DOPC

MS2-SYS100-3002

DOPCIII/PM-EX/DOPCII/DOPC Main UnitInstallation Manual

Copyright, Notices and Trademarks

Printed in Japan - Copyright 2011 by Yamatake Corporation

While this information is presented in good faith and believed to be accurate, YamatakeCorporation disclaims the implied warranties of merchantability and fitness for a particularpurpose and makes no express warranties except as may be stated in its written agreement withand for its customer.

In no event is Yamatake Corporation liable to anyone for any indirect, special or consequentialdamages. The information and specifications in this document are subject to change withoutnotice.

Advanced-PS, Harmonas-DEO, DOPC, DOFC, DOHS, DOBS, DOGS, DOMS, DOHL, and DOPLare registered trademarks of Yamatake Corporation in Japan.

Windows is a registered trademark of Microsoft Corporation in the United States and other countries. Ethernet is a registered trademark of XEROX Corporation. MELSEC is a registered trademark of Mitsubishi Electric Corporation, Ltd. InTouch is a trademark of Invensys plc. Other product names, model nos., and company names may be trademarks of the respective company.

To use Process Controller system safely

This manual provides safety instructions. Please read them carefully and observethem appropriately.

Read the following basic instructions to ensure correct and safe operation of thissystem. Yamatake will assume no responsibility for any problem resulting from afailure to read the safety instructions.

Caution on Environmental Condition

This system must be operated under appropriate environmental conditions.Follow the instructions related to temperature, humidity, power supply, dust,corrosive gas, and noise provided in Process Controller Installation Manual(MS2-SYS100-3001) : 3.1 Temperture, Humidity, Power Supply etc.When using in papermills, iron manufacturing related works, and any other placeswhere environmental conditions are concerned, contact sales representatives forconsultation before system installation. Also feel free to consult salesrepresentatives about magnetic fields.

It is recommended to operate the system under the standard operating conditions(normal temperature, normal humidity) specified in Section 3. This will ensurehigh reliability for a long period of time.

For Safety Operation and Prevention from System Damage

In installing the system, observe the following instructions:

During unloading, unpacking, delivering, extending, and disconnecting systemcomponents, dont give a shock or drop them. Equipment can be damaged orinjure workers.

Be sure to install and connect ground, power lines and cables according to theinstructions in Process Controller Installation Manual (MS2-SYS100-3001) :Section 5 Wiring and Connections.

Insert or remove the connector, holding the connector body between your fingers,so that the instrument is not damaged and you are not injured.

Caution on Installation

Be sure to use the standard products for communication equipment and parts (suchas cables, transceivers, terminators, GND terminal blocks, and hubs) for a ControlNetwork (Ethernet).When non-Yamatake standard parts are used, our service is ordinarily unavailablefor the problems.

Be sure to use a special tool for connecting a transceiver(MAU) to the trunk line.

In mounting Process Controller in a cabinet other than our standard cabinet, followthe instructions provided in Process Controller Installation Manual (MS2-SYS100-3001) : 3.1 Temperture, Humidity, Power Supply etc/4.3 Notes of Non-Standard Cabinet for Process Controller.Make sure especially that the ambient temperature and ventilation within thecabinet is appropriate.A cabinet that houses Process Controller must be ventilated to keep astospherictemperature at Process Controller below 45 degC.

Make proper grounding for the system equipment independently using dedicatedgrounding rod. Follow the instructions in Process Controller InstallationManual (MS2-SYS100-3001) : 5.3 Power and Grounding with special care.For power supply, follow conditions described in this manual and contact salesrepresentatives for consultation.If power disconnects for 200 millisecond or longer, use UPS.

