Delivery Board only, (US&S part number N451441-7101), there are
LEDs on the upper front edge of the board to indicate status of the
output bits. Normally they are all dark. In order to see the output
status, a push button on the card front should be pushed in. The LEDs
will display status of the outputs while the push button is held in. A
dark LED indicates a low (de-energized) output. A high (energized)
output will have the LED on.
Step 4. Input Boards
Page 3-6
a.
Address LEDs * Two LEDs are on the Input Boards that indicate
the board is being addressed. Access time to scan the inputs is too
quick for the LEDs to reflect the board addressing. These LEDs
normally appear to be dark at all times but a slight flicker may be
noticeable.
b.
Input Status LEDs On the new version of Standard Input Board

only, (US&S part number N451441-7201), LEDs on the upper front
edge of the board indicate the status of the input bits. A dark LED
indicates a low (de-energized) input. A high (energized) input will
have the LED on.
c.
Note* There is one case where address LEDs on an I/O board may be
on when the board is not being addressed. This will occur if 16 I/O
boards are defined in the system.
d.
The I/O board in the last slot (J18) will have its address, but not its
deliver LED on when no outputs are being delivered to Output
Boards. This is caused by no spare board addresses left in the system.
Some addresses must be present on the I/O bus at all times. When
active I/O is not being performed, the address of the last slot is left on
the bus.
SM6300E (1/98)

B.
Non-Working Systems The most common GENISYS problems can be resolved

through the Sections listed below:
Step 1. Check Power Supply for problems (refer to Maintenance and
Troubleshooting, Section II).
Step 2. Check Controller Board for reset problems (refer to Maintenance and
Troubleshooting, Section III).
Step 3. See Maintenance and Troubleshooting, Section IV for interface problems
if the system is not resetting and does not appear to be performing Local I/O.
Step 4. If serial lines do not appear operational, see Maintenance and
Troubleshooting, Section V for information to correct serial interface
problems.
II. Power Supply Converter Board

If there is a problem with a Power Supply Converter Board, several simple steps should be
followed to locate and correct the problem. These steps apply to all GENISYS Power
Supply Converter Boards. Test points, input pins and voltage levels may vary on different
supplies but the basic theory is the same. GENISYS Service Manual 6300B should be used
to determine correct test points and voltage specifications for the supply used.
A.
Power Supply Converter Checkout Procedure

Step 1. Check input voltage and connections
Information regarding correct input voltage specifications and card edge
connections can be found in GENISYS manuals. Make sure the input voltage
is within specifications for the Power Supply Converter that you are using.
Check also that input power is entering the correct pins on edge connector. If
any problems are encountered with inputs to the Power Supply Converter
Board, they must be corrected before any further action is taken.
Step 2. Check output(s) from converter module(s)
If the input voltage is within specifications and all connections are correct on
the card edge, check output(s) from converter module(s) on the Power Supply
Board. If any of the power converter modules are not producing the correct
output voltage, get a known good Power Supply Board and try it. If the
problem does not reoccur, the original Power Supply Board is bad and should
be returned to US&S for repair.
SM6300E (1/98)
Page 3-7

Step 3. Check Power Supply Board seating in cardfile
If a known good board does not work, there must be some other problem with
the system. Make sure the Power Supply Board is seated correctly in the
cardfile and making good connections to the cardfile backplane.
Step 4. Check cardfile motherboard
Check the motherboard in the cardfile to make sure the traces that carry power
to the other boards are intact and not shorted. Check to make sure that all
other boards are correctly seated in the cardfile.
Step 5. Isolate problem
If problem is still present, remove all other boards in the cardfile and try again.
If the problem clears up at this point, it is most likely not the Power Supply
Board, but the cardfile, one of the other boards or an external connection to the
field.
Step 6. Localize problem
Remove all edge connectors except the one supplying input voltage to the
Power Supply Board. Plug in the boards that were removed during Step 5,
one at a time until the problem returns. At this time, do not connect the boards
to the external world. If the problem returns, try swapping the board that
causes the problem with a known good board. If this does not correct problem
it may be caused by a bad cardfile. Swap cardfile for a known good one and
try again.
Step 7. Reinstall connectors and recheck
If all boards are plugged in and the problem does not return, start connecting
them to the external field, one at a time. If problem returns, check the
connector that caused the problem to return. Verify cable connections and
make certain that grounds are satisfactory. If all connections check out
proper, it may still be a board that a connector is attached to. Swap it with a
known good board.
Step 8. Recheck source of voltage supply to connector
If problem persists, check the source of the voltage supply to the connector
(for I/O cards only). If it is a separate supply from the input voltage to the
Power Converter Card, make sure that there are not crossed wires or
grounding problems with both supplies. If the system is reconnected and the
problem does not return, it may be the result of a poorly seated card.
Page 3-8
SM6300E (1/98)

