TOSHIBA NV-Series PLC - MET.

Introduction onUnified Controller nv seriesTransmission Distribution & Industrial Systems CompanyCopyright 2008, Toshiba Corporation.

Unified Controller nv series - Introduction1. General Description1.1 History of Toshiba Controller Products1.2 Product Concept1.3 Birth of Unified Controller nv series1.4 Background and Aim on Development1.5 Features on Unified Controller nvseries1.6 Product Coverage of Unified Controllernv series1.7 Measure to Improve Product Reliability2. Controller2.1 Specification and External View2.2 List of Modules2.3 System Configuration3. High Speed Serial I/O System TC-netI/O3.1 General Description of TC-net I/O3.2 Installation of I/O Modules3.3 TC-net I/O Loop3.4 Operation at Failure4. Control Network4.1 Control Network Configuration4.2 1Gbps-Ethernet4.3 TC-net 1005. Engineering Tool Ver.4 (nV-Tool4)5.1 Kinds and Connecting Style ofEngineering Tool5.2 Target System5.3 System Tree of Engineering Tool Ver.45.4 Program EditorUnified Controller nv series - Introduction2

1.1.1 History of Toshiba Controller ProductsIntegrated ControllerV seriesTOSDIC-CIE TMTOSDIC TMProsec TM T seriesUnified Controller nv series - Introduction3

1.1.2 Chronology of Toshiba Controller Products1975 1980 1985 1990 1995 2000 2005 2010(year)PowerController for Power StationGeneralIndustryTOSDIC TMCIEMAC TMCIEMAC TM -DSIron / SteelWaterTreatmentElectricMachineryTOSMATIC TM-16A PC100 PC200TOSDIC TMP2000PROSEC TM-2000Highway Facility TOSMATIC TMuilding Automation -12AMC20PC50PROSEC TMEX seriesPROSEC TMT seriesIntegrated ControllerV seriesUnifiedControllernv seriesUnified Controller nv series - Introduction4

1.2 Product ConceptController IntegrationI/O System IntegrationIntegrationReliability& SafetyHigh Reliability,Relief & Safety, SuccessionEnvironmentalHarmonizationEnvironmental Harmonized Products,Conformation to RoHS Directive,Global Environment ProtectionUnified Controller nv series - Introduction5

1.3 Birth of Unified Controller nv seriesUnified:【jú:nəfàid】, This is a word expresses “Unity”.General introduction of our new productSeries name Type name Release date Sales target System priceUnified Controllernv seriestype1(for Electric control)type2(for Instrumentation)Jan. 2008250 systems/year(Total of series)More than15 million yen(without applicationsoftware)Unified Controller nv series - Introduction6

1.4 Background and Aim on DevelopmentBackgroundRecently, the supervisory and control system becomes higher performance and more complexity inthe manufacturing premises of paper, the pulp, oil, the chemistry, steel, the metal, and the upperand lower water service system, etc. for which an industrial controller is used.On the other hand, the robust and reliable system is requested because of the stable supply of theproduct.Moreover, needs from the market to the cost reduction, the international and industrialstandardization, and the globalization have been risen.Toshiba‟s ActionIndustrial controller "Unified controller nv series" that has the feature (high speed, high performance,and the high trust), equips with I/O system 'TC-net I/O' by the dual loop network of 100Mbps at thetransmission speed and can be used in both instrumentation and electric control field, tocorrespond to such requirements has been commercialized.We will expand the sales scale of this product in the future.Unified Controller nv series - Introduction7

