Bailey E96-213 User manual

®
®
Process Control and
Automation Solutions
from Elsag Bailey Group
E96-213
Multi-Function Controller
(IMMFC05)

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.
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
fitness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the information
contained herein and/or for the fitness for any particular use and/or for the performance of any material and/
or equipment selected in whole or part with the user of/or in reliance upon information contained herein.
Selection of materials and/or equipment is at the sole risk of the user of this publication.
This document contains proprietary information of Elsag Bailey, Elsag Bailey Process Automation, and
is issued in strict confidence. Its use, or reproduction for use, for the reverse engineering, development
or manufacture of hardware or software described herein is prohibited. No part of this document may be
photocopied or reproduced without the prior written consent of Elsag Bailey.

I-E96-213A
Preface
This document explains how to configure, install, operate, and
troubleshoot the Multi-Function Controller Module (MMFC05).
Related hardware such as I/O slave modules, termination
units, etc. are also presented. A complete list of hardware doc-
uments is listed in Section 1 under the Reference Documents
heading.
Carefully read this document before putting the module into
operation.

I-E96-213A
®
List of Effective Pages
Total number of pages in this instruction 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 3-6 Original
4-1 through 4-8 Original
5-1 through 5-4 Original
6-1 through 6-7 Original
7-1 Original
8-1 Original
9-1 through 9-3 Original
A-1 through A-9 Original
B-1 through B-3 Original
C-1 through C-3 Original
D-1 through D-3 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-E96-213A 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 ensure that contact with
energized parts is avoided when servicing.
SPECIFIC
WARNINGS Disconnect power before installing dipshunts for slave modules on
the MMU backplane (slave expander bus). Failure to do so could
result in severe or fatal shock. (p. 3-6)
Strict adherence must be made with regard to the rules set forth in
this document. Follow all steps in the sequence given and at no
time change configurations or remove the module before the LEDs
instruct you to do so. Failure to heed this warning and follow proper
procedures could result in unpredictable MFC operation and/or loss
of output data. (p. A-2)

viii I-E96-213A
Sommaire de Sécurité
®
AVERTISSEMENTS
D’ORDRE
GÉNÉRAL
Environnement de l’équipement
Ne pas soumettre les composants à une atmosphère corrosive lors
du transport, de l’entreposage ou l’utilisation.
Risques de chocs électriques lor de l’entretien
S’assurer de débrancher l’alimentation ou de prendre les précau-
tions necessaires a éviter tout contact avec des composants sours
tension lor de l’entretien.
AVERTISSEMENTS
D’ORDRE
SPÉCIFIQUE
Couper l'alimentation avant d'installer les dipshunts sur la plaque
arriere du chassis de montage de modules (MMU). Toute negli-
gence a cet egard constitue un risque de choc pouvant entrainer
des blessures graves, voire moretlles. (p. 3-6)
Les procedures decrites dans ce document doivent etre suivies a la
lettre. Respecter l'ordre des etapes, et ne jamais apporter de
changements a la configuration ou retirer le module du chassis de
montage avant que les temoins DEL ne l'autorisent. Tout ecart a la
procedure decrite peut mener a un fonctionnement anormal du
MFC et/ou entrainer la perte des signaux de sortie. (p. A-2)

Table of Contents
Page
I-E96-213A iii
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
SPECIFICATIONS.........................................................................................................1-7
SECTION 2 - DESCRIPTION AND OPERATION........................................................................2-1
INTRODUCTION...........................................................................................................2-1
MODULE DESCRIPTION ..............................................................................................2-1
Microprocessor ......................................................................................................2-1
Clock/Timer ..........................................................................................................2-2
Memory .................................................................................................................2-2
Slave Expander Bus...............................................................................................2-2
I/O Section ............................................................................................................2-2
Module Bus ...........................................................................................................2-3
Redundancy Link...................................................................................................2-3
Station Link...........................................................................................................2-3
COMMUNICATION .......................................................................................................2-3
Data Transfer on Slave Expander Bus ....................................................................2-3
SECURITY FUNCTIONS................................................................................................2-4
Hardware Module Security Functions.....................................................................2-4
Internal Software Security Functions .....................................................................2-4
Control Software Security ......................................................................................2-4
I/O Security...........................................................................................................2-5
SECTION 3 - INSTALLATION.....................................................................................................3-1
INTRODUCTION...........................................................................................................3-1
HANDLING...................................................................................................................3-1
Special Handling....................................................................................................3-1
General Handling...................................................................................................3-1
SETUP .........................................................................................................................3-2
Module Address - Switch SW3................................................................................3-2
Options - Switch SW4 ............................................................................................3-2
SETUP FOR COMMUNICATION HIGHWAY ENVIRONMENT ..........................................3-4
INFI-NET/Superloop ..............................................................................................3-4
Plant Loop .............................................................................................................3-4
SPECIAL OPERATIONS ................................................................................................3-4
PHYSICAL INSTALLATION............................................................................................3-5

