Introduction on Unified Controller nv series

Copyright 2007, Toshiba Corporation.

Introduction on Unified Controller nv series

Industrial Systems Company

Unified Controller nv series - Introduction 2

Unified Controller nv series - Introduction1. General Description

1.1 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 nv

series1.6 Product Coverage of Unified Controller

nv series1.7 Measure to Improve Product Reliability

2. Controller2.1 Specification and External View2.2 List of Modules2.3 System Configuration

3. High Speed Serial I/O System TC-net I/O3.1 General Description of TC-net I/O3.2 Installation of I/O Modules3.3 TC-net I/O Loop3.4 Operation at Failure

4. Control Network4.1 Control Network Configuration4.2 1Gbps-Ethernet4.3 TC-net 100

5. Engineering Tool Ver.4 (nV-Tool4)

5.1 Types and Connecting Style of Engineering Tool

5.2 Target System5.3 System Tree of Engineering Tool

Ver.45.4 Program Editor


1.1.1 History of Toshiba Controller Products

TOSDIC-CIETM

Integrated Controller V series

TOSDICTM

ProsecTM T series


1.1.2 Chronology of Toshiba Controller Products

1975 1980 1985 1990 1995 2000 2005 2010(year)

Power

General Industry

Iron / Steel

Water Treatment

Electric Machinery

TOSDICTM

CIEMACTM

CIEMACTM-DS

TOSMATICTM-16A PC100 PC200

MC20PC50

TOSMATICTM-12A

PROSECTM-2000

TOSDICTMP2000

PROSECTM

EX seriesPROSECTM

T series

Integrated ControllerV series

Highway FacilityBuilding Automation

Unified Controller nv series

Controller for Power Station

▲ CIE Integration ▲ Integrated controller

▲ Unified controller


1.2 Product Concept

Controller IntegrationI/O System Integration

High Reliability,Relief & Safety, Succession

Reliability & Safety

Environmental Harmonization

Integration

Environmental Harmonized Products,Conformation to RoHS Directive,

Global Environment Protection


1.3 Birth of Unified Controller nv series

Series name Type name Release date Sales target System price


type1(for Electric control)

Jan. 2008 250 systems/year(Total of series)

More than 15 million yen

(without application software)

type2(for Instrumentation)

Unified：【 jú:nəfàid】 , This is a word expresses “Unity”.

General introduction of our new product

TC-net I/O modules

Base unit


1.4 Background and Objective on DevelopmentBackground

Recently, the supervisory and control system becomes higher performance and more complexity in the manufacturing premises of paper, the pulp, oil, the chemistry, steel, the metal, and the upper and 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 the product. Moreover, needs from the market to the cost reduction, the international and industrial standardization, and the globalization have been risen.

Toshiba’s Action

Industrial 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 the transmission speed and can be used in both instrumentation and electric control field, to correspond to such requirements has been commercialized.

We will expand the sales scale of this product in the future.


1.5.1 Features on Unified Controller nv series <1>

“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 language directly

The execution time of the sequence instructions can be set 20 ns (1/2 compared with our company product) and the control cycle from 0.5 ms or more, because it is designed to execute international standard language IEC 61131-3 instructions directly by hardware logic on hardware.

2. High reliability has been achieved by the card redundant configuration and the ECC 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 also the 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 these industries.

The transmission speed is 100Mbps, and field I/O system that can be the loop duplex configuration is the first product in these industries. High-speed I/O data can be collected, and the minimum setting time of the collection cycle is 100 us. The ordinary transmission line is a dual (transmission and reception) loop, and the configuration in which it is duplex further is possible.


1.5.2 Features on Unified Controller nv series <2>

4. High reliability can be achieved by configuration of 1Gbps transmission speed and 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 can be applied to the network between controllers. It is considered that it is possible to connect them via the switching hub 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 been succeeded 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 green procurement corresponding to the RoHS directive concerning the restriction of the use of certain hazardous substances.


1.5.3 Speed Ties Trust – Unified Controller nv series–

Certain speed provides us high class control. Speed has brought us ‘reliability’ and ‘high quality’.

20ns - high speed / IEC language direct executing language processor

Instruction executing time (our products data) IEC language direct executing language processor

0 20 40 60 80 100 120

Instruction executing time (nsec)

nv series

S3/S2(S2PU82)

S2(S2PU72A)/S2T(PU672T)

S2T(PU662T)

S2E


TC-net I/O loop

TC-net I/O module

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 transmission periodFast serial transmission, flexible system configuration, high reliability with dual loop by ‘TC-net 100’ that has become an international standard are provided.