Step 9. Check input voltage with oscilloscope for noise
If the problem appears to be intermittent, check input voltage with an
oscilloscope capable of detecting noise or glitches on input voltage. A voltage
meter will not be able to detect noise on the line since it gives only a DC or
RMS level. If the input voltage appears to be a good, clean signal, re-check
the entire system. If all else fails, try swapping out the cardfile for a known
good one. If this does not resolve the problem, there MUST be a problem with
the input voltage. CHECK IT AGAIN. Make sure there is sufficient current
available, that input voltage is steady and that it does not drop significantly
when a load is placed upon it.
III. System Reset Checkout Procedure
A. Controller Board is Resetting
Step 1. Check Power Supply Module Outputs
If any LEDs on the power supply are dark or the Watchdog LED is flashing,
check Power Supply Module outputs to make certain that proper voltages are
being produced. See Section II for power supply problems.
Step 2. Check Controller Board Components
If power supply outputs appear to be correct and Watchdog LED is still
flashing, check all components on Controller Board for correct installation,
which includes executive, application PROMs, and switches.
Verify checksums on executive and application PROMs are correct. Check
executive revision numbers against the revision history for any applicable
notes.
Make sure PROMs are installed in correct sockets and have not been inserted
backwards: verify that pin 1 markers on the chips are in the correct position
as identified on the silkscreen.
Step 3. Check Power Supply and Controller Cards
Check both Power Supply and Controller Cards for proper seating in their
correct slots in cardfile. If in doubt, try reseating them. Verify that they have
been correctly installed and are fully inserted into the connector on the cardfile
backplane.
Step 4. Swap Controller Cards
If everything appears correct, try swapping the Controller Card with a known
good board. Remove an application PROM from an old board and place it
SM6300E (1/98)
Page 3-9

correctly in the board you plan to try, plus also check executive PROM of new
board. If it is not installed, take the executive PROM out of old board and
place it correctly in board you want to use. If system is now running,
Controller Board is probably bad and should be returned to US&S for repair.
Step 5. Remove I/O Boards, Connectors and Cables
If system is still resetting, remove all I/O boards plus connectors and
disconnect any cables on the back of the Controller Board. The only external
connection to cardfile should be the ground connections and the input to the
Power Supply Converter Board. If system stops resetting, go to Step 11.
Step 6. Check Controller Card power inputs
If Watchdog is still flashing, check power inputs at test points on the
Controller Card. Controller Board voltages should read as follows:
Between test points
TP2 (ov) & TP1
TP2 (ov) & TP3
TP2 (ov) & TP4

VDC
VDC
+5
+/-
0.10
-12
+/-
0.10
+12
+/-
0.10
If voltage readings on Controller Card are within these limits, continue to

Step 9.
Step 7. Double check power supply outputs
If any voltages are incorrect, double check power supply outputs as in Step 1.
If power supply outputs are correct, remove Controller Card and check
voltages present at the connector on the cardfile motherboard. This is
referenced as the B connector and voltages should read as follows:
Between points
B22 (ov) & B17
B22 (ov) & B 9
B22 (ov) & B19

VDC
VDC
+5
+/-
0.10
-12
+/-
0.10
+12
+/-
0.10
If voltages are not correct at connector, replace Power Supply Converter Board
with a known good board. Even through voltage outputs may be correct at test
points on Power Supply Board, it is still possible that voltages never reach the
connector.
Page 3-10
SM6300E (1/98)

Step 8. Recheck Controller Board voltages
Recheck voltage presence at Controller Board bottom connector as in Step 7.
If voltage readings are still incorrect, try swapping out the cardfile.
Step 9. Check power supply with oscilloscope for noise
Monitor +5 volt output of the power supply with an oscilloscope. The signal
should be a steady +5 volts with no dips or spikes. If this signal is not clean,
see power supply troubleshooting portion in Section II. Check inputs to power
supply and make sure that input voltage is within spec for the module being
used and that the ground is connected. Be certain also that you have sufficient
current flow.
Step 10. Swap multiple components
If you reach this point and the system is still resetting, get a known good
cardfile, power supply, power supply cable, and Controller Board. The only
connections that you should have at this time will be the input to the Power
Supply Board. Do not install any I/O boards at this time. Double check
power input, cable and grounds. If this system also resets, there must be a
problem with the input to the Power Supply Converter Board. Refer to
Section II and repeat procedures.
Step 11. Localize problem
If you have removed all I/O cards and the Watchdog LED quits flashing, you
may have a bad cardfile, I/O Board or serial connection. At this time, do not
connect the boards to the external world. Remove all edge connectors except
the one supplying input voltage to the Power Supply Board. Plug in the I/O
Boards one at a time until the problem returns. If Watchdog starts resetting
again, try swapping the board that caused the problem with a known good
board.
If this fails to correct problem, it may be caused by a bad motherboard in the
cardfile. Swap cardfile with a known good one and try again.
Step 12. Isolate problem
If all I/O boards are plugged in and system does not reset, start connecting
them to the field, one at a time. If a reset problem returns, check connector
that caused it to appear. Do a continuity check on the cable to make sure that
there are good grounds and all connections are correct. If the connections are
correct, it may still be the board attached to the connector. Swap it with a
known good board.
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Step 13. Recheck source of voltage supply to connector
If the problem persists, check source of voltage supply to the connector (for
I/O cards only). If it is a separate supply from the input voltage to the Power
Converter Card, be sure there are no crossed wires or grounding problems with
both supplies. If connector in question is the serial interface cable on the
Controller Card, make sure that signal common is connected between
Controller and its serial partner or modem.
If the system is reconnected and the problem does not return, it may have been
due to a poorly seated card.
IV. Local Interface Problems
If the controller board is not resetting and does not appear to be performing LOCAL I/O, the
problem is most likely due to either lack of communication with some I/O point or errors in
application logic. To determine if there is an application problem, we first attempt to
eliminate all other causes, assuming that the application logic has been properly compiled,
simulated, and debugged. If this assumption is invalid, please check the application program
for logic errors before continuing.
A. Local I/O Problems
Step 1. Check Controller Card LEDs for serial line status
At this point, the system should have all boards installed and connected. The
power supply converter board should have input power applied and the switch
should be turned on. If there are serial ports defined, check appropriate LEDs on
the Controller Card to determine status of the serial lines. If normal
communications do not seem to be established, skip to Section V for information
on troubleshooting serial lines. Proper functioning of these LEDs does not assure
that the serial link is functioning correctly, but they are normally good indicators.
There are several other possible problem areas to check out before dealing with the
serial line in more detail.
Check top two bits (rockers 1 & 2) on switch SW7 on GENISYS Controller
Board. They must be in the CLOSED position for system to operate. If either of
the rockers are open, the executive will go into a modem test mode and will not
perform logic or I/O.
Step 2. Check physical I/O
Check the physical I/O. If controls, even though they may be wrong, can be
delivered to each output board, you know that all boards are being accessed
through a backplane. Likewise, try changing indications to make sure that there is
some result. This verifies that all input boards are installed and recognized by the
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SM6300E (1/98)