1.5.1 Features on Unified Controller nv series “Unified Controller nv series” has the following features with high performance,high reliability and the succession from the existing products.1. High operation performance powered by the capability to perform IEC languagedirectlyThe execution time of the sequence instructions can be set 20 ns (1/2 compared with our company product) andthe control cycle from 0.5 ms or more, because it is designed to execute international standard language IEC61131-3 instructions directly by hardware logic on hardware.2. High reliability has been achieved by the card redundant configuration and theECC circuit applied to internal memories.The duplex system that prepares 2 pieces of power supplies, CPUs, and the transmission cards can be configured.In addition, ECC circuit is applied to the internal memories on each card, and not only the error detection but alsothe error correction can be performed. Moreover, the number of parts is reduced by the high integration with ASIC,and the failure rate of the device is reduced at in a complex circuit.3. First high-speed serial I/O system 'TC-net I/O„ has been equipped in theseindustries.The transmission speed is 100Mbps, and field I/O system that can be the loop duplex configuration is the firstproduct in these industries. High-speed I/O data can be collected, and the minimum setting time of the collectioncycle is 100 us. The ordinary transmission line is a dual (transmission and reception) loop, and the configuration inwhich it is duplex further is possible.Unified Controller nv series - Introduction8

1.5.2 Features on Unified Controller nv series 4. High reliability can be achieved by configuration of 1Gbps transmission speedand redundancy on the supervisory and control network.One Gbps-Ethernet at the transmission speed is adopted in the supervisory and control network, and, in addition,the transmission line can be doubled. Moreover, Real-Time Ethernet 'TC-net 100' of the international standard canbe applied to the network between controllers. It is considered that it is possible to connect them via the switchinghub and the gateway with the conventional systems so far.5. Succession by three basic elements of the supervisory and control systemEngineering Tool: It conforms to International Standard IEC 61131-3 also adopted for the conventional products.Moreover, the symbol can be customized according to user's favor because it is made easily to use.Supervisory and Control Network: It conforms to open network Ethernet, and its transmission speed is 1 Gbps.Moreover, past Real-Time Ethernet 'TC-net 100' can be used.Operator Station: Conventional model 'OIS-DS' can be connected, and conventional operativeness has beensucceeded to. Moreover, the function as the OPC server can be added in OIS-DS.6. Corresponds to the RoHS directive considering the environment.It is a design to consider the global environment by using of lead free soldering and the part selection by the greenprocurement corresponding to the RoHS directive concerning the restriction of the use of certain hazardoussubstances.Unified Controller nv series - Introduction9

1.5.3 Speed Ties Trust –Unified Controller nv series–Certain speed provides us high class control. Speed has broughtus „reliability‟ and „high quality‟.20ns - high speed / IEC language direct executing languageprocessorS2ES2T(PU662T)S2(S2PU72A)/S2T(PU672T)S3/S2(S2PU82)nv series0 20 40 60 80 100 120Instruction executing time (nsec)Instruction executing time (our products data)IEC language direct executinglanguage processorUnified Controller nv series - Introduction10

1.5.4 Speed Ties Freely –Unified Controller nv series–TC-net I/O loop provides us „Full remote I/O‟.TC-net based fast serial I/O busFast scan with 100 us / Optimal control by setting scan transmissionperiodFast serial transmission, flexible system configuration, high reliabilitywith dual loop by „TC-net 100‟ that has become an international standardare provided.TC-net I/O loopTC-net I/O moduleUnified Controller nv series - Introduction11

1.5.5 Speed Ties the Techniques –Unified Controller nvseries–Properties of V series existing systems can be succeeded.Present technique will be succeeded and tied to future properties.Engineering tool „nV-Tool4‟ supports “IEC61131-3” programminglanguage.Application programs can be succeeded.Unified Controller nv series - Introduction12

1.6 Product Coverage of Unified Controller nv seriesSystemscaleLargescaleMediumscaleSmallscaleUnified Controllernv seriesPLCV seriesDCSSingle LoopControllerProcessComputerIndustrialComputerS: SequenceControlL: LoopControlC:ComputerControlUsageThe area of a computer control and a small-scale system will be achieved bymeans of the model expansion in the future.Unified Controller nv series - Introduction13