1.5.5 Speed Ties the Techniques – Unified Controller nv series–

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” programming language.

Application programs can be succeeded.


Process Computer

Single Loop Controller

Industrial Computer

PLC

System scale

Large scale

Medium scale

Small scale

DCS

S: Sequence Control

L: Loop Control

C:Computer Control

Usage

V series

1.6 Product Coverage of Unified Controller nv series

Unified Controller

nv series

The area of a computer control and a small-scale system will be achieved by means of the model expansion in the future.


Item For electric control (type1) For instrumentation (type2)

Program capacity 256 K step 512 K step

Local variable/Global variable 256 K word 256 K word

I/O variable 16 K word 16 K word

Tag －Standard input/output(Process alarm management) OIS-DS interface

Task

Periodical task

• Ultra high speed: 0.5 – 500 ms• High speed: 0.5 – 500 ms• RIO: 0.5 – 500 ms• Main: 0.5 – 1,000 ms

• High speed: 10 – 500 ms• Main: 100 – 10,000 ms

Event taskSelectable• Event: 8 entry• I/O interruption: 16 entry

• Event: 8 entry• I/O interruption: 16 entry

Rask switching time Less than 60 us

Calculation performanceContact instruction: 20 nsInteger add instruction: 20 nsFloating point add instruction: 120 ns

Programming language

Four languages conformed to IEC 61131-3• LD (Ladder)• FBD (Function Block Diagram)• SFC (Sequential Function Chart)• ST (Structured Text)

2.1.1 Specifications for Unified Controller nv series


2.1.2 External View of Unified Controller nv series

Power modules

Example of dual configurationController modules 1Gbps Ethernet modules

1Gbps Ethernet modulesTC-net 100 modules TC-net 100 modules


2.2 List of Modules That Compose Basic Unit

Module name Type code type1 type2 Slot width Max installed

Controller Module

Controller module type1 PU811 ○ － 2 1

Controller module type2 PU821 － ○ 2 1

Ethernet Module

General purpose GB/100MB (E) EN811 ○ － 1 4 Note1

General purpose GB (O) EN821 ○ － 1 4 Note1

OIS-DS connection GB/100MB (E) FN812 － ○ 1 1

TC-net Module

TC-net 100 (E/Single) TN811 ○ ○ 1 4 Note1

TC-net 100 (E/Dual) TN812 ○ ○ 1 4 Note1

TC-net 100 (O/Single) TN821 ○ ○ 1 4 Note1

TC-net 100 (O/Dual) TN822 ○ ○ 1 4 Note1

Others

Profibus moduleNote 2 ○ ○ 1 2

SIF (For extended TC-net I/O)Note 2 － ○ 1 3

Note 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.


2.3.1 System Configuration (type1/Iron and Steel Plant)

I/O

I/O

I/O

*SIO

Existing I/O

Small Drive

TC-net 100 network ( 100Mbps )

Ethernet ( 1Gbps )

Supervisory and Information LAN

Transmission between controllers

Ethernet

Po

we

r m

od

ule

1G

bp

s E

the

rne

t T

C-n

et1

00

C ontro ller m odule


SIO

I/O

I/O

I/O

I/O BU

BU

BU

BU

BU SIO

I/O

I/O

I/O

I/O BU

BU

BU

BU

BU

TC-net I/O bus

TC-net I/O

Loop HUB

Driv

e

O/E

O/E

D

rive

Driv

e

Driv

e

TC-net I/O bus

TC-net I/O loop

D up lex: O ctob er 2007 M ulti contro ller: D ecem b er 2007

Additional I/O for steel plant: March 2008 G3-I/O adapter: planning


Interface to drive equipment: March 2008

General purpose SCADA

General purpose SCADA

TC-net I/O


2.3.2 System Configuration (type1/for social facilities)　

I/O

I/O

I/O

*SIO

Existing I/O

Ethernet Network （ 1Gbps ）

Control LAN

Ethernet

Controller module

Po

we

r m

od

ule

1G

bp

s E

the

rne

t


Po

we

r m

od

ule

1G

bp

s E

the

rne

t

*SIO SIO

I/O

I/O

I/O

I/O BU

BU

BU

BU

BU

SIO BU

SIO

I/O

I/O

I/O

I/O BU

BU

BU

BU

BU

SIO BU

TC-net I/O loop

TC-net I/O bus


TC-net I/O

HIS HIS


2.3.3 System Configuration (type2/for general industries)

I/O

I/O

I/O

*SIO

Existing I/O

*SIO SIO

I/O

I/O

I/O

I/O

SIO

BU

BU

BU

BU

BU

BU

SIO

I/O

I/O

I/O

I/O

SIO

BU

BU

BU

BU

BU

BU

Ethernet network ( 1Gbps )

