Bailey INFI 90 INPPR01 Instruction

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Process Control and Automation Solutions from Elsag Bailey Group

Plant Loop to Plant Loop Remote Interface

(INPPR01)

E96-624

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 EQ UIPMENT WITHOUT READING, UNDERSTANDING, AND FOLLOWING THE PROPER DAMAGE MAY RESULT.

Elsag Bailey

INSTRUCTIONS AND MANUALS; OTHER WISE, INJURY OR

RADIO FREQUENCY INTERFERENCE

MOST ELECTRONIC EQUIPMENT IS INFLUENCED BY RAD IO FREQUENCY INTERFERENCE (RFI). CAUTION SHOULD BE EXERCISED WITH REGARD TO THE USE OF PORTABLE COMMUNICATIONS EQUIPMENT 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 PORTABLE COMMUNICATIONS EQUIPMENT.

POSSIBLE PROCESS UPSETS

MAINTENANCE MUST BE PERFORMED ONLY BY QUALIFIE D PER SONNEL AN D ONLY AFTE R SEC URING 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 CET ÉGARD POURRAIT ÊTRE UNE C AUSE D’ACC IDENT OU DE DÉFAILL ANCE DU MA TÉRIEL.

Elsag Bailey

. TOUTE NÉGLIGENCE À

PERTURBATIONS PAR FRÉQUENCE RADIO

LA PLUPART DES ÉQUIPEMENTS ÉLECTRONIQUES SONT SENSIBLES AUX PERTURBATIONS PAR FRÉQUENCE RADIO. DES PRÉCAUTIONS DEVR ONT ÊTRE PRISES LORS DE L’UTILISATION DU MATÉRIEL DE COMMUNICATION PORTATIF. LA PRUDENCE EXIGE QUE LES PRÉCAUTIONS À PRENDRE DANS CE CAS SOIENT SIGNALÉES AU X ENDROITS VO ULUS DANS VOTR E 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’EXTRACTION DE CE PRODUIT PEUT OCCAS IONNER DES À-COUPS AU PROCÉD É CONTRÔLE LORSQU’IL EST INSÉRÉ DANS UNE SYSTÈME ACTIF. CES À-COUPS PEUVENT ÉGALEMENT OCCASIONNER DES BLESSURES OU DES DOMMAGES M ATÉREILS.

NOTICE

The information contained in this docume nt is s ubj ect to change wi thout noti ce. Elsag Bailey, i ts af fili at es , em pl oye es , an d a gen ts, a n d th e a u thor s an d co ntr ib utors to this publ ica ti on specif-

ically disclaim all liabilities and warranties, express and implied (including warranties of merchantability and fitness for a pa rt icu lar p urp os e) , fo r the ac cur a cy, cur r en cy, co mple t en ess, an d/ o r r eliability of t he i nfo r mati on 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 i nformation of Elsag Baile y, Elsag Bailey Proces s Automation, and is issued in strict confidence. Its use, or reproduc tion for use, for the re verse engineering, de velopment or manufacture of hardware or software described herein is prohibited . No part of this docume nt may be photocopied or reproduced without the prior written c onse nt of El sag B aile y.

Preface

The Plant Loop to Plant Loop Remote Interface (INPPR01) enables communication between a local and remote Plant Loop. The interface consists of three modules, the Plant Loop to Plant Loop Transfer Module (INPPT01), the Bus Transfer Module (INBTM01) and the Loop Interface Module (INLIM03). Plant Loop to Plant Loop Remote Interfaces connect through cable, modem or microwave link.

This instruction explains PPR features, specifications, and operation. It also includes installation and troubleshooting procedures for the interface.

The system engineer or technician using the INPPR01 should read and understand this instruction before installing the interface modules. In addition, a complete understanding of the INFI 90 system is beneficial to the user.

I-E96-624A

List of Effective Pages

Total number of pages in this manual is 62, 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 3-13 Original 4-1 through 4-10 Original 5-1 through 5-5 Original 6-1 Original 7-1 Original 8-1 Original A-1 through A-5 Original

B-1 through B-2 Original C-1 through C-4 Original D-1 through D-2 Original

When an update is received, insert the latest changed pages and dispose of the superseded pages.

NOTE:

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.

On an update page, the changed text or table is indicated by a vertical bar in the outer mar-

I-E96-624A

Safety Summary

GENERAL

WARNINGS

SPECIFIC

WARNINGS

SPECIFIC

CAUTIONS

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.

Special Handling

This unit uses Electrostatic Sensitive Devices (ESD).

Disconnect power befo re installing dip shunts for slave mo dules on the MMU backplane (sla ve expander bus). Failure to do so could result in severe or fatal shock. (p. 3-10)

Ensure that the cable end marked J1 is connected to P1 on the NICL01, and J2 is connected to the LIM. Failure to do so could result in module damage (see Figure D-1). (p. D-1)

I-E96-624A vii

Sommaire de Sécurité

AVERTISSEMENTS

D’ORDRE

GÉNÉRAL

AVERTISSEMENTS

D’ORDRE

SPÉCIFIQUE

ATTENTIONS

D’ORDRE

SPÉCIFIQUE

Envirmonent de l'dquipement

Ne pas soumettre le s comp osants a une atmo sphere corr osive lors du transport, de l'entreposage ou de l'utilisation.

Rissques de chocs electriques lors de l'entretien

S'assurer de debranche r l'alimentation ou de prendre les precautions necessaires a eviter tout contact avec des composants sours tension lors de l'enretien.

Precautions de manutention

Ce module contient des composantes sensibles aux decharges electro-statiques.

Couper l'alimentation avant d'installer les dipshunts sur la plaque arrlere du chassis de montage de modules (MMU). Toute negligence a cet egard constitue un risque de choc pouvant entrainer des blessures graves, voire moretlles. (p. 3-10)

S'assuree que L'extremite ide ntifiee par J1 est reli ee a P1 du module NICL01 et que J2 est r eliee au modu le LIM. S inon, les mo dules pouiraient etre endommages (voir la figure D-1). (p. D-1)

viii I-E96-624A

Page

SECTION 1 - INTRODUCTION....................................................................................................1-1

OVERVIEW ..................................................................................................................1-1

INTENDED USER.........................................................................................................1-1

HARDWARE DESCRIPTION..........................................................................................1-2

Plant Loop to Plant Loop Transfer Module (INPPT01) ..............................................1-2

Bus Transfer Module (INBTM01) ............................................................................1-2

Loop Interface Module (INLIM03)............................................................................1-2

Additional Hardware ..............................................................................................1-2

FEATURES...................................................................................................................1-2

INSTRUCTION CONTENT .............................................................................................1-3

HOW TO USE THIS MANUAL .......................................................................................1-3

GLOSSARY OF TERMS AND ABBREVIATIONS .............................................................1-4

REFERENCE DOCUMENTS..........................................................................................1-5

NOMENCLATURE ........................................................................................................1-5

SPECIFICATIONS.........................................................................................................1-6

SECTION 2 - DESCRIPTION AND OPERATION........................................................................2-1

INTRODUCTION...........................................................................................................2-1

LOCAL/REMOTE COMMUNICATIONS..........................................................................2-1

DATA INTEGRITY.........................................................................................................2-2

TIMING INTERVAL .......................................................................................................2-2

Transmit/Receive Timing .......................................................................................2-3

SECTION 3 - INSTALLATION .....................................................................................................3-1

INTRODUCTION...........................................................................................................3-1

SPECIAL HANDLING ....................................................................................................3-1

UNPACKING AND INSPECTION ....................................................................................3-1

INPPT01 SWITCH SETTINGS........................................................................................3-1

Option Switch (U72)...............................................................................................3-2

Serial Port Communication Rate (U73) ...................................................................3-3

Loop Address (U75)................................................................................................3-4

INLIM03 SWITCH SETTINGS........................................................................................3-5

INBTM01 SWITCH SETTINGS.......................................................................................3-7

TERMINATION UNIT (MODULE) CONFIGURATION .......................................................3-8

NTMF01/NIMF01/NIMF02 Configuration...............................................................3-8

One-way Control..............................................................................................3-8

Two-way Control............................................................................................3-10

NTCL01/NICL01 Configuration ............................................................................3-10

INSTALLING THE INTERFACE MODULES ..................................................................3-10

Installing the INPPT01 .........................................................................................3-10

Installing the INLIM03 and INBTM01 ...................................................................3-11

INSTALLING A REDUNDANT INTERFACE...................................................................3-12

INTERFACE CONFIGURATION ...................................................................................3-12

SECTION 4 - OPERATING PROCEDURES................................................................................4-1

INTRODUCTION...........................................................................................................4-1

PLANT LOOP TO PLANT LOOP TRANSFER MODULE LEDs AND CONTROLS ................4-1

Status LED ............................................................................................................4-2

CPU LEDs..............................................................................................................4-2

Memory LEDs ........................................................................................................4-2

I-E96-624A iii

Table of Contents

SECTION 4 - OPERATING PROCEDURES

Stop Pushbutton ................................................................................................... 4-2

Reset Pushbutton.................................................................................................. 4-2

LOOP INTERFACE MODULE LEDs .............................................................................. 4-3

BUS TRANSFER MODULE LED ................................................................................... 4-3

MODES OF OPERATION .............................................................................................. 4-3

Configure Mode ..................................................................................................... 4-4

Execute Mode........................................................................................................ 4-4

Error Mode............................................................................................................ 4-5

One-Way Control................................................................................................... 4-5

Two-Way Control ................................................................................................... 4-6

REDUNDANT INTERFACE OPERATION ....................................................................... 4-6

INTERFACE POINT CAPACITY ..................................................................................... 4-7

MEMORY USAGE EXAMPLE........................................................................................ 4-8

Memory Usage in the Local PPT .............................................................................4-8

Memory Usage in the Remote PPT.......................................................................... 4-8

SECURITY FUNCTIONS ............................................................................................... 4-9

Hardware Checks .................................................................................................. 4-9

Software Checks.................................................................................................... 4-9

Utilities .................................................................................................................4-9

(continued)

Page

(continued)

SECTION 5 - TROUBLESHOOTING...........................................................................................5-1

INTRODUCTION .......................................................................................................... 5-1

Status Bytes.......................................................................................................... 5-2

SECTION 6 - MAINTENANCE.....................................................................................................6-1

INTRODUCTION .......................................................................................................... 6-1

MAINTENANCE SCHEDULE ........................................................................................6-1

SECTION 7 - REPAIR/REPLACEMENT PROCEDURES...........................................................7-1

INTRODUCTION .......................................................................................................... 7-1

MODULE REPAIR/REPLACEMENT.............................................................................. 7-1

SECTION 8 - SUPPORT SERVICES...........................................................................................8-1

INTRODUCTION .......................................................................................................... 8-1

REPLACEMENT PARTS AND ORDERING INFORMATION ............................................. 8-1

TRAINING.................................................................................................................... 8-1

TECHNICAL DOCUMENTATION................................................................................... 8-1

APPENDIX A - TERMINATION UNIT CONFIGURATION (NTMF01) ........................................ A-1

INTRODUCTION ..........................................................................................................A-1

APPENDIX B - TERMINATION UNIT CONFIGURATION (NTCL01)......................................... B-1

INTRODUCTION ..........................................................................................................B-1

APPENDIX C - TERMINATION MODULE CONFIGURATION (NIMF01/NIMF02) .................... C-1

INTRODUCTION ..........................................................................................................C-1

iv I-E96-624A

Table of Contents

(continued)

