K5BMC EI Manual

K5BMC

ELECTRONIC
INTERLOCKING
MANUAL

ENGINEER LEVEL

KYOSAN INDIA PVT LTD.

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Troubleshooting Manual

for K5BMC Electronic Interlocking System

Document No. Z914-C36000237

Version 1
14. Mar. 2014

© 2014 Kyosan Electric Mfg. Co., Ltd., All Rights Reserved, Printed in
Japan
THIS DOCUMENT AND ITS CONTENTS ARE THE PROPERTY OF KYOSAN ELECTRIC MFG. CO., LTD.
FURNISHED TO YOU ON THE FOLLOWING CONDITIONS : (1) NO RIGHT OR LICENSE IN RESPECT
TO THIS DOCUMENT OR ITS CONTENTS IS GIVEN OR WAIVED IN SUPPLYING THIS DOCUMENT TO
YOU. (2) THIS DOCUMENT OR ITS DETRIMENT ARE NOT TO BE COPIED, REPRODUCED,
DISCLOSED TO OTHERS, OR DISPOSED OF EXCEPT WITH PRIOR WRITTEN CONSENT.

29-1, Heiancho 2 chome, Tsurumi-ku, Yokohama, JAPAN

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Document Revision History

Ver.
Date Nature of Revision Author(s)
No.
1 14.Mar.2014 First Edition Y. Kanno
2
3

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Table of Contents
1 INTRODUCTION ............................................................................................................................ 8

2 SUB-RACK CONFIGURATIONS ................................................................................................... 9

2.1 LOGIC SUB-RACK ..................................................................................................................... 9

2.2 ET-PIO SUB-RACK ....................................................................................................................11

2.3 ET-MMIF SUB-RACK ............................................................................................................... 12

2.4 JOURNAL MODULE ................................................................................................................ 13

2.5 SPHC-TT/PW............................................................................................................................. 14

3 TROUBLESHOOTING.................................................................................................................. 16

3.1 MTC DISPLAY STATUS ........................................................................................................... 17

4 TROUBLESHOOTING FROM MTC ............................................................................................ 18

4.1 DISPLAY TRANSITION DIAGRAM ........................................................................................ 18

4.2 GENERAL SYSTEM DISPLAY ................................................................................................ 19

4.2.1 LOGIC RACK AND ET RACK MOUNTING DISPLAY........................................................... 21

4.2.1.1 LOGIC SUB-RACK ............................................................................................................... 23

4.2.1.1.1 IPU6C SCREEN ............................................................................................................... 25

4.2.1.1.2 F486-4I AND DID SCREEN............................................................................................. 27

4.2.1.1.3 FSIO AND FIO7-[P] SCREEN ......................................................................................... 29

4.2.1.1.4 FSIO-EX AND EXTFIO7P SCREEN ............................................................................... 31

4.2.1.2 ET-PIO SUB-RACK............................................................................................................... 33

4.2.1.2.1 LINE2B SCREEN ............................................................................................................. 35

4.2.1.2.2 ET-PIO2 SCREEN ............................................................................................................ 37

4.2.1.3 JOURNAL MODULE............................................................................................................ 39

4.2.2 CONTROL PANEL (CCIP) DISPLAY....................................................................................... 41

4.2.2.1 ET-MMIF SUB-RACK........................................................................................................... 43

4.2.2.1.1 LINEM2 SCREEN ............................................................................................................ 45

4.2.2.1.2 MMIF2 SCREEN .............................................................................................................. 47

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5 TROUBLESHOOTING BY CHECKING THE LED INDICATIONS OF EACH UNIT .............. 49

5.1 LOGIC RACK ............................................................................................................................ 50

5.1.1 LOGIC SUB-RACK ................................................................................................................... 51

5.1.1.1 IPU6C CARD......................................................................................................................... 52

5.1.1.2 F486-4I CARD ....................................................................................................................... 54

5.1.1.3 FSIO CARD ........................................................................................................................... 56

5.1.1.4 FSIO-EX CARD..................................................................................................................... 58

5.1.2 ET-PIO SUB-RACK ................................................................................................................... 60

5.1.2.1 LINE2B CARD ...................................................................................................................... 61

5.1.2.2 ET-PIO2 CARD...................................................................................................................... 63

5.1.3 JOURNAL MODULE ................................................................................................................ 65

5.1.3.1 KDD172-KY48-2 CARD ........................................................................................................ 66

5.1.3.2 ZPEN3 CARD ........................................................................................................................ 68

5.1.3.3 ZNIO2 CARD......................................................................................................................... 70

5.1.3.4 ZSIO2 CARD ......................................................................................................................... 72

5.1.4 SPHC-TT.................................................................................................................................... 74

5.2 CCIP (CONTROL PANEL)........................................................................................................ 76

5.2.1 ET-MMIF SUB-RACK ............................................................................................................... 76

5.2.1.1 LINEM2 CARD ..................................................................................................................... 77

5.2.1.2 MMIF2 CARD ....................................................................................................................... 79

5.3 MTC (MAINTENANCE CONSOLE) ........................................................................................ 81

5.3.1 INIO2 CARD.............................................................................................................................. 81

5.4 OPC (OPERATOR CONSOLE) ................................................................................................. 83

5.4.1 INIO2 CARD.............................................................................................................................. 83

6 RECOVERY PROCEDURES......................................................................................................... 85

6.1 LOGIC RACK ............................................................................................................................ 85

6.1.1 LOGIC SUB-RACK ................................................................................................................... 85

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6.1.1.1 IPU6C .................................................................................................................................... 85

6.1.1.1.1 DC24/DC5.......................................................................................................................... 85

6.1.1.1.2 DC24/DC24........................................................................................................................ 86

6.1.1.2 F486-4I AND DID.................................................................................................................. 87

6.1.1.2.1 CPU, ROM, RAM .............................................................................................................. 87

6.1.1.2.2 IC CARD............................................................................................................................ 88

6.1.1.2.3 CTRL DATA TX................................................................................................................. 89

6.1.1.2.4 INDIC. DATA TX .............................................................................................................. 90

6.1.1.2.5 INTER-SYS TX/RX RX ..................................................................................................... 91

6.1.1.2.6 INTER-SYS TX/RX TX ..................................................................................................... 92

6.1.1.2.7 DID .................................................................................................................................... 93

6.1.1.3 FSIO AND FIO7-[P] .............................................................................................................. 94

6.1.1.3.1 CTRL DATA RX, INDIC. DATA TX, MTC CH TX,

ET CH1 TX, ET CH2 TX, ET CH3 TX ............................................................................. 94

6.1.1.3.2 MTC CH RX ...................................................................................................................... 95

6.1.1.3.3 ET CH1/CH2/CH3 RX....................................................................................................... 96

6.1.1.4 FSIO-EX AND EXTFIO7P .................................................................................................... 97

6.1.1.4.1 CTRL DATA RX, INDIC. DATA TX, ET CH4 TX, ET CH5 TX........................................ 97

6.1.1.4.2 ET CH4/CH5 RX ............................................................................................................... 98