Control LAN

Ethernet

Controller module

Po

we

r m

od

ule

1G

bp

s E

the

rne

t

Controller module

Po

we

r m

od

ule

1G

bp

s E

the

rne

t

Operator station OIS-DS （FA3100S model9000 based）

TC-net I/O loop

TC-net I/O bus


TC-net I/O


Item Electric Interface Optical Interface

Topology Dual loop (Send/receive)

Transmission speed

100Mbps

I/O interface 32 node/loop

I/O module 16 module/node

Transmission cableCategory 5 twisted pair cable

with shieldOptical fiber cable GI 50/125

Maximum

cable lengthMaximum 10 m Maximum 2 km

Total cable length Maximum 100 m Maximum 4 km

Scan periodHigh speed scan: 100us -

Medium speed scan: 1ms -

Redundant

Configuration

Bypass control at transmission line trouble

Dual configuration available on dual loop

3. High Speed Serial I/O System TC-net I/O

Specifications for High Speed Serial I/O System TC-net I/O


3.1.1 General Description of TC-net I/O

First 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 minimum setting time of gathering period is ‘0.1 ms’.

Basic transmission line is dual (send/receive), moreover, its duplex configuration is available.

Abundant I/O modules

Installation to DIN rail


3.1.2 TC-net I/O Module List <1>Type code Module name Function and Specification

TC-net I/O bus adapter

SA911 TC-net I/O bus adapter TC-net I/O, electricalNote 1 TC-net I/O bus adapter TC-net I/O, optical

General TC-net I/O module

DI934 Digital input module 24 Vdc/5 mA, digital filter, 32 ch/non isolation

DI944 Digital input module 48 Vdc/2.5 mA, digital filter, 32 ch/non isolation

DI935 Digital input module 24 Vdc/4 mA, digital filter, 64 ch/non isolation

DI936 Digital input module 24Vdc/8mA , digital filter, each ch individual common, 16 ch/isolation

DI937 Digital input module 24Vdc/8mA, contact input, 16 ch/non isolation

IN956 Digital input module 100/120 Vac(dc)/8 mA(2.3 mA), each ch individual common, 16 ch/isolation

DO934 Digital output module 24 Vdc/100 mA, sink output, 32 ch/non isolation

DO935 Digital output module 24 Vdc/50 mA, sink output, 64 ch/non isolation

RO966 Relay output module 240 Vac/30 Vdc/1.5 A(100 Vdc/0.1 A) (resistor load), 16ch/isolation


3.1.3 TC-net I/O Module List <2>Type code Module name Function and Specification

AI914 Analog input module 0～ 5V, 14 bit, 1 ms period, 4 ch/isolation

AI918 Analog input module 0～ 5V, 14 bit, 0.5 ms period, 8 ch/isolation

AI919 Analog input module 0～ 5V, 14 bit, 50 ms period, 16 ch/ non isolation

AI929D Analog input module AI919 with distributor, 16 ch/non isolation

TC919 Thermocouple input module

Thermocouple (B, R, S, J, K, T, E type), Individual type or range setting is available on each channel, 16 ch/isolation

RT918C RTD input module RTD: Pt100, JPt100, Individual type or range setting is available on each channel, 8 ch/isolation

AO928 Analog output module 0～ 20 mA, 14 bit, response within 1 ms period, 8 ch/isolation

AO928F Analog output module 0～ 20 mA, 16 bit, response within 1 ms period, 8 ch/isolation

AO929 Analog output module 0～ 20 mA, 14bit,response within 20 ms period, 16 ch/non isolation

PI918 Pulse input module DC～ 50 Hz (contact)/DC～ 50 Hz, single pulse, 12～ 24 V, 8 ch/isolation

Special purpose TC-net I/O module

FL911 FL-net module FL-net interface

MD911 Modbus module Modbus-RTU (with RS232C port)