Page

APPENDIX D - TERMINATION MODULE CONFIGURATION (NICL01)...................................D-1

INTRODUCTION..........................................................................................................D-1

List of Figures

No. Title Page

1-1. Diagram of Plant Loop to Plant Loop Remote Interfaces in Two-Way Control Mode ..1-1

2-1. Send/Receive Timing Diagram ...............................................................................2-4

3-1. Switch Locations on the PPT (CPU board) ...............................................................3-2

3-2. LIM Switch Locations.............................................................................................3-5

3-3. BTM Switch (SW1) Location ...................................................................................3-7

3-4. NTMF01 and NTCL01 in a Redundant Installation .................................................3-9

3-5. NIMF01/NIMF02 and NICL01 in a Redundant Installation .....................................3-9

3-6. Redundant Transceiver ........................................................................................3-13

4-1. PPT Faceplate LEDs ...............................................................................................4-1

4-2. LIM Faceplate LEDs ...............................................................................................4-3

4-3. BTM Faceplate LEDs..............................................................................................4-4

4-4. Local Plant Loop Using Bosth Serial Ports in One-Way Control ...............................4-5

4-5. Local and Remote Plant Loops in Two-Way Control ................................................4-6

4-6. PPT Utilities Menu ...............................................................................................4-10

A-1. Dipshunt Configuration for PPT Acting as DTE (Requires Modem or Other DCE) ... A-1

A-2. Dipshunt Configuration for Direct Connection with Local PPT Acting as DTE ........ A-2

A-3. Dipshunt Configuration for Direct Connection with Remote PPT Acting as DCE ..... A-3

A-4. Dispshunt Configuration for Diagnostic Terminal (Port 1 only) .............................. A-4

A-5. DB-25 Pin Assignments and RS-232-C Signals ..................................................... A-5

B-1. NTCL01 Termination Unit and Terminal Assignments ........................................... B-2

C-1. Dipshunt Configuration for PPT Acting as DTE (requires Modem or Other DCE) .... C-1

C-2. Dipshunt Configuration for Direct Connection of Local PPT Acting as DTE ............ C-2

C-3. Dipshunt Configuration for Direct Connection of Remote PPT Acting as DCE ........ C-3

C-4. Dispshunt Configuration for Diagnostic Terminal.................................................. C-4

D-1. Typical Twinax Cable Connection for the NICL01 .................................................. D-2

I-E96-624A v

List of Tables

No. Title Page

3-1. Option Switch (U72) Settings ................................................................................ 3-2

3-2. Serial Port Communication Rate (U73)................................................................... 3-3

3-3. Message Throughput ............................................................................................. 3-4

3-4. U75 Loop Addresses ............................................................................................. 3-4

3-5. LIM Event Counter Addresses (SW1) ...................................................................... 3-5

3-6. LIM Error Counter Addresses (SW1) ...................................................................... 3-6

3-7. LIM Node Address Setting (SW2) ............................................................................ 3-7

3-8. BTM Options (SW1) ............................................................................................... 3-8

3-9. INPPR01 Function Codes..................................................................................... 3-13

4-1. PPT Status LED States ..........................................................................................4-2

4-2. BTM Status LEDs States ....................................................................................... 4-4

4-3. Memory Usage in Receiving Communication .......................................................... 4-7

4-4. Memory Usage in Sending Communication ............................................................ 4-8

5-1. PPT Error Codes .................................................................................................... 5-1

5-2. Status Bytes.......................................................................................................... 5-2

5-3. Status Byte Definitions.......................................................................................... 5-3

5-4. LIM Edge Connector P3 Pin Assignments ............................................................... 5-3

5-5. BTM Edge Connector P1 Pin Assignments.............................................................. 5-4

5-6. PPT CPU Board Edge Connector P2 Pin Assignments .............................................5-4

5-7. PPT CPU Board Edge Connector P3 Pin Assignments .............................................5-4

6-1. Maintenance Schedule........................................................................................... 6-1

B-1. NTCL01 Terminal Assignments..............................................................................B-1

B-2. BNC Terminal Assignments ...................................................................................B-1

B-3. Jumper Settings and Cable Types..........................................................................B-2

D-1. NICL01 Terminal Assignments...............................................................................D-1

D-2. BNC Assignments..................................................................................................D-1

D-3. Jumper Settings and Cable Types..........................................................................D-2

vi I-E96-624A

OVERVIEW

INTENDED USER

SECTION 1 - INTRODUCTION

The Plant Loop to Plant Loop Remote Interface (INPPR01) enables communication between a local and remote Plant Loop. Two modes (user-selectable) of control are available. A local Plant Loop is able to issue control commands and receive Exception Report (XR) data from up to 32 remote Plant Loops when it is in the one-way mode. Only the local Plant Loop can initiate control commands and request exception reports in the one-way mode. The two-way mode connects only two Plant Loops. In the two-way mode, either Plant Loop is able to initiate control commands and request exception reports. Plant Loop to Plant Loop Remote Interfaces can connect through cable, modem or microwave link. Figure 1-1 shows a block diagram of Plant Loop to Plant Loop Remote Interfaces in two-way control. The INPPR01 is a direct replacement of the Network 90 Plant Loop to Plant Loop Gateway (NPPG02).

System engineers and technicians should read this manual before installing and operating the INPPR01 module. Refer to the Table of Contents to find specific information after the module is operating.

INPPR01 INPPR01

LIM PPT

ICL IMFIMF ICL

LEGEND: BTM = B US TRANSFER MODULE IMF = MULTI-FUNCTION CONTROLLER TERMINATION MOD U L E ICL = COMM U N IC ATION TERMINATION M OD ULE LIM = LOOP INTERFACE MO D U L E PPT = PLANT LOOP TO PLANTLOOP T RANSFER MODULE

BTM BTMPPT LIM

DMA

CABLE

MODULE BUS MODULE BUS

PLANT LOOP PLANT LOOP

DMA

CABLE

Figure 1-1. Diagram of Plant Loop to Plant Loop Remote Interfaces in

Two-Way Control Mode

T00417A

OVERVIEW

I-E96-624A 1 - 1

INTRODUCTION

HARDWARE DESCRIPTION

The Plant Loop to Plant Loop Remote Interface acts as another node on the Plant Loop. The interface consists of three modules on a dedicated module bus.

Plant Loop to Plant Loop Transfer Module (INPPT01)

This module processes incoming and outgoing Plant Loop messages, buffers data and communicates with other PPT modules in remote Plant Loops. The PPT is a double circuit board module. It has a memory board and CPU board. The user selects general operating characteristics and point definitions through software configuration. Other characteristics such as type of control (one-way or two-way), Node ID and port options are user-configured through dipswitches on the CPU board.

Bus Transfer Module (INBTM01)

The BTM is responsible for translating messages from the LIM and placing them on the module bus. It also receives messages from the PPT. It translates those messages and sends them to the LIM through a direct memory access (DMA) cable.

Loop Interface Module (INLIM03)

The LIM provides the communication link between the Plant Loop and the PPT. It receives messages from Plant Loop nodes and monitors loop status. The LIM forwards messages from the loop to the PPT (though the BTM) via a direct memory access (DMA) cable. Additionally, it receives messages from the PPT (through the BTM) and sends them to the proper node on the loop.

Additional Hardware

Some applications require additional hardware such as a modem network, radio link or microwave link. This hardware is not part of the INPPR01 standard hardware. INFI 90 Digital Slave Modules (IMDSO01 through IMDSO04, IMDSM05) support control signals to these devices.

FEATURES

The Plant Loop to Plant Loop Remote Interface provides communication between a local loop and one or more remote loops. This interface has user selectable control modes. Selecting the one-way mode enables a local loop to receive exception reports from up to 32 remote loops. In the one-way mode, only the local loop can initiate control commands. The two-way mode enables bidirectional control and exception reporting between

HARDWARE DESCRIPTION 1 - 2 I-E96-624A

INSTRUCTION CONTENT

INTRODUCTION

a local and one remote loop. This interface handles a maximum capacity of 5,000 blocks of exception report data.

The INPPR01 can handle a mixture of point types. Point types include analog and digital station, remote control memory, manual set constant and device driver. The user can select the interface communication rate, up to 19.2 kbaud.

This document is divided into eight sections. Introduction provides an overview of the individual modules of the PPR, a list of related documents, glossary of terms and abbreviations and specifications. Description and Operation explains how PPR communication occurs. Installation covers preliminary module setup, physical installation and configuration. Operat-

ing Procedures explains faceplate LEDs, controls and inter-

face operating modes. Troubleshooting explains how to troubleshoot problems with the interface modules using error codes and status byte information and lists the corrective action. Maintenance contains a maintenance schedule for the slave module. Repair/Replacement Procedures explain how to replace the PPR modules. Support Services explains the customer training Bailey Controls Company provides and information about ordering replacement parts.

HOW TO USE THIS MANUAL

Read this manual in sequence. It is important to become familiar with the entire contents of this manual before using the PPR. The organization of this manual enables the user to find needed information quickly.

1. Read and do the steps in Section 3.

2. Read Section 4 thoroughly before powering up the station.

3. Refer to Section 5 if a problem occurs.

4. Refer to Section 6 for scheduled maintenance requirements.

5. Use the Section 8 for a list of replacement parts and warranty information.

INSTRUCTION CONTENT

I-E96-624A 1 - 3

INTRODUCTION

GLOSSARY OF TERMS AND ABBREVIATIONS

Term Definition

DCE

DTE

Dipshunt EWS

Module Bus

Node

OIS

PCI

PCU

Plant Loop RS-232-C

Slave Expander Bus

Data Circuit-Terminat ing Equipment - The term ination point of a communication circuit such as a line driver or modem.

Data Terminal Equipment - End-user machine of a communication circuit such as a terminal or computer.

A dual in-line package with shorting bars. Engineering Work Station - An integrated hardware and software personal computer

system for configuring and monitoring INFI 90/Network 90 modules. The serial communication link between a process control module and other process

control modules. Device(s) on the INFI 90/Network 90 Plant Loop, Superloop or INFI-NET (maximum

of 63 on Plant Loop, 250 on Superloop/INFI-NET). A node can be an Operator Interface Station (OIS), a Process Control Unit (PCU) or Engine ering Work Station (EW S) in any combination.

Operator Interface Station - Integrated operator console with data acquisition and reporting capabilities. It provides a window into the process for flexible control and monitoring.

Plant Loop to Computer Interface (INPCI01/02) - A Plant Loop communication interface that provides configuration and control of the Plant Loop through a host computer.

Process Control Unit - Rack type industrial cabinet that contains master, slave and communication modules and their communication paths.

INFI 90 data communication highway with 63 node capacity. One in a series of standards developed b y the Ele ctro nic s In dus try As so cia tio n (EIA)

that specifies what signals and volt ag es wil l b e used to transmit data from D TE (computer) to DCE (modem).

Parallel address/data bus between the master module and the slave.

Exception Report - A function block that reports a monitored point value when that value changes and is polled by a communication or master module.

GLOSSARY OF TERMS AND ABBREVIATIONS 1 - 4 I-E96-624A

REFERENCE DOCUMENTS

INTRODUCTION

The following documents provide additional information about INPPR01 support hardware and software. Please refer to them as needed.

