Bailey infi 90 Modular Power System II User manual

WARNING notices as used in this instruction apply to hazards or unsafe practices that could result in
personal injury or death.
CAUTION notices apply to hazards or unsafe practices that could result in property damage.
NOTES highlight procedures and contain information that assists the operator in understanding the
information contained in this instruction.
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. PRUDENT PRACTICE DICTATES THAT SIGNS
SHOULD BE POSTED IN THE VICINITY OF THE EQUIPMENT CAUTIONING AGAINST THE USE OF POR-
TABLE COMMUNICATIONS EQUIPMENT.
POSSIBLE PROCESS UPSETS
MAINTENANCE MUST BE PERFORMED ONLY BY QUALIFIED PERSONNEL AND ONLY AFTER SECURING
EQUIPMENT CONTROLLED BY THIS PRODUCT. ADJUSTING OR REMOVING THIS PRODUCT WHILE IT IS
IN THE SYSTEM MAY UPSET THE PROCESS BEING CONTROLLED. SOME PROCESS UPSETS MAY
CAUSE INJURY OR DAMAGE.
AVERTISSEMENT
MANUELS D’OPÉRATION
NE PAS METTRE EN PLACE, RÉPARER OU FAIRE FONCTIONNER L’ÉQUIPEMENT SANS AVOIR LU,
COMPRIS ET SUIVI LES INSTRUCTIONS RÉGLEMENTAIRES DE Elsag Bailey. TOUTE NÉGLIGENCE À
CET ÉGARD POURRAIT ÊTRE UNE CAUSE D’ACCIDENT OU DE DÉFAILLANCE DU MATÉRIEL.
PERTURBATIONS PAR FRÉQUENCE RADIO
LA PLUPART DES ÉQUIPEMENTS ÉLECTRONIQUES SONT SENSIBLES AUX PERTURBATIONS PAR
FRÉQUENCE RADIO. DES PRÉCAUTIONS DEVRONT ÊTRE PRISES LORS DE L’UTILISATION DU MATÉ-
RIEL DE COMMUNICATION PORTATIF. LA PRUDENCE EXIGE QUE LES PRÉCAUTIONS À PRENDRE
DANS CE CAS SOIENT SIGNALÉES AUX ENDROITS VOULUS DANS VOTRE USINE.
PERTURBATIONS DU PROCÉDÉ
L’ENTRETIEN DOIT ÊTRE ASSURÉ PAR UNE PERSONNE QUALIFIÉE EN CONSIDÉRANT L’ASPECT
SÉCURITAIRE DES ÉQUIPEMENTS CONTRÔLÉS PAR CE PRODUIT. L’AJUSTEMENT ET/OU L’EXTRAC-
TION DE CE PRODUIT PEUT OCCASIONNER DES À-COUPS AU PROCÉDÉ CONTRÔLE LORSQU’IL EST
INSÉRÉ DANS UNE SYSTÈME ACTIF. CES À-COUPS PEUVENT ÉGALEMENT OCCASIONNER DES
BLESSURES OU DES DOMMAGES MATÉREILS.
NOTICE
The information contained in this document is subject to change without notice.

I-E96-202B
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.
This instruction manual provides information about how the
IMMFP02 module functions and how to install, configure,
operate, and troubleshoot the module.

I-E96-202B
®
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
4-1 through 4-4 Original
5-1 through 5-12 Original
6-1 through 6-4 Original
7-1 Original
8-1 Original
A-1 through A-4 Original
B-1 through B-6 Original
C-1 through C-5 Original
D-1 through D-5 Original
Index-1 through Index-2 Original
When an update is received, insert the latest changed pages and dispose of the super-
seded pages.
NOTE: On an update page, the changed text or table is indicated by a vertical bar in the outer mar-
gin of the page adjacent to the changed area. A changed figure is indicated by a vertical bar in the
outer margin next to the figure caption. The date the update was prepared will appear beside the
page number.

I-E96-202B vii
Safety Summary
GENERAL
WARNINGS Equipment Environment
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).
SPECIFIC
WARNINGS Disconnect power before installing dipshunts on the module mount-
ing unit backplane. Failure to do so will result in contact with cabinet
areas that could cause severe or fatal shock. (p. 3-7)
Wear eye protection whenever working with cleaning solvents.
When removing solvents from printed circuit boards using com-
pressed air, injury to the eyes could result from splashing solvent as
it is blown off the printed circuit board. (p. 6-1)
SPECIFIC
CAUTIONS Never operate the MFP module with the machine fault timer circuit
disabled (jumper pins connected). Unpredictable module outputs
and configuration corruption may result. The unpredictable module
outputs may damage control equipment connected to t e MFP
module. (p. 3-9)
To avoid potential module damage, evaluate your system for com-
patibility prior to module installation. This module uses connections
to t e module mounting unit backplane that served other functions
in early Network 90 systems. (p. 3-10)