3.1.4 TC-net I/O System Configuration

TC-net I/O base (Terminal block type)

I/O

I/O

I/O

*SIO

Controller

M odule

PS

TN

EN

SIF

SIO

I/O

I/O

I/O

I/O

TC-net I/O bus (RS485)

SIO

I/O

I/O

I/O

I/O

I/O

I/O

I/O

*SIO

TC-net I/O loop (TC-net 100)

Existing I/Os

Intelligent serial PI/Os F series serial PI/Os G3 I/Os G2 I/Os

TC-net I/O loop (TC-net 100)

TC-net I/O base (Terminal block type)

Existing I/Os

TC-net I/O bus adapter (SIO)

TC-net I/O ASIC (Fenix2)


3.2 Installation of I/O Modules

TC-net I/O bus connector (upper side)

TC-net I/ bus connector (lower side)

Power terminal block

Termination connector TR901 (Accessory of BU901)

Base unit (BU901)

Terminator TR901 (Accessory of BU901)

Connecting cable CN9C3 (Accessory of BU905)

Maximum 16 base units (BU905) are connectable

Extending cable (CN9R5, 50 cm) is used for daisy chain connection at lower end.

Extension cable CN9R5 (Accessory for sale)

Terminator TR901 (Accessory of BU901)

Central part of cable shall be fixed with inshlock.

DIN rail installation

Daisy chain connection

with terminal blocks and

cables

Connection to next

column by using extending

cable

Maximum 16 units / node

Termination resistor is

needed at end base


3.3.1 TC-net I/O Loop -Single Loop System-

S I O (P)

S I O (S)

I / O

S I O (P)

S I O (S)

I / O

S I O (P)

S I O (S)

I / O

Controller

（Primary）

Online

Controller

（Secondary）

Standby

(1) Wiring diagram

Controller

（Primary）

Controller

（Secondary）

TC-net I/O loop (P) TC-net I/O loop (S)

SIO（P） SIO（S）

I/O

(2) Logic diagram

Cross circuit

TC-net I/O bus (Transmission

line duplex)

type1


3.3.2 TC-net I/O Loop -Dual System-

S I O (P)

S I O (S)

I / O

S I O (P)

S I O (S)

I / O

S I O (P)

S I O (S)

I / O

Controller

（Primary）

Online

Controller

（Secondary）

Standby

(1) Wiring diagram

Controller

（Primary）

Controller

（Secondary）

TC-net I/O loop (P) TC-net I/O loop (S)

SIO（P） SIO（S）

I/O

SIO 1 (P)

SIO 2 (P)

SIO n (P)

･･･

Online

Standby

Online

SIO 1 (S)

SIO 2 (S)

SIO n (S)

･･･

Standby

Online

Standby

(3) Receive data selection

(2) Logic diagram

Cross circuit

TC-net I/O bus (Transmission

line duplex)

type2


3.4.1 Operation at Failure -Dual Loop-

Controller m

odule

Controller m

odule

Tracking bus

SIO

SIO

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

SIO

SIO

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

SIO

SIO

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

TC-net I/O cable

a

×

b

×

c

×

Operation can be continued under disconnection at 3 points.


4.1 Control Network Configuration“CIEMAC DS/nv System” Configured on Networks

ＨＭＩ

コントローラ

I/Oシステム

センサ

操作端

インターネット

ファイアウォール

リモートエンジニアリング端末

コントロールバルブリレー、スイッチモータなど

制御ＬＡＮ

情報系ＬＡＮ

生産計画系コンピュータ

エンジニアリングツール

情報制御サーバ

ＨＭＩ

コントローラ

I/Oシステム

センサ

操作端





制御ＬＡＮ

情報系ＬＡＮ




ＨＭＩ

コントローラ

I/Oシステム

センサ

操作端





制御ＬＡＮ

情報系ＬＡＮ




GB EthernetTC-net 100

Controller

TC-net I/OSystem

Control LAN

HMI

Sensor

Actuator

Control valve, Relay, Switch,

Motor, etc.