1.7 Measure to Improve Reliability on Unified Controller nv seriesRequirementAnalysis■Fundamental plan• ECC circuit• Duplex configuration by Single CPU• Check of duplex configuration• Simplified hardwareSystem testBasic DesignCombination Test■Initial evaluationby modeling method• State transition design techniqueapplied to overall CPU controland I/O system control• Checking by check toolDetail DesignInstallationUnit test■Prior solution of simple bug• Coding rule• Rule for source check■Reliability assessment• Long term reliability on BGA soldering■Testwithout insufficiency• Application of tableto check verificationcovering level• Test on RAS functionby real machine■ Operation checkwithout real machine• Check by software simulatorUnified Controller nv series - Introduction14

2.1.1 Specifications for Unified Controller nv seriesItem For electric control (type1) For instrumentation (type2)Program capacity 256 K step 512 K stepLocal variable/Globalvariable256 K word 256 K wordI/O variable 16 K word 16 K wordTagTaskPeriodical taskEvent taskTask switching timeCalculation performanceProgramming language-• Ultra high speed: 0.5 – 500 ms• High speed: 0.5 – 500 ms• RIO: 0.5 – 500 ms• Main: 0.5 – 1,000 msSelectable• Event: 8 entry• I/O interruption: 16 entryLess than 60 usContact instruction:Integer add instruction:Floating point add instruction:Standard input/output(Process alarm management)OIS-DS interface• High speed: 10 – 500 ms• Main: 100 – 10,000 ms• Event: 8 entry• I/O interruption: 16 entry20 ns20 ns120 nsFour languages conformed to IEC 61131-3• LD (Ladder)• FBD (Function Block Diagram)• SFC (Sequential Function Chart)• ST (Structured Text)Unified Controller nv series - Introduction15

2.1.2 External View of Unified Controller nv seriesExample of dual configurationController modules1Gbps Ethernet modulesPower modulesTC-net 100 modules1Gbps Ethernet modulesUnified Controller nv series - IntroductionTC-net 100 modules16

2.2 List of Modules That Compose Basic UnitController ModuleModule name Type code type1 type2 Slot width Max installedController module type1 PU811 ○ - 2 1Controller module type2 PU821 - ○ 2 1Ethernet ModuleGeneral purpose GB/100MB (E) EN811 ○ - 1 4 Note1General purpose GB (O) EN821 ○ - 1 4 Note1OIS-DS connection GB/100MB (E) FN812 - ○ 1 1TC-net ModuleOthersTC-net 100 (E/Single) TN811 ○ ○ 1 4 Note1TC-net 100 (E/Dual) TN812 ○ ○ 1 4 Note1TC-net 100 (O/Single) TN821 ○ ○ 1 4 Note1TC-net 100 (O/Dual) TN822 ○ ○ 1 4 Note1Profibus module Note 2 ○ ○ 1 2SIF (For extended TC-net I/O) Note 2 - ○ 1 3Note 1: Maximum total number of Ethernet module and TC-net module shall be 4 modules.Note 2: These modules will be released in the future.Unified Controller nv series - Introduction17

Power moduleI/OI/OI/ODriveDriveTC-net100Drive1Gbps EthernetDrive2.3.1 System Configuration (type1/Iron and Steel Plant)GeneralpurposeSCADAGeneralpurposeSCADASupervisory and Information LANTransmission between controllersUnified Controller nv seriesEthernet( 1Gbps )TC-net 100 network( 100Mbps )EthernetControllermoduleControllermodule G3-I/O adapter: developingTC-net I/O loopLoop HUBSIOBU*SIOExisting I/OSIOBUI/OBUTC-net I/O busI/OBUI/OI/OBUBUO/EO/EI/OI/OBUBUI/OBUSmall DriveI/OBUTC-net I/OTC-net I/O busTC-net I/OUnified Controller nv series - Introduction18

Power module1Gbps Ethernet1Gbps EthernetPower moduleI/OI/OI/O2.3.2 System Configuration (type1/for social facilities)HISHISControl LANEthernet Network(1Gbps )ControllermoduleControllermoduleUnified Controller nv seriesEthernetTC-net I/O loopI/OSIOSIOBUBUBUTC-net I/O busI/OSIOSIOBUBUBU*SIO*SIOExisting I/OI/OI/OBUBUI/OI/OBUBUTC-net I/OI/OBUI/OBUUnified Controller nv series - Introduction19