When UPS is used, be sure load capacity does not exceed value in thespecifications of UPS.

iTable of Contents

Table of Contents

Section 1. Introduction ...................................................... 1

Section 2. System Configuration...................................... 32.1 Sampled Harmonas-DEO System Diagram................................... 3

Section 3. Controller Main Unit of Harmonas-DEO......... 53.1 Controller Main Unit ..................................................................... 5

3.1.1 Main Unit for X-bus Input/Output Equipment Connection .... 53.1.2 Main Unit for FX-bus Input/Output Equipment Connection .. 9

3.2 Contact I/O Terminal (Controller Terminal) ................................. 123.2.1 WDT (TB1-3): 1 point ............................................................ 123.2.2 HOT (TB1-9): 1 point ............................................................. 123.2.3 Circuit of Terminal Unit .......................................................... 13

3.3 I/O Address Setting Range ............................................................ 143.4 Network Connection Method......................................................... 15

3.4.1 Connection .............................................................................. 153.5 Address Setting .............................................................................. 19

3.5.1 Procedure for Setting Node Address ....................................... 193.5.2 Procedure for Setting IP Address ............................................ 20

Section 4. Process Controller II / Process Manager EX Base Unit .... 214.1 Components ................................................................................... 23

4.1.1 Redundant Main Base Plate(HD-MBU200/J-MBU200) ........ 234.1.2 Control Module (HD-MSC300/200, J-MSC300/200) ............ 254.1.3 Ethernet Interface Module (HD-ETM200, J-ETM200) .......... 264.1.4 X-Bus Interface Module (HD-XBM200, J-XBM200) ............ 274.1.5 Terminal Block Interface Module

(HD-TRM300/200, J-TRM300/TRM200) .............................. 284.1.6 Backup Battery Module (HD-BPS200, J-BPS200) ................ 29

4.2 Setting Switches ............................................................................. 304.2.1 Setting node numbers and setting IP addresses ....................... 304.2.2 Function setting switches ........................................................ 31

4.3 External inputs and outputs............................................................ 324.4 Ethernet Cable Connection ............................................................ 364.5 I/O Address Setting Range ............................................................ 38

ii

Table of Contents

Section 5. Process Controller III / Process Manager EX Base Unit ... 395.1 Components ................................................................................... 42

5.1.1 Redundant Main Base Plate .................................................... 425.1.2 Non-redundant Main Base Plate ............................................. 445.1.3 Control Module (HD-MSC300, J-MSC300) ........................... 475.1.4 Ethernet Interface Module (HD-ETM210, J-ETM210) .......... 485.1.5 X-Bus Interface Module (HD-XBM200, J-XBM200) ............ 495.1.6 Terminal Block Interface Module (HD-TRM300, J-TRM300) .... 505.1.7 Backup Battery Module (HD-BPS200, J-BPS200) ................ 51

5.2 Setting Switches ............................................................................. 525.2.1 Setting node numbers and setting IP addresses ....................... 525.2.2 Function setting switches ........................................................ 53

5.3 External inputs and outputs............................................................ 545.4 Ethernet Cable Connection ............................................................ 585.5 I/O Address Setting Range ............................................................ 60

Appendix A. Consumption Current ................................... 61

Appendix B. Dimension of Controller Equipment ............ 63B.1 Main Base Plate for Non-redundant Control (HAS-MBU75H) .... 63B.2 Main Base Plate for Non-redundant Control (HD-MBU75) ......... 64B.3 Main Base Plate for Redundant Control (HD-MBU85) ................ 65B.4 DOPC Modules .............................................................................. 65B.5 Main Base Plate for Redundant DOPC II / DOPC III / PM-EX.... 66B.6 Main Base Plate for Non-redundant DOPC III .............................. 67B.7 Main Base Plate for Non-redundant DOPC III .............................. 68B.8 DOPC II / DOPC III / PM-EX Modules ........................................ 68

1

Section 1. IntroductionThis installation manual provides the information necessary for installing the ProcessController (DOPC)/Process Controller II (DOPCII)/Process Controller III (DOPCIII) thatserves as the core of the system configuration equipment when the Harmonas-DEO Systemis installed.Although this manual presents the latest data available for time being, the information maybe corrected or changed.

Reference Documents

Document Nane Document No.

