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Bailey Infi 90 Instruction

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  • Page 2 WARNING INSTRUCTION MANUALS DO NOT INSTALL, MAINTAIN, OR OPERATE THIS EQUIPMENT WITHOUT READING, UNDERSTANDING, AND FOLLOWING THE PROPER Elsag Bailey INSTRUCTIONS AND MANUALS; OTHERWISE, INJURY OR DAMAGE MAY RESULT. RADIO FREQUENCY INTERFERENCE MOST ELECTRONIC EQUIPMENT IS INFLUENCED BY RADIO FREQUENCY INTERFERENCE (RFI). CAU- TION SHOULD BE EXERCISED WITH REGARD TO THE USE OF PORTABLE COMMUNICATIONS EQUIP- MENT IN THE AREA AROUND SUCH EQUIPMENT.
  • Page 3 Preface The IMMFP02 Multi-Function Processor Module is a powerful stand-alone controller for use in complex control applications. It has the processing speeds and storage capabilities necessary for advanced control applications. The IMMFP02 module is a user-configurable device that receives process input and out- put through a variety of analog and digital I/O modules.
  • Page 4 ® List of Effective Pages Total number of pages in this instruction is 72, consisting of the following: Page No. Change Date Preface Original List of Effective Pages Original iii through viii Original 1-1 through 1-6 Original 2-1 through 2-4 Original 3-1 through 3-10 Original...
  • Page 5 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. Special Handling This module uses electrostatic sensitive devices (ESD).
  • Page 6 Sommaire de Sécurité viii I-E96-202B ®...
  • Page 7 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. Special Handling This module uses electrostatic sensitive devices (ESD).
  • Page 8 Sommaire de Sécurité viii I-E96-202B ®...

  • Page 9: Table Of Contents

    Table of Contents Page SECTION 1 - INTRODUCTION ....................1-1 OVERVIEW ........................1-1 INTENDED USER ......................1-1 HARDWARE DESCRIPTION..................1-1 Faceplate .......................1-2 Circuit Board ......................1-3 HARDWARE APPLICATION...................1-3 FEATURES........................1-3 INSTRUCTION CONTENT .....................1-3 HOW TO USE THIS MANUAL ..................1-4 REFERENCE DOCUMENTS..................1-4 NOMENCLATURE ......................1-4 GLOSSARY OF TERMS AND ABBREVIATIONS .............1-5 SPECIFICATIONS ......................1-6 I-E96-202B...
  • Page 10 Table of Contents (continued) Page I-E96-202B...
  • Page 12 List of Tables (continued) Title Page I-E96-202B I-E96-202B ®...

  • Page 13: Section 1 - Introduction

    (especially function codes) would help when con- figuring the MFP module. HARDWARE DESCRIPTION The multi-function processor module consists of a faceplate and circuit board. ® INFI 90 is a registered trademark of Elsag Bailey Process Automation. OVERVIEW I-E96-202B 1 - 1...
  • Page 14 INTRODUCTION HARDWARE DESCRIPTION 1 - 2 I-E96-202B ®FaceplateThe t h e p a r e n t t h r o u g h v i d e s B e s i d e s c a b i n e t . P R O C E S S C O N T R O L U l o c k i n g...

  • Page 15: Circuit Board

    (RAM), read only memory (ROM), a microproces- sor running at 16 megahertz, direct memory access (DMA) cir- cuits, Bailey custom bus circuits and various support circuitry. The board attaches to the faceplate with two screws. The module assembly occupies one slot in a module mounting unit.

  • Page 16: How To Use This Manual

    INTRODUCTION ® Support Services A list of the replacement parts and an explanation of the war- ranty policy are contained in this section. Appendices These appendices provide quick reference information for the hardware configuration of the IMMFP02 module and associ- ated termination units and modules and step by step instruc- tions for performing on-line configuration.

  • Page 17: Glossary Of Terms And Abbreviations

    A point of interconnection to a network. Process control unit. A node on the plantwide communication network containing control and I/O modules. ® Network 90 is a registered trademark of Elsag Bailey Process Automation. GLOSSARY OF TERMS AND ABBREVIATIONS I-E96-202B...