6.1.2 ET-PIO SUB-RACK ................................................................................................................... 99

6.1.2.1 LINE2B.................................................................................................................................. 99

6.1.2.1.1 DC24/DC5.......................................................................................................................... 99

6.1.2.1.2 ET CTRL DATA OE CONVERSION .............................................................................. 100

6.1.2.1.3 ET INDIC. DATA EO CONVERSION............................................................................ 101

6.1.2.2 ET-PIO2 ............................................................................................................................... 102

6.1.2.2.1 DC24/DC5........................................................................................................................ 102

6.1.2.2.2 ET CTRL DATA RX......................................................................................................... 103

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6.1.2.2.3 ET INDIC. DATA RX ...................................................................................................... 104

6.1.2.2.4 I/O PORT......................................................................................................................... 105

6.1.2.2.5 PIO2 ID CHECK ............................................................................................................. 106

6.1.3 JOURNAL MODULE .............................................................................................................. 107

6.1.3.1 KDD172-KY48-2.................................................................................................................. 107

6.1.3.2 ZPEN3 ................................................................................................................................. 108

6.1.3.3 ZNIO2 .................................................................................................................................. 109

6.1.3.4 ZSIO2....................................................................................................................................111

6.1.3.5 SPHC-TT ..............................................................................................................................113

6.2 CCIP (CONTROL PANEL).......................................................................................................114

6.2.1 ET-MMIF SUB-RACK ..............................................................................................................114

6.2.1.1 LINEM2................................................................................................................................114

6.2.1.1.1 DC24/DC5.........................................................................................................................114

6.2.1.1.2 ET CTRL DATA OE CONVERSION ...............................................................................115

6.2.1.1.3 ET INDIC. DATA EO CONVERSION.............................................................................116

6.2.1.2 MMIF2..................................................................................................................................117

6.2.1.2.1 ET CTRL DATA RX..........................................................................................................117

6.2.1.2.2 ET INDIC. DATA RX .......................................................................................................118

6.2.1.2.3 MMIF ID CHECK ............................................................................................................119

7 HANDLING METHODS ............................................................................................................. 120

7.1 CARD AND IC CARD REPLACING METHOD..................................................................... 120

7.1.1 CARD REPLACING METHOD .............................................................................................. 120

7.1.2 IC CARD REPLACING METHOD ......................................................................................... 121

7.2 LOGIC SUB-RACK HANDLING PRECAUTIONS................................................................ 122

7.3 ELECTRONIC TERMINAL SUB-RACK HANDLING PRECAUTIONS.............................. 124

7.4 FIBER OPTIC HANDLING PRECAUTIONS........................................................................ 126

8 VOLTAGE MEASUREMENT PROCEDURES........................................................................... 130

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8.1 LOGIC SUB-RACK ................................................................................................................. 130

8.1.1 IPU6C ...................................................................................................................................... 130

8.2 ET-PIO SUB-RACK ................................................................................................................. 131

8.2.1 LINE2B.................................................................................................................................... 131

8.3 ET-MMIF SUB-RACK ............................................................................................................. 132

8.3.1 LINEM2 ................................................................................................................................... 132

8.4 LOGIC MODULE .................................................................................................................... 133

8.5 SPHC-TT/PW........................................................................................................................... 134

9 POWER SWITCHES ................................................................................................................... 135

9.1 LOGIC SUB-RACK ................................................................................................................. 135

9.1.1 IPU6C ...................................................................................................................................... 135

9.2 ET-PIO SUB-RACK ................................................................................................................. 136

9.2.1 LINE2B.................................................................................................................................... 136

9.2.2 PIO2-LOG ................................................................................................................................ 137

9.3 JOURNAL MODULE .............................................................................................................. 138

9.4 SPHC-TT/PW........................................................................................................................... 139

9.5 ET-MMIF SUB-RACK ............................................................................................................. 140

9.5.1 LINEM2 ................................................................................................................................... 140

9.5.2 MMIF2 ..................................................................................................................................... 141

9.6 MTC/OPC................................................................................................................................. 142

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

1 Introduction

This manual provides general guidelines for troubleshooting and recovery of
K5BMC Electronic Interlocking System.

Personnel in charge of troubleshooting are requested to read thoroughly this
manual to ensure the safety of people and operation of the equipment.

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2 Sub-rack Configurations
This section describes the sub-rack configuration used for K5BMC EI system.

2.1 Logic Sub-rack

a b cd

System 1 System 2
Front
a. IPU6C card
b. F486-4I card
c. FSIO card
d. FSIO-Ex

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e f g h

System 2 System 1
Rear
e. EXTFIO7P card
f. FIO7-[P] card
g. DID card
h. IPU6C power input terminal

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2.2 ET-PIO Sub-rack

a b

Front

Rear
a. LINE2B card
b. PIO2-LOG card
c. LINE2B power input terminal
d. Optical Line Input

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2.3 ET-MMIF Sub-rack

a b c

Front Rear

a. LINEM2 card
b. MMIF2 card
c. LINEM2 power input terminal

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2.4 Journal Module

a b c d

Front

Rear

a. ZPEN3 card
b. ZNIO2-S1 and ZNIO2-S2 card
c. ZSIO2 card
d. KDD172-KY48-2 card

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2.5 SPHC-TT/PW

System 1 System 2

Front

a. SPHC-TT card
b. SPHC-PW card

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System 2 System 1

c d
Back
c. SPHC-PW power input terminal
d. SPHC-PW power output terminal
e. SPHC-TT power input terminal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

3 Troubleshooting
If malfunction occurs, try the following steps to resolve the problem.
Malfunction
occured

Check if MTC is
operational
(refer to section 3.1)

YES NO
Operational?

Refer to section 5.3

YES
Recovered?

NO

Refer to section 4
Refer to
section 5

NO
Recovered?

YES

Inform the manufacturer

End

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

3.1 MTC Display Status

An example of Maintenance Console (MTC) display is shown below.
An asterisk “*” at the upper right of the window indicates the MTC display
status.
Check if MTC is operational by determining the status of the asterisk indication
or the MTC display itself as shown below.

Blinking = Normal transmission

with the interlocking device at
least on a subsystem

ON/OFF = no transmission with the

interlocking device

No Display on MTC = out of order

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Document No. Z914-C36000237 Ver. 1

4 Troubleshooting from MTC

This section describes the display indication of Maintenance Console (MTC). The
malfunction that occurred can be traced from the display indication of MTC up to
card level display.
While looking at the status of the malfunctioned rack, unit or part of the unit
from the MTC display, follow the instructions given in the following sections to
resolve the problem.