1. Process Controller Installation Manual .......................MS2-SYS100-30012. Control Network Site Planning Guide ........................MS2-SYS100-30033. FX-bus Input/Output Equipment Hardware Manual ......MS2-SYS100-30044. X-bus Input/Output Equipment Hardware Manual .......MS2-SYS100-30055. Noise Suppression and Lightning Protection Guideline .....MS2-SYS100-30106. Signal Unit I/O Installation Manual .................................MS2-HDS900-3001

Section 1. Introduction

2

Section 1. Introduction

M E M OM E M O

3

Section 2. System Configuration2.1 Sampled Harmonas-DEO System Diagram

This section provides the basic system configuration of the Harmonas-DEO system.

Web ClientClient PC

Information Network(Ethernet)

DOHS(History Station)

TSS(Thin ClientSupervisoryServer)

DOSS (Supervisory Station)

DOGS(Gateway Station)

Control Network(Ethernet)

DOPC III(ProcessController III)

DOPL II(PLC Linker II)

I/O

MELSECNT

ProgrammableController(MELSEC)

DGPL II(General PurposeLinker II)

ProgrammableController

ProgrammableController: MELSEC SYSMAC FA-M3 MICREX-SX

Figure 2-1. System Architecture

2.1 System Configuration Diagram

4

Section 2. System Configuration

2.2 Sampled Advanced-PS/PM-EX System Diagram

Controller Control Network(UCN-EX)

Local ControlNetwork (LCN )

Controller Control Network(UCN) Engineering Station(ES)

PLC Linker Module EX(PL-EX)

Process Manager EX(PM-EX)

Signal Unit I/O

Base Unit I/O

Field Instruments

Programmable Controller(MELSEC)

Application Module(AM)

History Module(HM)

Highway Gateway(HG)

Network Interface Module(NIM)

Highway Network

Process ManagerController

Open UniversalStation

Interface Module(E-IM)

Figure 2-2. Advanced-PS/PM-EX System Architecture

5

Section 3. Controller Main Unit of Harmonas-DEO3.1 Controller Main Unit

3.1.1 Main Unit for X-bus Input/Output Equipment ConnectionThe DOPC and DOPCII for X-bus input/output equipment connection adopt non-redundant configuration and redundant configuration. They are shown below.

3.1.1.1 Base unit for non-redundant control (HD-DCSD70)

J1

LD1

J2

F1 TB1

J3 J4

0.32A

MSC70 REGR70 ETM70 AUIR70

Name

Power supply connector

Power supply LED

Contact I/O terminal

J2

LED1

TB1

+24 VDC power input

Comes on with +24 VDC supplied

Channels AChannels B

Connector for battery cableBattery case

X-bus connector

Fuse

Battery connector

F1

J1

Function

EXT24 V

EXTCOM

WDT

HOTRTN

NC

24 V

SG

WDTSRCHOTRTN

NC

1

2

3

4

5

6

7

8

9

10

Key No.

Fuse of 0.32 A for protecting WDT drive circuit power supply

J3J4

Note 1 Jumpers are used beforehand at shipment to connect portions between1 and 6 and between 2 and 7. Disconnect these jumpers as needed.

Note 2 At shipment, the connector for backup battery (standard accessory) isnot connected on the main base unit. Before the usage, connect theconnector of the backup battery to the J1 connector.

Figure 3-1. Main Base Unit (For Non-redundant Control)

3.1 Controller Main Unit

6

Section 3. Controller Main Unit of Harmonas-DEO

3.1.1.2 Base unit for redundant control (HD-DCDD70)MSC70 REGR70 ETM70 AUIR70MSC70REGR70ETM70AUIR70 UDM70

J1

LD1

J2

F1 TB1

J3 J4

0.32A

Name


Power supply LED


J2

LED1

TB1

+24 VDC power input


Channels AChannels B


X-bus connector

Fuse

Battery connector

F1

J1

Function

EXT24 V

EXTCOM

WDT

HOTRTN

NC

24 V

SG

WDTSRCHOTRTN

NC

1

2

3

4

5

6

7

8

9

10

Key No.