Document Number Document

I-E96-309 Digital Slave Module (I MDSM05) I-E96-310 Digital Slave Output Module (IMDSO01/02/03) I-E96-313 Digital Slave Output Module (IMDSO04) I-E93-905-2 Enhanced CIU Programmer's Reference Manual I-E93-900-20 Function Code Application Manual I-E96-611 Loop Interface/Bus Interface Module

(INLIM03/INBIM02) I-E96-110 Operator Interface Station I-E96-620 Plant Loop to Computer Interface (INPCI01) I-E96-621 Plant Loop to Computer Interface (INPCI02) I-E93-900-5 Site, Planning and Equipment Installation I-E93-911 Termination Unit Manual

NOMENCLATURE

Hardware Nomenclature

Field Termination Panel NFTP01 Module Mounting Unit IEMMU01/02 Multi-Function Controller Termi nation Module

Redundant Termination Module Cable

Multi-Funct ion Controller Termination Unit

Cable

Communication Termination Module

Cable

Communication Termination Unit

Cable

Termination Mounting Unit NTMU01/02

NIMF01 NIMF02 NKTM01

NTMF01 NKTU01

NICL01 NKLS04

NTCL01 NKLS03

REFERENCE DOCUMENTS

I-E96-624A 1 - 5

INTRODUCTION

SPECIFICATIONS

Memory

PPT

256 kbytes UVROM 512 kbytes RAM 80 kbytes NVM (non-volatile memory)

LIM

BTM

I/O Ports Communication Rates Power Requirements

PPT

LIM

BTM

Environmental

Electromagnetic/Radio Frequency Interference

Ambient Temperature Relative Humidity

Altitude

2 kbytes RAM 4 kbytes ROM

32 kbytes RAM 16 kbytes ROM

2 RS-232C serial ports 50 to 19,200 baud (user selectable)

6 amps @ +5 VDC; 30 watts 37 mA @ +15 VDC; 0.55 watts 18 mA @ -15 VDC; 0.27 watts

+5 VDC @ 2.0 amps; 10 watts nominal

15 VDC @ 80 mA; 1.2 watts nominal

+5 VDC @ 1.0 amps; 5 watts nominal +15 VDC @ 150 mA; 2.25 watts nominal

-15 VDC @ 120 mA; 1.80 watts nominal

Values are not avail able a t th is time. Keep cabi net doo rs clo sed. Do no t use co mmunication equipment any closer than two meters from the cabinet.

to 70oC (32o to 158oF)

0 0 to 95% up to 55

0 to 45% at 70

C (131oF) (non-condensing)

C (158oF) (non-condensing)

Sea level to 3 Km (1.86 miles)

Air Quality

Certification

Noncorrosive All INPPR01 modules have been individually CSA certified for use as process

control equipment in an ordinary (nonhazardous) environment.

Specifications Subject To Change Without Notice

SPECIFICATIONS 1 - 6 I-E96-624A

SECTION 2 - DESCRIPTION AND OPERATION

INTRODUCTION

This section explains the operation of the Plant Loop to Plant Loop Remote Interface.

LOCAL/REMOTE COMMUNICATIONS

Local and remote PPTs communicate with each other through a series of commands and replies over the serial ports. In the one-way mode, the local PPT issues commands only; in two-way, both the local and remote PPTs issue commands. The command format is:

12345

Loop Number

where:

Message Byte Count

Command Code

Command Data

Checksum or CRC

1. Loop number is the loop that responds to the command (1 byte field).

2. Message byte count is the total length of the message (2 byte field).

3. Command code is the command code the PPT processes (1 byte field).

4. Command data is the specific command (variable length field).

5. Checksum is the sum of all the bytes in the command (1 byte field) or CRC, the cyclic redundancy check word computed for all of the bytes in the command using the CRC-16 algorithm (2 byte field).

All communications between interfaces use this format. INPPR01 commands are a modified form of Plant Loop to Computer Interface commands (refer to I-E93-905-9 for command details). The PPT format eliminates the key field from the PCI command. In addition to PCI commands, the PPT processes a command (code 29) that permits passage of a required PPT message.

INTRODUCTION

I-E96-624A 2 - 1

DESCRIPTION AND OPERATION

DATA INTEGRITY

Verification of data integrity consists of even parity checking and the checksum in each command and reply format. The interface retries a transaction whenever it detects a communication error.

There are two levels of communication breakdown detection. The first level detects a complete failure of the communication link. Should this occur, Function Code 130 output block one will be set (logic one) and the alarm status bit set if port 1 fails. If port 0 fails, the output of block two will be set (logic one) and the alarm status bit set.

The second level of communication failure concerns the loss of a single remote interface. If this occurs, all blocks coming from that remote interface are bad quality. The PPR makes use of a user-configurable watchdog timer or absolute retry count in determining the sensitivity to these failures (refer to I-E93-200-20 for information about Function Code 130, S10 and S12).

TIMING INTERVAL

The local interface attempts communication twice a second with all the remote interfaces. Each successful transaction resets the communication watchdog timer. Therefore, if the communication link is faulty, no transactions occur successfully. After the watchdog time period expires, the link is marked bad.

For all communication transactions, the watchdog timer is reset on the reception of each character. If the time interval between characters in a transaction exceeds 1.25 seconds, the transaction is flushed and the remote interface is marked as being suspect. This condition causes retry logic to begin. Retry logic consists of retrying communication once per second for a number of times equal to one-fourth the watchdog time period if the absolute retry count is set to zero. A non-zero absolute retry count causes a specific number of retries (the number of the retry count). If the failure persists after the retry period expires, the remote interface is internally marked off-line and the quality of all the points it provides are marked bad.

Thereafter, a single retry of the failed remote interface occurs at a period equal to one half the watchdog timer period until a successful transaction occurs. The local interface sets the quality of all the points to their original state (before the communication failure). It also does a one time poll of the current value of each point.

A user-configurable time delay envelopes each command/reply sequence. This time delay accommodates the keying up/down

DATA INTEGRITY 2 - 2 I-E96-624A

Transmit/Receive Timing

DESCRIPTION AND OPERATION

of modems and transmission equipment. The interface coordinates this activity through the RTS (Request-To-Send) signal of the RS-232-C port for modems or through digital outputs when using Digital Slave Modules (IMDSM05, IMDSO01/02/03/04) to enable other transmission equipment.

The user can set up the RS-232-C ports to operate as Data Circuit-Terminating Equipment (DCE) or Data Terminal Equipment (DTE). In the DCE mode, the Request-To-Send (RTS) line is always asserted. In the DTE mode, the RTS line is asserted before data transmission and inhibited after data transmission occurs.

The following events occur (see Figure 2-1) on port 0 when transmitting a command:

1. Assert RTS on the RS-232-C port (DTE mode) or set digital outputs 1 and 4 on the digital slave module.

2. A delay occurs between the time the port 0 asserts the RTS (or the digital outputs are set) and the command transmission occurs. Function Code 130 (S5) sets this delay (in milliseconds).

3. Output 4 is reset.

4. A delay occurs between the time output 4 is reset and output 1 is reset. Function Code 130 (S6) sets the length of this delay.

5. Output 1 is reset and RS-232-C RTS signal is inhibited (DTE mode).

6. A delay set by S5 of Function Code 130 occur between the output 1 reset and the reception of the reply.

7. The remote target issues a reply.

The following events occur (see Figure 2-1) when Port 0 receives a command:

1. The port receives the command.

2. A time delay set by S6 of Function Code 130 occurs.

3. The RS-232-C asserts the RTS signal (DTE mode) or set outputs 1 and 4 on the digital slave modules.

4. A time delay set by S5 of Function Code 130 occurs.

TIMING INTERVAL

I-E96-624A 2 - 3

DESCRIPTION AND OPERATION

5. The remote interface transmits a reply to the interface sending the command.

6. Output 4 is reset.

7. A time delay set by S6 of Function Code 130 occurs.

8. Output 1 resets, RS-232-C RTS signal is inhibited (DTE mode).

DELAYS5DELAY

RTSASSERTED (DTE MODE) SET OUT1 A ND OUT4

DELAY

RTSASSERTED (DTE MODE) SET OUT2 A ND OUT5

TRANSMIT

COMMAND

TxTxTxTxTxTx

RESET OUT4 RTS INHIBITED (DTE MOD E)

RECEIVE

COMMAND

RxRxRxRxRxRx

TRANSMIT

COMMAND

TxTxTxTxTxTx

RESET OUT5 RTS INHIBITED (DTE MOD E)

NOTE:

RTS assert and inhibit apply to DTE mode only. RTS is

always asserted for DCE mode.

SENDING A COM MAND, PORT 0 (P0)

DELAY

RESET OUT1

RECEIVING A REPLY, PORT 0 (P0)

DELAY

RTSASSERTED (DTE MODE) SET OUT1 AND OUT4

SENDING A COM MAND, PORT 1 (P1)

DELAY

RESET OUT2

DELAY

RECEIVE

RxRxRxRxRxRx

TRANSMIT

TxTxTxTxT xTx

RECEIVE

RxRxRxRxRxRx

RESET OUT4 RTSINH IBITED (DTE MODE)

DELAY

RESET OUT1

DELAY

TIME

RECEIVING A REPLY, PORT 1 (P1)

RECEIVE

COMMAND

RxRxRxRxRxRx

DELAY

RTSASSERTED (DTE MODE) SET OUT2 AND OUT5

DELAY

TRANSMIT

TxTxTxTxT xTx

DELAY

TIME

RESET OUT5 RTSINH IBITED (DTE MODE)

RESET OUT2

T00418A

Figure 2-1. Send/Receive Timing Diagram

TIMING INTERVAL 2 - 4 I-E96-624A

INTRODUCTION

SPECIAL HANDLING

SECTION 3 - INSTALLATION

This section explains special handling procedures, switch settings for each interface module, and how to install related hardware. Complete the preliminary procedures in this section before placing the INPPR01 into operation.

Plant Loop to Plant Loop Interface modules use Electrostatic Sensitive (ESD) devices. Follow these handling procedures:

1. Keep the modules in their special anti-static bags until you are ready to install them in the system. Save the bags for future use.

2. Ground the anti-static bag before opening.

3. Verify that all devices connected to the modules are properly grounded before using them.

4. Avoid touching the circuitry when handling the module.

UNPACKING AND INSPECTION

1. Examine the PPT, LIM and BTM immediately to verify that they have not been damaged in transit.

2. Notify the nearest Bailey Controls Sales Office of any such damage.

3. File a claim for any damage with the transportation company that handled the shipment.

NOTE:

when working with interface modules. This kit connects the static dissipative work surface and technician to the same ground point.

Always use the Bailey Field Static Kit (P/N 1948385A1)

4. Use the original packing material and/or container to store the modules.

5. Store the module in an environment of good air quality and free from temperature and moisture extremes.

INPPT01 SWITCH SETTINGS

The INPPT01 consists of two circuit boards, a memory board and a CPU board. The memory board has no user-configurable

INTRODUCTION

I-E96-624A 3 - 1

INSTALLATION

operating options. The CPU board has three dipswitches that set the module operating characteristics. These switches provide the means of establishing the type of control, serial port communication rate, and loop address. Figure 3-1 shows the dipswitch locations on the CPU board.