  • Page 18: Specifications

    32 bit processor (162bit external bus) running at216 MHzMemoryTotalAvailable5122kbytes ROM5122kbytes RAM Occupies one slot in a standard INFI 90 module mounting unit. Sixty-four 40-kbaud serial stations (IISAC01) or eight 5-kbaud2serial stations (NDCS03 or NDIS01).Redundant Communication Link Rate and Type1 Mbaud serial link.Electromagnetic/RadioFrequency InterferenceValues not2available at this time. Keep cabinet doors closed. Do not use communication equipment any closer than 22meters from the cabi-net.Programmability...
  • Page 19 SECTION 2 - DESCRIPTION AND OPERATION INTRODUCTION The IMMFP02 Multi-Function Processor Module functions like a series of functional blocks working together. To explain how the MFP module works, this section shows MFP module func- tionality as a block diagram (see Figure 2-1) and then explains each block in the following text.
  • Page 20 I/O data between control and I/O modules. It supports up to 64 low power I/O modules. The bus uses a protocol designed by Bailey Controls Company to ensure data integrity. The bus bandwidth is 500 kilobytes per second, however actual throughput is about 100 kilobytes per second.
  • Page 21 32 connections. The Controlway interface is provided by a custom Bailey Controls integrated circuit that links the MFP module to the Controlway. It has full DMA capabilities (allowingdfor quicker operation), and two redundant, independent communication channels.
  • Page 22 DESCRIPTION AND OPERATION ® There are two separate communication paths on the module mounting unit backplane circuit allotted for Controlway com- munications. Data is transmitted over both channels simulta- neously and received in separate receivers where it is checked for integrity. In this way, the Controlway minimizes the chances that a failure on a circuit board, or the backplane will cause loss of module communication.
  • Page 23 Early Network 90 systems applied -30 VDC to pins 3 and 4 of the module connector P1. This voltage is not required for INFI 90 mod- ules. In INFI 90 systems, pin 4 is used for the Controlway bus. If your system contains modules that require -30 VDC, set jumper J5 to the 30 VDC position.
  • Page 24 INSTALLATION UNPACKING AND INSPECTION 3 - 2 I-E96-202B...
  • Page 25 INSTALLATION -3 0 V D C S Y S T E M (D E F A U L T ) C O N T R O L W A Y 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 S W 3 S W 4 M A C H IN E F A U L T T IM E R...
  • Page 26 INSTALLATION SETUP AND PHYSICAL INSTALLATION 3 - 4 I-E96-202B...
  • Page 27 It is applica- ble only to INFI-NET systems. NOTE: 0 = CLOSED or ON, 1 = OPEN or OFF. ® Registered trademark of Elsag Bailey Process Automation. SETUP AND PHYSICAL INSTALLATION I-E96-202B...
  • Page 28 INSTALLATION SETUP AND PHYSICAL INSTALLATION 3 - 6 I-E96-202B...
  • Page 29 NOTE: Two unlabeled jumper pins are located at the front of the MFP circuit board. These are for Bailey Controls development per- sonnel only. They are used to disable the machine fault timer circuit. If this function is disabled (jumper pins connected) and a problem develops in the MFP module, the module will not halt which may result in configuration corruption and unpredictable module outputs.
  • Page 30 INSTALLATION mounting unit backplane.NOTE: Due to high spee INSTALLING THE TERMINATION UNIT OR MODULE the bottom three tabs on the lower left of the n 2. Attach (in the s a me seq ue nc e ) the othe r e nd of the cab ure 3-2.
  • Page 31 INSTALLATION 2. Install the termination unit on the termination unit panel and secure into place. 3. Connect the hooded end of the NKTU01 or NKTU11 cable to the rear of the module mounting unit slot assigned to the MFP module. 4.
  • Page 32 INSTALLATION INSTALLING THE MODULE 3 - 10 I-E96-202B ®...