J3J4



Figure 3-2. Main Base Unit (For Redundant Control)

7

3.1.1.3 Connect to X-bus CableX-bus input/output equipment is divided into signal unit I/O (SIO) and base unit mountedtype I/O module. The signal unit I/O and base unit mounted type I/O adopt different X-buscable connection methods. For details, refer to the X-bus Input/Output EquipmentHardware Manual: MS2-SYS100-3005.

An example of the base unit mounted I/O module is described below.As shown in Figure 3-3, the I/O base unit is mounted just under the main base unit. If an I/O base unit is mounted on other side (back side and adjacent cabinet), mount the I/O baseunit at the top of the side.

X-bus cable

Jumper for termination resistance

JP1

C13

C14

JP2

J3 J4

A B

I/O base unit

J3 J4

A B

I/O base unit

J3 J4

A B

Main base unit

JP1

C13

C14

JP2

JP1

C13

C14

JP2



Remove jumpers JP1 and JP2

Figure 3-3. X-bus Cabling and Termination Method


8


X-bus cables are terminated in base units at both ends of X-bus connections. In the figureabove, the X-bus cable is to be terminated in the main base unit and the lowermost I/O baseunit. Therefore, remove JP1 and JP2 from the I/O base unit at the middle position becausetermination is preparatory for these jumpers.

File to be terminated: With jumpers JP1 and JP2 File not to be terminated: Remove jumpers JP1 and JP2

Installation of Base Units on a Different SideWhen connections between the main base unit and the I/O base unit or between I/O baseunits are made via another side, long X-bus cables are used. The short section (45cm) ofthis cable is for making a connection between base units mounted adjacent to each otherabove and below. The longer section (605 cm) is for making a connection between abase unit mounted at the bottom inside the cabinet and a base unit mounted at the top ofa different side in the cabinet. Figure 3-4 shows examples of allowable base unitinstallation and X-bus cabling.

MBU

I/OBU

MBU

I/OBU

I/OBU

I/OBU

Figure 3-4. Installation of Base Units on Different Sides

9

3.1.2 Main Unit for FX-bus Input/Output Equipment ConnectionThe DOPC for FX-bus input/output equipment connection adopt non-redundantconfiguration and redundant configuration. They are shown below.

3.1.2.1 Base unit for non-redundant control (HD-DCSD80)

J1LED1

J2F1

TB1

J14

0.32A

MSC80 REGS70 ETM70 AUIR70

J13J12 J15

X-BUS X-BUS

X-BUSJ3A

J4B

J101A

J111B

2A 2B 3A 3B

Name


Power supply LED


J2

LED1

TB1

+24 VDC power input


Channels 1-A, 2-A and 3-AChannels 1-B, 2-B and 3-B


X-bus connector(Distributed I/O)

Fuse

Battery connector

F1

J1

Function

EXT24 V

EXTCOM

WDT

HOTRTN

NC

24 V

SG

WDTSRCHOTRTN

NC

1

2

3

4

5

6

7

8

9

10

Key No.

1A , 1B2A , 2B3A , 3B




Figure 3-5. Main Base Unit (For Non-redundant Control)


10


3.1.2.2 Base unit for redundant control (HD-DCDD80)MSC80 REGR70 ETM70 AUIR70MSC80REGR70ETM70AUIR70 UDM75

J1LED1

J2F1

TB1

J14

0.32A

J13J12 J15

X-BUS X-BUS

X-BUSJ3A

J4B

J101A

J111B

2A 2B 3A 3B

Name


Power supply LED


J2

LED1

TB1

+24 VDC power input


Channels 1-A, 2-A and 3-AChannels 1-B, 2-B and 3-B


X-bus connector(Distributed I/O)

Fuse

Battery connector

F1

J1

Function

EXT24 V

EXTCOM

WDT

HOTRTN

NC

24 V

SG

WDTSRCHOTRTN

NC

1

2

3

4

5

6

7

8

9

10

Key No.