iv I-E96-213A
Table of Contents (continued)
Page
®
SECTION 4 - CONFIGURATION.................................................................................................4-1
INTRODUCTION .......................................................................................................... 4-1
FUNCTION BLOCKS .................................................................................................... 4-1
FUNCTION CODES ...................................................................................................... 4-5
Function Code 81 - Executive ................................................................................ 4-5
Function Code 82 - Segment Control ..................................................................... 4-6
Function Code 90 - Extended Executive................................................................. 4-8
SECTION 5 - OPERATION..........................................................................................................5-1
INTRODUCTION .......................................................................................................... 5-1
PUSHBUTTONS ........................................................................................................... 5-1
Stop Pushbutton ................................................................................................... 5-1
Reset Pushbutton .................................................................................................. 5-2
LED INDICATORS........................................................................................................ 5-2
Group LEDs .......................................................................................................... 5-2
Status LED............................................................................................................ 5-2
OPERATING MODES ................................................................................................... 5-3
Execute Mode........................................................................................................ 5-3
Configure Mode ..................................................................................................... 5-3
Error Mode ............................................................................................................ 5-3
Diagnostic Mode .................................................................................................... 5-4
SECTION 6 - TROUBLESHOOTING...........................................................................................6-1
INTRODUCTION .......................................................................................................... 6-1
ON-BOARD DIAGNOSTICS .......................................................................................... 6-3
Switch Selection .................................................................................................... 6-3
STATUS WORD DISPLAYS ........................................................................................... 6-5
EDGE CONNECTOR PIN OUTS .................................................................................... 6-7
SECTION 7 - MAINTENANCE.....................................................................................................7-1
INTRODUCTION .......................................................................................................... 7-1
MAINTENANCE SCHEDULE ........................................................................................ 7-1
SECTION 8 - REPAIR/REPLACEMENT PROCEDURES...........................................................8-1
INTRODUCTION .......................................................................................................... 8-1
MODULE REPLACEMENT............................................................................................ 8-1
SECTION 9 - SUPPORT SERVICES...........................................................................................9-1
INTRODUCTION .......................................................................................................... 9-1
REPLACEMENT PARTS AND ORDERING INSTRUCTIONS ............................................ 9-1
Ordering an MFC................................................................................................... 9-1
Ordering Firmware ................................................................................................ 9-2
TRAINING.................................................................................................................... 9-2
TECHNICAL DOCUMENTATION................................................................................... 9-3

I-E96-213A v
Table of Contents (continued)
Page
APPENDIX A - ON-LINE CONFIGURATION .............................................................................A-1
INTRODUCTION.......................................................................................................... A-1
SETUP ........................................................................................................................ A-1
OPERATION ................................................................................................................ A-1
Backup Cycle........................................................................................................ A-4
Primary Cycle ....................................................................................................... A-7
APPENDIX B - NTMF01 TERMINATION UNIT CONFIGURATION...........................................B-1
INTRODUCTION.......................................................................................................... B-1
CONFIGURING NTMF01.............................................................................................. B-2
CABLE CONNECTIONS ............................................................................................... B-3
APPENDIX C - NIMF01 TERMINATION MODULE CONFIGURATION.....................................C-1
INTRODUCTION.......................................................................................................... C-1
CONFIGURING NIMF01............................................................................................... C-2
CABLE CONNECTIONS ............................................................................................... C-3
APPENDIX D - NIMF02 TERMINATION MODULE CONFIGURATION.....................................D-1
INTRODUCTION.......................................................................................................... D-1
CONFIGURING NIMF02............................................................................................... D-2
CABLE CONNECTIONS ............................................................................................... D-3

vi I-E96-213A
No. Title Page
List of Tables
®
3-1. Switch SW3 Module Address ................................................................................. 3-2
3-2. Switch SW4 Options .............................................................................................. 3-3
3-3. Switch SW4 Special Operations ............................................................................. 3-5
4-1. Function Block Execution Rates ............................................................................ 4-2
4-2. Function Code 81 Specifications ............................................................................ 4-5
4-3. Function Code 81 Block Outputs (System Constraints) .......................................... 4-5
4-4. Function Code 82 Specifications ............................................................................ 4-6
4-5. Function Code 82 Block Outputs........................................................................... 4-7
4-6. Function Code 90 Specifications ............................................................................ 4-8
4-7. Function Code 90 Block Outputs........................................................................... 4-8
6-1. CPU LED Error Codes............................................................................................ 6-1
6-2. Diagnostic Test IDs................................................................................................ 6-4
6-3. Digital Slave Setup for Diagnostic IDs .................................................................... 6-5
6-4. Status Bytes.......................................................................................................... 6-6
6-5. Status Byte Descriptions ....................................................................................... 6-6
6-6. Edge Connector P1 Pin Outs .................................................................................. 6-7
6-7. Edge Connector P2 (Slave Expander Bus) Pin Outs ................................................ 6-7
6-8. Edge Connector P3 (Field I/O) Pin Outs ................................................................. 6-7
7-1. Maintenance Schedule........................................................................................... 7-1
8-1. Recommended Spare Parts List.............................................................................. 8-1
List of Figures
No. Title Page
1-1. IMMFC05 Application Example.............................................................................. 1-1
2-1. IMMFC05 Block Diagram....................................................................................... 2-1
3-1. User Configured Switch Locations ......................................................................... 3-3
5-1. MFC Faceplate Pushbuttons and Indicators........................................................... 5-1
9-1. IMMFC05 Firmware Revision Level Location .......................................................... 9-2
A-1. LED Legend...........................................................................................................A-3
A-2. Backup MFC Operation Cycle ................................................................................A-4
A-3. Primary MFC Operation Cycle................................................................................A-9
B-1. NTMF01 Termination Unit .....................................................................................B-1
B-2. NTMF01 Dipshunt Configurations .........................................................................B-2
B-3. NTMF01 Cable Connections...................................................................................B-3
C-1. NIMF01 Termination Module .................................................................................C-1
C-2. NIMF01 Dipshunt Configuration............................................................................C-2
C-3. NIMF01 Terminal Assignments ..............................................................................C-3
C-4. NIMF01 Cable Connections ...................................................................................C-3
D-1. NIMF02 Termination Module .................................................................................D-1
D-2. NIMF02 Dipshunt Configurations ..........................................................................D-2
D-3. NIMF02 Terminal Assignments ..............................................................................D-3
D-4. NIMF02 Cable Connections ...................................................................................D-3