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E96-211 ® ® Multi-Function Controller (IMMFC03) Process Control and Automation Solutions from Elsag Bailey Group...
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The information contained in this document is subject to change without notice. Elsag Bailey, its affiliates, employees, and agents, and the authors and contributors to this publication specif- ically disclaim all liabilities and warranties, express and implied (including warranties of merchantability and...
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Preface This document explains how to configure, install, operate, and troubleshoot Multi-Function Controller Module (IMMFC03). Related hardware such as I/O slave modules, termination units, etc. are also presented. A complete list of hardware doc- under the Reference Documents uments is listed in Section 1 heading.
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® List of Effective Pages Total number of pages in this manual is 68, consisting of the following: Page No. Change Date Preface Original List of Effective Pages Original iii through viii Original 1-1 through 1-7 Original 2-1 through 2-5 Original 3-1 through 3-7 Original...
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Safety Summary GENERAL Equipment Environment WARNINGS All components, whether in transportation, operation or storage, must be in a noncorrosive environment. Electrical Shock Hazard During Maintenance Disconnect power or take precautions to insure that contact with energized parts is avoided when servicing. SPECIFIC Disconnect power before installing dipshunts for slave modules on WARNINGS...
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® Sommaire de Sécurité AVERTISSEMENTS Environnement de l’équipement D’ORDRE Ne pas soumettre les composants à une atmosphère corrosive lors GÉNÉRAL du transport, de l’entreposage ou l’utilisation. Possibilité de chocs électriques durant l’entretien Débrancher l’alimentation ou prendre les précautions pour éviter tout contact avec des composants sous tension durant l’entretien.
Table of Contents Page SECTION 1 - INTRODUCTION ....................1-1 OVERVIEW ........................1-1 INTENDED USER ......................1-1 MFC DESCRIPTION......................1-2 FEATURES........................1-2 Redundancy......................1-2 On-Line Configuration ...................1-2 Inputs/Outputs .....................1-3 INSTRUCTION CONTENT .....................1-3 HOW TO USE THIS MANUAL ..................1-4 REFERENCE DOCUMENTS..................1-4 GLOSSARY OF TERMS AND ABBREVIATIONS .............1-5 NOMENCLATURE ......................1-6 Nomenclature of the Control and Slave Modules .............1-6 Nomenclature of the Termination Units ..............1-7...
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® Table of Contents (continued) Page SECTION 3 - INSTALLATION (continued) MEMORY BOARD JUMPER SETTINGS ................ 3-4 SETUP FOR COMMUNICATION HIGHWAY ENVIRONMENT.......... 3-5 INFI-NET/Superloop....................3-5 Plant Loop ......................3-5 SPECIAL OPERATIONS ....................3-6 INSERTING THE MFC IN THE MODULE MOUNTING UNIT ........... 3-7 SECTION 4 - CONFIGURATION ....................4-1 INTRODUCTION ......................
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Table of Contents (continued) Page SECTION 9 - SUPPORT SERVICES ...................9-1 INTRODUCTION......................9-1 REPLACEMENT PARTS AND ORDERING INSTRUCTIONS ..........9-1 Ordering Firmware....................9-2 TRAINING ........................9-2 TECHNICAL DOCUMENTATION ...................9-3 APPENDIX A - ON-LINE CONFIGURATION ................A-1 INTRODUCTION......................A-1 SETUP ........................A-1 OPERATION ........................ A-1 Backup Cycle......................
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® List of Tables Title Page 3-1. U72 Switch Settings ....................3-3 3-2. U73 Switch Settings ....................3-3 3-3. U75 Switch Settings ....................3-4 3-4. Memory Board Jumpers ..................3-5 3-5. Switch U72 Special Operations ................3-6 4-1. Function Block Execution Rates ................4-2 4-2.
SECTION 1 - INTRODUCTION OVERVIEW The Multi-Function Controller Module (IMMFC03) is a powerful member of the INFI 90 controller family. It runs user designed analog, digital, batch and advanced control strategies, with up to 64 slave modules for inputs/outputs (I/O). Also, the module can run 4,000 lines of BASIC or 5,000 lines of C programs.
INTRODUCTION ® MFC DESCRIPTION The IMMFC03 consists of two printed circuit boards connected by a ribbon cable. The boards are the central processing unit (CPU) board and the memory (MEM) board. The boards attach to a faceplate. Visible through the faceplate are several LEDs. The status LED, on the top left side, shows the operating mode (run, configure, error).