4.1 Display Transition Diagram

An example of display transition diagram for an interlocking station is shown
below. The display transition may vary depending on the system configuration
of a station.
（Ｂｌｏｃｋ　Ｂｕｔｔｏn） (Logic Rack Mounting Display) （Card Level Display)
General System
Display
LOGIC RACK LOGIC RACK Each Card

（Ｂｌｏｃｋ　Ｂｕｔｔｏn） (Control Panel Display) （Card Level Display)

Electronic ELECTRONIC
Each Card
Terminal Rack TERMINAL

（Ｂｌｏｃｋ　Ｂｕｔｔｏn） (Control Panel Display) （Card Level Display)

CONTROL
CONTROL PANEL Each Card
PANEL

（Ｂｌｏｃｋ　Ｂｕｔｔｏn） (Out Field Equipment Display)

OUTFIELD POINT MOVEMENT and
EQUIPMENT FILAMENT BURN OUT

Operator
Console
(OPC)

Maintenance
Console
(MTC)

Dotted-line shows only status indication and not Button.

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4.2 General System Display

An example of General System Display of MTC is shown below.
The display may vary depending on the system configuration of a station.
Unless specified, system status is to be indicated in green when normal and in
red when out of order.

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Start

From the display above,

determine which Rack did the
malfunction occurred

Logic Rack/ YES

ET Rack?

NO
refer to section 4.2.1

Other
malfunctioned
rack/block

Control Panel OPC OUT FIELD Equipment

refer to refer to refer to the

section 4.2.2 section 5.4 troubleshooting
manual of the other
equipment that
malfunctioned

Return

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4.2.1 Logic Rack and ET RACK Mounting Display

An example of LOGIC RACK Mounting Display of MTC is shown below.
The display may vary depending on the system configuration of a station.

By pressing LOGIC RACK button on the General System Display

(section 3.2), the screen shifts to LOGIC RACK Mounting Display as
shown below.
The same process also applies for ET RACK.
Each card status is to be indicated in green when normal and in red
when out of order.

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Start

From the display

above, determine
which sub-rack
malfunctioned

Malfunctioned
Sub-rack

Logic Sub-rack ET-PIO Sub-rack Journal Module SPHC-TT

refer to refer to refer to refer to

section 4.2.1.1 section 4.2.1.2 section 4.2.1.3 section 5.1.4

Return

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4.2.1.1 Logic Sub-rack

When any card portion in Logic Sub-rack is clicked in the LOGIC RACK
mounting display as shown below, its card level will be displayed as shown in
the following sections.
Each Card Level Display can be indicated in each system (system 1 and system
2).

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Start

From the display

above, determine
which unit
malfunctioned

YES
IPU6C card?

NO
refer to section 4.2.1.1.1

YES NO
Recovered?

Other
malfunctioned
units

F486-4I and DID card FSIO and FIO7-[P] card FSIO-EX and EXTFIO7P card

refer to section 4.2.1.1.2 refer to section 4.2.1.1.3 refer to section 4.2.1.1.4

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

4.2.1.1.1 IPU6C Screen

The status of each part is indicated in green when normal and in red when out
of order.

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Start

Record the LED Status

of the IPU6C card

From the display above,

determine which part of
the unit malfunctioned

Malfunctioned part

DC24/DC5 DC24/DC24

refer to section 6.1.1.1.1 refer to section 6.1.1.1.2

NO YES
Recovered?

Change the IPU6C card

(refer to sections 7.1 and 7.2)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

4.2.1.1.2 F486-4I and DID Screen

The status of each part is indicated in green when normal and in red when out
of order.

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Start

Record the LED Status

of the F486-4I card

From the display above,

determine which part of
the unit malfunctioned

Malfunctioned part

CPU/ROM/RAM IC card Ctrl Data Tx Indic. Data Tx Inter-sys Tx/Rx Rx Inter-sys Tx/Rx Tx DID

refer to section refer to section refer to section refer to section refer to section refer to section refer to section
6.1.1.2.1 6.1.1.2.2 6.1.1.2.3 6.1.1.2.4 6.1.1.2.5 6.1.1.2.6 6.1.1.2.7

Return

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Document No. Z914-C36000237 Ver. 1

4.2.1.1.3 FSIO and FIO7-[P] Screen

The status of each part is indicated in green when normal and in red when out
of order.

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Start

Record the LED Status

of the FSIO card

From the display above,

determine which part of
the unit malfunctioned

Malfunctioned part

MTC CH Rx ET CH1 Rx ET CH2 Rx ET CH3 Rx

Ctrl Data Rx/Indic. Data Tx/
MTC CH Tx/ET CH1 Tx/
ET CH2 Tx/ET CH3 Tx

refer to refer to refer to refer to refer to

section 6.1.1.3.1 section 6.1.1.3.2 section 6.1.1.3.3 section 6.1.1.3.3 section 6.1.1.3.3

Return

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4.2.1.1.4 FSIO-EX and EXTFIO7P Screen

The status of each part is indicated in green when normal and in red when out
of order.

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Start

Record the LED Status

of FSIO-EX

From the display above,

determine which part of
the unit malfunctioned

Malfunctioned part

Ctrl Data Rx/ ET CH4 Rx ET CH5 Rx

Indic. Data Tx/
ET CH4 Tx/
ET CH5 Tx

refer to refer to refer to

section 6.1.1.4.1 section 6.1.1.4.2 section 6.1.1.4.2

Return

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 Troubleshooting Manual for K5BMC EI
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4.2.1.2 ET-PIO Sub-rack

When any card portion in ET-PIO Sub-rack is clicked in the LOGIC RACK
mounting display as shown below, its card level will be displayed as shown in
the following sections.
Each Card Level Display can be indicated according to mounted cards of each
system.

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Start

From the display

above, determine
which unit
malfunctioned

YES
LINE2B card?

NO
refer to section 4.2.1.2.1

YES NO
Recovered?

YES
ET-PIO2 card?

NO
refer to section 4.2.1.2.2

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

4.2.1.2.1 LINE2B Screen

The status of each part is indicated in green when normal and in red when
out of order.

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Start

Record the LED Status

of the LINE2B card

From the display above,

determine which part of
the unit malfunctioned

YES
DC24/DC5?

NO

refer to
section 6.1.2.1.1

Other
malfunctioned
part

ET Ctrl Data OE ET Indic. Data EO

transform transform

refer to refer to
section 6.1.2.1.2 section 6.1.2.1.3

NO YES
Recovered?

Change the LINE2B card

(refer to sections 7.1 and 7.3)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

4.2.1.2.2 ET-PIO2 Screen

The status of each part is indicated in green when normal and in red when
out of order.

The result of status of Circuit No. of ET-PIO2 I/O is displayed collectively in

fours (for example, 1 2 3 4, 5 6 7 8, etc.).

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Start

Record the LED Status

of ET-PIO2

From the display above,

determine which part of the
unit malfunctioned

YES
DC24/DC5?

NO
refer to
section 6.1.2.2.1

Other
malfunctioned
part

ET Ctrl ET Indic. Data Tx I/O Port PIO2 ID Check

Data Rx?

refer to refer to refer to refer to

section 6.1.2.2.2 section 6.1.2.2.3 section 6.1.2.2.4 section 6.1.2.2.5

Return

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4.2.1.3 Journal Module

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Start

From the display

above, determine
which unit
malfunctioned

KDD172-KY48-2 YES
card?