Power module1Gbps Ethernet1Gbps EthernetPower moduleI/OI/OI/O2.3.3 System Configuration (type2/for general industries)Operator station OIS-DS(FA3100S model9000 based)Control LANEthernet network( 1Gbps )ControllermoduleControllermoduleUnified Controller nv seriesEthernetTC-net I/O loopI/OSIOSIOBUBUBUTC-net I/O busI/OSIOSIOBUBUBU*SIO*SIOExisting I/OI/OI/OBUBUI/OI/OBUBUTC-net I/OI/OBUI/OBUUnified Controller nv series - Introduction20

3. High Speed Serial I/O System TC-net I/OSpecifications for High Speed Serial I/O System TC-net I/OItem Electric Interface Optical InterfaceTopologyTransmissionspeedI/O interfaceI/O moduleTransmission cableMaximumcable lengthDual loop (Send/receive)100Mbps32 node/loop16 module/nodeCategory 5 twisted pair cablewith shieldMaximum 10 mOptical fiber cable GI 50/125Maximum 2 kmTotal cable length Maximum 100 m Maximum 4 kmScan periodRedundantConfigurationHigh speed scan: 100us -Medium speed scan: 1ms -Bypass control at transmission line troubleDual configuration available on dual loopUnified Controller nv series - Introduction21

3.1.1 General Description of TC-net I/OFirst field I/O system that its transmission speed is 100 Mbps,and is dual loop configurable in the industries.High speed I/O data gathering is available, and minimumsetting time of gathering period is „0.1 ms‟.Basic transmission line is dual (send/receive), moreover, itsduplex configuration is available.Installation to DIN railAbundant I/O modulesUnified Controller nv series - Introduction22

3.1.2 TC-net I/O Module List Type code Module name Function and SpecificationTC-net I/O bus adapterSA911 TC-net I/O bus adapter TC-net I/O, electricalNote 1TC-net I/O bus adapter TC-net I/O, opticalGeneral TC-net I/O moduleDI934 Digital input module 24 Vdc/5 mA, digital filter, 32 ch/non isolationDI944 Digital input module 48 Vdc/2.5 mA, digital filter, 32 ch/non isolationDI935 Digital input module 24 Vdc/4 mA, digital filter, 64 ch/non isolationDI936 Digital input module 24Vdc/8mA , digital filter, each ch individualcommon, 16 ch/isolationDI937 Digital input module 24Vdc/8mA, contact input, 16 ch/non isolationIN956 Digital input module 100/120 Vac(dc)/8 mA(2.3 mA), each chindividual common, 16 ch/isolationDO934 Digital output module 24 Vdc/100 mA, sink output, 32 ch/non isolationDO935 Digital output module 24 Vdc/50 mA, sink output, 64 ch/non isolationRO966 Relay output module 240 Vac/30 Vdc/1.5 A(100 Vdc/0.1 A) (resistorload), 16ch/isolationUnified Controller nv series - Introduction23

3.1.3 TC-net I/O Module List Type code Module name Function and SpecificationAI914 Analog input module 0~5V, 14 bit, 1 ms period, 4 ch/isolationAI918 Analog input module 0~5V, 14 bit, 0.5 ms period, 8 ch/isolationAI919 Analog input module 0~5V, 14 bit, 50 ms period, 16 ch/ non isolationAI929D Analog input module AI919 with distributor, 16 ch/non isolationTC919Thermocouple inputmoduleThermocouple (B, R, S, J, K, T, E type),Individual type or range setting is available on eachchannel, 16 ch/isolationRT918C RTD input module RTD: Pt100, JPt100, Individual type or range setting isavailable on each channel, 8 ch/isolationAO928 Analog output module 0~20 mA, 14 bit, response within 1 ms period, 8ch/isolationAO928F Analog output module 0~20 mA, 16 bit, response within 1 ms period, 8ch/isolationAO929 Analog output module 0~20 mA, 14bit,response within 20 ms period, 16 ch/nonisolationPI918 Pulse input module DC~50 Hz (contact)/DC~50 Hz, single pulse,12~24 V, 8 ch/isolationSpecial purpose TC-net I/O moduleFL911 FL-net module FL-net interfaceMD911 Modbus module Modbus-RTU (with RS232C port)Unified Controller nv series - Introduction24