executive. If any I/O boards can not be accessed, go to Step 3 for information on
troubleshooting I/O Boards.
If all I/O boards can be accessed and the system is still not functioning properly,
take a closer look at the serial link, if one is present. Continue to Section V if
there is a serial link, even though the LEDs indicate that there is communication
on the serial line.
If there is no serial line and all physical I/O boards can be accessed, there may still
be a bad board in the system, but it is more likely that the problems being
encountered are related either to external field wiring or application logic. Skip to
Step 11 for details to resolve these problems.
Step 3. Verify I/O construction
If a serial link appears to be functioning normally or is not defined in the
application program, check physical I/O. Be sure that I/O Boards installed in the
cardfile are the same as those defined in the application logic. Remember, output
boards must be installed in the cardfile in a group to the left of the inputs. There
may be blank slots left anywhere in the cardfile, but they should only have spare
bits defined on them in the application logic. If a blank slot is to be left in the
cardfile anywhere other than after all defined boards, there must still be a board
defined for that slot in the application logic. Inputs must start in the correct
position in the cardfile in order for a system to work.
Once you have verified that I/O construction is correct, continue with Step 4.
Remember that the GENISYS system does not check to see that the I/O cards
installed match those requested. The Controller will simply not be able to deliver
outputs to or read inputs from an incorrect board.
Step 4. Verify output boards can be accessed
Now make sure the output boards can be accessed by the Controller Board. This
can be done by resetting the system and using the option of clearing the output
boards. To accomplish this, you can reset the system by using the push buttons on
the edge of the Controller Board.
Push in and hold switch SW4. This is the upper of the two push buttons. While
holding the button in, reset the system by pushing in and then releasing switch
SW8. This is the lower of the two push buttons and is marked RESET. While
the reset switch is pushed in, Watchdog (LED 9) should start flashing. The
executive should now access each output board in order to clear it. Once the
executive has started to clear output boards, SW4 can be released.
There should be a series of deliver pulses, one for each output board. The deliver
LED on the Controller Board (LED 10) should pulse on and off. Each time it
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Page 3-13

pulses on, the address/deliver LEDs on an output board should also pulse starting
with the first board and continuing through the cardfile to the last output board
installed.
If any output boards are not cleared or an attempt is made to clear an input board,
recheck the application program. The LOCAL I/O requirements defined in the
INTERFACE Section may not match the boards installed. If the proper boards are
installed in the cardfile, then the cardfile itself may be bad. Try swapping it for a
known good cardfile and see if all output boards can now be cleared.
Step 5. Check if output boards can have controls delivered
Once it has been determined that all output boards can be cleared, check to see if
any of them can have a control delivered to them. Reset the unit by pushing in
reset button (SW8) on Controller Board. The GENISYS unit should reset, read
inputs, process logic and attempt to deliver outputs. All output boards should have
some controls delivered to them shortly after reset. If some, but not all boards
receive controls, go on to Step 7. If some incorrect controls are delivered to all
boards, go to Step 9.
Step 6. Check application logic for cyclic logic
If controls can not be delivered to any output board, check the application logic
for continuous or cyclic logic. This is any point in the application logic that will
cause some logic to always be on the logic queues. For example, if you wanted to
create a flasher by using the equation
ASSIGN FLASH TO FLASH
and FLASH is not a timer bit, this equation would continue to toggle the value of
FLASH and never reach a stable state. As long as there is logic to be done, no
outputs can be delivered. You should use the simulator to check the logic. Make
sure that input bits in the simulator reflect the state that physical input bits were in
when the system came out of reset. It is possible for a cyclic logic state to be
masked under some input conditions. If there is cyclic logic in your application
program, correct it.
Step 7. Check status of validation switch
Next, determine status of the V (validation) switch, which is software set in
application logic. If validation is turned on (V+), check to see if unassigned bits
are on the output boards. If there are, either write logic equations to assign values
to them or make them spare. If this does not resolve the problem, check input
boards in cardfile for proper seating.
Page 3-14
SM6300E (1/98)