JUMPER S

J1, J2, J3

STOPSW2

RESET SW1

Option Switch (U72)

J1 J2 J3

U72 U73 U75

1234

5678 1234

OPEN

OPTION SWITCH

5678 1234

OPEN

BAUD RATE

SWITCH

OPEN

DIAGNOSTICS

SWITCH

Figure 3-1. Switch Locations on the PPT (CPU board)

U72 is an eight position dipswitch that determines the operating options of the module. Table 3-1 lists the U72 option settings. Record the U72 settings in the space provided. When setting switches, 0 = Closed (on) and 1 = Open (off).

T00387A

Table 3-1. Option Switch (U72) Settings

Position Setting Function

ROM checksumming enabled ROM checksumming disabled

RS-232-C port in DCE mode (direct connecti ons ) RS-232-C port in DTE mode (modem connections)

Equipment select output de-energized Equipment select output energized

Port 1 option interface communication Port 1 utility option

Interface ID local

Interface ID remote Interface mode two-way control

Interface mode one-way control

User

Setting

INPPT01 SWITCH SETTINGS 3 - 2 I-E96-624A

INSTALLATION

Table 3-1. Option Switch (U72) Settings

Position Setting Function

0 = Closed (on), 1 = Open (off)

NOTES:

1. A unique equipment select output can exist between the primary and secondary PPT. The equipment select output is digital output three of a digital slave (IMDSM05 or IMDSO01/02/03/04).

2. Port 1 responds as DCE when it is configured as a utility port. Set switch position 4 = 1 if port 1 is not used as a communication interface.

3. Define only one interface as a local interface (position 5).

4. The following conditions apply when using two-way control (position 6 = 0): a. The port 1 option defaults to interface communication (position 4 = 0). b. The local INPPR01 uses port 0 as its command port and port 1 as its reply port. c. The remote INPPR01 uses port 1 as its command port and port 0 as its reply port. d. Both the local and remote interface must have a loop address of 0 (U75).

Don not initialize NVM Initialize NVM

Primary/Secondary (one module of redundant pair is set to 0, the other module is set to 1)

(continued)

User

Setting

Serial Port Communication Rate (U73)

U73 is an eight pole dipswitch that sets the serial port communication rate. The communication rate directly affects data throughput. Refer to Table 3-2 for communication rates. Table

3-3 lists message throughput for different point types. Record

the U73 setting in the space provided.

Table 3-2. Serial Port Communication Rate (U73)

Switch Position

Port 0

1234

Port 1

5678

0000 0000 50 1000 1000 75 0100 0100 110 1100 1100 134.5 0010 0010 150 1010 1010 300 0110 0110 600 1110 1110 1200 0001 0001 1800 1001 1001 2000 0101 0101 2400 1101 1101 3600 0011 0011 4800 1011 1011 7200 0111 0111 9600 1111 1111 19200

: 0 = Closed (on), 1 = Open (off)

NOTE

Baud Rate

User Setting

Port 0

1234

Port 1

5678

INPPT01 SWITCH SETTINGS

I-E96-624A 3 - 3

INSTALLATION

Table 3-3. Message Throughput

Loop Address (U75)

Point Type

Number of

Bytes

Time per

Point

Points per

Second

Station 19 10.4 msec 96 Analog 8 4.7 msec 214 Digital 5 3.1 msec 322 Remote Control Mem-

7 4.1 msec 241

ory (RCM) Remote Manual Set

7 4.1 msec 241

Constant (RMSC) Device Driver 7 4.1 msec 241

1. These figures are based on the calculated throughput of the various Exception Report data types (at 19200 baud). Regard less of commun ication rat e, the software overhead is app roximatel y 0.5 millisecond per point.

Dipswitch U75 sets the loop address. Valid addresses are 0 through 31. Table 3-4 shows examples of switch settings for the loop address. Record the loop address in the space provided.

Table 3-4. U75 Loop Addresses

Example Settings

Address

Example

Switch Position 12345

Binary Value 168421 0 00000 9 01001

26 11010

User Setting

User

Address

0 = Closed (on), 1 = Open (off)

NOTE:

Switch Position 12345

Binary Value 168421

INPPT01 SWITCH SETTINGS 3 - 4 I-E96-624A

INLIM03 SWITCH SETTINGS

The Loop Interface Module (INLIM03), shown in Figure 3-2, has two user-configurable dipswitches: Event/Error Counter Address Switch SW1 and Address Switch SW2. Tables 3-5 and

3-6 list the switch settings for the Event and Error Counters.

The LIM faceplate LEDs display the contents of the event/error counters. Switch SW2 poles 1 and 2 are CLOSED for normal operation. Refer to Table 3-7 for SW2 settings. The LIM can have any address from 1 to 63.

XU4

EVENT/ERROR

COUNTER ADDRESS

1234

5678

OPEN

1234

5678

OPEN

INSTALLATION

EDGE

CONNECTORS

P4 CONNECTOR

RIBBON CABLE

ATTACHES HERE

NODE ADDRESS

Figure 3-2. LIM Switch Locations

Table 3-5. LIM Event Counter Addresses (SW1)

Counter

Address

48 30 00110000 Total messages transmitted, including

49 31 00110001 Transmit retries. 50 32 00110010 Composite BTM Receive/Transmit, 4 bits

51 33 00110011 Messages taken from the BTM transmit

52 34 00110100 Messages stored in BTM receive buffer. 53 35 00110101 Interrupt Requests (IRQs) sent by BTM. 54 36 00110110 High Priority (HP) messages transmitted. 55 37 00110111 High Priority messages received. 56 38 00111000 Commands issued by the BTM. 57 39 00111001 Missed BTM transmit requests.

Hex

Address

Switch Position

12345678

Description

forwarding.

each. Receive is viewed at the top LED.

buffer.

T00403A

User

Setting

INLIM03 SWITCH SETTINGS

I-E96-624A 3 - 5

INSTALLATION

Counter

Address

Hex

Address

Table 3-5. LIM Event Counter Addresses (SW1)

Switch Position

12345678

Description

(continued)

58 3A 00111010 Spurious Non-Maskable Interrupts (NMI)

caused by address present.

59 3B 00111011 HEY (request for an interrupt; generated

by BTM) message sent.

60 3C 00111100 Messages discarded when the destination

is off-line. 61 3D 00111101 HEY time expirations. 62 3E 00111110 Passes through the IDLE level

(2 bytes wide).

0 = Closed (on), 1 = Open (off)

NOTE:

Table 3-6. LIM Error Counter Addresses (SW1)

Counter

Address

64 40 01000000 Composite error count developed every

65 41 01000001 Unresolved NMI interrupts. 66 42 01000010 Unresolved IRQ interrupts. 67 43 01000011 Unresolved timer interrupts. 68 44 01000100 Unused. 69 45 01000101 Queue overflows. 70 46 01000110 Unresolved BTM IRQs. 71 47 01000111 Sequence errors. 72 48 01001000 Header CRC/OVRN errors. 73 49 01001001 Data CRC/OVRN errors. 74 4A 01001010 Messages developing data CRC errors on

75 4B 01001011 Transmission failures. 76 4C 01001100 Watchdog timer expirations. 77 4D 01001101 Data length errors. 78 4E 01001110 Loop - 1 Receive (RCV) failure. 79 4F 01001111 Loop - 2 Receive failures. 80 50 01010000 Loop - 1 Transmit (TX) failure. 81 51 01010001 Loop - 2 Transmit failures.

0 = Closed (on), 1 = Open (off)

NOTE:

Hex

Address

Switch Position

12345678

Description

handshake period - the summation of all

other error counters.

route to destination.

User

Setting

User

Setting

INLIM03 SWITCH SETTINGS 3 - 6 I-E96-624A

1 0 0000001

T00401A

RESET

SWITCH

SW1

OPTION SWITCH

EDGE

CONNECTORS

OPEN

9 0 0001001 63 0 0111111

NOTE: 0 = Closed (on), 1 = Open (off)

INBTM01 SWITCH SETTINGS

Address

Example

User

Address

INSTALLATION

Table 3-7. LIM Node Address Setting (SW2)

Example Settings

Switch Position 1 2345678 Binary Value 1286432168421

User Setting

Switch Position 1 2345678 Binary Value 1286432168421

The Bus Transfer Module (INBTM01), shown in Figure 3-3, has one user-configured dipswitch (SW1). SW1 enables module diagnostics. Refer to Table 3-8 and set SW1 for normal operation.

Figure 3-3. BTM Switch (SW1) Location

INBTM01 SWITCH SETTINGS

I-E96-624A 3 - 7

INSTALLATION

Table 3-8. BTM Options (SW1)

Switch Position

12345

00000 Normal operation. 00010 Normal BTM operation without catastrophic error checking (for Test Pur-

poses ONLY). 00100 RAM test mode. If Status LED turns red, the module has failed the test. 00110 ROM test mode. If Status LED turns red, the module has failed the test. 01000 Execute Interrupt Request (IRQ) LIM handshake diagnostic. Used in

combination with the LIM off-line diagnostics.

NOTE: 0 = Closed (on), 1 = Open (off)

Function User Setting

TERMINATION UNIT (MODULE) CONFIGURATION

Two of the interface modules (INLIM03, INPPT01) require termination. The INPPT01 terminates with the NTMF01 or NIMF01/NIMF02. The INLIM03 terminates with the NTCL01 or NICL01. Appendices A through D contain disphunt configuration information. Figure 3-4 shows a diagram of the NTMF01 and NTCL01 in a redundant installation. Figure 3-5 shows a diagram of the NIMF01/NIMF02 and NICL01 in a redundant installation.

NTMF01/NIMF01/NIMF02 Configuration

The TMF and IMF provide the INPPT01 with two RS-232-C ports. Configure these ports to operate as DTE, DCE or diagnostic terminal. Refer to Figures A-1, A-2, and A-3 for NTMF01 dipshunt configurations. Refer to Figures C-1, C-2, and C-3 for NIMF01/NIMF02 dipshunt configurations.

NOTE:

tion modules to terminate a redundant interface. Non-redundant interfaces need only the NIMF01.

You must use the NIMF01 and NIMF02 whe n usi ng term in a-

ONE-WAY CONTROL

Configure port 0 on the local and remote interfaces to act as DTE. One local INPPR01 can communicate with up to 32 remote interfaces in the one-way control mode. Additional communication equipment such as a modem network, radio link or microwave link is required when interfacing multiple remotes. The user supplies any additional equipment that is needed.

TERMINATION UNIT (MODULE) CONFIGURATION 3 - 8 I-E96-624A

COMMUNICATION HIGHWAY(PLANT LOOP)

INSTALLATION

TWINAX OR COA X

TWINAX

OR COA X

SLAVE EXPANDER BUS

NTCL01

P1 P1

NKLS03

DMA

CABLE

MODULE BUS

INBTM01INLIM03 INLIM 03INPPT01

P3 P3

P1 P3

INPPT01

NKTU01NKTU01

MODULE BUS

NKLS03

INBTM01 INLIM03

DMA

CABLE

NTMF01

TERMINATION UNIT

COMMUNICATIONS

PORT 0

PORT 1 COMMUNICATIONS OR UTILITY

TO OTHER PPR

Figure 3-4. NTMF01 and NTCL01 in a Redundant Installation

NTCL01

T00419A

COMMUNICATION HIGHWAY(PLANT LOOP)

TWINAX OR COA X

SLAVE EXPANDER BUS

NICL01

NKLS04

DMA

CABLE

MODULE BUS

INBTM01INLIM03 INLIM 03INPPT01

P3 P3

NIMF01

TERMINATION

MODULE

J2 J3

COMMUNICATIONS

PORT 0

MODULE BUS

INPPT01

NKTM01NKTM01

NIMF02

TERMINATION

MODULE

INBTM01 INLIM03

PORT 1 COMMUNICATIONS OR UTILITY

TO OTHER PPR

Figure 3-5. NIMF01/NIMF02 and NICL01 in a Redundant Installation

DMA

CABLE

TWINAX

OR COA X

NKLS04

NICL01

T00420A

TERMINATION UNIT (MODULE) CONFIGURATION

I-E96-624A 3 - 9

INSTALLATION

When directly connecting only one remote interface in one-way control, set port 0 on the local interface to act as a DTE. Set port 0 on the remote interface to act as DCE.