INTRODUCTION uses the present values of process outputs in the primary MFC. This feature permits bumpless transfer of control to the new configuration. The Configuration section explains the steps for on-line configuration. NOTE: There are constraints to what changes can be made. Refer to the Backup Cycle section of Appendix A for more information.
INTRODUCTION ® HOW TO USE THIS MANUAL Read this manual before using the MFC. Refer to the sections in this list as needed for more information. 1. Read Section 3 before you connect the MFC. 2. Read Section 4 before you power up the MFC. 3.
INTRODUCTION GLOSSARY OF TERMS AND ABBREVIATIONS Term Definition Analog A signal with an infinite number of values as opposed to a digital value that is either 0 or 1. Checksum The sum of the bytes in a command except the checksum byte and the command terminator.
INTRODUCTION ® NOMENCLATURE This list contains the nomenclature and functions of the equip- ment used with the MFC. Nomenclature of the Control and Slave Modules Name Nomenclature Function Analog Control Station IISAC01 (L) Provides the operator with single loop monitoring and control.
INTRODUCTION Nomenclature of the Termination Units Name Nomenclature Function Termination Unit* NTMF01 Provides link to Control Stations and redundant MFCs. Provides Serial Ports for Basic, C and sequential event recorder. Termination Module* NIMF01 NIMF02 Provides link to Control Stations and redundant MFCs.
SECTION 2 - DESCRIPTION AND OPERATION INTRODUCTION This section explains the functional blocks that make up the MFC. It also describes data bus communications and security functions of the hardware. MODULE DESCRIPTION The IMMFC03 is a series of functional blocks working together. To help you understand how the MFC works, this section shows MFC functionality as a block diagram and then explains each block in the following text.
I/O data from slave modules. It is capable of supporting 64 low power slaves (both Network 90 and INFI 90). The bus uses Bailey-designed protocol to ensure data integrity. The bus bandwidth is 500 kilobytes per second.
DESCRIPTION AND OPERATION Serial Channels There are two independent, general purpose serial channels on the MFC. One is used for language support (C and BASIC). Each channel is capable of supporting standard baud rates up to 19.2 kilobaud. Standard D-type connectors are available on the NTMF01 termination unit or NIMF01 termination module.
DESCRIPTION AND OPERATION ® The MFC always initiates the data transfer operation. When a data transaction occurs, the MFC addresses a slave, requests the information, and reads/writes the data. SECURITY FUNCTIONS The hardware and software handle a variety of module security functions that detect normal failures.
DESCRIPTION AND OPERATION As a background idle task, the module status check constantly verifies ROM and NVM checksums. If a discrepancy is found in any checksum, the error is displayed on the front panel LEDs and the module stops immediately. Control Software Security The control software is responsible for Local I/O problems, remote I/O problems, station problems, and redundancy...
E93-911, Termination Unit Product Instruction. HANDLING NOTE: Always use Bailey's Field Static Kit (P/N 1948385A2 - con- sists of wrist strap, ground cord assembly, alligator clip) when work- ing with modules. The kit is designed to connect a technician and the static dissipative work surface to the same ground point to pre- vent damage to the modules by electrostatic discharge.
INSTALLATION ® 5. Store the module in an environment of good air quality, and free from temperature and moisture extremes. CPU BOARD SWITCH SETTINGS The CPU Board (Figure 3-1) has three user configured switches: U72 - Options, U73 - Baud Rates, and U75 - Module Address.
INSTALLATION Table 3-1. U72 Switch Settings User Settings Switch Position Function Not used. Disable On-Line Configuration. Enable On-Line Configuration. Perform ROM checksum routine. Inhibit ROM checksum routine. Not used. Inhibit ROM (CPU Board) check. Perform ROM check. Compact configuration - moves configured blocks to the top of NVM while moving free space to the bottom (this is known as compacting).
INSTALLATION ® Switch U75 Module Address The MFC must have a unique address to enable it to commu- nicate with other modules. Valid ranges are 2 through 31. Switch U75 is used to set the MFC's address. Refer to Table 3-3.
INSTALLATION Table 3-4. Memory Board Jumpers Jumper Configuration JP1 - JP10 Jumper pins 2 and 3 Selects 8K x 8 NVM JP11 Removed Not used - The MFC will NOT function properly with this jumper in place. Jumper pins 2 and 3 Selects 256K ROM SETUP FOR COMMUNICATION HIGHWAY ENVIRONMENT INFI-NET/Superloop To configure the MFC for use in the INFI-NET/Superloop envi-...