Step 8. Contact US&S product specialist
At this time, if there is an output board that has not had controls delivered to it, try
turning validation off (V-). Once all other problems have been resolved, it can be
turned back on.
If validation is off and no cyclic logic is occurring, but output boards are not being
delivered, a major problem still remains. Fill out a GENISYS fact sheet and call
the US&S product specialist.
Step 9. Swap boards and cardfile
If all output boards can now receive controls, there may still be problems with
some input. If there is any type of serial link, be sure that correct communications
protocol is being followed. See Section V for troubleshooting serial
communications.
If there are no serial lines or they are operating correctly and you are having
trouble with input boards, look at the application logic versus current outputs and
try to determine which inputs are not being received. Try changing the indications
and check results. At this point, the problems should be at board level and not
related to individual input bits.
If the problem can be narrowed down to particular board(s), swap in known good
input boards. If all suspect boards have been replaced and there are still indication
board(s) that can not be read, you may have a bad cardfile. Try swapping the
cardfile for a known good one.
Step 10. Verify executive can read inputs from input boards.
At this point, the system should be capable of delivering controls to all of the
output boards. Now verify that executive can read inputs from all of the input
boards. Change at least one indication on each input board to make sure that they
are all being accessed. As long as there is some result from the changed
indication, even though it may be incorrect, you know that board is being
accessed.
If there is any board that does not produce a result, check the logic to see if the
inputs are being used in logic equations and are not just spares. Make sure that
you have chosen an input that will have some effect on the physical outputs so the
changed input state can be verified. If there is still no action taken when
indications are changed, the input board may be bad. Try swapping it for a known
good input board. If this board still appears not to be responding to changed
inputs, check the connector. Check input cable to verify that inputs are correctly
wired.
SM6300E (1/98)
Page 3-15

Step 11. Monitor I/O
If this is a first attempt to get a particular installation working, it is a good idea to
have a method of monitoring the I/O other than through actual connections. If you
are using either of the new I/O boards (N451441-7101 or 7201), this is taken
care of by board LEDs. Otherwise, small switch and LED panels that mount on
edge connectors in place of actual connections to the field would be useful to help
separate wiring problems from bad boards.
If you have N451441-7201 input boards, check LEDs on the board to verify that
inputs you are requesting are connected the way you expect them to be. As you
change inputs, LEDs on the board should change state. If LEDs on the board do
not follow the field inputs, there is either a bad board or wiring problem. Try
swapping board for a known good board. If the LEDs are still not following the
field requests, there must be a wiring error. Trace connection to find out where
the error has occurred.
If you do not have 7201 input boards, try connecting the edge mountable switch
panel. If system still responds the same way as it did previously, it may be
assumed that the problem is not with input wiring. You may either reconnect the
proper input cable or continue with the switch panel until a phase of the testing
has been reached for you to verify field connections.
If a switch panel is not available or you get different results than were obtained
with field wiring, reconnect input cable and check voltage inputs at the test points
on the input board to verify that they follow field inputs.
Step 12 Use simpler application program in a test PROM
If you still seem to have problems that are not related to logic, a simpler
application program may help narrow down where problems are originating.
Write and compile a small application program that defines nothing other than
LOCAL I/O in the same configuration that you have in the cardfile. Do simple
mapping from input to output. Make sure that validation is turned off (%$V-).
Remove the current application PROM and put this test PROM in the unit and
check out the I/O. If any bad inputs or outputs are found, swap out any boards
that seem to have problems. If board swapping does not correct problem, check
input wiring and I/O power supply. If all else fails, try swapping the Controller
Board and finally the cardfile.
Page 3-16
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V. Serial Interface Problems
Serial interface problems must be viewed from an entire system perspective. Any unit of a
multi-unit installation could cause an entire system to malfunction. In the following
discussion, the terms MASTER and SLAVE will be used to refer to a unit acting in that
capacity, even though it may not be a GENISYS unit. By now the Controller Board should
be a good board; if not, swap it for a good working board to eliminate the possibility of a
defective serial port.
A. Introduction
Before any attempt is made to troubleshoot serial links, several terms and concepts must
be understood. The following is a brief treatment on control/data lines used in serial
communications and their functions in different GENISYS operating modes.
Control/data lines and their functions are also described with respect to the Controller
Board. If other devices are connected to serial ports, the control/data lines may have other
functions and designations than those presented here. For example, the receive data line
is actually a modem output line and would be connected to a receive data input line on a
GENISYS Controller Board. In the Guide, it has been assumed that GENISYS units, are
directly connected and the control/data lines referred to are those on GENISYS units
unless stated otherwise.
Three output and four input lines are available for each serial communications port on a
Controller Board. They are:
1.
DTR Data Terminal Ready output control

A control line that indicates the serial port is enabled and ready to perform
communication functions. In a GENISYS system, this line is normally not
connected, but it may be connected to a modem Data Set Ready line if required by
modem specifications.
2.
RTS - Request to Send output control

A control line is enabled when this unit is ready to transmit. It should be connected
to a Data Carrier Detect line on the correct port of a receiving unit.
3.
TXD - Transmit Data output data

Data that is transmitted from the unit. It should be connected to the Receive Data
line on the correct port of a receiving unit.
4.
DSR - Data Set Ready input control

An unused input control line on the GENISYS serial ports. It may be tied to plus or
minus voltage but should not be allowed to float. It should not be tied to the receive
SM6300E (1/98)
Page 3-17

common, since this would cause the internal value to oscillate from one state to the
other, overloading the executive with interrupts.
5.
DCD - Data Carrier Detect input control