TWO-WAY CONTROL

The interface requires both serial communication ports in the two-way control mode. Connect port 0 of the local Plant Loop to port 0 of the remote Plant Loop. Connect port 1 of local Plant Loop to port 1 of the remote Plant Loop.

Configure the termination unit to act as DTE to enable the Plant Loop to Plant Loop Transfer Module to communicate with DCE (i.e, a modem). Configure the termination unit to act as DCE to enable the PPT to communicate with DTE (i.e., a terminal). Figure A-4 shows how the termination dipshunt configuration directs the RS-232-C signals.

NTCL01/NICL01 Configuration

The TCL and ICL provide the INLIM03 with Plant Loop termination. The user has the option of using Twinax or Coax cable to connect the interface to the Plant Loop. Tables B-3 (NTCL01) and D-3 (NICL01) show the jumper settings for twinax and coax cables. Set the jumpers accordingly for your application.

NOTE:

interface communication port. The PPT option switch (U72) position 4 must be set to 0 (utility option). Port 1 will always act as a DCE in this configuration.

Always configure port 1 as a utility port if it is not used as an

NOTE:

to the

For complete cable and TU/TM installation information, refer

Termination Unit Manual

l (

I-E93-911

INSTALLING THE INTERFACE MODULES

If the switch settings on the interface modules are complete, they are ready to be installed in the Module Mounting Unit (MMU).

Installing the INPPT01

WARNING Disconnect power before installing dipshunts for slave mod-

ules on the MMU backplane (slave expander bus). Failure to do so could result in severe or fatal shock.

AVERTISSEMENT Couper l'alimentation avant d'installer les dipshunts sur la

plaque arrlere du chassis de montage de modules (MMU). Toute negligence a cet egard constitue un risque de choc pouvant entrainer des blessures graves, voire moretlles.

INSTALLING THE INTERFACE MODULES 3 - 10 I-E96-624A

INSTALLATION

To install the PPT:

1. Verify the PPT slot assignment in the MMU.

a. If you are installing redundant PPTs, install a 24 pin disphunt in the Slave Expander Bus socket between the slot used by the primary PPT and the slot used by the secondary PPT. Both PPTs must reside on the same Slave Expander Bus.

b. Each PPT must reside on its own module bus.

2. Attach the hooded end of the cable (NTKU01 for the NTMF01; NKTM01 for the NIMF01 and NIMF02) to the MMU backplane cable connector opening for the PPT. The other end of the cable attaches to the termination unit or backplane of the Termination Mounting Unit (NTMU01).

3. Guide the top and bottom edges of the circuit card along the top and bottom rails of MMU.

4. Slide the module into the slot; push the module until the front panel is flush with the top and bottom of the MMU frame.

5. Turn the two captive latches a half turn to lock the module in place.

Installing the INLIM03 and INBTM01

The LIM and BTM should be installed as a pair in adjacent slots. To install the LIM/BTM:

1. Verify the MMU slot assignments for the modules. If you are installing redundant LIM/BTM pairs, each BTM must be installed on the module bus that belongs to its related PPT.

2. Attach the hooded end of the cable (NKLS03 for NTCL01; NKLS04 for the NICL01) to the MMU backplane cable connector opening for the LIM. The other end of the cable attaches to the termination unit or TMU backplane.

3. Connect one end of the Bailey supplied ribbon cable (DMA cable) to the P4 connector on the LIM. Connect the other end of the DMA cable to the P4 connector on the BTM (see Figures 3-2 and 3-3).

4. Guide the top and bottom edges of both circuit cards along the top and bottom rails of adjacent slots in the MMU.

5. Slide the modules into the slot; push the module until the front panels are flush with the top and bottom of the MMU frame.

INSTALLING THE INTERFACE MODULES

I-E96-624A 3 - 11

INSTALLATION

6. Turn the two captive latches a half turn to lock the module in place.

INSTALLING A REDUNDANT INTERFACE

Installing a redundant interface requires an additional set of INPPT01, INLIM03 and INBTM01 modules. Both PPT modules must be on the same Slave Expander Bus, but reside on separate Module Bus. Each PPT has a pair of LIM/BTM modules on a dedicated Module Bus.

Observe the following conditions when installing a redundant interface:

1. U72 position 8 must be set to 0 on the primary PPT.

2. U72 position 8 must be set to 1 on the secondary PPT.

3. SW1 all positions must be set to 0 on both BTMs.

4. The slave expander bus of two adjacent MMUs (one on top of the other) are connected with the expander bus extender cable (Bailey P/N 1958502A0340).

5. The module bus between these MMUs are not connected.

Applications that use redundant communication equipment may require additional hardware. Figure 3-6 shows a diagram of the interface using the IMDSM05 to enable redundant transceivers. Function Code 130 provides the software the PPT needs to enable the transceivers. Voltage levels and polarities of enable signals to transceivers and other communication equipment may vary. Refer to the applicable user manual when connecting this equipment to the IMDSM05, IMDSO01/02/ 03/04 Digital Slave Module.

INTERFACE CONFIGURATIO N

The user must configure the PPT with the proper function codes before it can be placed into service. The PPT configuration determines interface operating characteristics such as time synchronization, serial communication rate, node definition, point definitions and general execution characteristics.

Table 3-9 lists the function codes used by the INPPR01. Refer to the Function Code Application Manual (I-E93-900-20) for information about the function codes in Table 3-9.

INSTALLING A REDUNDANT INTERFACE 3 - 12 I-E96-624A

INSTALLATION

PRIMARY

SECONDARY

DSM05PPT

PPT

NTMF01

–

NKTU01 CABLES

NTDI01

RS232 (LINES 1-5, 8, 20)

+ –

Figure 3-6. Redundant Transceiver

Table 3-9. INPPR01 Function Codes

SELECT

ENABLE

ANTENNA

SWITCH

PRIMARY

TRANSCEIVER

REDUNDANT

TRANSCEIVER

MODEM

T00421A

Function Code Title

FC 127 Plant Loop Gateway Node Map FC 130 Plant Loop Gateway Executive FC 131 Plant Loop Gateway Point Definition

INTERFACE CONFIGURATION

I-E96-624A 3 - 13

SECTION 4 - OPERATING PROCEDURES

INTRODUCTION

This section explains how to place the INPPR01 in operation It covers faceplate LEDs, modes of operation, and the two control types. Additionally, it provides information concerning redundant operation and interface memory utilization.

PLANT LOOP TO PLANT LOOP TRANSFER MODULE LEDs AND CONTROLS

The faceplate of the PPT has the following components (see Figure 4-1):

1. Status LED

2. 8 CPU LEDs

3. 2 Memory Status LEDs

4. Stop pushbutton

5. Reset pushbutton

INPPT01

STATUS LED

1 2 3 4

CPU

5 6 7 8

STOP

RESET

PUSHBUT TON

Figure 4-1. PPT Faceplate LEDs

MEM

T00422A

INTRODUCTION

I-E96-624A 4 - 1

OPERATING PROCEDURES

Status LED

The Status LED is a red/green LED that displays the operating status of the PPT. It has five possible states. Table 4-1 lists the meaning of the status LED states. Refer to Section 5 for corrective action if the status LED indicates that an operating error exists.

Table 4-1. PPT Status LED States

LED State Meaning

Off No power to the PPT. Solid Green The PPT is in the EXECUTE Mode. Flashing Green (once per second) The PPT is in the EXECUTE M ode and d etects a NVM checksum

error. Flashing Green (4 times per second) The PPT is in the CONFIGURE or ERROR Mode. Solid Red The PPT diagnostics detect a hardware failure or configuration

problem. CPU LEDs displ ay an error co de when the status LED

is red.

CPU LEDs

Memory LEDs

Stop Pushbutton

During normal operation, the CPU LEDs keep a count of the internal and external messages that pass through the PPT. If a communication error occurs, these LEDs display an error code and the Status LED turns RED. Refer to Table 5-1 for a list of CPU LED error codes and corrective action.

There are two Memory LEDs. MEM LED 2 is on while the module is correcting single bit errors. Both LEDs are on when a two-bit error or a complete memory failure occurs.

Push the stop pushbutton before removing a PPT from the Module Mounting Unit. The stop pushbutton causes the following actions to occur:

1. Allows any NVM write in progress to complete.

2. Forces control from a primary to a secondary PPT in redundant configurations.

Reset Pushbutton

Pressing the reset pushbutton causes:

1. Restoration of PPT to power-up values after a halt.

PLANT LOOP TO PLANT LOOP TRANSFER MODULE LEDs AND CONTROLS 4 - 2 I-E96-624A

2. Recovery from an operator-initiated stop or a module timeout.

LOOP INTERFACE MODULE LEDs

There are eight LEDs on the LIM faceplate (see Figure 4-2). These LEDs display the contents of event and error counters, and pass/fail information when on-board diagnostics are run (refer to Tables 3-4 and 3-5 for a list of event and error counter codes).

OPERATING PROCEDURES

INLIM03

1 2 3 4 5 6 7 8

T00399A

Figure 4-2. LIM Faceplate LEDs

BUS TRANSFER MODULE LED

The Bus Transfer Module has one red/green LED that displays the module's operating condition (see Figure 4-3). The BTM Status LED has three possible states. Refer to Table 4-2 for BTM Status LED states and their meaning. Section 5 explains the corrective action to take if the Status LED displays a BTM hardware failure.

MODES OF OPERATION

The Plant Loop-to-Plant Loop Remote Interface has three modes of operation: Configure, Execute and Error. Within the Execute mode the module has two methods of control: one-way or two-way control.

LOOP INTERFACE MODULE LEDs

I-E96-624A 4 - 3

OPERATING PROCEDURES

INBTM01

STATUS LED

Configure Mode

Execute Mode

T00413A

Figure 4-3. BTM Faceplate LEDs

Table 4-2. BTM Status LEDs States

LED States Meaning

Off No power to th e BTM. Solid Green Normal Operation. Solid Red BTM hardware failure.

This mode applies to the INPPT01 module. Module configuration requires an INFI 90 operator interface device (i.e., Operator Interface Station, Management Command System, Engineering Work Station, etc.). Refer to Section 3 and to the instruction for your operator interface device for information about interface configuration.

This is the normal mode of operation for the PPR. In the execute mode, the PPR issues requests for exception reports (XRs) twice a second, collects XRs, exercises control (local to remote), allows the operator to adjust tunable module specifications and configure modules in remote loops. The interface enters one of the two control types that the user configures during installation.

MODES OF OPERATION 4 - 4 I-E96-624A

Error Mode

One-Way Control

OPERATING PROCEDURES

The PPT enters this mode if the built-in system diagnostics detect a hardware or configuration error. If the PPT detects a hardware error, the module halts and displays an error code on the CPU LEDs. If the CPU LEDs display a configuration error, the module remains in the error mode. Refer to Section 5 for corrective action when the PPT enters the error mode.