INSTALLATION ® SPECIAL OPERATIONS The special operations feature which allows you to configure the MFC to do a one-time special operation rather than enter- ing its normal mode of operation. Steps 1 through 8 explain how to set the MFC for special operations and reset it for nor- mal operation.
INSTALLATION 7. Reset poles 2 through 6 per Table 3-1. 8. Insert the module in its slot. It will enter its normal operat- ing mode. INSERTING THE MFC IN THE MODULE MOUNTING UNIT After performing the necessary switch configurations, the module is ready to be installed in the module mounting unit (MMU).
SECTION 4 - CONFIGURATION INTRODUCTION The variety of control and math functions residing in IMMFC03 firmware enables the module to perform analog and digital control, computations, and advanced control schemes. Func- tions from the library are user selected and serially linked by function blocks.
CONFIGURATION ® Function Code 19 PID: 36 Bytes NVM 116 Bytes RAM 690 microseconds execution rate Function Code 82 Segment Control: 60 Bytes NVM 256 Bytes RAM NOTE: In this example, execution time for this function is negligible. 2. Specify the number of blocks for both types. In this exam- ple, 205 square root blocks, 205 PID blocks, and 2 segment control blocks are configured.
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CONFIGURATION 5. Calculate the amount of RAM the configuration uses: a. PID blocks use 116 bytes. Therefore, multiply 205 PID blocks by 116 = 23,780 bytes RAM. b. Square Root blocks use 44 bytes. Therefore, multiply 205 Square Root blocks by 44 = 9,020 bytes RAM. c.
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CONFIGURATION ® b. Calculate the amount of CPU time that is used each time the normal priority function blocks are executed. 100 PID blocks x 690 microseconds = 0.069 seconds 100 Square Root blocks x 190 microseconds = +0.019 seconds 0.088 seconds c.
CONFIGURATION 10. Subtract the total CPU time from the maximum amount of CPU time specified. 2.000 seconds available -0.968 seconds used by the control blocks 1.032 seconds of CPU time still available. The results of the previous calculations determine that the example will run.
CONFIGURATION ® Table 4-3. Function Code 81 Block Outputs (System Constraints) Block Data Number Type Description Boolean Logic 0 Boolean Logic 1 Boolean 0 or Real 0.0 Real -100.0 Real -1.0 Real Real Real 100.0 Real -9.2E18 (maximum negative value) Real +9.2E18 (maximum positive value) Boolean...
CONFIGURATION Table 4-4. Function Code 82 Specifications (continued) Spec. Default Range Data Type Tune* Value Min. Max. Description 1.000 Real(3) 0.0 to Minimum report time for all exception reports 9.2E18 in this segment (in seconds) 60.000 Real(3) 0.0 to Maximum report time for all exception reports 9.2E18 in this segment (in seconds) 2.000...
CONFIGURATION ® Table 4-5. Function Code 82 Block Outputs (continued) Block Number Description Checkpoint overrun count number. The number of cycles executed over that specified by S4. This output is used to verify that the checkpoint period is being met. A continual upward ramp indicates that the segment is never getting the link for dynamic data transfer.
CONFIGURATION Table 4-7. Function Code 90 Block Outputs Block Data Number Type Description Real Time of day, hours Real Time of day, minutes Real Time of day, seconds Boolean Time/date synchronization flag 0 = time/date invalid 1 = valid Real Calendar year (0 - 99) Real Calendar month (1 - 12)
SECTION 5 - OPERATION INTRODUCTION This section explains the indicators, controls, and operating modes of the IMMFC03. INDICATORS AND CONTROLS The MFC front panel (Figure 5-1) has the following: Status LED, eight CPU LEDs, two Memory Status LEDs, and Stop and Reset pushbuttons.
The eight CPU LEDs provide operating and error information. The information provided by these LEDs is provided in the Troubleshooting section. NOTE: When contacting Bailey personnel about problems with your IMMFC03, it is important to indicate the error codes shown on the CPU LEDs.
OPERATION Reset Pushbutton The Reset pushbutton is used to: Reset the MFC to power up (default) status after a stop. • Recover from a user initiated stop or module timeout. • OPERATING MODES The MFC has three modes of operation. They are: Execute, Configure, and Error.
OPERATION ® Error Mode Enter the Error Mode: When a configuration error is detected when going from the • Configure to Execute mode. After resetting due to a red light condition as a result of a • hardware problem (e.g., NVM or ROM checksum error). When the MFC is unable to communicate with other mod- •...