viii I-E96-202B
Sommaire de Sécurité

I-E96-202B vii
Safety Summary
GENERAL
WARNINGS Equipment Environment
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).
SPECIFIC
WARNINGS Disconnect power before installing dipshunts on the module mount-
ing unit backplane. Failure to do so will result in contact with cabinet
areas that could cause severe or fatal shock. (p. 3-7)
Wear eye protection whenever working with cleaning solvents.
When removing solvents from printed circuit boards using com-
pressed air, injury to the eyes could result from splashing solvent as
it is blown off the printed circuit board. (p. 6-1)
SPECIFIC
CAUTIONS Never operate the MFP module with the machine fault timer circuit
disabled (jumper pins connected). Unpredictable module outputs
and configuration corruption may result. The unpredictable module
outputs may damage control equipment connected to t e MFP
module. (p. 3-9)
To avoid potential module damage, evaluate your system for com-
patibility prior to module installation. This module uses connections
to t e module mounting unit backplane that served other functions
in early Network 90 systems. (p. 3-10)

viii I-E96-202B
Sommaire de Sécurité

Table of Contents
Page
I-E96-202B iii
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

iv I-E96-202B
Table of Contents (continued)
Page

List of Tables (continued)
No. Title Page
vi I-E96-202Bvi I-E96-202B

OVERVIEW
I-E96-202B 1 - 1
SECTION 1 - INTRODUCTION
OVERVIEW
The IMMFP02 Multi-Function Processor Module (MFP) is one of
the workhorses of the INFI 90®control module line. It is a mul-
tiple loop analog, sequential, batch and advanced controller
that provides powerful solutions to process control problems. It
also handles data acquisition and information processing
requirements providing true peer-to-peer communications. The
comprehensive set of function codes supported by this module
handles even the most complex control strategies. The INFI 90
system uses a variety of analog and digital I/O modules to
communicate with and control the process. The MFP module
communicates with a maximum of 64 modules in any combi-
nation (see Figure 1-1).
The MFP module has three operating modes: execute, configure
and error. In the execute mode, the MFP module executes con-
trol algorithms while constantly checking itself for errors. When
an error is found, the front panel LEDs display an error code
corresponding to the type of error found. In the configure mode,
it is possible to edit existing or add new control algorithms. In
this mode, the MFP module does not execute control algorithms.
If the MFP module finds an error while in execute mode, it auto-
matically goes into error mode. Refer to the Section 4 of this
instruction for operating mode details.
A one megabaud CPU to CPU communication link allows the
MFP module to accommodate redundant processors. This link
enables a backup MFP module to wait in a hot standby mode
while the primary MFP module executes the control algorithms.
If the primary MFP module goes off-line for any reason, a bump-
less transfer of control to the backup MFP module occurs.
INTENDED USER
Personnel installing, operating, or maintaining the MFP mod-
ule should read this manual before performing any installa-
tion, operation, or maintenance procedures. Installation
requires an engineer or technician with experience handling
electronic circuitry. Formal training in INFI 90 systems and
configuration (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.

INTRODUCTION
HARDWARE DESCRIPTION
1 - 2 I-E96-202B

INTRODUCTION
HARDWARE APPLICATION
I-E96-202B 1 - 3
Circuit Board
The circuit board features state-of-the-art circuitry. On the
board are nonvolatile random access memory (NVRAM), random
access memory (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.
HARDWARE APPLICATION
The multi-function processor module is ideally suited for appli-
cations requiring multiple loop control and module I/O. Since
it handles both analog and digital signals, the MFP module fits
into virtually any control scheme.
FEATURES
The MFP module has the following features:
•A high speed redundancy link.
•A serial communication port for station support.
•Two general purpose serial channels.
•Direct memory access circuitry.
•512 kilobytes of RAM memory.
•256 kilobytes of NVRAM memory.
INSTRUCTION CONTENT
This manual consists of eight sections and four appendices:
Introduction This section provides an overview of the module, a description
of the hardware, a glossary of unique terms, and a table of
physical, electrical, and environmental specifications.
Description and
Operation How the key circuits function is explained in this section.
Installation The handling, inspection, hardware configuration, and instal-
lation aspects of the module are described in this section.
Operating Procedures Front panel indicators and controls, and everyday operations
are discussed in this section.
Troubleshooting This section features detailed flow charts and tables that
enable quick diagnosis of error conditions and provide correc-
tive actions.
Maintenance Scheduled module maintenance is covered by this section.
Repair/Replacement
Procedures This section describes how to maintain and replace the module.