The PPT option switch setting (set during installation) determines if the module is in one-way control. In one-way control, the local Plant Loop requests XRs from all remotes twice a second. The operator does module tuning and configuration, and issues control commands to the remote Plant Loops through the operator interface.

This type of control requires only one serial port (port 0). Port 1 can also be used as an additional link through which the local loop issues commands. Using both ports increases the total throughput of the PPT (see Figure 4-4).

PCU

OIS

REMOTE

PLANTLOOP

PPR

SERIALPORT 0

LEGEND: OIS = OPERATOR INTERFACESTATION PCI = PLANT LOOP TO COMPUTER INTERFACE PCU = PROCESS CONTROL UNIT PPR = PLANT LOOP TO PLANT LOOP REMOTE INTERFACE

PCU

LOCAL PLANT LOOP

SERIAL PORT

PPR

PCU

REMOTE

PLANT LOOP

PPR

SERIALPORT 1

PCU

PCI

OIS

T00423A

Figure 4-4. Local Plant Loop Using Both Serial Ports in One-Way

Control

MODES OF OPERATION

I-E96-624A 4 - 5

OPERATING PROCEDURES

Two-Way Control

In two-way control, bidirectional communication requires both ports on both Plant Loops (Port 0 to Port 0; Port 1 to Port 1). Both loop interfaces can issue requests, control commands and do module tuning and configuration. The local interface uses one serial port to issue commands and receive replies (see Figure 4-5). The remote interface uses the other port for the same purpose. As in one-way control, the PPT requests XRs twice a second; control and configuration commands are through operator action.

REDUNDANT INTERFACE OPERATION

Redundant interface configurations require two sets of LIM/ BTM and PPT modules. Each set of modules reside on a separate module bus. Redundant interfaces share a common slave expander bus. Upon start-up, one interface assumes the primary role; the other waits in a backup role. The primary PPT

PCU

OIS

PPR

LOCAL

PLANTLOOP

OIS

PCU

REMOTE

PLANTLOOP

SERIAL PORTS

LOCAL XMIT/RCVREMOTE XMIT/RCV

SERIAL PORTS

PCU

T00424A

Figure 4-5. Local and Remote Plant Loops in Two-Way Control

REDUNDANT INTERFACE OPERATION 4 - 6 I-E96-624A

downloads the interface configuration to the secondary (redundant modules are identically configured to their primary counterpart). If the primary interface fails, the redundant unit takes over and re-establishes the point data.

INTERFACE POINT CAPACITY

There are three factors that determine the maximum number of points in a PPT configuration. Those factors are: point type (exception report data type), the number of devices that receive interface generated exception reports and the total memory available (440,000 bytes). Table 4-3 lists the required memory bytes for all point types when memory usage is for:

1. The local PPT receiving points from the remote PPT.

2. The remote PPT (in two-way mode) receiving points from the local PPT.

OPERATING PROCEDURES

Table 4-3. Memory Usage in Receiving Communication

Point Type

Digital 16 Analog 30 Station 76 Remote Control Memory (RCM) 22 Remote Manual Set Constant (RMSC) 38 Device Driver 22

Add 6 bytes per point per destination being sent.

NOTE:

Memory Bytes

Required

Table 4-4 lists the required memory bytes for all point types when the memory usage is for:

1. The remote PPT sending points to the local PPT.

2. The local PPT (in two-way mode) sending points to the remote PPT.

NOTE:

The PPT has a capacity of 5,000 blocks.

INTERFACE POINT CAPACITY

I-E96-624A 4 - 7

OPERATING PROCEDURES

Digital 18 Analog 22 Station 70 Remote Control Memory(RCM) 22 Remote Manual Set Constant (RMSC) 26 Device Driver 22

NOTE:

that sources Exception Reports.

MEMORY USAGE EXAMPLE

In this example, a pair of interfaces in one-way mode has the following mix of points in their configuration:

500 digital points (S3 of FC131 = 0) 200 analog points (S3 of FC131 = 1) 50 stations (S3 of FC131 = 2)

Table 4-4. Memory Usage in Sending Communication

Point Type Memory Bytes Required

Add 16 byte s fo r ea ch PCU th at sou rc es Ex cept ion R epo rts. Ad d 10 by te s fo r eac h mod ul e

Distribution of 750 total points on the remote loop is among 20 modules residing in 10 different PCUs. There are five OISs on the local loop. Each OIS receives all of the points.

Memory Usage in the Local PPT

The points are coming to the local from the remote, therefore, Table 4-3 applies. The calculations are:

500 digital points x 16 bytes/point = 8,000 bytes 200 analog points x 30 bytes/point = 6,000 bytes 50 station points x 76 bytes/point = 3,800 bytes

Each OIS receives all 750 points: 5 OIS x 750 points x 6 bytes/point = 22,500 bytes Total memory used in the local PPT = 40,300 bytes

Memory Usage in the Remote PPT

These points are to be sent to the local, therefore, Table 4-4 applies. The calculations are:

500 digital points x 18 bytes/point = 9,000 bytes 200 analog points x 22 bytes/point = 4,400 bytes 50 station points x 70 bytes/point = 3,500 bytes 20 modules x 10 bytes/module = 200 bytes 10 PCUs x 16 bytes/PCU = 160 bytes Total memory used in the remote PPT = 17,260 bytes

MEMORY USAGE EXAMPLE 4 - 8 I-E96-624A

SECURITY FUNCTIONS

Hardware Checks

Software Checks

OPERATING PROCEDURES

The PPT performs both hardware and software security checks to insure module integrity.

The PPT does the following hardware checks:

1. Error Detection and Correction - Detects single bit and double bit errors in the dynamic RAM. Corrects single bit errors; halts PPT operation on double bit errors.

2. Illegal Address Detection - Detecting an illegal address generates a bus error and the PPT halts operation.

3. Machine Fault Timer - The microprocessor updates this timer. A machine fault timeout halts module operation.

Utilities

The PPT does the following software checks:

1. Module Diagnostics - Module diagnostics execute automatically on system power up. PPT faceplate LEDs display error conditions if the diagnostic tests fail.

2. Module Status Check - This test verifies checksums of the UVROM and NVM. Discrepancies cause the PPT Status LED to flash green and PPT operation halts.

The utilities menu shown in Figure 4-6 is available to the user by attaching a diagnostic monitor to serial port 1. Items 1, 4 and 5 are used for Bailey Engineering purposes. Items 2 and 3 are available to the user.

When 2 is keyed in, the following appears:

2 - Which Loop? reply: not configured or communicating or communication failed, will retry in x seconds

When 3 is keyed in, the following appears:

3 - Enter Slave Address: enter new digital outputs: reply 0 or 1

SECURITY FUNCTIONS

I-E96-624A 4 - 9

OPERATING PROCEDURES

PPT UTILITIESM ENU,REVISION X.X

1 DEBUG 2 LOOP C OMM. REPORT 3 DIGITAL OU TPUT TEST 4 CP U UTILIZATION 5READMEMORY

T00425A

Figure 4-6. PPT Utilities Menu

SECURITY FUNCTIONS 4 - 10 I-E96-624A

INTRODUCTION

SECTION 5 - TROUBLESHOOTING

If errors occur while the interface is operating, the CPU LEDs on the PPT faceplate display error codes. Table 5-1 lists the error codes and corrective action.

NOTE:

Status LED is red. A 0 represents a LED that is off and a 1 represents a LED that is on.

Codes are displayed only when the PPT is halted and the

Table 5-1. Table 5-1. PPT Error Codes

LED

87654321

00000001 An error affecting the NVM checksum has

occurred.

00000010 An error occurred while the PPT was writing

to its non-volatile memory.

00000011 External communication equipment failure

detected.

00001011 Contact 7 of Option Switch U72 has been

set (NVM initialized). 00001100 NVM write in progress when power lost. None. 00001101 An error occurred in communication

between primary PPT and redundant PPT. 00001110 PPT redundancy switches (Option Switch

U72 contact 8) are the same.

00001111 Primary PPT failed before its configuration

was copied to the backup. 00010000 Secondary PPT loop address (U75) does

not match primary PPT.

00010001 Secondary PPT control mode or RS-232C

mode (DCE or DTE) or ID (local or remote)

does not match primary PPT. 00010010 BTM not responding. Replace the BTM. 00010011 ROM checksum error. Reset the PPT. 00110000 The system tried to force control to the

redundant PPT while the primary PPT was

still functioning. 00110001 A fault in either the CPU or MEM boards

exists. 00110010 An addressing error occurred on internal

microprocessor address bus. 00110011 Attempt to execute an illegal processor

instruction.

Meaning Corrective Action

None.

Check the exter nal communica tion equipment.

None.

Set U72 (position 8) on secondary PPT to 0 and U72 on the primary PPT to 1.

Reset the secondary PPT and enter the configuration.

Set secondary PPT loop address to match the primary PPT loop address.

Check the opti on switch settings (U72) on the secondary PPT.

None.

Replace the PPT.

Reset the PPT.

INTRODUCTION

I-E96-624A 5 - 1

TROUBLESHOOTING

Table 5-1. Table 5-1. PPT Error Codes

LED

87654321

00110101 Microprocessor received spurious excep-

tion vector.

00110110 A divide by 0 or CHK instruction was

expected. 00110111 TRAP instruction was executed. None. 00111111 The PPT has stopped because the user

pressed the Stop pushbutton.

00000000

10000000

1. These codes apply to the secondary PPT in a redundant configuration.

The secondary PPT configuration is not

copied from the primary PPT yet.

The secondary PPT correct ly copi ed the p ri-

mary config uration and is ready to take

over.

Meaning Corrective Action

Status Bytes

Five status bytes provide information about Plant Loop to Plant Loop Transfer Module status. These bytes are available through any operator interface such as the Operator Interface Station (OIS). Refer to the instruction for your operator interface for an explanation of how to access status bytes. Table 5-2 lists the status bytes. Table 5-3 lists the status byte definitions.

(continued)

Reset the PPT.

None.

