Unified Controller Nv Series

Uniﬁ ed Controller nv Series Product Application Guide

metalscranes miningtesting oil & gas paperutilities cement

TMEIC nvSeries Controller Brochure.indd 1 12/7/2011 11:44:00 AM Unifi ed Controller nv Series Toshiba’s latest industrial controller, the Unifi ed nv The main features of this powerful controller are: Series controller, is a big step beyond the existing • Fault tolerant ring 100 Mbps I/O communication V series used in industry around the world. The • Enhanced speed by direct execution of IEC standard capabilities include high-speed logic, sequencing, control languages in ASIC hardware motor speed control, and continuous control. High- speed I/O communication uses the industry’s fi rst 100 • Higher reliability using redundant modules, and Mbps fault tolerant ring network “TC-net I/O”, linking error checking and correcting ECC memory remote, fi eld mounted I/O. • Gigabit supervisory control network

nv Controller board, Second nv Controller TC-net 100 board Ethernet board up to three per chassis

Power supply

Third nv Controller

Input/Output LAN TC-net I/O Loop, 100 Mbps System Network - Ethernet, 1 Gbps Input/Output LAN TC-net I/O Loop return Control Network TC-net 100 – Fiber-optic, 100 Mbps Option: TC-net 1 G - Fiber optic, 1 GBs

Feature Details High-speed processing Bit and integer processing: 20 ns; ﬂ oating point add/multiply: 120 ns

Short control cycle Three separately scheduled periodic tasks: 0.5 ms to 1,000 ms

Large program capacity Programs up to 256 kilo steps (instructions), up to 385 periodic programs

High data capacity Local/global variables 256 K words; I/O variables 16,384 16-bit words

Interrupts Total of 16 interrupt tasks Up to three controllers per chassis; up to 4 communication modules; redundant Multiple controllers controller and network conﬁ gurations possible Programming ﬂ exibility Four IEC 61131-3 standard languages: LD, FBD, SFC, and ST

Memory reliability An error-correcting ECC circuit in the internal memory of each module

TMEIC nvSeries Controller Brochure.indd Sec1:2 12/7/2011 11:44:13 AM Field Mounted I/O To reduce hundreds of long wiring runs between the greatly reduced. To protect the modules against electrical room and the machinery, the nv controller conditions close to the machinery, the enclosure features ﬁ eld mountable I/O modules communicating is rated IP54, which gives protection against dust, with the controller over an optical loop. Using this vibration, water splash and drips. Field I/O is housed approach, wiring material and labor costs can be in cabinets like the one shown below.

Two networks link the controller with the input/output modules: Supervisory HMI HMI • The Electrical ring (blue) services I/O local to the controller Computer Server • The Optical ring (red) services ﬁ eld distributed I/O local to the machinery. Field I/O is housed in the cabinet shown below. System Network - Ethernet Serial communication (SIO) Module Control Network TC-net 100

nv Controllers . . . .

Electro- optical Hub TC-net I/O optical loop or star ......

TMdrive-10 Field I/O cabinet

Limit I/O Solenoid M M M Switch . . . . Valve

Motors Field I/O cabinet Control system topology

Field wiring terminals IO Module

Field Enclosure. The typical ﬁ eld enclosure is 1200 Electric Room Enclosure. This is the same size mm wide, 2100 mm high, and 600 mm deep. The enclosure used for the ﬁ eld I/O, but with electric enclosure contains the circuit breakers, power TC-net I/O cabling to the SIO modules. An optical supplies and other components on the left hand side, interface is used if cabling distance requires one. and the DIN-rail mounted I/O modules on the right. Controller arrangements can be made for up to three The enclosure is rated IP54. Other sizes are available CPUs. This enclosure rating is IP20. to suit the application, such as pedestal or wall mount.

TMEIC nvSeries Controller Brochure.indd Sec1:3 12/7/2011 11:44:13 AM I/O Communications over TC-net I/O

The nv series I/O modules can be mounted in the Large drives such as the cabinet-mounted TMdrive- electrical room or remotely, adjacent to the machinery 10e2, 30, 50, and 70 are connected in star conﬁ guration or process. TC-net I/O communication with the local to a hub device. Smaller TMdrive-10e2 family drives I/O is over an electrical Cat5e fault tolerant ring mounted in multistage panels share an electrical (shown in blue), which connects to electrical serial multidrop cable using an optical-electrical converter I/O modules (SIO). Field mounted I/O is connected mounted in the drive panel. Other communication using fault tolerant optical rings (shown in red), which networks such as Modbus and Proﬁ bus (shown in connect to optical SIOs, while the drives typically use green) can communicate over TC-net I/O using special an optical converter or hub, (shown in yellow). modules.