NO
refer to section 6.1.3.1

YES NO
Recovered?

Other
malfunctioned
unit

ZPEN3 card ZNIO2-S1 card/ ZSIO2 card

ZNIO2-S2 card

refer to refer to refer to

section 6.1.3.2 section 6.1.3.3 section 6.1.3.4

Return

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4.2.2 Control Panel (CCIP) Display

An example of CONTROL PANEL STATUS Display of MTC is shown below.

By pressing CONTROL PANEL button on the General System

Display (section 3.2), the screen shifts to CONTROL PANEL STATUS
Display as shown below.
Each Card Status is to be indicated in green when normal and in red
when out of order.

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

From the display

above,
Determine which unit
malfunctioned

refer to
section 4.2.2.1

Return

14.Mar.2014 Page 42 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

4.2.2.1 ET-MMIF Sub-rack

Each Card Level Display can be indicated according to mounted cards of each
system.

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

From the display

above, determine
which unit
malfunctioned

YES
LINEM2 card?

NO
refer to section 4.2.2.1.1

YES NO
Recovered?

YES
MMIF2 card?

NO
refer to section 4.2.2.1.2

Return

14.Mar.2014 Page 44 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

4.2.2.1.1 LINEM2 Screen

The status of each part is indicated in green when normal and in red when out
of order.

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Record the LED Status

of LINEM2

From the display above,

determine which part of
the unit malfunctioned

YES
DC24/DC5?

NO

refer to
section 6.2.1.1.1

Other
malfunctioned
part

ET Ctrl Data OE ET Indic. Data EO

transform transform

refer to refer to
section 6.2.1.1.2 section 6.2.1.1.3

NO YES
Recovered?

Change the LINEM2 card

(refer to section xxxx)

Return

14.Mar.2014 Page 46 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

4.2.2.1.2 MMIF2 Screen

The status of each part is indicated in green when normal and in red when out
of order.

In this screen, the indication of I/O port and the right side from No.1 to 64 shall
be totally colored gray, since there is no indication condition.

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Record the LED Status

of MMIF2

From the display above,

determine which part of
the unit malfunctioned

Malfunctioned
part

ET Ctrl ET Indic. Data Tx MMIF2 ID Check

Data Rx

refer to refer to refer to

section 6.2.1.2.1 section 6.2.1.2.2 section 6.2.1.2.3

Return

14.Mar.2014 Page 48 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5 Troubleshooting by checking the LED Indications of each unit

This section describes the LED indications of each unit in K5BMC EI system.
The LED indications of each unit specified in this section can be used to
determine which unit malfunctioned.
Follow the instructions given in the following sections to resolve the problem.
Start

Check the
Logic Rack
(refer to section 5.1)

NO YES
Recovered?

Check the
ET Rack
(refer to section 5.1.2)

YES
Recovered?

NO

Check the
CCIP
(refer to section 5.2)

Check the
MTC
(refer to section 5.3)

Check the
OPC
(refer to section 5.4)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1 Logic Rack

Start

refer to section 5.1.1

refer to section 5.1.2

refer to section 5.1.3

refer to section 5.1.4

Return

14.Mar.2014 Page 50 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.1 Logic Sub-rack

The LED indications of each unit of Logic Sub-rack are shown below.
Check the LED indications of each unit of each system to determine which unit
malfunctioned.

Start

refer to section 5.1.1.1

IPU６C card NO
Recovered?

YES

refer to section 5.1.1.2

refer to section 5.1.1.3

refer to section 5.1.1.4

Return

14.Mar.2014 Page 51 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.1.1 IPU6C Card

PW ON = Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indication of IPU6C
card specified above

YES
Normal?

NO

Record the LED Status

of the IPU6C card

refer to section 6.1.1.1.1

refer to section 6.1.1.1.2

NO YES
Recovered?

Change the IPU6C card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 53 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.1.2 F486-4I Card

WT Blinking = Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indications of F486-4I
card specified above

YES
Normal?

NO

Record the LED Status

of the F486-4I card

Restart the IPU6C card

(refer to section 9.1.1)

NO YES
Recovered?

Check that the IC card is

properly inserted

NO YES
Recovered?

Change the F486-4I card

(refer to sections 7.1 and 7.2)

NO YES
Recovered?

Change the Logic Sub-rack

Return

14.Mar.2014 Page 55 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.1.3 FSIO Card

D6 LED blinking = MTC Tx/Rx normal

WT LED blinking = Normal

1T LED blinking = CH1 Tx normal

1R LED blinking = CH1 Rx normal

2T LED blinking = CH2 Tx normal

2R LED blinking = CH2 Rx normal

3T LED blinking = CH3 Tx normal

3R LED blinking = CH3 Rx normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indications of FSIO card
specified above

YES
All normal?

NO

Record the LED Status

of the FSIO card

Malfunctioned part

MTC CH Tx/ET CH1 Tx/ MTC CH Rx ET CH1 Rx ET CH2 Rx ET CH3 Rx

ET CH2 Tx/ET CH3 Tx

refer to refer to refer to refer to refer to

section 6.1.1.3.1 section 6.1.1.3.2 section 6.1.1.3.3 section 6.1.1.3.3 section 6.1.1.3.3

Return

14.Mar.2014 Page 57 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.1.4 FSIO-EX Card

D6 LED blinking= MTC Tx/Rx normal

WT LED blinking = Normal

1T LED blinking = CH4 Tx normal

1R LED blinking = CH4 Rx normal

2T LED blinking = CH5 Tx normal

2R LED blinking = CH5 Rx normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indications of FSIO-Ex
card specified above

YES
All normal?

NO

Record the LED Status

of FSIO-EX card

Malfunctioned part

ET CH4 Rx ET CH5 Rx
ET CH4 Tx/
ET CH5 Tx

refer to refer to refer to

section 6.1.1.4.1 section 6.1.1.4.2 section 6.1.1.4.2

Return

14.Mar.2014 Page 59 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.2 ET-PIO Sub-rack

The LED indications of each unit of ET-PIO Sub-rack are shown below.
Check the LED indications of each unit of each system to determine which unit
malfunctioned.
Start

refer to section 5.1.2.1

NO
Recovered?

YES

refer to section 5.1.2.2

Return

14.Mar.2014 Page 60 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.2.1 LINE2B Card

NORMAL LED ON = Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indication of LINE2B
card specified above

YES
Normal?

NO

Record the LED Status

of the LINE2B card

refer to section 6.1.2.1.1

NO YES
Recovered?

Change the LINE2B card

(refer to sections 6.1 and 6.3)

Return

14.Mar.2014 Page 62 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.2.2 ET-PIO2 Card

NORMAL LED ON = Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indication of ET-PIO2
card specified above

YES
Normal?

NO

Record the LED Status

of the ET-PIO2 card

refer to section 6.1.2.2.1

Return

14.Mar.2014 Page 64 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.3 Journal Module

The LED indications of each unit of Journal Module are shown below.
Check the LED indications of each unit of each system to determine which unit
malfunctioned.