I/OI/OI/OI/OI/OI/O3.1.4 TC-net I/O System ConfigurationControllerPS Module SIF TN ENTC-net I/O loop(TC-net 100)TC-net I/O bus adapter(SIO)I/OI/OI/OI/OSIOTC-net I/O ASIC(Fenix2)*SIOTC-net I/O bus(RS485)Existing I/OsI/OI/OI/OI/OSIOTC-net I/O loop(TC-net 100)TC-net I/O base(Terminal block type)*SIOExisting I/Os Intelligent serial PI/Os F series serial PI/Os G3 I/Os G2 I/OsTC-net I/O base(Terminal block type)Unified Controller nv series - Introduction25

3.2 Installation of I/O ModulesPow er term inalblockConnecting cable CN9C3(Accessory of BU905)Maximum 16 base units(BU905) are connectableTC-net I/O bus connector (upper side)Termination connectorTR901(Accessory of BU901)Base unit (BU901)TC-net I/ bus connector (lower side)Extending cable (CN9R5, 50 cm) is used for daisychain connection at lower end.TerminatorTR901(Accessory ofBU901)Central part ofcable shall befixed withinshlock.DIN rail installationDaisy chain connectionwith terminal blocks andcablesConnection to nextcolumn by using extendingcableMaximum 16 units / nodeTermination resistor isneeded at end baseTerminator TR901(Accessory ofBU901)Extension cableCN9R5(Accessory for sale)Unified Controller nv series - Introduction26

3.3.1 TC-net I/O Loop -Single Loop System-OnlineController(Primary)StandbyController(Secondary)type1ControllerController(Primary)(Secondary)SIO(P)SIO(S)I/OTC-net I/O loop (P)TC-net I/O loop (S)SIO(P)SIO(S)I/OSIO(P)Cross circuitSIO(S)I/OTC-net I/O bus(Transmissionline duplex)SIO(P)SIO(S)I/O(2) Logic diagram(1) Wiring diagramUnified Controller nv series - Introduction27

3.3.2 TC-net I/O Loop -Dual System-OnlineControllerStandbyControllertype2Controller(Primary)Controller(Secondary)(Primary)(Secondary)TC-net I/O loop (P)TC-net I/O loop (S)SIO(P)SIO(S)I/OSIO(P)Cross circuitSIO(S)SIO(P)SIO(S)I/OI/O(2) Logic diagramTC-net I/O bus(Transmissionline duplex)OnlineSIO 1 (P)StandbySIO 1 (S)SIO(P)SIO(S)I/OStandbySIO 2 (P)・・・OnlineSIO 2 (S)・・・OnlineSIO n (P)StandbySIO n (S)(1) Wiring diagram(3) Receive data selectionUnified Controller nv series - Introduction28

Controller moduleController module3.4.1 Operation at Failure -Dual Loop-cTC-net I/O cablea×××Tracking busbOperation can be continuedunder disconnection at 3 points.SIOSIOI/OI/OI/OI/OI/OI/OI/OI/OSIOSIOI/OI/OI/OI/OI/OI/OI/OI/OSIOSIOI/OI/OI/OI/OI/OI/OI/OI/OUnified Controller nv series - Introduction29

4.1 Control Network Configuration“CIEMAC DS/nv System” Configured on NetworksHMIProductionplanningcomputerRemoteengineeringterminalInternetControllerTC-net I/OSystemSensorInformationmanagementserverFire wallInformation system LANEngineeringToolActuatorControl valve,Relay, Switch,Motor, etc.Control LANGB EthernetTC-net 100Unified Controller nv series - Introduction30