Electrical Room Equipment nv controller nv E TC board Net Net

Local I/O cabinet

SIO I/O I/O TC-net I/O Loop HUB (UTLH21) Electric fault tolerant ring Max distance: 10 m Total distance: 100 m SIO I/O I/O Optical cables: Optical fault tolerant ring Each line is two fibers Max distance: 2 km SIO I/O I/O Total distance: 4 km

Pulpit Desk Field Distributed I/O

TC-net I/O Loop HUB TC-net I/O Loop HUB Optical-Electric Optical-Electric SIO I/O I/O SIO I/O I/O (UTLH21) (UTLH21) Converter Converter USIO21 USIO21 SIO I/O I/O

Serial I/O DRIVE M DRIVE M Interface PA912 D D D D D D D D D D D D DRIVE M DRIVE M PROFIBUS- R R R R R R R R R R R R DRIVE M DRIVE M DP Slave I I I I I I I I I I I I PROFIBUS-DP V V V V V V V V V V V V DRIVE M DRIVE M Master E E E E E E E E E E E E PROFIBUS- DP Slave DRIVE M DRIVE M Variable M M M M M M M M M M M M speed motors Multistage panel Multistage panel Field Distributed Self-supporting panels Self-supporting panels Max 12 drives Max 12 drives I/O cabinet

TC-net I/O Features Details Fault tolerant rings, each cable has a transmit and receive wire or ﬁ ber. Any loop Topology connection can be severed without loss of communication Data rate Transmission and reception at 100 Mbps Number of interfaces 32 SIO interfaces per loop plus up to 200 drives per controller Electrical SA911; Optical SA912; Proﬁ bus DP Master PA912 (optical); Serial interfaces, SIO Modbus RTU MD911-M Number of modules 16 I/O modules per SIO interface Scan cycle High-speed scan: 100μsec or more; medium speed scan: 1 ms or more Cable length Electrical distance between nodes 10 m (32 ft.); optical distance 2 km (6,550 ft) Cable type Electrical cable is category 5 shielded twisted pair; optical cable is GI 50/125

TMEIC nvSeries Controller Brochure.indd Sec1:4 12/7/2011 11:44:15 AM Input/Output I/O Module Family

The the table below shows a partial list of I/O modules with brief speciﬁ cations. Rack mount versions are also available. I/O Module dimensions: Serial I/O Communication W 35 mm (1.377 in) Module H 185 mm (7.28 in) Communicates with up to 16 I/O D 95 mm (3.74 in) modules Module and Base dimensions: W 92 mm (3.62 in) Optical SA912 and electrical H 200 mm (7.87 in) SA911 versions available D 115 mm (4.53 in) Redundant serial I/O interfaces External Power Supply: are on option 24 Vdc