SECTION 6 - TROUBLESHOOTING INTRODUCTION This section contains the CPU LED displays, the status words for communication and non critical errors and the signals on the IMMFC03 edge connectors. Table provides the defined CPU LED displays, what they mean, and what corrective action(s) to take. Table 6-1.
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Set module bus switch same as primary's. not same as primary. 0 0 0 1 0 0 1 1 Bad UVROM. Contact Bailey Field Service. 0 0 0 1 0 1 0 0 Inconsistent module/loop setup. Refer to SETUP FOR COMMUNICATION (i.e., module configured for Plant...
TROUBLESHOOTING STATUS WORD DISPLAYS Communication and other noncritical error types are detailed in Table and Table 6-3. These Status Words provide detailed information on MFC error conditions. Any of the INFI 90 operator interface devices can be used to access these words. Refer to the product instruction for your specific interface device for details.
SECTION 7 - MAINTENANCE INTRODUCTION The Multi-Function Controller (IMMFC03) requires limited maintenance. This section contains a maintenance schedule. MAINTENANCE SCHEDULE Perform the tasks in Table at the specified intervals. Table 7-1. Maintenance Schedule Task Interval Clean and tighten all power and Every 6 months or during plant grounding connections.
SECTION 8 - REPAIR/REPLACEMENT INTRODUCTION Repair procedures are limited to module replacement. If the MFC module fails, remove and replace it with another. Verify that firmware revision levels match and that replacement switch settings are the same as the failed module. Refer to Table for a list of recommended spare parts.
SECTION 9 - SUPPORT SERVICES INTRODUCTION Bailey Controls is always ready to assist you with the operation and repair of its products. Requests for sales and/or applica- tion services along with installation, repair, overhaul and/or maintenance contract services should be directed to your near- est Bailey Controls sales/service office.
Call your Bailey Sales Representative with this information; tell him you want the latest version. TRAINING Bailey Controls has a modern training center, equipped to pro- vide service and repair instruction, which is available for in-plant training of customer personnel. Specific information regarding course content and scheduling can be obtained from your nearest Bailey sales/service representative.
SUPPORT SERVICES TECHNICAL DOCUMENTATION Price and delivery of additional copies of this publication can be obtained through your nearest Bailey sales/service office. If any questions arise on the ordering procedure, please con- tact your Bailey representative. Our Global Technical Support Department is also available to answer your technical ques- tions at 1-800-4-BAILEY.
APPENDIX A - ON-LINE CONFIGURATION INTRODUCTION This section provides a basic procedure for on-line configura- tion, and shows both the state of LEDs 7 and 8 as well as the contents of the second module status byte (specifically bits 7, 6, 3 and 1).
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ON-LINE CONFIGURATION ® Engineering Workstation (EWS) with PC-90 Ladder Software or CAD/TEXT. NOTE: Be careful when using either PC-90 Ladder Software or CAD/TEXT to avoid deleting blocks and/or adding blocks in the mid- dle of existing ones. Refer to the note preceding Step 3 of the backup cycle for a further explanation.
ON-LINE CONFIGURATION problem report option is available in the modify mode menu of the CAD/TEXT software. NOTE: The LED displays show the CPU operating state. Errors may occur during on-line configuration that are not exactly described by the LED displays listed in this section. The LED displays indicating these errors are written in the MFC Product Instruction manual.
ON-LINE CONFIGURATION ® BACKUP BACKUP INITIALIZE BUSCLK EEROM RESET PRIMARY (NO CHANGE) BACKUP BACKUP CHECKPOINT DATA CONFIGURATION IS COMPLETE IS COPIED TO THE BACKUP BUSCLK PRIMARY BACKUP RESET (CONFIGURATION NOT COPIED) RESET BUSCLK (CHANGES MADE) BUSCLK REQUEST CHECKPOINT BACKUP SHUTDOWN OF BACKUP BACKUP DATA IS...
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ON-LINE CONFIGURATION Primary Backup 2. Place the backup MFC in CONFIGURE mode. The green LED of the backup MFC will blink indicating CONFIGURE 01xx0x0x 00xx0x0x mode. Configuration Commands to the backup MFC are sent to the address of the primary MFC plus one. The primary MFC now indicates that the backup MFC is not available for auto- matic failover.