Start

refer to section 5.1.3.1

NO
Recovered?

YES

refer to section 5.1.3.2

refer to section 5.1.3.3

refer to section 5.1.3.4

Return

14.Mar.2014 Page 65 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.3.1 KDD172-KY48-2 Card

DC5V LED ON = Normal

DC12V LED ON = Normal
DC24V LED ON = Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indications of KDD172-
KY48-2 card specified
above

YES
All normal?

NO

refer to section 6.1.3.1

Return

14.Mar.2014 Page 67 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.3.2 ZPEN3 Card

WT LED ON = Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indication of ZPEN3
card specified above

YES
Normal?

NO

refer to section 6.1.3.2

Return

14.Mar.2014 Page 69 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.3.3 ZNIO2 Card

*ZNIO2 card is used for Logic System 1 and 2

separately.

WDT LED ON = Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indication of ZNIO2 card
specified above

YES
Normal?

NO

refer to section 6.1.3.3

Return

14.Mar.2014 Page 71 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.3.4 ZSIO2 Card

WDT LED blinking = Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indication of ZSIO2 card
specified above

YES
Normal?

NO

refer to section 6.1.3.4

Return

14.Mar.2014 Page 73 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.1.4 SPHC-TT

LED1 Blink when data receiving (TLR1 Optical Line)

LED2 Blink when data sending (TLT1 Optical Line)
LED3 Not used (TRR1Optical Line)
LED4 Not used (TRT1 Optical Line)
LED5 Blink when data sending (TLT2 Optical Line)
LED6 Blink when data receiving (TLR2 Optical Line)
LED7 Blink when data sending (TRT2 Optical Line)
LED8 Blink when data receiving (TRR2 Optical Line)

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

From the LED

indications specified
above, determine that
the SPHC-TT/PW is in
normal condition

YES
Normal?

NO

Record the LED Status

of SPHC-TT

refer to section 6.1.3.5

NO YES
Recovered?

Change the SPHC-TT

Return

14.Mar.2014 Page 75 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.2 CCIP (Control Panel)

5.2.1 ET-MMIF Sub-rack
The LED indications of each unit of ET-MMIF Sub-rack are shown below.
Check the LED indications of each unit of each system to determine which unit
malfunctioned.

Start

refer to section 5.2.1.1

NO
Recovered?

YES

refer to section 5.2.1.2

Return

14.Mar.2014 Page 76 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.2.1.1 LINEM2 Card

NORMAL LED ON = Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indication of LINEM2
card specified above

YES
Normal?

NO

Record the LED Status

of the LINEM2 card

refer to section 6.2.1.1.1

NO YES
Recovered?

Change the LINEM2 card

(refer to sections 7.1 and 7.3)

Return

14.Mar.2014 Page 78 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.2.1.2 MMIF2 Card

LED 7 ON = WDT Normal

LED 5 ON = Tx Normal
LED 6 ON = Rx Normal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indications of MMIF2
card specified above

YES
All Normal?

NO

Record the LED Status

of the ET-MMIF2 card

Malfunctioned
part

ET Ctrl ET Indic.
Data Rx Data Tx

refer to refer to
section 6.2.1.2.1 section 6.2.1.2.2

Return

14.Mar.2014 Page 80 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.3 MTC (Maintenance Console)

5.3.1 INIO2 Card

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indications of
INIO2 card specified
above

YES
Normal?

NO

Record the LED Status

of the INIO2 card

Restart the MTC

(refer to section 9.6)

NO YES
Recovered?

refer to section 5.1.4

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

NO YES
Recovered?

Change the INIO2 card

Return

14.Mar.2014 Page 82 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

5.4 OPC (Operator Console)

5.4.1 INIO2 Card

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

Start

Check the LED

indications of
INIO2 card specified
above

YES
Normal?

NO

Record the LED Status

of the INIO2 card

Restart the OPC

(refer to section9.6)

NO YES
Recovered?

Check the optical cable

connection of
INIO2 Tx and Rx

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

NO YES
Recovered?

Change the INIO2 card

Return

14.Mar.2014 Page 84 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6 Recovery Procedures
This section contains a series of flowcharts and figures that describe the
procedures and possible solutions to recover from malfunction that occurred.
Unit replacement might be required to recover from malfunction. However, if
spare parts are not available for replacement, skip and try to proceed to the next
step to resolve the problem.

6.1 Logic Rack

6.1.1 Logic Sub-rack
6.1.1.1 IPU6C
6.1.1.1.1 DC24/DC5

Start

Check the input voltage DC24V

of the Logic Sub-rack
(refer to section 8.1)

NO YES
21.6V to 26.4V?

Check the output Check the output voltage

voltage DC24V of the DC5V of the IPU6C card
DC/DC converter (refer to section 8.1)

NO YES NO YES
21.6V to 26.4V? 5V to 5.25V?

Change the DC/DC Restart the

Change the power IPU6C card
converter
cable between DC/DC (refer to section 9.1.1)
(refer to the manual of
converter and IPU6C
DC/DC converter)

Return

14.Mar.2014 Page 85 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.1.2 DC24/DC24

Start

Check the input voltage DC24V

of the Logic Sub-rack
(refer to section 8.1)

NO YES
21.6V to 26.4V?

Check the output Check the output voltage

voltage DC24V of the DC24V of the IPU6C card
DC/DC converter (refer to section 8.1)

NO YES NO YES
21.6V to 26.4V? 21.6V to 26.4V?

Change the DC/DC Restart the

Change the power IPU6C card
converter
cable between DC/DC (refer to section 9.1.1)
(refer to the manual of
converter and IPU6C
DC/DC converter)

Return

14.Mar.2014 Page 86 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.2 F486-4I and DID

6.1.1.2.1 CPU, ROM, RAM

Start

Restart the IPU6C crd

(refer to section 9.1.1)

NO YES
Recovered?

Change the F486-4I card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 87 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.2.2 IC CARD

Start

Check if IC Card is properly

inserted in the F486-4I
card slot

NO YES
Recovered?

Restart the IPU6C crd

(refer to section 9.1.1)

NO YES
Recovered?

Change the F486-4I Card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 88 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.2.3 Ctrl Data Tx

Start

Check from MTC display if

CPU, ROM and RAM of
F486-4I are normal

YES NO
Normal?

Change the F486-4I card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 89 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.2.4 Indic. Data Tx

Start

Check that FSIO or

FSIO-EX is normal
(refer to sections 5.1.1.3 and 5.1.1.4)

YES NO
Normal?

Change the F486-4I card

(refer to sections 7.1 and 7.2)

NO YES
Recovered?

Change FSIO or
FSIO-EX card
(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 90 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.2.5 Inter-sys Tx/Rx Rx

Start

Check from MTC display if

CPU, ROM and RAM of
F486-4I of the other system
are normal

YES NO
Normal?

Change the F486-4I card of Change the F486-4I card of

own system the other system
(refer to sections 7.1 and 7.2) (refer to sections 7.1 and 7.2)

NO YES
Recovered?