Module Name Channels Input-Output Description Accuracy Speed Discrete Input DI934T 32 24 Vdc 8 ma — — DI943S 32 24 Vdc 5.2 ma with strobe — < 1ms DI944 32 48 Vdc 2.5 ma — — DI936 16 12/24 Vdc 9.6 ma, independent pts — < 1ms DI937 16 24 Vdc 9.6 ma, contact input — < 1ms IN954 32 AC/DC 100/120V 10.2 mA (100 Vac-50Hz)/13.6 mA(110Vac-60Hz) — — IN956 16 AC/DC 100/120V 15 mA (100 Vac)/2.3 mA (110 Vac) — — IN966 16 200/240 Vac 10 ma (at 200 Vac-50 Hz) — 15 ms Discrete Out DO934 32 12-24 Vdc 100 ma sink output — < 1ms DO934P 32 12-24 Vdc 100 ma source output — < 1ms DO936 16 24 Vdc 2.0 A sink out, isolation — < 1ms DO933P 16 24 Vdc 2A protected source — — Analog Input AI929D 16 0-20 mA Non isolated 14 bits, 0.1% 50ms/16 ch. AI938 8 ±10 V Transformer isolation S+13 bits, 0.2% 0.5ms AI928 8 0-20 ma Transformer isolation 14 bits, 0.2% 0.5ms/8 ch. Thermocouple TC919 16 Thermocouples Type B, R, S, J, K, T, E 0.1% 0.8s/16 ch. Resistance TD RT918C 8 Pt100; JPt100 Platinum RTD ±0.1%CJC ±1% 0.8s/8 ch. RT918 8 Pt100; JPt100 Platinum RTD, isolated ±0.1% 0.8s/8 ch. Analog AO928F 8 0-20 ma Insulated channels 16 bits, 0.1% 1 ms/8 ch. Output AO938 -10 to 10 V Non-insulated 13 bits, 0.1% 5 ms/8 ch. AO934F 4 -10 to 10 V Insulated channels 15 bits, 0.1% 0.175ms/4 ch. AO954F 4 -10ma to 10ma Insulated channels 15 bits, 0.1% 0.175ms/4 ch. Pulse Output PI918 8 12/24 V Gated inputs 50 kHZ — — PI924 4 12/24 V Bipulse input, up-down, 50 kHz — — PI934 4 RS485 input Up/Dn:2.6 MHz, A-Quad-B:650kHz — — PI964 4 12/24 V Versatile A-Quad-B, 50 kHz — — Resolver Input AB932J 2 Poscoder Single-turn encoder — — AB933J 2 Poscoder Multi-turn encoder — — AB934J 2 Linear sensor Resolver type linear encoder — — AB932N 2 NSD Abscoder Single turn encoder — — AB933N 2 NSD Abscoder Multi-turn encoder — — AB934N NSD Linear Abs Linear encoder — — AB935N 2 JCC Line resolv Linear encoder, High resolution — — AB936N 2 JCC Line resolv Linear encoder, Medium resolution — — Linear Sensor TP912M 2 MTS Temposonics Up to 25-bit data — — sensor Modbus MD911-M Modbus-RTU Master module — — MD911-S Modbus-RTU Slave module — — Proﬁ bus PA912 Proﬁ bus-DP Master module — —

TMEIC nvSeries Controller Brochure.indd Sec1:5 12/7/2011 11:44:15 AM Controller Programming

Engineering Tool - choose from four International Standard Programming Languages The Engineering Tool software for the nv Series controller provides four IEC-61131-3 standard programming languages: Ladder Diagrams (LD), Function Block Diagrams (FBD), Sequential Function Charts (SFC), and Structured Text (ST). The ﬁ rst three can be mixed in the same program and displayed on the same screen.

Sequential Function Charts - SFC charts show the Ladder Diagrams LD is the preferred programming control ﬂ ow and the action unit, which shows the language for logic control and sequencing. It shows action performed at each step, and the transition relay circuit contacts and coils, and indicates power condition unit, which shows the conditions for ﬂ ow using color to allow easy test and debug of advancing to the next step. logic circuits before actual use.

Mix all three programs on one screen. Using all the graphical programs offers the best programming Function Block Diagrams - FBDs are a familiar graphical convenience. control representation using function blocks containing sections of logic or analog control for easy manipulation and connection. Custom control blocks can be kept for re- use. Features include high density notations, line crossing and skip, and return lines.

Structured Text Language - ST allows difﬁ cult applications not easily programmed with LDs, SFCs, or FBDs to be handled with languages such as Visual Basic or C. Note that Structured Text cannot be mixed with the other three languages.

TMEIC nvSeries Controller Brochure.indd Sec1:6 12/7/2011 11:44:16 AM Operator Accessible Machine Diagnostic Displays

The HMI brings the operator instant feedback on the cause of machinery problems, and presents the information in an easily understood way to reduce the time spent diagnosing the problem. During initial programming, permissive logic blocks, DIAG_D, are entered in the ladder logic program. The screens show the sequence of events when a machine problem occurs. Immediate Notiﬁ cation 1 A fault occurs, for example an open limit switch, and a permissive alarm is created on the operator HMI screen. This fault can subsequentially cause other faults to occur. When the alarm button is clicked or touched the permissive overview window is displayed. See Associated Groups 2 The permissive overview window shows all permissive groups associated with the particular function. Faulted groups are red and displayed at the top. When the faulted group is clicked or touched, the permissive group window is displayed. See Faulted Equipment 3 The permissive group window shows the equipment in the group, with faulted equipment red and displayed at the top. When the faulted equipment is clicked or touched, the permissive variable window is displayed.

See Problem Interlock 4 In the permissive variable window, only the problem interlock conditions are displayed. The lower ladder logic (Faulted) display shows the fi rst fault or cause condition, which must be addressed. Direct Access The upper present value display (Live) shows all In specifi c cases items which are out of sequence. diagnostic buttons can be confi gured If required, the original ladder logic program for direct access to 5 can be displayed using the Tool cross reference the root cause function.