The control line that signals when incoming data is to be expected. It should be
connected to a Request To Send line on the correct port of transmitting unit.
6.
RXD - Receive Data input data

A line for data being received by this unit. It should be connected to a Transmit Data
line on the correct port of the transmitting unit.
7.
CTS - Clear To Send input control

A control line that enables the transmitter that can be connected to an output control
line RTS to a modem CTS output or to plus voltage.
Four LEDs monitor the status of four major signals for serial communications to each
port, and they are arranged in the same sequence on each port. The first group of four are
for MASTER port (LEDs 1-4), the second group of four monitor slave port (LEDs 5-8).
From top to bottom they are:
Master
Slave
&
TXD - Transmit Data
&
RTS - Request To Send
&
RXD - Receive Data
&
DCD - Data Carrier Detect
B. Carrier Control (Half, Carrier and Full Duplex)

Another major function is carrier control, which refers to the functioning of the
RTS/DCD pair. Several terms will be used interchangeably throughout this document
and other GENISYS service manuals. The following information on Carrier Control
should clarify these terms.
The first item to be covered is the meaning of full versus half duplex. In a full duplex
system, a single serial port may be transmitting and receiving data at the same time. In a
half duplex system, a unit may be transmitting or receiving at any time but may not do
both at the same time. GENISYS protocol defines a HALF DUPLEX system as no unit
may be transmitting and receiving data at the same time. There are times in this Guide or
a GENISYS manual when a full duplex state may be mentioned. This terminology is
Page 3-18
SM6300E (1/98)

inaccurate and actually refers to a state called carrier duplex. In order to understand the
differences, look at an illustration of half duplex communications below.
Figure 3-2
In a half duplex system, neither control or data lines from the different ports are allowed
to overlap. Next look at an illustration of full duplex communications.
Figure 3-3
In a full duplex system, control and data lines from the different ports are allowed to
overlap. Now look at an illustration of carrier duplex communications.
Figure 3-4
In a carrier duplex system, control lines are allowed to overlap but data line lines are not.
GENISYS will work in a half duplex mode or a carrier duplex mode but not in a true full
duplex mode. A half duplex mode may be selected by placing Controller Board carrier
SM6300E (1/98)
Page 3-19

control toggle switch (SW3) in the OPERATE position. Placing this switch in CARRIER
position allows the system to function in a carrier duplex mode.
In order to make this explanation a little clearer, we start with a sequence when units are
operating in half duplex mode. The four LEDs, which are monitoring control/data lines
shown above, should function as follows on the MASTER port:
1.
MRTS comes on MASTER is ready to send data. At this time, the key-on delay
is started. When the key-on delay has expired, data transmission starts.
2.
MTXD starts flashing MASTER is now sending data. The length of time for
TXD depends on message length and baud rate. Not all messages are of the same
length.
3.
MTXD goes dark MASTER has finished transmitting its message. At this time,
key-off delay starts. When key-off delay has expired, carrier (MRTS) is turned
off.
4.
MRTS goes dark Key-off time has expired and the MASTER is waiting for a
response.
5.
MDCD comes on Signifies a slave station will be sending data as soon as that
slaves key-on delay expires.
6.
MRXD starts flashing Slave is now transmitting. The length of time for TXD
will depend on message length and baud rate. Not all messages are of the same
length.
7.
MRXD goes dark The slave has finished transmitting a message. At this time,
the slaves key-off delay starts. When key-off delay expires, carrier (SRTS) is
turned off.
8.
MDCD goes dark The slaves key-off time has expired. MASTER now formats
a new message and goes back to number 1.
The slave port is basically the same but in the opposite order.
1.
SDCD comes on Signifies master station will transmit data as soon as the
masters key-on delay expires.
2.
SRXD starts flashing Master is now transmitting. Length of time for TXD
depends on message length and baud rate. Not all messages are of the same
length.
3.
SRXD goes dark Master has finished transmitting its message. At this time,
Masters key-off delay starts. When key-off delay has expired, carrier (MRTS)
turns off.
Page 3-20
SM6300E (1/98)

4.
SDCD goes dark Masters key-off time has expired. If the message was
addressed to this slave, the sequence will continue to number 5. If the message
was addressed to a slave with a different address, all LEDs on the slave port will
go dark, while the other SLAVE answers the message. When the master starts the
next message, the sequence will continue as in number 1.
5.
SRTS comes on SLAVE is ready to send data. At this time, the SLAVEs keyon delay starts. When key-on delay has expired, data transmission starts.
6.
STXD starts flashing SLAVE is now sending data. The length of time for TXD
depends on message length and baud rate. Not all messages are of the same
length.
7.
STXD goes dark SLAVE has finished transmitting this message. At this time,
key-off delay starts. When key-off delay has expired, the carrier (SRTS) turns
off.
8.
SRTS goes dark Key-off time has expired and the SLAVE is waiting for the
next message from the MASTER.
GENISYS will work in a half duplex mode or a carrier duplex mode. The only difference
between carrier and half duplex involves the carrier timing. In carrier duplex, MASTER
RTS is on steady. This should also cause SLAVE DCD to be on steady. A slave unit,
since it will accept a constant incoming carrier, does not wait for a DCD signal to go
away before setting outgoing carrier high and starting key-on delay. Therefore, carrier
signals may overlap. Under no conditions, however, should transmit data signals from
MASTER and slave units overlap.
Depending upon baud rate used, it may or may not be possible to distinguish the flashing
of TXD/RXD LEDs. It may look as though they are on steady but not quite as bright as
RTS/DCD LEDs. At higher baud rates, it may not even be possible to distinguish the
timing difference between transmit and receive portions of the communication.
Before going any further, check top two bits (rockers 1 & 2) on switch SW7 on
GENISYS controller board. They must be in a CLOSED position in order for the system
to operate. If either of these rockers are open, the executive will go into a modem test
mode and will do no logic or I/O. Also check that jumpers J1 J10 on the GENISYS
controller board are in the correct position for your communications format.
Step 1. Check MASTER RTS and TXD line LEDs
First, determine if the MASTER unit is transmitting. If the MASTER unit is a
GENISYS unit, check the LEDs that correspond to MASTER RTS and TXD
lines. If a unit is operating correctly, there will be periodic active transmission
state followed by a receive state. If a MASTER TXD line is never active, the
SM6300E (1/98)
Page 3-21