1A , 1B2A , 2B3A , 3B




Figure 3-6. Main Base Unit (For Redundant Control)

11

3.1.2.3 FX-Bus Cable ConnectionFX-bus input/output equipment is divided into the following I/O modules. Distributed I/O module Signal unit I/O (SIO) Base unit mounted type I/O module

The FX-bus cable connection methods adopted by I/O module, signal unit I/O and base unitmounted type I/O are different from each other. For details on the method for connectingthe FX-bus input/output equipment, refer to the FX-bus Input/Output EquipmentHardware Manual: MS2-SYS100-3004.

An example of the distributed I/O module is described below.Up to three X-bus systems can be individually connected from one control communicationblock (Main Base Unit). From the base unit, an X-bus is connected to an X-bus cableadapter via an X-bus adapter cable. Each module is connected from the X-bus cable adaptervia an X-bus module cable.

At the end of an X-bus, the X-bus adopts a structure allowing it to be connected to a terminatoradapter or to be added by an X-bus cable adapter. Per X-bus system, the maximum length is10m, and the maximum number of I/O units connected (electrically limited) is 30.

Main Base Unit

X-Bus adapter cable

X-Bus adapter cable

DistributedI/O module












Cable adapter

Cable adapterCable adapterCable adapter

Cable adapterTerminatoradapter

Terminatoradapter

Terminatoradapter

Figure 3-7. X-Bus Cable Connection


12


3.2 Contact I/O Terminal (Controller Terminal)The main base unit provides the following contact inputs and outputs.

3.2.1 WDT (TB1-3): 1 pointOutputs the WDT status of a control unit having control authority (when WDT signal isON). Adoption of the redundant configuration moves the control authority to thesecondary control unit when a failure occurs in the primary control unit. In this case, theinput of the WDT signal is also switched at the same time. This means that monitoring theWDT signal shows the operation status of the control for DOPC adopting non-redundant orredundant configuration.This output signal is obtained by isolating a transistor output with a photo coupler.

WDT status of control unit : Transistor output ONRating : 24 VDCOperating range : 15 to 30 VDCLoad current : 0.2 A maximumLoad peak current : 0.5 AOff-state load peak current : 0.1 mA or lessOutput transistor on voltage : 1.5 V or less

3.2.2 HOT (TB1-9): 1 pointIf the actual short break time of the AC power supply is less than or equal to the set value onthe AC power down monitor, setting the HOT signal to ON allows DOPC to perform hotrestart. If the short break time is longer than the set value, the HOT signal remains OFF,and DOPC performs warm restart.When recovery from power failure of +24 VDC power supply takes place, the controllerreads this signal and then determines the restart mode. In this case, the control continues if+24 VDC power supply is normal with AC power supply turned off.This input signal is isolated by a photo coupler.

Contact capacity: On Current 3 mA min, Voltage 13 VDC min30 VDC max

Off Current 0.7 mA max, Voltage 4 VDC max

13

3.2.3 Circuit of Terminal UnitFigures 3-8 and 3-9 show circuits of the contact terminal unit. To use internal +24 VDC,short-circuit between 1 and 6, and between 2 and 7. In this case, the input/output circuit isnot insulated from the controller power supply side.

Example where internal power supply is used

1

2

3

4

5

6

7

8

9

10

HOT+HOT+

WDTOUT+

*

*

**

**

F10.23A

+24V

GND

TB1

WDT

HOTRTN

NC

24V

SG

WDTSRC

HOT

NC

External cableMain base unitControl unit

Note: * : Control unit for redundant configuration ** : Jumper connection is made with internal +24 VDC used. between 1 and 6, and between 2 and 7 in TB1)

LOADWDTOUT

AC POWER DOWNMONITOR

3.9K1K

Jumper connection is made at shipment.