INTRODUCTION
HOW TO USE THIS MANUAL
1 - 4 I-E96-202B
®
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.
HOW TO USE THIS MANUAL
Read this instruction in sequence. Read Section 3 thoroughly.
It is important to become familiar with the entire contents of
this instruction before using the MFP module. Refer to the
table of contents or index to find specific information after the
module is operating.
1. Read and perform all steps in Section 3.
2. Thoroughly read Section 4 before applying power to the
module.
3. Refer to Section 5 if a problem occurs. This section will help
to diagnose and correct a problem.
4. Refer to Section 6 for scheduled maintenance require-
ments.
5. Go to Section 7 to find instructions on how to replace the
module.
6. Refer to Section 8 for replacement part and warranty infor-
mation.
REFERENCE DOCUMENTS
Table 1-1 lists the documents that provide additional informa-
tion for related equipment. Refer to them as needed.
NOMENCLATURE
Table 1-2 lists the nomenclatures of the MFP module and asso-
ciated equipment used in this instruction.
Table 1-1. Reference Documents
Number Document
I-E96-200 Function Code Application Manual
I-E96-401 NIMP01/02 Multi-Function Processor Termination Module
I-E96-428 NTMP01 Multi-Function Processor Termination Unit

INTRODUCTION
GLOSSARY OF TERMS AND ABBREVIATIONS
I-E96-202B 1 - 5
GLOSSARY OF TERMS AND ABBREVIATIONS
Table 1-3 lists the definitions of terms and abbreviations used
in this instruction that are unique to Bailey Controls Com-
pany.
Table 1-2. Nomenclature
Nomenclature Hardware/Description
IMMFP02 Multi-function processor module
NIMP01/02 Multi-function processor module termination module
NKMP01 MFP redundancy cable
NKMR02 RS-232-C cable
NKSE01 Serial extension cable (PVC)
NKSE11 Serial extension cable (non-PVC)
NKTU01 Termination unit cable (PVC)
NKTU02 Termination module cable (PVC)
NKTU11 Termination unit cable (non-PVC)
NKTU12 Termination module cable (non-PVC)
NTMP01 Multi-function processor module termination unit
® Network 90 is a registered trademark of Elsag Bailey Process Automation.
Table 1-3. Glossary of Terms and Abbreviations
Term Description
Configuration The act of setting up equipment to accomplish specific functions or a list of parame-
ters associated with such a setup.
Controlway High speed, redundant, peer-to-peer communication link. Used to transfer informa-
tion between intelligent modules within a process control unit.
Dipswitch A dual in-line package that contains switches.
EWS Engineering work station.
Executive Block Fixed function block that determines overall module operating characteristics.
Function Block The occurrence of a function code at a block address of a module.
Function Code An algorithm which manipulates specific functions. These functions are linked
together to form the control strategy.
I/O Expander Bus Parallel communication bus between the master and I/O modules.
MFP Multi-function processor module. A multi-loop controller with data acquisition and
information processing capabilities.
MFT Machine fault timer. Reset by the processor during normal operation. If not reset
regularly, the MFT times out and the module stops.
MMU Module mounting unit. A card cage that provides electrical and communication sup-
port for INFI 90/ Network 90®modules.
Module Bus Peer-to-peer communication link used to transfer information between intelligent
modules within a process control unit.
Node A point of interconnection to a network.
PCU Process control unit. A node on the plantwide communication network containing
control and I/O modules.

INTRODUCTION
SPECIFICATIONS
1 - 6 I-E96-202B

INTRODUCTION
I-E96-202B 2 - 1
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.
MICROPROCESSOR
The microprocessor, operating at 16 megahertz, enables mod-
ule operation and control. The operating system instructions
and function code library of the microprocessor reside in read
only memory (ROM). Since the microprocessor is responsible
for overall module operation, it communicates with all the
functional blocks. The microprocessor also constantly triggers
the machine fault timer (MFT) circuit. If the microprocessor or
module software fails and the MFT circuit is not reset, the MFT

DESCRIPTION AND OPERATION
CLOCK AND TIMER
2 - 2 I-E96-202B
®
circuit issues a board-wide reset and the status LED turns red.
This condition is known as a fatal error.
CLOCK AND TIMER
The clock section provides the clock signals that drive the mod-
ule at 16 megahertz. Additionally, this section supplies the
lower order clock signals for the on-board serial links, and the
system timer for uniform control algorithm execution. All clock
signals originate from either the 32 megahertz or 7.3728 mega-
hertz oscillators on the multi-function processor module.
The timer section keeps the multi-function processor module
task scheduling at the proper intervals. One of the UART
devices used for serial communication contains the timer
section.
MEMORY
The MFP module contains 512 kilobytes of ROM memory, 512
kilobytes of random access memory (RAM) and 256 kilobytes of
nonvolatile random access memory (NVRAM). It is important to
remember that only 347,712 bytes of RAM memory and
194,752 bytes of NVRAM memory are available for user config-
urations. The ROM memory holds the operating system
instructions for the microprocessor. The RAM memory pro-
vides temporary storage and a copy of the module configura-
tion. The NVRAM memory holds the module configuration
(control strategy designed with function codes). The ability to
retain information when power is lost makes this type of mem-
ory unique. Back-up batteries in the NVRAM device that keep
the memory active makes this possible.
A key feature of the RAM and ROM memory of the MFP module
is that it requires only one wait state. This means that the
microprocessor need only wait one clock cycle before it can
check the data in memory. This results in quicker operation.
I/O EXPANDER BUS
The I/O expander bus resides on the backplane of the module
mounting unit. This bus, an eight bit parallel bus, provides the
communication path for 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.
I/O SECTION
The input and output section interface allows the microproces-
sor to read the switches that tell it how to operate and what