  • Page 33 SECTION 4 - OPERATING PROCEDURES INTRODUCTION Aot InelnL(ED)-5sn4( ill I)27illuDTa98herIsp51nL(ED8( ill changer) This section explains what happens to the IMMFP02 iuxp51n mhrt d˝57Tmi then otn D( )-12 illn Multi-Function Processor (MFP) Mod˝57Tmı˝0 thr(o)-7Tm then oo:n pP(d˝57Tmı˝rt)-7(i)-2 k,chsccIkd˝57sI(i t)78s c(o)-7nf(on )-12an(d˝57 bFu)-8ildd˝57sI nscces INTRODUCTION I-E96-202B 4 - 1...
  • Page 34 ®F r o n t P a n e l L E D OPERATING PROCEDURES a n d C o n t r o l s s t a r t - u p . F i g u r e 4 - 1 . I m o m e n t a r a t i n g c o n d i t i M F P m o d u l e o...
  • Page 35 OPERATING PROCEDURES Solid Green The MFP module is in execute mode. Flashing Green The MFP module is in execute mode but there is an NVRAM checksum error, or the MFP module is in configure or error mode. Solid Red The MFP module diagnostics have detected a hardware failure, configuration problem, etc.
  • Page 36 ® OPERATING PROCEDURES MODES OF OPERATION 4 - 4 I-E96-202B •Recover from a module time-out or operator-initiated stop.NOTE: Pressing and holding the stop/reset switch provides no addi-tional functionality over pressing and75.leasing the switch. To stopthe module, press and release the stop/reset switch. To reset themodule, press the stop/reset switch a second time. If the modulehalts due to an error (causing the status LED to turn red), a singlepush of the stop/reset switch resets the module.MODES OF OPERATIONThe MFP module has three operating modes. They are config-ure, execute, and error. These modes are explained in the fol-lowing paragraphs.Configure ModeUse the configure mode to enter control strategies. The MFPmodule receives configuration commands over Controlway ormodule bus and changes the data in the NVRAM memory.NOTE: The process of configuring the MFP module requires infor-mation from at least two documents. The first document is the Func-tion Code Applications Manual. This contains all of theinformation needed to design a control strategy. The second docu-ment is the instruction manual for the particular configuration tool(e.g., CAD/TXT EWS) being used. This instruction manual explainsthe steps85.quired to download control strategies into the MFP mod-ule memory. Execute ModeThe execute mode is the normal mode of operat...
  • Page 37 NVRAM memory opened Initialize the NVRAM memory. If the for write operation error recurs, replace the MFP module. If error recurs call Bailey field service. 0 0 0 0 1 1 0 1 Redundancy link Check the cable connection between communication error primary and secondary MFP modules.
  • Page 38 TROUBLESHOOTING INTRODUCTION 5 - 2 I-E96-202B...
  • Page 39 0 0 1 1 0 0 0 1 Memory or CPU fault Replace the MFP module. If error recurs, call Bailey field service. 0 0 1 1 0 0 1 0 Address or bus error Reset MFP module. If error recurs, call Bailey field service.
  • Page 40 TROUBLESHOOTING INTRODUCTION 5 - 4 I-E96-202B Figure 5-1. IMMFP02 Troubleshooting Flowchart (Serial Port)STARTF1OPEN ONTU/TM?REPLACE F1WI T H 1.0 A250 V FUSE +24 VDCCONNECTED TOTU/TM?MEASURE24 VDC ATTU/TM?NOYES NOREFER TO TMP/IMPI N STRUCTI O NS TOCONNECT POWERCHECK POWERCABLI N G TO TU/TM.CHECK POWERSYSTEM. YESNO TYPE OFT E R M IN A T IO NNTM P01NIM P01RS232CABLE W ITH NOCROSSOVERS CONNECTTU (P5 OR P6) TOCOMPUTER?NKMR02CABLE CONNECTS TM(P5 O R P6) T OCOMPUTER?DOTM/TUJUMPER SETTINGS MATCHAPPLICAT IO N?SET JUMPERSFO R APPLICAT IO NYESNOYESN...
  • Page 41 TROUBLESHOOTING TP36100B Figure 5-2. IMMFP02 Troubleshooting Flowchart (Status LED) CARD EDGE CONNECTORS Each MFP module has three card edge connectors that provide them with power and I/O. Tables 5-3, 5-4, and list the MFP module card edge connector pin assignments. CARD EDGE CONNECTORS I-E96-202B 5 - 5...
  • Page 42 TROUBLESHOOTING ® Table 5-4. IMMFP02 Connector P2 Pin Assignments Signal Signal Data Bit 1 Data Bit 0 Data Bit 3 Data Bit 2 Data Bit 5 Data Bit 4 Data Bit 7 Data Bit 6 Bus Clock Synchronization Reserved Reserved NOTE: All data bits are true low.