WDTOUT

HOT

HOT

Figure 3-8. Example Where DOPC Internal Power Supply Is Used

Example where external power supply is used

1

2

3

4

5

6

7

8

9

10

HOT+

HOT

HOT+

HOT

WDTOUT+

WDTOUT*

*

**

**

F10.23A

+24V

GND

TB1

EXT24V

EXTCOM

WDT

HOTRTN

NC

24V

SG

WDTSRC

HOT

NC

External cableMain base unitControl unit

LOADWDTOUT

AC POWER DOWNMONITOR

3.9K1K

Disconnect jumper connections when internal +24 VDC is applied.(2 places, between 1 and 6 and between 2 and 7 in TB1)

Note: * : Control unit for redundant configuration ** :

External power supply

Table 3-9. Example Where DOPC External Power Supply Is Used

Caution From TB1, remove jumpers between 1 and 6 and between 2 and 7.Supplying +24 V power with the jumpers connected may causefailure in the DOPC power module in some cases.

3.2 Contact I/O Terminal (Controller Terminal)

14


3.3 I/O Address Setting RangeI/O configuration numbers in the following range are settable in the DOPC.

Table 3-1. Range of I/O Configuration Numbers Settable in DOPCBase (Card) NumbersBlock (File)

Numbers

12345678

: Non-redundant I/O modules and redundant I/O modules can be configured.: Only non-redundant modules can be configured.: I/O modules cannot be configured.: Configurable only when the controller main unit adopts non-redundant configuration.

Note that the following restriction is put on analog input modules. For HD-CRAM and HD-CLAM, card Nos. 1 to 11 are settable.

15

3.4 Network Connection Method

3.4.1 ConnectionTwo types of connections are adopted between the DOPC and the control system DEO-NET: 10Base-5 and 10Base-T. For the connections, refer to the Control Network SitePlanning Guide: MS2-SYS100-3003

Outline of 10Base-5 and 10Base-T is as follows. 10Base-5

A 10Base-5 cable is a thick coaxial cable and is expandable to up to 500 m per segment.A mark is given to the coaxial cable every 2.5 m. MAU can be connected at this markedposition only.

10Base-TA 10Base-T cable is a twisted pair cable and adopts star topology. One-to-onecorrespondence is adopted in connections between hubs and nodes. This is a structurewhere noise and MAU failures cannot easily affect other nodes. The cable length inDEO-NET is up to 50 m.

Connection procedures are as follows.

3.4.1.1 Using 10Base-5 for ConnectionsMount a tap connector for MAU connection in the 10Base-5 cable. Attach 1-port 10Base-5MAU (HD-XCV510) or 2-port 10Base-5 MAU (HD-XCV520). Using AUI cable (HD-TCBLA##, HD-TCBLB##), make a connection between MAU and HD-AUIR70 connectors.HD-AUIR70 of DOPC has two sets of connectors for AUI cable connections (AUI connector).Connect the top side to system A, and connect the bottom side to system B.

Caution 10Base-5 MAU needs to be connected to a cable mark of 10Base-5coaxial cable given every 2.5 m. Neglecting to observe this cautionmay cause communication troubles.


16


Connecting non-redundant DOPC to 10Base-5

AUIR70

10Base-5 cable (HD-CBLNA : System A (yellow)

10Base-5 cable (HD-CBLNB ): System B (blue)

Tap connector

10Base-5 MAU(HD-XCV510 or HD-XCV520)

System B of AUI cable(HD-TCBLB )With blue mark

System A of AUI cable(HD-TCBLA )With yellow mark

Non-redundant DOPC node

Figure 3-10. Connection Using 10Base-5 (Non-redundant DOPC)

Connecting redundant DOPC to 10Base-5

AUIR70

10Base-5 cable (HD-CBLNA : System A (yellow)

10Base-5 cable (HD-CBLNB ): System B (blue)

Tap connector

10Base-5 MAU(HD-XCV520)

System B of AUI cable(HD-TCBLB )With blue mark

System A of AUI cable(HD-TCBLA )With yellow mark

Redundant DOPC nodeAUIR70

Figure 3-11. Connection Using 10Base-5 (Redundant DOPC)

17

3.4.1.2 Using 10Base-T for ConnectionsDirectly install MAU (HD-XCVT10) for 10Base-T at the AUI connector on the front face ofHD-AUIR70. Using special cables, make connections from 10Base-T MAU to 10M hub (HD-HUB5T8) and 10M/100M switching hub (HD-SWHUBX16/31/32) . Make a connection fromthe top of AUIR70 to system A, and make a connection from the bottom to system B.