MASTER unit is never attempting to send any data. Go to Step 3 for information
on troubleshooting this type of problem.
If a MASTER is not a GENISYS unit, check SLAVE DCD and RXD lines. If
they are connected to the RTS and TXD lines on the unit, which is acting as a
MASTER, it should be possible to monitor master transmit activity in this manner.
If a GENISYS SLAVE is not receiving information from a non-GENISYS
MASTER, correct this problem before going further.
Step 2. Check if SLAVE is attempting to respond to MASTER
If a MASTER is attempting to transmit data, check to see if a SLAVE is making
any attempt at a response. If the SLAVE is not responding at all, there should be a
wait state after MASTER transmission equal to the MASTERs no response time
out (default) for a GENISYS MASTER. This indicates a SLAVE, for whatever
reason, cannot respond correctly to this message. Go to Step 4 to attempt to
resolve problem.
If a slave unit is attempting to respond to the message, you can assume at this time
that the MASTER transmit and SLAVE receive lines are functioning correctly.
Skip to Step 13 for information on SLAVE transmit and MASTER receive pairs.
If any unit starts to transmit a message but aborts the message before it is
completed, there may be noise on the incoming CTS or DCD lines. This will
often be recognized by seeing the RTS line key on but the transmit data line never
becomes active. If a Datascope is being used to monitor the communication lines,
you may also notice messages that are started but never terminate with the correct
termination character $F6. Check CTS and DCD lines with an oscilloscope for
possible noise and glitches. If any noise is present, find the cause and eliminate it
before continuing.
Step 3. Determine cause of GENISYS MASTER not transmitting
If a GENISYS MASTER is not transmitting at all, it could be due to one of
several causes;
a - incoming DCD in half duplex
b - no CTS signal
c - continuous interrupts
d - incorrectly defined interface
e - unstable logic
Page 3-22
SM6300E (1/98)

Check position of carrier control toggle switch (SW3) on GENISYS controller
board. If it is in OPERATE mode, be sure that MASTERs DCD LED is not on.
An active incoming DCD signal will prevent a MASTER from starting
transmission. If a constant active state of a DCD signal is an acceptable
condition, carrier control toggle switch should be moved to CARRIER position
and the GENISYS unit should be reset. If the active DCD signal is not a normal
operating condition, see if it is caused by an active RTS from one of the slave
units or by a false active state on a modem line. Correct this problem and then
continue.
If the DCD line is inactive or the unit is operating in carrier duplex, an input
signal to the CTS line may not be connected. This line must be active for the
transmitter to be enabled. The CTS line should be tied high locally or connected
to the CTS modem output. If the MASTER is in half duplex and this signal is
being fed back from a modem, make certain that the MASTERs key-on delay is
long enough to allow the modem to key on and enable the CTS line. If possible,
this line should be tied high. It can be connected to +12 volts for EIA or +5 volts
for TTL. These voltages are available on the GENISYS cardfile edge connector.
Check Data Set Ready (DSR) line. It does not matter whether this line is pulled to
plus or minus voltage but it should not be allowed to float, which could cause
continuous processor interrupts. In most cases, the CTS and DSR lines can be tied
to plus voltage.
If all connections appear to be correct, make sure you have defined the proper
interface in the application program. This should be a MASTER station.
Next check to see if any LOCAL output can be done. If not, you may have a
problem within the application program. Check the logic for continuous or cyclic
logic. This is any part of the application logic that will cause some logic to always
be on the logic queues. For example, if you wanted to create a flasher by using an
equation:
ASSIGN FLASH TO FLASH
And FLASH was not defined as a timer bit, this equation will continuously toggle
the FLASH value and never come to a stable state. As long as there is logic to be
done, no physical or serial output can be done. Use the simulator to check logic.
If cyclic logic is in an application program, correct it.
Step 4. Verify MASTER is accepting incoming data
At this time, the MASTER should be transmitting data. If a Datascope is
available to monitor serial lines, the first message that is transmitted by the
MASTER should be a $FD to the first slave defined in the application logic. If
the slave does not respond, a $FD message will be repeated one time. If there is
SM6300E (1/98)
Page 3-23