Change the Logic Sub-rack

Return

14.Mar.2014 Page 91 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.2.6 Inter-sys Tx/Rx Tx

Start

Check from MTC display if

CPU, ROM and RAM of
F486-4I are normal

NO YES
Recovered?

Change the F486-4I card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 92 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.2.7 DID

Start

Check from MTC display if

CPU, ROM and RAM of
F486-4I of the other system
are normal

YES NO
Normal?

Change the F486-4I card of Change the F486-4I card of

own system the other system
(refer to sections 7.1 and 7.2) (refer to sections 7.1 and 7.2)

NO YES
Recovered?

Change the Logic Sub-rack

Return

14.Mar.2014 Page 93 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.3 FSIO and FIO7-[P]

6.1.1.3.1 Ctrl Data Rx, Indic. Data Tx, MTC CH Tx,
ET CH1 Tx, ET CH2 Tx, ET CH3 Tx

Start

Change the FSIO card

(refer to sections 7.1 and 7.2)

NO YES
Recovered?

Change the FIO7-[P] card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 94 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.3.2 MTC CH Rx

Start

Check the optical cable

connection of
MTC CH Tx
(from SPHC-TT to RD
of INIO2)

Check the optical cable

connection of
MTC CH Rx
(from SD of INIO2 to
SPHC-TT)

NO YES
Recovered?

Change the FIO7-[P] card

(refer to sections 7.1 and 7.2)

NO YES
Recovered?

Change the FSIO card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 95 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.3.3 ET CH1/CH2/CH3 Rx
Start

Check that ET CH is
connected to
Electronic Terminal
(CN1R & CN1T/CN2R &
CN2T/CN3R & CN3T of
FIO7-[P])

YES NO
Connected?

Check the optical cable

connection of
ET CH Tx
(CN1T/CN2T/CN3T of
FIO7-[P])

Check the optical cable

connection of
ET CH Rx
(CN1R/CN2R/CN3R of
FIO7-[P])

NO YES
Recovered?

Change the FIO7-[P] card

(refer to sections 7.1 and 7.2)

NO YES
Recovered?

Change the FSIO card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 96 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.4 FSIO-EX and EXTFIO7P

6.1.1.4.1 Ctrl Data Rx, Indic. Data Tx, ET CH4 Tx, ET CH5 Tx

Start

Change the FSIO-EX card

(refer to sections 7.1 and 7.2)

NO YES
Recovered?

Change the EXTFIO7P card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 97 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.1.4.2 ET CH4/CH5 Rx

Start

Check that ET CH5 is

connected to
Electronic Terminal
(CN11R &
CN11T/CN12R &
CN12T of EXTFIO7P)

YES NO
Connected?

Check the optical cable

connection of
ET CH Tx
(CN11T/CN12T of
EXTFIO7P)

Check the optical cable

connection of
ET CH Rx
(CN11R/CN12R of
EXTFIO7P)

NO YES
Recovered?

Change the EXTFIO7P card

(refer to sections 7.1 and 7.2)

NO YES
Recovered?

Change the FSIO-EX card

(refer to sections 7.1 and 7.2)

Return

14.Mar.2014 Page 98 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.2 ET-PIO Sub-rack

6.1.2.1 LINE2B
6.1.2.1.1 DC24/DC5
Start

Check the input voltage DC24V of the

ET-PIO Sub-rack (refer to section 8.2)

NO YES
21.6V to 26.4V?

Check the output Check the output voltage

voltage DC24V of the DC5V of the LINE2B card
DC/DC converter (refer to section 8.2)

NO YES NO YES
21.6V to 26.4V? 5V to 5.25V?

Change the DC/DC Change the power Restart the

converter cable between LINE2B card
(refer to the manual of DC/DC converter and (refer to section 9.2.1)
DC/DC converter) LINE2B card

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.2.1.2 ET Ctrl Data OE conversion

Start

Check the optical cable

connection of
LINE2B Rx
(from Ach R of LINE2B
to Tx of FIO7-[P] or
EXTFIO7P)

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.2.1.3 ET Indic. Data EO conversion

Start

Check the optical cable

connection of
LINE2B Tx
(from Ach T of LINE2B
to Rx of FIO7-[P] or
EXTFIO7P)

Check the optical cable

connection of
LINE2B Rx
(from Ach R of LINE2B
to Tx of FIO7-[P] or
EXTFIO7P)

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.2.2 ET-PIO2
6.1.2.2.1 DC24/DC5

Start

Check the input voltage DC24V of the

ET-PIO Sub-rack (refer to section 8.2)

NO YES
21.6V to 26.4V?

Check the output

voltage DC24V of Change the PIO2-LOG card
DC/DC converter (refer to sections 7.1 and 7.3)

NO YES
21.6V to 26.4V?

Change the DC/DC Change the power

converter cable between
(refer to the manual DC/DC converter
of DC/DC and ET-PIO Sub-
converter) rack

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.2.2.2 ET Ctrl Data Rx

Start

Check the optical cable

connection of
LINE2B Rx
(from Ach R of LINE2B
to Tx of FIO7-[P] or
EXTFIO7P)

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

NO YES
Recovered?

Change the PIO2-LOG card

(refer to sections 7.1 and 7.3)

NO YES
Recovered?

Change the LINE2B card

(refer to sections 7.1 and 7.3)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.2.2.3 ET Indic. Data Rx

Start

Check the optical cable

connection of
LINE2B Tx
(from Ach T of LINE2B
to Rx of FIO7-[P] or
EXTFIO7P)

Check the optical cable

connection of
LINE2B Rx
(from Ach R of LINE2B
to Tx of FIO7-[P] or
EXTFIO7P)

NO YES
Recovered?

Change the optical cable

(refer to section7.4)

NO YES
Recovered?

Change the PIO2-LOG card

(refer to sections 7.1 and 7.3)

Return

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6.1.2.2.4 I/O Port

Start

Restart the
PIO2-LOG card
(refer to section 9.2.2)

NO YES
Recovered?

Change the
PIO2-LOG card
(refer to sections 7.1 and 7.3)

YES NO
Recovered?

Leave the card in the

slot and observe if
malfunction occurs
again

YES Malfunction NO
occured
again?

Return

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6.1.2.2.5 PIO2 ID Check

Start

Restart the
PIO2-LOG card
(refer to section 9.2.2)

NO YES
Recovered?

Change the PIO2-LOG card

(refer to sections 7.1 and 7.3)

NO YES
Recovered?

Change the
ET-PIO Sub-rack

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.3 Journal Module

6.1.3.1 KDD172-KY48-2
Start

Record the LED Status

of the KDD172-KY48-2
card

YES DC24V NO
LED OFF?

Check the input voltage DC24V of the

Journal Module
(refer to section 8.4)

NO YES
21.6V to 26.4V?