Table 5-2. Status Bytes

Byte

1 ES MODE TYPE 2 FTX BAC RIO LIO N/A NVI CFG N/A 3 PCU MEM NEF N/A N/A N/A N/A N/A 4 LIE LRE LRE LTE LTE N/A N/A N/A 5 N/A N/A N/A N/A N/A N/A N/A N/A

76543210

Bit+

INTRODUCTION 5 - 2 I-E96-624A

TROUBLESHOOTING

Table 5-3. Status Byte Definitions

Field Value Description

Byte 1

ES MODE TYPE

Byte 2

FTX BAC RIO LIO N/A NVI CFG N/A

Byte 3

PCU MEM NEF Bits 0-4

Byte 4

LIE LRE LRE LTE LTE Bits 0-3

Byte 5

Bits 0-7 Not Applicable

80 60 1F

80 40 20 10

04 02

01 02 03

80 40 20 40 80

Error Summary (0-OK, 1-Error) Module Mode (00-Config, 01-Error, 11-Exec) Module Type Code = Hex 11 (INPPT01)

First Time in Execute (0-No, 1-Yes) Backup PPT Status (0-OK, 1-Bad) Summary Remote I/O Status (0-OK, 1-Bad) Summary Local I/O Status (0-OK, 1-Bad) Not Applicable NVM Checksum Error (0-OK, 1-Bad) Default Configuration (0-No, 1-Yes) Not Applicable

One or more PCUs offline (0-No, 1-Yes) Memory Full (0-No, 1-Yes) Node Environment Failure (0-No, 1-Yes) Not Applicable

LIM Internal Error Loop Receive Error Channel 1 Loop Receive Error Channel 2 Loop Transmit Error Channel 1 Loop Receive Error Channel 2 Not Applicable

Table 5-4. LIM Edge Connector P3 Pin Assignments

Pin No. Signal Pin No. Signal

1 Loop 2 In (+) 13 Loop 2 Bypass Control 2 Loop 2 In (-) 14 Cable Shield 3 Cable Shield A Cable Shield 4 Loop 1 Out (+) D Loop 1 Out (-) 5 Loop 1 Out (+) E Loop 1 Out (-) 6 Loop 1 In (+) F Ca ble Shield 7 Loop 1 In (-) H Loop 2 Bypass Control 8 Cable Shield K Loop 2 Out (-)

9 Loop 2 Out (+) L Loop 2 Out (-) 10 Loop 2 Out (+) M Cable Shield 11 Cable Shield S Cable Shield

INTRODUCTION

I-E96-624A 5 - 3

TROUBLESHOOTING

Table 5-5. BTM Edge Connector P1 Pin Assignments

Pin No. Signal Pin No. Signal

1 +5 VDC 2 +5 VDC 3N/C 4N/C 5 Common 6 Common 7 +15 VDC 8 -15 VDC 9 Power Fail Interrupt 10 Power Fail Interrupt

11 Module Bus 12 Module Bus

Table 5-6. PPT CPU Board Edge Connector P2 Pin Assignments

Pin No. Signal Pin No. Signal

1 Data Bit D1 2 Data Bit D0 3 Data Bit D3 4 Data Bit D2 5 Data Bit D5 6 Data Bit D4 7 Data Bit D7 8 Data Bit D6 9 Clock 10 Sync

11 N/C 12 N/C

All data bits are low true.

NOTE:

Table 5-7. PPT CPU Board Edge Connector P3

Pin Assignments

Pin No. Signal Pin No. Signal

1 SAC Link (+) A SAC Link (-) 2 Redundancy Link

Transmit Data (+)

3 Redundancy Link

Receive Data (-)

4 Terminal Port

Transmit Data

5 Terminal Port

Request to Send

6 Terminal Port

Data Carrier Detect

7 Printer Port

Transmit Data

8 Printer Port

Request to Send

9 Printer Port

Data Carrier Detect

B Redundancy Link

Transmit Data (-)

C Redundancy Link

Receive Data (+)

DTerminal Port

Receive Data

ETerminal Port

Clear to Send

FN/A

H Printer Port

Receive Data

J Printer Port

Clear to Send

KN/A

INTRODUCTION 5 - 4 I-E96-624A

TROUBLESHOOTING

Table 5-7. PPT CPU Board Edge Connector P3

Pin Assignments

Pin No. Signal Pin No. Signal

10 Digital Output 1 (+) L Digital Output 1 (-) 11 Digital Output 2 (+) M Digital Output 2 (-) 12 N/A N N/A 13 N/A P N/A 14 N/A R N/A 15 N/A S N/A

(continued)

INTRODUCTION

I-E96-624A 5 - 5

INTRODUCTION

SECTION 6 - MAINTENANCE

The Plant Loop to Plant Loop Remote Interface (INPPR01) requires minimal maintenance. The following maintenance schedule will ensure trouble free service.

MAINTENANCE SCHEDULE

NOTE:

Only qualified personnel should perform maintenance.

The PPR maintenance schedule is shown in Table 6-1. Perform these tasks at the specified intervals.

Table 6-1. Maintenance Schedule

Task Interval

Clean and check all cable connections to the INLIM03, INBTM01 and INPPT01.

Use a static vacuum cleaner to remove dust from:

Modules Module Mounting Unit Fan Assembly Power Entry Panel

Every 6 months or during plant shutdown, whichever occurs first.

INTRODUCTION

I-E96-624A 6 - 1

SECTION 7 - REPAIR/REPLACEMENT PROCEDURES

INTRODUCTION

This section explains the replacement procedures for the Plant Loop to Plant Loop Remote Interface (INNPPR01). There are no special tools required to replace an interface module.

NOTE:

when working with th e interf ace m odules . This kit co nnects the s tatic dissipative work surface and technician to the same ground point.

MODULE REPAIR/REPLACEMENT

If you determine an interface module is faulty, replace it with a new one. DO NOT try to repair the module; replacing components may affect the module performance. You can remove the module while system power is supplied. To replace a module:

1. Press the stop pushbutton and wait for the status LED to turn red.

2. Push and turn the two front panel captive latches one half turn to unlatch the module. It is unlatched when the slots on the latches are vertical and the open end of the slots face away from the module.

3. Gently slide the module out of the MMU.

4. Configure the replacement module switch and jumper settings. Ensure they are set the same as the original module.

Always use the Bailey Field Static Kit (P/N 1948385A1)

5. In the same slot assignment as the original module, align the replacement module with the guide rails in the MMU; gently slide it in until the front panel is flush with the top and bottom of the MMU frame.

6. Push and turn the two captive retaining latches on the module faceplate one half turn to the latched position. It is latched when the slots on the latches are vertical and the open ends face the center of the module.

7. Return to normal operation.

INTRODUCTION

I-E96-624A 7 - 1

SECTION 8 - SUPPORT SERVICES

INTRODUCTION

Bailey Controls is ready to assist in the use of its products. Requests for sales, applications services, installation, repair, overhaul and maintenance contract services should be made to the nearest sales office.

REPLACEMENT PARTS AND ORDERING INFORMATION

If you are making repairs at your own facility, replacement parts should be ordered through a Bailey sales office. Provide the following information for parts orders:

1. Part description, part number and quantity.

2. Model, serial number (if applicable) and ratings of the assembly containing the ordered part.

3. Bailey publication number and reference used in identifying the part.

When ordering standard parts from Bailey Controls, use the part number and description from the Replacement Parts section of the manual. Parts not having a commercial description in the Replacement Parts section must be ordered from a Bailey Controls sales office.

TRAINING

Bailey Controls has a modern training facility equipped to provide service and repair instructions. This facility is available for in-plant training of your personnel. Contact a Bailey Controls sales office for information on available classes and scheduling.

TECHNICAL DOCUMENTATION

You can obtain additional copies of this manual through the nearest Bailey sales office. Copies, over and above those provided with the original purchase, are available at a minimum charge to the customer. Contact a Bailey Controls sales office for information.

INTRODUCTION

I-E96-624A 8 - 1

APPENDIX A - TERMINATION UNIT CONFIGURATION

P1 CONN ECTOR

STATION

COMMUNICATION

P2 CONN ECTOR

TERMINAL PORT

PRINTER PORT

PORT

F1 FUSE

+24 V (E2)

COM (E 3)

T00426A

CONNECTOR

XU1

XU2

XU4

XU2

XU3

XU1

+24 VDC

RXD

RTS

CTS

TXD

DCD

CABLE SHIELDING GROUND

DB-25 PIN ASSIGNMENT

7 9

14 12

LOCAL AND REMOTE

(NTMF01)

INTRODUCTION

The INPPT01 uses the NTMF01 for termination. Figure A-1 shows the dipshunt configuration required when connecting a local and remote PPT (DTE) via a modem (DCE). Figure A-2 and

A-3 show the dipshunt configuration required when directly

connecting a local PPT (DTE) to a remote PPT (DCE) via a cable. Figure A-4 shows how to configure the dispshunts so that port 1 can drive a diagnostics terminal. Figure A-5 shows the RS-232-C signals and the associated DB-25 pin assignments.

Figure A-1. Disphunt Configuration for PPT Acting as DTE (Requires Modem or Other DCE)

I-E96-624A A - 1

INTRODUCTION

TERMINATION UNIT CONFIGURATION (NTMF01)

TERMINAL PORT

PRINTER PORT

P1 CONN ECTOR

STATION

COMMUNICATION

P2 CONN ECTOR

F1 FUSE

+24 V (E2)

COM (E 3)

XU1

XU2

XU3

XU4

CONNECTOR

XU1

XU2

XU3

XU4

DCD

CTS RTS RXD TXD

DCD

CTS RTS RXD TXD

LOCAL

+24 VDC

1 2 3 4 5 6 7 8 9

CABLE

SHIELDING

GROUND

18 17 16 15 14 13 12 11

20 19 18 17 16 15 14 13 12 11

CTS RTS RXD TXD

DB-25 PIN ASSIGNMENT

5 4 3 2

+24 VDC

CABLE SHIELDING GROUND

DB-25 PIN ASSIGNMENT

5 4 3 2

PORT

T00427A

Figure A-2. Dipshunt Configuration for Direct Connection with Local PPT Acting as DTE

INTRODUCTION A - 2 I-E96-624A

TERMINATION UNIT CONFIGURATION (NTMF01)

P1 CONN ECTOR

STATION

COMMUNICATION

P2 CONN ECTOR

TERMINAL PORT

PRINTER PORT

PORT

F1 FUSE

+24 V (E2)

COM (E 3)

T00428A

CONNECTOR

XU1

XU2

XU4

XU2

XU4

XU3

XU1

XU3

+24 VDC

RTS

RXD

TXD

CTS

DCD

RXD

TXD

CTS

RTS

CABLE SHIELDING GROUND

DB-25 PIN ASSIGNMENT

7 9

14 12

REMOTE

Figure A-3. Dipshunt Configuration for Direct Connection with Remote PPT Acting as DCE

I-E96-624A A - 3

INTRODUCTION

TERMINATION UNIT CONFIGURATION (NTMF01)

P1 CONN ECTOR

STATION

COMMUNICATION

P2 CONN ECTOR

F1 FUSE

+24 V (E2)

COM (E 3)

Figure A-4. Dipshunt Configuration for Diagnostic Terminal (Port 1 only)

CONNECTOR

XU1

XU2

XU3

XU4

TERMINAL PORT

PRINTER PORT

LOCAL OR REMOTE

DCD

RXD

TXD

3 4

CTS

DCD CTS

5 6 7 8 9

1 2 3 4 5 6 7 8 9

XU3

XU4

+24 VDC

TXD

RXD

3 17 16 15 14 13

12 11

20 19 18 17 16

DCD

CTS

5 13 12 11

PORT 1

ONLY FOR

DIAGNOSTIC

TERMINAL

T00429A

INTRODUCTION A - 4 I-E96-624A

TERMINATION UNIT CONFIGURATION (NTMF01)

TXD RXD RTS REQUEST TO SEND CTS DCD

DCD RXD TXD CTS RTS

CTS CTS CTS

RTS CTS DCD CTS RTS RXD TXD

TRANSMIT DATA RECEIVE DATA

CLEARTO SEND RECEIVED LINE SIGNAL DETECT

+24V

DTE

1 2 3 4 5 6 7 8 9

XU1 XU3

XU2 XU4

20 19 18 17 16 15 14 13 12 11

2 TRANSMIT DATA

3 RECEIVE DATA

RTS

4 RE Q UE ST TO SE ND

CTS

5 CLEAR TO SEND

DCD

8 RECEIVED LINE SIGNAL DETECT

SDCE

9+VOLTS

12 SECONDARY RECEIVE SIGNAL DETECT

SRD

16 SECONDARY RECEIVE SIGNAL 25 BUSY

1 PROTECTIVE GROUND

DTR

20 DATATERM INAL READY

DSR

6 DATA SET READY

7 SIGNAL GROUND

DCE

22 RING DETECT

STD

14 SECONDARY T RANSMITTED DATA

11 EQUALIZER MO DE

Figure A-5. DB-25 Pin Assignments and RS-232-C Signals

T00375A

INTRODUCTION

I-E96-624A A - 5

APPENDIX B - TERMINATION UNIT CONFIGURATION

(NTCL01)

INTRODUCTION

The INLIM03 uses the NTCL01 for termination. Table B-1 lists the terminal assignments and Table B-2 lists the BNC terminal assignments for the loop input/output connections. Table B-3 provides jumper settings associated with cable type. Figure B-1 shows twinax cable connections for the NTCL01.