no response to the second message, a MASTER will go on and attempt to establish
communications with the rest of the slave stations.
If any of the slave stations are responding, verify the MASTER is accepting the
incoming data. This can be done by looking at the $FD sequence. When the
MASTER sends a $FD message, the SAVE should respond with a $F2 message.
The MASTER should then send a $FA and the SLAVE will respond with either a
$F1 or $F2 message. If it is a $F2 message, the MASTER will send another $FA
and this sequence will continue until the SLAVE sends a $F1 message. At this
time, the MASTER should go on with the next SLAVE in the polling cycle. If the
MASTER is not accepting the incoming data, skip to Step 9.
If the MASTER has established communications with any of the SLAVEs, nonresponding slave station(s) should be checked and set up in the same fashion as
the responding stations.
Step 5. Verify the SLAVE is not attempting to respond
If a GENISYS slave station is not responding to the MASTER poll, check the
hardware connections. Be sure that MASTER TXD and RTS signal are
physically being received by a slave station. Verify also that SLAVE is not
attempting to respond by checking LEDs on the slave unit. If the SLAVE is
attempting to respond but no indication of this is being received at the MASTER
station, there must be a wiring of modem problem. Check all connections and the
modem settings to attempt to rectify the situation. Confirm also that a common
signal from the MASTER or the modem is connected to the proper pin on the
slave port.
Step 6. Confirm SLAVE station information is in application program.
Confirm that SLAVE station has a proper interface description and station address
in the application program. The SLAVEs address may be defined in the SLAVE
interface section or on a hardware switch. In order to use the hardware setting, an
address of 0 must be used in the application program. If any other value is used,
the address in the application program is the address to which this unit will
respond, regardless of hardware switch setting.
Step 7. Check slave unit for proper connections
Next check slave unit for the same connections defined for the MASTER unit in
Step 3.
Check position of carrier control toggle switch. If it is in the OPERATE position,
make sure that SLAVE's DCD LED is not on. An active incoming DCD signal
will prevent the SLAVE from starting a transmission. If a constant active state of
the DCD signal is an acceptable condition, carrier control toggle switch should be
Page 3-24
SM6300E (1/98)

moved to CARRIER position and the GENISYS unit should be reset. If the
active DCD signal is not a normal operating condition, see if it is caused by an
active RTS from the MASTER unit or by a false active state on a modem line.
Correct this problem and then continue. If MASTER unit has carrier control
switch in the CARRIER position, the slave unit also must be set to CARRIER.
If the DCD line is inactive or the unit is operating in carrier duplex, and input
signal to the CTS line may not be connected. This line must be active for the
transmitter to be enabled. The CTS line should be tied high locally or connected
to the CTS output of the modem. If this signal is being fed back from a modem,
make sure the SLAVE key-on delay is long enough to allow the modem to key on
and enable the CTS line. If possible, this line should be tied high. It can be
connected to +12 volts for EIA or +5 volts for TTL. These voltages are available
on the edge connector of the GENISYS cardfile.
Check Data Set Ready (DSR) line. It does not matter whether this line is pulled to
plus or minus voltage, but it should not be allowed to float, which could cause
continuous processor interrupts. In most cases, the CTS and DSR lines can be tied
to plus voltage.
Step 8. Check baud rates
Check baud rates. Both MASTER and slave units must be set to the same baud
rate. For the MASTER unit, a software switch may be set in the application
program. If it has not been set, baud rate will take a default value of 1200 BPS.
For the slave unit, baud rate may also be set with a software switch. However, if
the switch is not set, baud rate will default to a value determined by the hardware
switch on the Controller Board. The current values of software switches should
appear at the bottom of the application program list file. Values associated with
the hardware switch can be found in the GENISYS Service Manual. If units are
not set to the same baud rate, decide what baud rate you wish to operate and set
MASTER and all SLAVEs to that rate.
Check modem baud rate setting. If one is being used, it must be operating at the
same rate as GENISYS units.
Step 9. Check data byte format
Check data byte format. GENISYS default is one start bit, eight data bits, no
parity and one stop bit. If the revision of the GENISYS executive PROM
(N451575-0901) is 0-6, this is the format that must be used. In revisions 7 and
up, an extra stop bit or a parity bit may be selected by a system designer. Rockers
6, 7 and 8 on switch SW7 on Controller Board are used to select these options. In
order to use default byte format, all three of these bits should be in the CLOSED
position. Make sure the modem is also set to the chosen parameters.
SM6300E (1/98)
Page 3-25

Step 10. Check key-on and key-off delays
If MASTER unit is operating in carrier duplex, make sure the key-on and key-off
delays are long enough to allow proper framing of data transmission. If they are
set improperly, the first or last byte could be lost. Do not forget to account for
modem timing factors when determining settings for key-on and key-off delays.
Step 11. Check modem transmission parameters
If modems are being used, check the transmission parameters of modems on both
ends of line. Make sure that none of the modems have drifted out of the
acceptable bandwidth and the signal on the SLAVE receive port has not been
degraded to a point that a GENISYS receiver can not detect it correctly. If you are
monitoring the communications with a Datascope, please keep in mind that some
Datascopes are capable of detecting a signal that GENISYS will not. What may
look like valid messages on the Datascope may not be received properly by a
GENISYS unit. Check the incoming signal with an oscilloscope to confirm that
pulses are not skewed and that the voltage level is high enough to be received
correctly. If there is a problem with a modem signal, the modem test feature of
the GENISYS executive can be used to help adjust the modem to the correct
levels.
Step 12. Record MASTER and SLAVE communication information
By this point, the slave unit should at least be attempting to respond to a
MASTER poll. If it is not, record all the communication information for both
MASTER and SLAVE on the GENISYS station fact sheet and call the product
specialist.
Step 13. Check connections and modem settings
If the SLAVE is attempting to respond but no indication of this is being received
at the MASTER station, there must be a wiring or modem problem. Check all
connections and mode settings to attempt to rectify the situation. Confirm also
that the common signal from the MASTER or modem is connected to the proper
pin on the slave port.
Step 14. Verify only one SLAVE is responding to same address.
If a MASTER unit receives, but does not accept a SLAVEs transmission, be sure
only one SLAVE is responding to the same station address. If more that one
SLAVE attempts to transmit at the same time, the data will overlap and a valid
message cannot be decoded. Each SLAVE should have a unique address.
Page 3-26
SM6300E (1/98)