Check the output YES DC12V LED or NO

voltage DC24V of the DC5V LED OFF?
DC/DC converter

Restart the
NO YES KDD172-KY48-2 card
21.6V to 26.4V?
(refer to section 9.3)

Change the DC/DC Change the power

converter cable between NO YES
(refer to the manual of DC/DC converter Recovered?
DC/DC converter) and Journal Module
Change the KDD172-KY48-2
card
(refer to section 7.1)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.3.2 ZPEN3

Start

Record the LED Status

of the ZPEN3 card

Restart the
Journal Module
(refer to section 9.3)

NO YES
Recovered?

Change the ZPEN3 card

(refer to section 7.1)

Return

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 Troubleshooting Manual for K5BMC EI
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6.1.3.3 ZNIO2

ChA RD LED blinking = Normal

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Start

Record the LED Status

of the ZNIO2 card

Check the LED

indication of ZNIO2 card
specified above

YES NO
Normal?

Check the optical cable

Restart the connection of
Journal Module ZNIO2 Rx
(refer to section 9.3) (from SPHC-TT to RD
of ZNIO2)

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

NO YES
Recovered?

Change the ZNIO2 card

(refer to section 7.1)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.3.4 ZSIO2

ChA SD blinking = Normal

ChA RD blinking = Normal

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Start

Record the LED Status

of the ZSIO2 card

Check the LED

indications of ZSIO2
card specified above

NO YES
Normal?

Restart the Check the RS232C

Journal Module cable connection of
(refer to section 9.3) ZSIO2
(from Data Logger)

NO YES
Recovered?

Change the RS232 cable

NO YES
Recovered?

Change the ZSIO2 card

(refer to section 7.1)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.1.3.5 SPHC-TT

Start

Check the input voltage DC5V of the

SPHC-TT
(refer to section 8.5)

NO YES
5V to 5.25V?

Check the output

voltage DC5V of the
SPHC-PW
(refer to section 8.5)

NO YES
5V to 5.25V?

Check the input voltage Change the power

DC24V of the SPHC- cable between
PW SPHC-PW and
(refer to section 8.5) SPHC-TT

NO YES
21.6V to 26.4V?

Check the output

voltage DC24V of the Change the SPHC-PW
DC/DC converter

NO YES
21.6V to 26.4V?

Change the DC/DC Change the power cable

converter between DC/DC
(refer to the manual of converter and SPHC-
DC/DC converter) PW

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.2 CCIP (Control Panel)

6.2.1 ET-MMIF Sub-rack
6.2.1.1 LINEM2
6.2.1.1.1 DC24/DC5
Start

Check the input voltage DC24V of the

ET-MMIF2 Sub-rack
(refer to section 8.3)

NO YES
21.6V to 26.4V?

Check the output Check the output voltage

voltage DC24V of the DC5V of the LINEM2 card
DC/DC converter (refer to section 8.3)

NO YES NO YES
21.6V to 26.4V? 5V to 5.25V?

Change the DC/DC Change the power Restart the

converter cable between LINEM2 card
(refer to the manual of DC/DC converter and (refer to section 9.5.1)
DC/DC converter) LINEM2 card

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.2.1.1.2 ET Ctrl Data OE conversion

Start

Check the optical cable

connection of
LINEM2 Rx
(from ACh R of LINEM2
to Tx of FIO7-[P] or
EXTFIO7P)

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.2.1.1.3 ET Indic. Data EO conversion

Start

Check the optical cable

connection of
LINEM2 Tx
(from ACh T of LINEM2
to Rx of FIO7-[P] or
EXTFIO7P)

Check the optical cable

connection of
LINEM2 Rx
(from ACh R of LINEM2
to Tx of FIO7-[P] or
EXTFIO7P)

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.2.1.2 MMIF2
6.2.1.2.1 ET Ctrl Data Rx

Start

Check the optical cable

connection of
LINEM2 Rx
(from Tx of FIO7-[P] or
EXTFIO7P to ACh Rx of
LINEM2)

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

NO YES
Recovered?

Change the MMIF2 card

(refer to section 7.1)

NO YES
Recovered?

Change the LINEM2 card

(refer to section 7.1)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.2.1.2.2 ET Indic. Data Rx

Start

Check the optical cable

connection of
LINEM2 Tx
(from ACh T of LINEM2
to Rx of FIO7-[P] or
EXTFIO7P)

Check the optical cable

connection of
LINEM2 Rx
(from Tx of FIO7-[P] or
EXTFIO7P to ACh R of
LINEM2)

NO YES
Recovered?

Change the optical cable

(refer to section 7.4)

NO YES
Recovered?

Change the MMIF2 card

(refer to sections 7.1 and 7.3)

Return

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

6.2.1.2.3 MMIF ID Check

Start

Restart the
MMIF2 card
(refer to section 9.5.2)

NO YES
Recovered?

Change the MMIF2 card

(refer to section 7.1)

Return

14.Mar.2014 Page 119 of 142

 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

7 Handling Methods
7.1 Card and IC Card replacing method
If the card fails sporadically, or F486-4I card is replaced, or LDC circuit
diagram is modified, replace the card and IC Card and maintain the equipment.
7.1.1 Card Replacing Method
(a) Removing the card
Turn OFF the power switch of each card. Remove card fixing screws.
Next, pull out the card straight.

Pull out the

Card straight

(b) Inserting the card

Confirm that the power switch of the card is OFF, and carefully insert the
card along the guide rail. If incorrectly inserted, interlocking functions
might be disabled. Completely fix the card with fixing screws, turn ON
the power switch. Check the sub- rack mounting drawing and confirm
where to mount the card, and replace it with a new card.
Correct example Incorrect example

Unfitted
Fit the card with
for the
the rail, and
insert the card

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 Troubleshooting Manual for K5BMC EI
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7.1.2 IC Card Replacing Method

(a) Removing IC Card
Turn OFF the power switch of IPU6C card. After removing inject button
guard, push the inject button fully up to the innermost and then the IC
Card comes out slightly. Next, hold the top and bottom of the IC Card
firmly and pull out the Card straight.

Push the
After this,
button
Pull out the
fully
Card

Inject

(b) Inserting the IC Card

After carefully confirming that device type and data version of the IC Card
are correct, replace the Card. Confirm that the power switch of the IPU6C
card is OFF, turn the surface of IC Card to right side and carefully insert
the IC Card along the guide rail. Confirm that the IC Card is inserted
fully up to the innermost and so that the inject button comes out. After
returning the inject button guard to the original position, turn ON the
power switch.

Correct example Incorrect example

Unfitted for the rail

Insert the
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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

7.2 Logic Sub-rack handling precautions

WARNING
！
If the power switch is inadvertently turned OFF, the EI
equipment might fail or stop functioning. Do not switch OFF
the Logic Module in operation.

Before replacing a card, be sure to turn OFF the power switch.

Otherwise, the card might fail, and in addition, all functions of
the card might stop.

CAUTION
！
The EI Logic Module consists of a number of cards. If a card
is inserted into an incorrect slot, the card might fail and
interlocking functions might stop.

Do not replace an IC etc. on a card board of the Logic

Module or disassemble a stack of cards, using screwdriver.