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ON-LINE CONFIGURATION ® Primary Backup 4. The backup MFC can now be placed in EXECUTE mode provided no errors remain in the new configuration. 01xx0x0x 00xx1x0x Additional configuration changes can be made by entering CONFIGURE mode (Step 2). If no changes have been made at this point, a stop and reset returns the backup MFC to Step 1.
ON-LINE CONFIGURATION Primary Backup 8. The backup MFC requests the primary MFC to shutdown and assume the role of a hot backup. The backup MFC waits to 01xx0x0x 11xx1x0x act as the primary MFC. (A hot backup is a backup which remains on-line and ready to assume control if an error is detected in the new configuration).
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ON-LINE CONFIGURATION ® Primary Backup 2. When the shutdown request is received from the backup MFC (Step 8 of the backup cycle), the primary MFC stops exe- 01xx0x0x 11xx1x0x cuting and removes the bus clock. 3. The primary MFC is now acting as the hot backup. All the Primary Backup old configuration and block output information remains intact...
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ON-LINE CONFIGURATION SHUTDOW N REQUESTED PRIMARY PRIMARY SHUTDOW N COMPLETE BUSCLK BUSCLK BACKUP BACKUP RESET CHECKPOINT DATA IS COMPLETE COPY THE PRIMARY'S CONFIGURATION BACKUP BACKUP LEGEND: STEP ROLE EXT = EXECUTE MODE MODE BUSCLK = LOSS OF BUS CLOCK TP50245A Figure A-3.
APPENDIX B - NTMF01 TERMINATION UNIT CONFIGURATION INTRODUCTION The Multi-Function Controller module (IMMFC03) uses an NTMF01 to connect with its output devices. Dipshunts on the termination unit configure the outputs. Figure shows the input connectors, dipshunts and output ports on the termination unit. CR22 MCA B ACTIVE DIPSHUNT...
NTMF01 TERMINATION UNIT CONFIGURATION ® CONFIGURING NTMF01 Figure shows the possible configurations for the dipshunts on the termination unit. It has 4 sockets numbered XU1 through XU4. The dipshunts control the output circuits for the terminal port and printer port. Connecting Application/ Dipshunt...
NTMF01 TERMINATION UNIT CONFIGURATION CABLE CONNECTIONS Figure shows the cable connections from the NTMF01 to the MFC and the output devices. The output devices are the monitor, printer and Control Station Termination Unit (NTCS02). RS-232-C TERMINAL IMMFC03/04/05 NKTU01 TERMINAL PORT NKSE01 NKTU01 PRINTER...
APPENDIX C - NIMF01 TERMINATION MODULE CONFIGURATION INTRODUCTION The Multi-Function Controller module (IMMFC03) uses an NIMF01 to connect with output devices. Dipshunts on the ter- mination module configure the inputs. For redundant systems, the MFC module uses both an NIMF01 and NIMF02 to connect with output devices (refer to Appendix D).
NIMF01 TERMINATION MODULE CONFIGURATION ® CONFIGURING NIMF01 Figure shows the dipshunts on the termination module. It has 4 sockets numbered XU1 through XU4. The dipshunts control the I/O circuits for the terminal port and printer port. Figure shows the shows the terminal assignments for NIMF01.
NIMF01 TERMINATION MODULE CONFIGURATION TERMINAL NUMBER – SERIAL LINK T00016A Figure C-3. NIMF01 Terminal Assignments CABLE CONNECTIONS Figure shows the cable connections from the NIMF01 to the MFC and the output devices. The output devices are the monitor, printer and control station termination module (NICS01).
APPENDIX D - NIMF02 TERMINATION MODULE CONFIGURATION INTRODUCTION The redundant Multi-Function Controller module (IMMFC03) uses an NIMF02 to connect with output devices. Note that the NIMF02 is used only to connect the redundant MFC. In redun- dant systems, the primary MFC module uses an NIMF01 and the redundant MFC uses the NIMF02 to connect output devices.
NIMF02 TERMINATION MODULE CONFIGURATION ® CONFIGURING NIMF02 Figure shows the dipshunts on the termination module. It has 4 sockets numbered XU1 through XU4. The dipshunts control the I/O circuits for the terminal port and printer port. NOTE: For redundant systems, be sure dipshunts are the same on both termination modules.
NIMF02 TERMINATION MODULE CONFIGURATION TERMINAL NUMBER T00019A Figure D-3. NIMF02 Terminal Assignments CABLE CONNECTIONS Figure shows the cable connections from the NIMF02 to the MFC and the output devices. The output devices are the monitor, printer and control station termination module (NICS01).
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