Step 15. Confirm key-on and key-off delays are long enough
Confirm key-on and key-off delays are long enough to allow proper framing of the
data transmission. If they are set improperly, the first or last byte could be lost.
Do not forget to account for modem timing factors when determining settings for
key-on and key-off delays. Make sure that key-on delay of slave unit is not longer
than a no response time out of MASTER. If it is, the MASTER will have timed
out before the SLAVE starts its transmission, since the no response time out is
halted by the first data character received and not by the DCD signal. In executive
PROM (N451575-0901) Revisions 0-6, the MASTER no response time out is 1
second. In Revisions 7 and up, this is a user definable time with a default value of
1 second. See the GENISYS Service Manual section on compiler switches.
Step 16. Check modem transmission parameters on both ends
If modems are being used, check transmission parameters of modems on both ends
of the line. Make sure that none of the modems have drifted out of the acceptable
bandwidth and that the signal on MASTER receive port has not been degraded to
a point that a GENISYS receiver can not detect it correctly. If you are monitoring
communications with a Datascope, please keep in mind that some Datascopes are
capable of detecting a signal that GENISYS will not. What may look like valid
messages on a Datascope might not be received properly by GENISYS. Check
incoming signal with an oscilloscope to confirm that pulses are not skewed and
voltage level is high enough to be received correctly. If a modem signal problem
occurs, the modem test feature of the GENISYS executive can be used to help
adjust the modem to correct levels.
SM6300E (1/98)
Page 3-27

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Service Manual 6300E

645 Russell Street

An ANSALDO Affiliated Company

Working and Non-Working Systems................................................................ 3-4

Power Supply Converter Board ........................................................................ 3-7

System Reset Checkout Procedure ................................................................... 3-9

Local Interface Problems ................................................................................ 3-12

Serial Interface Problems................................................................................ 3-17

Tables and Figures

Cardfile ................................................................................................. 1-1

Controller Board LED Indicators.......................................................... 1-5

Controller Board Slave Baud Rate (SW1) ............................................ 1-6

Controller Board Control Delivery Time (SW2) .................................. 1-6

Controller Board Carrier Mode Switch (SW3) ..................................... 1-7

Controller Board Slave Address Switch (SW5).................................... 1-7

Controller Board Key On/Off Delay Switch (SW6)............................. 1-8

Controller Board System Reset (SW8) ................................................. 1-9

Controller Board Communication Jumpers .......................................... 1-9

Controller Board ................................................................................. 1-10

Controller Board Switch Options........................................................ 1-11

Constant Delivery Output Board LED Indicators............................... 1-13

Output Board -Constant Delivery - with LEDs (N451441-7101) ...... 1-14

High Threshold Input Board Input Limits .......................................... 1-15

High Threshold Input Board LED Indicators ..................................... 1-16

High Threshold Input Board (N451441-7202) ................................... 1-17

Typical DC Input Power Circuit........................................................... 2-4

Typical Control Delivery or Constant Delivery PCB Output

Typical Control Delivery or Constant Delivery PCB Output

Typical Input PCB Circuit - Type I ...................................................... 2-6

Typical Input PCB Circuit - Type II..................................................... 2-6

Typical Master Port to Modem Slave Port to Master Port

Typical Master Port to Modem and Multiple Slave Port

Typical Slave Port to Modem Communication Circuit - TTL .............. 2-7

Typical Master Port to Modem Communication Circuit - TTL............ 2-7

Typical Slave Port to Modem Communication - EIA........................... 2-8

Typical Master Port to Modem Communication - EIA......................... 2-8

Basic Tools for GENISYS Installation ................................................. 3-3

GENISYS LEDs (Representative Configuration)................................. 3-4

Half-Duplex Carrier Control Mode (SW3)......................................... 3-19

Full-Duplex Carrier Control Mode .................................................... 3-19

Carrier-Duplex Mode.......................................................................... 3-19

GENISYS Hardware Descriptions

There is a limit of 256 output or input bits per card file.

GENISYS Hardware Descriptions

19-inch rack mounting.

14-inches vertical rack space.

10.5 inches rack depth.

Removable front cover with fasteners.

Card file has 18 PCB positions.

Position J1 power supply only.

Position J2 Controller Only.

Position J3 to J18 output or input (user defined).

Each card file position has two (2) connection points.

A 44-Pin double keyed connector.

Handles all external connections.

A 44-pin single keyed connector.

Handles all internal connections.

This connector is mounted on an internal mother board.

GENISYS Hardware Descriptions

9.5 to 35 Volt DC with less than 5% ripple.

Maximum input power is 52 watts.

Nominal input power is 15 watts.

+5 Volts +/- 2% at 3 Amps