EngineeringTool

Information management

server

Remote engineering

terminal

Production planning computer

Internet

Fire wall

Information system LAN


4.2 Supervisory/Control Network -1Gbps-Ethernet-

1Gbps-Ethernet Specification

Item Specification

Topology Star-type

Ethernet frame DIX System

Number of nodes Max 254 node/system (Single transmission line)

Number of repeater hubs

10BASE-T: Max 4 module (cascade connection)

100BASE-TX: Max 2 module (cascade connection)

1000BASE-T: Max 1 module

Number of LAN switches No restrictions

Number of Ethernet modules

Transmission module: Max 4 module


4.3 Network between Controllers -TC-net 100-

TC-net 100 SpecificationItem Specification

Distance between hub and station 2 km

Cable Multi mode optical fiber

Configuration Single transmission line/Dual transmission line

Topology Star type

Transmission mode

Scan transmission– High speed: 1 ms – 160 ms– Medium speed: 10 ms – 1,000 ms– Low speed: 100 ms – 10,000 ms

Message transmission– TCP/UDP/IP/ARP/ICMP

Capacity of scan transmission

128 KW/system2048 block/system (64 W/block)Transmission capacity/node

– High speed: 64 block– Medium speed: 128 block– Low speed: 384 block

Status change detectionNumber of status change detection word: 128 KWDetection period: number of words x 30 usInterval of detection signal: more than 50 ms

Number of nodes Max 254 node/system


Item Specification

Model　 type1/type2

Operating

environment

Hardware PC/AT compatible

OS

Windows XP Professional SP1 or later

(Standalone version/Client side)

Windows Server 2003 or later (Server side)

Programming language

IEC 61131-3 conforming– LD (Ladder diagram),

– FBD (Function block diagram),

– SFC (Sequential function chart),

– ST (Structured text)

Controller interface Ethernet

利用形態 Standalone / Client-server

Support language Japanese/English/Chinese Planning

5. Engineering Tool Ver.4 -nV-Tool4-

Specification of Engineering Tool Ver.4 (nV-Tool4)


5.1 Kinds and Connecting Style of Engineering Tool (nV-Tool4)

Language

Japanese English Chinese

nV-Tool4 client/server version ○ ○ ○※1

nV-Tool4 standalone version ○ ○ ○※1

nV-Tool4server

nV-Tool4 client

Ethernet

Intranet/Internet

nV-Tool4 client

nV-Tool4 client

PHS

RS-232C

※1 planning


5.2 Target System of Engineering Tool (nV-Tool4)

<1> Unified Controller

nv series

<2> unified Controller nv series

+ Integrated Controller V series

<3> Integrated Controller V series

Target System

<1> System composed by “Unified Controller nv series” only<2> System composed by both “Unified Controller nv series” and “Integrated Controller V series”<3> System composed by “Integrated Controller V series” only


5.3 System Tree of Engineering Tool (nV-Tool4)

　 Application configured by nV-Tool4　 Correspondence of one to one with hardware configuration　 Structure that is easy to understand


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 language

Efficient description: Efficient description of complex operational expression and repetition processing

Variable/Constant/Syntax: Description of Variable, constant, operator, assignment statement, IF statement, CASE statement, FOR statement, WHILE statement, REPEAT statement, call statement for functions and function blocks etc.


5.5 Program Editor (Full Graphic Editor)Program editor that is used for drawing, storing and compilation, monitoring the program LD (ladder diagram), FBD (function block diagram), SFC (sequential function chart) based on IEC 61131-3 with instruction symbols on each field together


5.6 Program Editor (Custom Symbol Editor)

Custom made symbol can be made easily as follows.


1.7 Measure to Improve Reliability on Unified Controller nv series

Requirement

Analysis System test

Basic Design

Detail Design

Installation

Unit test

Combination Test

■Fundamental plan• ECC circuit• Duplex configuration by Single CPU• Check of duplex configuration• Simplified hardware

■Fundamental plan• ECC circuit• Duplex configuration by Single CPU• Check of duplex configuration• Simplified hardware

■Initial evaluation by modeling method• State transition design techniqueapplied to overall CPU control and I/O system control• Checking by check tool

■Initial evaluation by modeling method• State transition design techniqueapplied to overall CPU control and I/O system control• Checking by check tool

■Prior solution of simple bug• Coding rule• Rule for source check■Reliability assessment• Long term reliability on BGA soldering

■Prior solution of simple bug• Coding rule• Rule for source check■Reliability assessment• Long term reliability on BGA soldering

■ Operation check without real machine• Check by software simulator

■ Operation check without real machine• Check by software simulator

■Test without insufficiency• Application of table to check verification covering level• Test on RAS function by real machine

■Test without insufficiency• Application of table to check verification covering level• Test on RAS function by real machine


Documents

Introduction on Unified Controller nv series