  • Page 43 TROUBLESHOOTING The typical procedure is to select a diagnostic test to execute, set the module dipswitches accordingly, reset the module, and observe the results on LEDs one through eight. The selected test executes repeatedly until the MFP module is reset and another test is selected.
  • Page 44 TROUBLESHOOTING ® display the diagnostic test number but LED eight will illumi- nate. LED seven is not used in test number display mode. Pole two of dipswitch SW4 selects a halt on error feature. In this mode, the MFP module halts diagnostic test execution whenever the selected test detects an error.
  • Page 45 TROUBLESHOOTING I/O Expander Bus Stall Sets a latch enabling a level 7 interrupt to occur. LED Display The front panel LEDs (see Figure 5-4) are used during diagnos- tic mode operation to display test results. DIAGNOSTICS I-E96-202B 5 - 9...
  • Page 46 TROUBLESHOOTING MODULE STATUS SUMMARY 5 - 10 I-E96-202B ®...
  • Page 47 TROUBLESHOOTING Table 5-9. IMMFP02 Module Status Report Byte MODE MODULE TYPE Bytes 3-5 combine to define other errors. Extended module type = 24 8 - 13 Unused Nomenclature (decimal digit) Firmware revision level (ASCII letter) Firmware revision level (ASCII digit) NOTE: 1.
  • Page 48 TROUBLESHOOTING MODULE STATUS SUMMARY 5 - 12 I-E96-202B ®Bytes through (continued)34502...
  • Page 49 éclaboussures qui risquent d'atteindre les yeux. The reliability of any stand-alone product or control system is affected by the maintenance of the equipment. Bailey Controls Company recommends that all equipment users practice a pre- ventive maintenance program that will keep the equipment operating at an optimum level.
  • Page 50 ®EQUIPMENT MAINTENANCE EQUIPMENT AND TOOLS REQUIRED 6 - 2 I-E96-202B...
  • Page 51 MAINTENANCE GENERAL CLEANING AND WASHING If the printed circuit board needs minor cleaning, remove dust and residue from the printed circuit board surface using clean, dry, filtered compressed air or an antistatic field service vac- uum cleaner. Another method of washing the printed circuit board is: 1.
  • Page 52 MAINTENANCE PREVENTIVE MAINTENANCE PROCEDURES 6 - 4 I-E96-202B ® N OTE:...
  • Page 53 SECTION 7 - REPAIR/REPLACEMENT PROCEDURES INTRODUCTION Repair procedures are limited to module replacement. If the IMMFP02 Multi-Function Processor Module fails, remove and replace it with another. Verify that firmware revision levels match and that the replacement module switch and jumper settings are the same as those of the failed module.
  • Page 54 SECTION 8 - SUPPORT SERVICES INTRODUCTION Bailey Controls is ready to help in the use and repair of its products. Contact the nearest sales office to make requests for sales, applications, installation, repair, overhaul and mainte- nance contract services. REPLACEMENT PARTS AND ORDERING INFORMATION When making repairs, order replacement parts from a Bailey sales office.
  • Page 55 APPENDIX A - QUICK REFERENCE M.929 9ERIAL INTRODUCTION This appendix provides quick reference information to aid in the hardware configuration of the IMMFP02 Multi-Function Processor Module. Table show the settings for dipswitches SW3 and SW4. Table shows the jumper set- tings for jumper J5.
  • Page 56 QUICK REFERENCE MATERIAL INTRODUCTION A - 2 I-E96-202B ® 8 Primary MFP module.1 Redundant MFP module.NOTES: 0 = CLOSED or ON, 1 = OPEN or OFF.
  • Page 57 QUICK REFERENCE MATERIAL Table A-4. IMMFP02 Module Error Codes (continued) Code Condition 8 7 6 5 4 3 2 1 0 0 0 1 0 0 1 0 Primary and secondary module addresses are different 0 0 0 1 0 0 1 1 ROM memory checksum error 0 0 0 1 0 1 0 0 MFP set for INFI-NET, when actu-...
  • Page 58 QUICK REFERENCE MATERIAL INTRODUCTION A - 4 I-E96-202B ® T able A-5. Other IMMFP022Module LED ConditionsLED Condition Problem...
  • Page 59 APPENDIX B - ON-LINE CONFIGURATION INTRODUCTION Using on-line configuration in conjunction with redundant IMMFP02 Multi-Function Processor Modules enables the mak- ing of configuration changes without affecting the primary MFP module or interrupting the control process. INTRODUCTION I-E96-202B B - 1...
