NOTE: if you are replacing a suspected faulty module, make sure the module firmware of the new module is the same: I.e. if original or ‘good’ module is G-8: BOTH primary and redundant must be G-8
1. With the MFP12 module laying on the bench and the faceplate to the left, Identify 8 pole switches: SW3 and SW4, located at the top RH end of module – SW3 being the LH of the 2 switch sets. See digram Below:
2. Each pole is numbered (from left to right), 1 through 8. NOTE that for a setting of ‘0’ the pole is CLOSED or ON and for ‘1’ it’s OPEN or OFF. If the PCU uses older style Module Bus: pole 3 of SW3 will be set to 1 (poles 1 and 2 will be 0). Poles 4 through 8 are the module address switches, with pole 8 being the LSB and pole 4 being the MSB.. The highest assignable address being 63 i.e. a module with Address 12 would have SW3 set as thus:
Pole: 1 2 3* 4 5 6 7 8
0 0 1 0 1 1 0 0
*Note:This example is for a PCU with Module Bus, if the PCU was on Controlway,
pole 3 would be set to '0'
3. SW4. This switch is used to set the role of the controller and some options i.e. primary or redundant module in a redundant pair: Pole 8 is set ‘0’ for PRIMARY module, but pole 8 must be ‘1’ if it is the BACKUP module. NOTE that all switches and jumpers MUST be set IDENTICALLY on BOTH modules EXCEPT pole 8 (the primary / redundant option) of SW4. Therefore, For normal operations IF IT’S THE PRIMARY module: the Poles 1 through 6 should be set thus:
Pole: 1 2 3 4 5 6 7 8
0 1 0 0 0 0 0 0
If it is the BACKUP module in a redundant pair the setting for SW4 is thus:
Pole: 1 2 3 4 5 6 7 8
0 1 0 0 0 0 0 1
4. TO INITIALIZE module, ONLY the poles of SW4 are used. Make sure ALL switch settings and jumper settings are IDENTICAL for both primary and redundant modules, EXCEPT pole 8 of SW4, before you start any initialization of either module. Pole 8 must be set as 1 on ONLY ONE of the 2 modules – all other switch and jumper settings MUST be the SAME when
modules are put back into normal operation...
5. To initialize a module:
i) Use a toothpick or similar thing object to stop module (if not already stopped with RED status LED)
ii) Remove module from MMU and NOTE the settings of SW4, paying CLOSE ATTN to poles 2 and pole 8 (pri / red option) these 2 poles MUST BE RETURNED the same ‘as found’ when initialization is complete.
iii) Select 0 for ALL poles of SW4 EXCEPT pole 7, this must be set as ‘1’ (temporarily) Therefore settings are pole: 1 2 3 4 5 6 7 8
0 0 0 0 0 0 1 0
After setting SW4 as above, return module to MMU and wait (say 2 mins) after about 30 seconds, the green status LED should turn to STEADY red and error LEDS 1, 2 and 4 will be red - on. All other LEDS will be off. After waiting about 1 minute, remove module from MMU and return SW4 pole 7 to ‘0’ & all poles of SW4 to their original positions (normally only Pole 2 and 8 would be changed if it is a BACKUP module (pole 8 = 1) but if a PRIMARY module, only pole 2 would be returned to ‘1’
Put module back into MMU and module should return to normal operation after waiting anywhere between 2 and 10 minutes, ‘normal’ being steady GREEN status light and error LED 8 only on, but initially error LED 7 will come on then once the primary and redundant modules are properly synched (both configs are identical), error LED 7 will turn off, replaced by LED 8 only – that is in standby mode – ready to fail over if there is a problem with the primary or when online config is performed.
6. If the module does NOT return to normal operation, (RED Status and any error code LEDs) try repeating the initialization procedure or, if still unsuccessful: the module could be faulty, so if possible try another module and initialize it using above procedure, but MAKE SURE THE FIRMWARE is the SAME as the other module. I.e. if original (good module) is G-4, both must be G-4... There is a FULL factory initialization procedure that might fix a ‘stubborn’ module sometimes, but normally the above procedure will clear any erroneous or corrupted configuration from any ‘healthy’ IMMFPxx Controller module. If you need to know the procedure for a full factory reset and initialization (which may or may not fix a ‘stubborn’ module), please request here - the same as your inquiry / question for this procedure...
Source: ABB Doc: IMMfp123.pdf