4.2 Supervisory/Control Network -1Gbps-Ethernet-1Gbps-Ethernet SpecificationTopologyItemEthernet frameNumber of nodesNumber of repeaterhubsNumber of LAN switchesNumber of EthernetmodulesSpecificationStar-typeDIX SystemMax 254 node/system (Single transmission line)10BASE-T: Max 4 module (cascade connection)100BASE-TX: Max 2 module (cascade connection)1000BASE-T: Max 1 moduleNo restrictionsTransmission module: Max 4 moduleUnified Controller nv series - Introduction31

4.3 Network between Controllers -TC-net 100-TC-net 100 SpecificationItemDistance between hub andstationCableConfigurationTopologyTransmission modeCapacity of scantransmissionStatus change detectionNumber of nodes2 kmMulti mode optical fiberSpecificationSingle transmission line/Dual transmission lineStar typeScan transmission– High speed: 1 ms – 160 ms– Medium speed: 10 ms – 1,000 ms– Low speed: 100 ms – 10,000 msMessage transmission– TCP/UDP/IP/ARP/ICMP128 KW/system2048 block/system (64 W/block)Transmission capacity/node– High speed: 64 block– Medium speed: 128 block– Low speed: 384 blockNumber of status change detection word: 128 KWDetection period: number of words x 30 usInterval of detection signal: more than 50 msMax 254 node/systemUnified Controller nv series - Introduction32

5. Engineering Tool Ver.4 -nV-Tool4-Specification of Engineering Tool Ver.4 (nV-Tool4)ItemSpecificationModelHardwareOperatingenvironment OSProgramming languageController interface利 用 形 態Support languagetype1/type2PC/AT compatibleWindows XP Professional SP1 or later(Standalone version/Client side)Windows Server 2003 or later (Server side)IEC 61131-3 conforming– LD (Ladder diagram),– FBD (Function block diagram),– SFC (Sequential function chart),– ST (Structured text)EthernetStandalone / Client-serverJapanese/English/Chinese PlanningUnified Controller nv series - Introduction33

5.1 Kinds and Connecting Style of Engineering Tool (nV-Tool4)nV-Tool4 clientPHSIntranet/InternetnV-Tool4 clientnV-Tool4 clientnV-Tool4serverEthernet※1 planningLanguageJapanese English ChinesenV-Tool4 client/server version ○ ○ ○ ※1nV-Tool4 standalone version ○ ○ ○ ※1Unified Controller nv series - Introduction34

5.2 Target System of Engineering Tool (nV-Tool4) Unified Controllernv seriesTarget System unified Controller nv series+ Integrated Controller V series Integrated ControllerV series System composed by “Unified Controller nv series” only System composed by both “Unified Controller nv series”and “Integrated Controller V series” System composed by “Integrated Controller V series” onlyUnified Controller nv series - Introduction35

5.3 System Tree of Engineering Tool (nV-Tool4)Application configured by nV-Tool4Correspondence of one to one with hardware configurationStructure that is easy to understandUnified Controller nv series - Introduction36

5.4 Program Editor (Text Editor)Text editor which supports ST language based on IEC 61131-3.ST(Structured Text): Structured text language which is similar to PASCAL or C languageEfficient description: Efficient description of complex operational expression and repetitionprocessingVariable/Constant/Syntax: Description of Variable, constant, operator, assignment statement, IFstatement, CASE statement, FOR statement, WHILE statement, REPEAT statement, call statementfor functions and function blocks etc.Unified Controller nv series - Introduction37

5.5 Program Editor (Full Graphic Editor)Program editor that is used for drawing, storing and compilation, monitoring the programLD (ladder diagram), FBD (function block diagram), SFC (sequential function chart) basedon IEC 61131-3 with instruction symbols on each field togetherUnified Controller nv series - Introduction38

5.6 Program Editor (Custom Symbol Editor)Custom made symbol can be made easily as follows.Unified Controller nv series - Introduction39

Unified Controller nv series - Introduction40