  • Page 60 ON-LINE CONFIGURATION OPERATION 1 76543210176543210 B - 2 I-E96-202B ®...
  • Page 61 ON-LINE CONFIGURATION OPERATION I-E96-202B B - 3...
  • Page 62 ON-LINE CONFIGURATION OPERATION B - 4 I-E96-202B...
  • Page 63 ON-LINE CONFIGURATION Figure B-1. Backup MFP Module Operating Cycle This information is provided for status purposes. Follow the backup cycle procedures to perform on-line configuration. OPERATION I-E96-202B B - 5 1BACKUPEXT10PRIMARYEXTCONFIGURATIONIS COPIED TOTHE BACKUPRESET(NO CHANGE)INITIALIZEEEROMCFGBUSCLK RESET (CONFIGURATIONNOT COPIED) BUSCLK BUSCLK CFGCHECKPOINT DATAIS COMPLETERESET(CHANGES MADE) CHECKPOINTDATA ISCOMPLETEEXT EXT2BACKUPCFG4BACKUPEXT5BACKUPEXT9PRIMARYEXT6BACKUPEXT7BACKUPEXT8BACKUPEXT3BACKUPERR...
  • Page 64 ON-LINE CONFIGURATION OPERATION B - 6 I-E96-202B ® n F 4 B B 5 = S C...
  • Page 65 INTRODUCTION The IMMFP02 Multi-Function Processor Module can use the NTMP01 termination unit for termination. Jumpers on the NTMP01 unit configure the two RS-232(3)--12(t9r)0(2(t)13p(n)3(rts)-12 port. Refer to the NTMP01 product instruction for complete information on applications. Figures through show the jumper configurations for jumpers J1 and J2.
  • Page 66 NTMP01 TERMINATION UNIT CONFIGURATION INTRODUCTION C - 2 I-E96-202B ®Figure...
  • Page 67 NTMP01 TERMINATION UNIT CONFIGURATION J1 AND J2 TXD-A DB25-3 RXD-A DB25-2 RTS-A DB25-4 CTS-A DB25-5 TP22116A Figure C-4. NTMP01 Loopback Jumper Configuration +12 V J6 AND J8 DB25-6 J5 AND J9 DB25-8 J7 AND J10 DB25-20 J4 AND J3 PROT-GND DB25-1 DB25-7 NOTE: JUMPERS J3, J8, J9 AND J10 RELATE TO...
  • Page 68 NTMP01 TERMINATION UNIT CONFIGURATION INTRODUCTION C - 4 I-E96-202B ® F C P C P J C P C P J...
  • Page 69 NTMP01 TERMINATION UNIT CONFIGURATION TO NTCS04 (CABLE REQUIRED ONLY IF STATIONS ARE USED) NKTU01 NKSE01 NKSE01 NKTU11 NKSE11 NKSE11 IMMFP0_ RS-232-C PORTS NKTU01 NTMP01 NKTU11 NOTE: P5 AND P7 CANNOT BE IMMFP0_ USED AT THE SAME TIME. RS-485 PORT REDUNDANT IMMFP0_s WITH OR WITHOUT STATIONS (NDCS03/IISAC01 AND/OR NDIS01) AND WITH RS-232-C PORTS TP36172A Figure C-8.
  • Page 70 P7 is used instead of P5. NOTES: RS-232-C port connections on the IMP module are through DB-9 connectors. Use Bailey Controls cable NKMR02 to connect a standard piece of equipment (computer or printer with a DB-25 con- nector) to the IMP module.
  • Page 71 NIMP01/NIMP02 TERMINATION MODULE CONFIGURATION ® J1 AND J2 TXD-A DB9-2 RXD-A DB9-3 RTS-A DB9-7 CTS-A DB9-8 TP22148A Figure D-1. DTE Jumper Configuration for NIMP01 Termination Module TXD-A RXD-A RTS-A CTS-A TP22147A Figure D-2. DCE Jumper Configuration for NIMP01 Termination Module INTRODUCTION D - 2 I-E96-202B...
  • Page 72 NIMP01/NIMP02 TERMINATION MODULE CONFIGURATION J1 AND J2 DB9-2 TXD-A RXD-A DB9-3 RTS-A DB9-7 DB9-8 CTS-A TP22149A Figure D-3. NIMP01 Nonhandshake Jumper Configuration TP22150A Figure D-4. NIMP01 Loopback Jumper Configuration Figure D-5. NIMP01 Jumpers J5 through J10 Configuration INTRODUCTION I-E96-202B D - 3...
  • Page 73 NIMP01/NIMP02 TERMINATION MODULE CONFIGURATION INTRODUCTION D - 4 I-E96-202B...
  • Page 74 NIMP01/NIMP02 TERMINATION MODULE CONFIGURATION IMMFP0_ IMMFP0_ Figure D-8. NIMP01 and NIMP02 Cable Connections for Redundant MFP Modules Figure D-9. NIMP01 Cable Connections for a Single MFP Module INTRODUCTION I-E96-202B D - 5...
  • Page 75 Index Abbreviations.............. 1-5 I-E96-XXXx DSD 28 February 1994 Index - 1...
  • Page 76 Index (continued) Index - 2 28 February 1994 DSD I-E96-XXXx LLatching screws ............3-10L...
  • Page 77 For prompt, personal attention to your instrumentation and control needs or a full listing of Bailey representatives in principal cities around the world, contact the Bailey location nearest you. Australia Japan United Kingdom Elsag Bailey Pty. Limited Bailey Japan Company, Ltd.

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