Handling precautions of optical fiber cords or cables

- When an optical fiber connector is not used, be sure to apply
caps. (Dust-proof)
- Keep a bending radius of no less than 500 mm.
- Do not step or put anything on them.
- When pulling an optical fiber connector, keep a tension of
less than 5 kg.
- Do not strongly vibrate or impact a cord or cable.

Carefully protect an IC card from static electricity, and

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 Troubleshooting Manual for K5BMC EI
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never touch contacts of the card during handling. Otherwise,

the IC card might fail.

The F486-4I card normally mounts an IC card. This IC card

stores interlocking data. Be careful that if this IC card is
removed, interlocking functions might stop.

If the setting of card switch (Dip-Switch) in the Logic Module

is changed, interlocking functions stop. Do not touch the Dip
Switch.

The surface of the card is hot, so when replacing the card, do

not touch it with bare hands. Otherwise, your hands might be
scalded.

Be sure to house spare parts or replaced card in static

electricity protective bags.

Otherwise, they might break down due to static electricity.

Do not operate with wet hands. Otherwise you might receive
an electric shock.

Because the power card is hot, when replacing the card, grip
the front panel with both hands. Otherwise, your hands might
be scalded.

Be sure to house replaced cards in static electricity protective

bags.
Otherwise, they might break down due to static electricity.

After replacing the power supply card, install wires to the

terminal board exactly according to the prescribed procedure.
Do not operate the equipment with wet hands. Otherwise,
you might receive an electric shock.

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7.3 Electronic Terminal Sub-rack handling precautions

WARNING
！
Do not turn OFF the power switch without performing
prescribed preparations, otherwise Electronic Interlocking
functions might stop.

Before replacing a card, turn OFF the power switch.

If a card is inserted or removed with power supplied, the card
might fail and all card functions might stop.

CAUTION
！
When replacing a card, pull out the card board while taking
care not to insert finger etc. between the housing and the card.
If you drop the card board, the card might fail or you might be
injured.

Do not loosen fixing screws of housing, rack and cables or

overhaul any of them for purposes other than mounting or
removing a device. Otherwise, equipment failure or damage
might occur.

Before replacing a card, turn OFF the power switch. If a card

is inserted or removed with power supplied, the card might
fail and all card functions might stop.
Do not remove ROM in the MMIF2 card without performing
prescribed preparations. Otherwise, the card might fail. In
addition, interlocking functions might be lost.

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The surface of the card is hot, so when replacing the card, do

not touch it with bare hands. Otherwise, your hands might
be scalded.

Be sure to house spare parts or replaced card in static

electricity protective bags.

Otherwise, a card might break down due to static electricity.

Do not work with wet hands, otherwise you might receive an

electric shock.

When replacing a card board, be careful not to touch wires,

boards, etc. inside the rack. Otherwise, you might receive an
electric shock.

Because the power card is hot, when replacing the card, grip
the front panel with both hands. Otherwise, your hands
might be scalded.

Be sure to collect replaced cards in static electricity protective

bags.
Otherwise, they might break down due to static electricity.

After replacing the power supply card, install wires to the

terminal board exactly according to the prescribed procedure.
Do not operate the equipment with wet hands. Otherwise,
you might receive an electric shock.

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

7.4 Fiber Optic Handling precautions

Optical fiber handling precautions are described below.

Cabling precautions
Minimum bending
30(mm)
radius
Short permissible
98(N)
tension

WARNING
！
Do not bend an optical fiber with a radius of less
than rated
value. Otherwise, the optical fiber might break
down.

To remove or insert an optical fiber, grip connector

(FC) and insert it straight. After insertion, confirm
that the connector is inserted firmly. If the fiber
cord or fiber is pulled strongly, the fiber might be
destroyed.

Do not apply a load to an optical fiber cord or cable.

Otherwise, the fiber may break down.

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CAUTION
！
Do not disassemble the optical fiber cable.
Otherwise, the optical fiber connector or cable may
be destroyed.

Do not touch the tip of an optical connector.

Do not stick a PVC tape etc. on the tip.

Otherwise, a loss of the optical fiber might become
large during operation, and the connector at the
optical fiber unit might be defective.

Do not place anything on an optical fiber during

storage.

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 Troubleshooting Manual for K5BMC EI
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Removing the Fiber Optic Cable from the terminal

1 2

1. Rotate the connector counterclockwise.

2. Gently remove the fiber optic cable from the terminal.

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Inserting the Fiber Optic Cable into the Terminal

2
1

1. Gently insert the fiber optic cable into the terminal.

2. Turn the connector clockwise to secure the fiber optic cable.

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

8 Voltage Measurement Procedures

This section describes the power input/terminal of each sub-rack. Check the
voltage level from the terminals described below. The red arrow specifies (+)
terminal and gray arrow specifies (-) terminal.

8.1 Logic Sub-rack

8.1.1 IPU6C

24Vdc
output terminal

5Vdc
output terminal

Front

Remove the power

cable and measure
voltage from the
terminal specified

24Vdc from
DC/DC converter

Back

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 Troubleshooting Manual for K5BMC EI
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8.2 ET-PIO Sub-rack

8.2.1 LINE2B

5Vdc
output terminal

Front

24Vdc
input terminal

Back

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 Troubleshooting Manual for K5BMC EI
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8.3 ET-MMIF Sub-rack

8.3.1 LINEM2

5Vdc
output terminal

Front

24Vdc
input terminal

Back

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8.4 Logic Module

Journal Module
24Vdc input
terminal

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

8.5 SPHC-TT/PW

SPHC-TT 5Vdc
SPHC-PW 24Vdc
input terminal
input terminal

Back

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

9 Power Switches
This section describes the units with power switches used to turn on/off the unit
itself or the whole sub-rack where the unit belongs in some cases.

9.1 Logic Sub-rack

9.1.1 IPU6C

Turn the switch up to

power ON and down to
power OFF

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 Troubleshooting Manual for K5BMC EI
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9.2 ET-PIO Sub-rack

9.2.1 LINE2B

Turn the switch up to

power ON and down to
power OFF

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 Troubleshooting Manual for K5BMC EI
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9.2.2 PIO2-LOG

Turn the switch up to

power ON and down to
power OFF

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 Troubleshooting Manual for K5BMC EI
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9.3 Journal Module

Pull the power cable

apart to turn off the
Journal Module.

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 Troubleshooting Manual for K5BMC EI
Document No. Z914-C36000237 Ver. 1

9.4 SPHC-TT/PW

System 2 System 1

Unplug the power cable

Unplug the power cable
to turn off the SPHC-PW
to turn off the SPHC-TT
and SPHC-TT

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 Troubleshooting Manual for K5BMC EI
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9.5 ET-MMIF Sub-rack

9.5.1 LINEM2

Turn the switch up to

power ON and down to
power OFF

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9.5.2 MMIF2

Turn the switch up to

power ON and down to
power OFF

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 Troubleshooting Manual for K5BMC EI
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9.6 MTC/OPC

Press the power button

when starting the
computer.
The computer can be
normally shut down from
the windows display.

14.Mar.2014 Page 142 of 142