NOTE:

nect to the BNC connectors.

Twinax cables connect to the terminals. Coax cables con-

Table B-1. NTCL01 Terminal Assignments

Terminal

Number

TB1

1 2 3 4 5 6 7 8

Assignments

Loop 1 In, + Loop 1 In, Loop 1 In, Shield no connection Loop 1 Out, + Loop 1 Out, Loop 1 Out, Shield Power System Status 1

Table B-2. BNC Terminal Assignments

BNC

Number

J1 J2

Assignments

Loop 1 In Loop 1 Out

Terminal

Number

TB3

1 2 3 4 5 6 7 8

BNC

Number

J8 J9

Assignments

Loop 2 In, + Loop 2 In, Loop 2 In, Shield no connection Loop 2 Out, + Loop 2 Out, Loop 2 Out, Shield Power System Status 2

Assignments

Loop 2 In Loop 2 Out

INTRODUCTION

I-E96-624A B - 1

TERMINATION UNIT CONFIGURATION (NTCL01)

Table B-3. Jumper Settings and Cable Types

NLIM03

NLIM03 - PLANT LOOP

JUMPER NO.

J3, J10

J4-J7, J11-J14

J15-J18

NKLS03 (NLIM03)

TWINAX COAX

123

POST

NUMBERS

NTCL01

E2E2COM E1E1+24V

NTCL01

COM +24V

TB2

TB1

TB2

TB1

LOOP2

87654321 87654321

LOOP1

LOOP2

87654321

SH- IN+

87654321

LOOP1

T00365A

NKPL01

T00366A

Figure B-1. NTCL01 Termination Unit and Terminal Assignments

INTRODUCTION B - 2 I-E96-624A

INTRODUCTION

APPENDIX C - TERMINATION MODULE

CONFIGURATION (NIMF01/NIMF02)

The INPPT01 can use the NIMF01 for termination. The NIMF02 is required when terminating redundant interfaces. The dispshunt configurations shown in Figure C-1 through C-4 apply to the NIMF01 and NIMF02. Figure C-1 shows the dipshunt configuration required when connecting a local and remote PPT (DTE) via a modem (DCE). Figure C-2 and C-3 show the dipshunt configuration required when directly connecting a local PPT (DTE) to a remote PPT (DCE) via a cable.

+24 VDC

DCD

+24 VDC

DCD

CABLE SHIELDING GROUND

XU1

XU3

XU2

CTS RTS RXD TXD

CABLE SHIELDING GROUND

XU4

CTS RTS RXD TXD

CTS

RTS RXD TXD

DB-25 PIN

ASSIGNMENTS

3 2

PORT 0

CTS

RTS RXD TXD

DB-25 PIN

ASSIGNMENTS

3 2

PORT 1

TERMINAL PORT

XU1

LOCAL AND REMOTE

P1 EDGE

CONNECTOR

XU2

XU3

XU4

PRINTERPORT

PORT 0

PORT 1

T00430A

Figure C-1. Dipshunt Configuration for PPT Acting as DTE (requires Modem or Other DCE)

INTRODUCTION

I-E96-624A C - 1

TERMINATION MODULE CONFIGURATION (NIMF01/NIMF02)

Figure C-3 shows how to configure the dispshunts so that port 1 can drive a diagnostics terminal.

+24VDC

DCD

+24VDC

CABLE SHIELDING GROUND

XU1

XU3

XU2

CTS RTS RXD TXD

CABLE SHIELDING GROUND

XU4

CTS

RTS RXD TXD

DB-25 PIN

ASSIGNMENTS

3 2

PORT 0

CTS

RTS RXD TXD

DB-25 PIN

ASSIGNMENTS

3 2

PORT 1

DCD

LOCA L

CTS RTS RXD TXD

TERMINAL PORT

XU1

P1 EDGE

CONNECTOR

XU3

XU2

XU4

PORT 0

PORT 1

PRINTER PORT

T00431A

Figure C-2. Dipshunt Configuration for Direct Connection of Local PPT Acting as DTE

INTRODUCTION C - 2 I-E96-624A

TERMINATION MODULE CONFIGURATION (NIMF01/NIMF02)

20118317416515

147138129111020118317416515

14713812911

2 3 4

+24 VDC

XU4

DCD

TXD

CABLE SHIELDING GROUND

RXD

TXD CTS

RTS

CTS

XU3

DB-25 PIN ASSIGNMENTS

PORT 1

20118317416515

147138129111020118317416515

14713812911

2 3 4

+24 VDC

XU2

DCD

TXD

CABLE SHIELDING GROUND

RXD

TXD CTS

RTS

CTS

XU1

DB-25 PIN ASSIGNMENTS

PORT 0

REMOTE

T00432A

TERMINAL PORT

PRINTER PORT

PORT 0

PORT 1

P1 EDGE

CONNECTOR

XU3

XU1

XU4

XU2

Figure C-3. Dipshunt Configuration for Direct Connection of Remote PPT Acting as DCE

INTRODUCTION

I-E96-624A C - 3

TERMINATION MODULE CONFIGURATION (NIMF01/NIMF02)

+24 VDC

RXD TXD

20118317416515

XU3

DIAGNOSTICTER MINAL

147138129111020118317416515

XU4

DCD

CTS

(PORT 1 ONLY )

14713812911

CONNECTOR

P1 EDGE

TXD RXD DCD CTS

9 2

DB-25 PIN

ASSIGNMENTS

8 5

PORT1

TERMINAL PORT

XU3 XU4

PRINTER PORT

PORT 0

PORT 1

T00433A

Figure C-4. Dispshunt Configuration for Diagnostic Terminal

INTRODUCTION C - 4 I-E96-624A

INTRODUCTION

APPENDIX D - TERMINATION MODULE

CONFIGURATION (NICL01)

The INLIM03 can use the NICL01 for termination. Table D-1 lists the terminal assignments for the loop input/output connections. Table D-2 provides jumper settings associated with cable type. Figure D-1 shows twinax cable connections for NICL01.

NOTE:

nect to the BNC connectors.

Twinax cables connect to the terminals. Coax cables con-

CAUTION Ensure that the end marked J1 is connected to P1 on the

NICL01, and J2 is connected to the LIM. Failure to do so could result in module damage (see Figure

D-1

ATTENTION S'assuree que L'extremite identifiee par J1 est reliee a P1 du

module NICL01 et que J2 est reliee au module LIM. Sinon, les modules pouiraient etre endommages (voir la figure

Table D-1. NICL01 Terminal Assignments

TB1

Terminal

1 2 3

Assignments

Ground Common +24 VDC

TB2

Terminal

4 5 6

7 8

9 10 11

Assignments

Power System Status 1 Power System Status 2 Loop 2 In, + Loop 2 In, Loop 2, Shield Loop 2 Out, + Loop 2 Out, Loop 2 Out, Shield

TB3

Terminal

25 26 27 28 29 30 31 32

Assignments

Loop 1 Out, Shield Loop 1 Out, Loop 1 Out, + Loop 1 In, Shield Loop 1 In, Loop 1 In, + no connection no connection

D-1

Table D-2. BNC Assignments

BNC Number Assignments

J1 J2 J8 J9

Loop 1 In Loop 1 Out Loop 2 In Loop 2 Out

INTRODUCTION

I-E96-624A D - 1

TERMINATION MODULE CONFIGURATION (NICL01)

Table D-3. Jumper Settings and Cable Types

NLIM03

NLIM03 - PLANT LOOP

JUMPER NO.

J3, J10

J4-J7, J11-J14

J15-J18

NKLS04

(NLIM03)J2 J1

P3 P1

TWINAX COAX

123

POST

NUMBERS

TERMINAL 25 TO 28

NICL01

J1 J2 J9 J8

TB3

TB2

TB1

30 29 28

11 10

3 2 1

T00365A

26 TO 29 27 TO 30

NKPL01

NICL01

J1 J2 J9 J8

TB3

TB2

TB1

Figure D-1. Typical Twinax Cable Connection for the NICL01

27 26 25

11 10

3 2 1

T00396A

INTRODUCTION D - 2 I-E96-624A

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Bailey INFI 90 INPPR01 Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

List of Effective Pages

Safety Summary

Sommaire de Sécurité

Table of Contents

List of Figures

List of Tables

OVERVIEW

INTENDED USER

SECTION 1 - INTRODUCTION

HARDWARE DESCRIPTION

Plant Loop to Plant Loop Transfer Module (INPPT01)

Bus Transfer Module (INBTM01)

Loop Interface Module (INLIM03)

Additional Hardware

FEATURES

INSTRUCTION CONTENT

HOW TO USE THIS MANUAL

GLOSSARY OF TERMS AND ABBREVIATIONS

REFERENCE DOCUMENTS

NOMENCLATURE

SPECIFICATIONS

SECTION 2 - DESCRIPTION AND OPERATION

INTRODUCTION

LOCAL/REMOTE COMMUNICATIONS

DATA INTEGRITY

TIMING INTERVAL

Transmit/Receive Timing

INTRODUCTION

SPECIAL HANDLING

SECTION 3 - INSTALLATION

UNPACKING AND INSPECTION

INPPT01 SWITCH SETTINGS

Option Switch (U72)

Serial Port Communication Rate (U73)

Loop Address (U75)

INLIM03 SWITCH SETTINGS

INBTM01 SWITCH SETTINGS

TERMINATION UNIT (MODULE) CONFIGURATION

NTMF01/NIMF01/NIMF02 Configuration

ONE-WAY CONTROL

TWO-WAY CONTROL

NTCL01/NICL01 Configuration

INSTALLING THE INTERFACE MODULES

Installing the INPPT01

Installing the INLIM03 and INBTM01

INSTALLING A REDUNDANT INTERFACE

INTERFACE CONFIGURATIO N

SECTION 4 - OPERATING PROCEDURES

INTRODUCTION

PLANT LOOP TO PLANT LOOP TRANSFER MODULE LEDs AND CONTROLS

Status LED

CPU LEDs

Memory LEDs

Stop Pushbutton

Reset Pushbutton

LOOP INTERFACE MODULE LEDs

BUS TRANSFER MODULE LED

MODES OF OPERATION

Configure Mode

Execute Mode

Error Mode

One-Way Control

Two-Way Control

REDUNDANT INTERFACE OPERATION

INTERFACE POINT CAPACITY

MEMORY USAGE EXAMPLE

Memory Usage in the Local PPT

Memory Usage in the Remote PPT

SECURITY FUNCTIONS

Hardware Checks

Software Checks

Utilities

INTRODUCTION

SECTION 5 - TROUBLESHOOTING

Status Bytes