TMEIC’s Library of Control Modules

Engineering Tool contains project-speciﬁ c control modules developed over 50 years of mill experience. A few are listed here. Hot Mill and Cold Mill Function Blocks Process Lines Function Blocks All-Purpose Function Blocks • Hydraulic Gap Control • Zone Tension control • Position Regulator • Gauge Control • Loop Car/Tower control • Special PID • Coiler Automatic Jump Control • Coiler Sequencing control • Coiler Sequencing Control • Hydraulic/Electric Interstand Looper Control • Cold Mill Interstand Tension Control

PAYOFF REEL BRIDLE 1 ROLL 1 BRIDLE 1 ROLL 2 MOTOR POWER (KW) MOTOR POWER (KW) MOTOR POWER (KW) POSITION CONTROL CONTROL INERTIA + INERTIA + INERTIA + STAND GAP/ CYLINDER LOSSES (KW) LOSSES (KW) LOSSES (KW) FORCE FORCE REGULATOR FRICTION FRICTION FRICTION + + + LOSSES (KW) LOSSES (KW) LOSSES (KW)

FEEDBACK ROLL 1 LOAD X ROLL 1 LOAD X Metal Rolling CONSTANT (%) CONSTANT (%) Strip Transport

GAP POSITION Gap Control TENSION TENSION Tension Control Block Diagram POWER (KW) POWER (KW) Block Diagram X LS X LS FEEDBACK SENSORS CONST CONST LOAD CELL / FORCE PRESSURE – ++ – TRANSDUCER ROLLS DOWN BRUSHES DOWN

FEEDBACK FLATTENER PRECLEANER LOSSES (KG) LOSSES (KG) METAL-IN- STAND ZERO (KG) PAYOFF TENSION (KG) LS = LINE SPEED (METERS/MINUTE)

TMEIC nvSeries Controller Brochure.indd Sec1:7 12/7/2011 11:44:17 AM

Global Ofﬁ ce Locations:

TMEIC Corporation TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL Roanoke, Virginia, USA SYSTEMS CORPORATION Tel: +1-540-283-2000 Shanghai, China Email: [email protected] Tel: +86-21-6236-0588 Web: www.tmeic.com Email: [email protected] Web: www.tmeic-cn.com TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION TMEIC Asia Company Ltd. Tokyo, Japan Kowloon Bay, Hong Kong Tel: +81-3-5441-3828 Tel: +852-2243-3221 Web: www.tmeic.co.jp Web: www.tmeic.com

TMEIC Europe Limited TMEIC Asia Company, Ltd. Rep. Ofﬁ ce Uxbridge, Middlesex, United Kingdom Kaohsiung, Taiwan Tel: +44-870-950-7220 Tel: +886-7-223-9425 Email: [email protected] Web: www.tmeic.com Web: www.tmeic.com

TMEIC Industrial Systems India Private Limited nv Controller is covered by U.S. Patent number: USP7.643.888 Andhra Pradesh, India TC-net 100 has IEC Standard Certiﬁ cation IEC 61784-2 (Real Time Ethernet) TMdrive is a registered trademark of Toshiba Mitsubishi-Electric Industrial Systems Corporation. Tel +91-40-4034-0000 TMEIC is a registered trademark of Toshiba Mitsubishi-Electric Industrial Systems Corporation. Web: www.tmeic.in TM is a registered trademark of Toshiba Mitsubishi-Electric Industrial Systems Corporation. “We drive industry” is a registered trademark of TMEIC Corporation.

TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL All specifi cations in this document are subject to change without notice. The above brochure is provided free of charge and without obligation to the reader or to TMEIC Corporation. TMEIC SYSTEMS CORPORATION Corporation does not accept, nor imply, the acceptance of any liability with regard to the use Beijing, China of the information provided. TMEIC Corporation provides the information included herein as is and without warranty of any kind, express or implied, including, but not limited to, any implied Tel +86-10-5873-2277 statutory warranty of merchantability or fi tness for particular purposes. The information is Email: [email protected] provided solely as a general reference to the potential benefi ts that may be attributable to the technology discussed. Individual results may vary. Independent analysis and testing of each Web: www.tmeic-cn.com application is required to determine the results and benefi ts to be achieved from the technology discussed. © 2011 TMEIC Corporation, All Rights Reserved.

P-1101

TMEIC nvSeries Controller Brochure.indd Sec1:8 12/7/2011 11:44:17 AM