Connecting non-redundant DOPC to 10Base-T hub

AUIR70

10M hub (HD-HUB5T8)

Cable of system B(HD-CBLTSB )Boot color: blue

Non-redundant DOPC node

10Base-T MAU(HD-XCVT10)

Cable of system A(HD-CBLTSB )Boot color: gray

Figure 3-12. Connection Using 10Base-T (Non-redundant DOPC)

Connecting redundant DOPC to 10Base-T hub

10M hub (HD-HUB5T8)

Cable of system B(HD-CBLTSB )Boot color: blue

Redundant DOPC node

10Base-TMAU(HD-XCVT10)

Cable of system A(HD-CBLTSB )Boot color: gray

AUIR70 AUIR70

Figure 3-13. Connection Using 10Base-T (Redundant DOPC)


18


In the following case, it is recommended that 10Base-T be used for connection.

When the electrically cabling range is within the same cabinet line board (or same room)When a 10Base-5 cable is used, MAU can only be installed every 2.5 m in a coaxialcable. This means that use of multiple DOPCs in a cabinet line board makes it difficult toinstall coaxial cables and MAUs. In particular, this applies to the case where more thanor equal to three sets of DOPCs are installed in the same line board (or in the sameroom). In this case, however, 10Base-5 or 10Base-F with optical fiber cables are to beused to make connections with other equipment installed at distance. (See the figuresbelow. These figures show only a single system of the communication system. Actually,another equivalent system of the communication system is connected.)

Cabinet line board

10Base-5 cable

10Base-5 transceiver

Transceiver cable

DOPC

Figure 3-14. Connections via 10Base-5 Cables

Cabinet line board

10M hub

To 10Base-5, 10Base-F, etc.

Twisted pair cable

DOPC

Figure 3-15. Connection in line board via 10Base-T cable

19

3.5 Address SettingEach of the DOPC and has two sets of characteristic addresses. One is a node number, andthe other is an IP address for communication. A controller needs to set an address differentfrom that of the other. Methods for setting addresses are shown below.

3.5.1 Procedure for Setting Node AddressA node address is to be a value that is set in the node configuration. This value is given indecimal ranging from 1 to 126. The value must be different from the values set to othernodes connected to the same DEO-NET. If DOPC adopts a redundant configuration, thesame value must be set for each of the right and left ETM70 addresses. When setting nodeaddresses actually, open the front door of ETM70, and then use three sets of internal rotaryDIP switches. Using the upper, middle and lower switches, set the number of hundreds,tens, and units, respectively.

Examples If the node configuration sets the node number to 1, set the top, middle, andlower switches to 0, 0, and 1, respectively. In the same way, if the nodenumber is set to 126, set the top, middle, and lower switches to 1, 2 and 6,respectively.

ETM70

Setting node numbers

Sets the number of tensSets the number of units

Sets the number of hundreds

Note: These three switches can be set in decimal. Of these switches, set the upper switch (setting the number of hundreds) to 0 or 1 only.

Figure 3-16. Setting a Node Address

3.5 Address Setting

20


3.5.2 Procedure for Setting IP Address

3.5.2.1 Expressing IP AddressesAn IP address is expressed in four fields delimited by dots (.).

Field_1.Field_2.Field_3.Field_4Each field is expressed in decimal and is set to a value ranging from 0 to 255.

(Example of expression: 192.168.10.13)

3.5.2.2 IP Address Set ValueGenerally, IP addresses in use are called Class C. The addresses are set to the default valuesat shipment. To use an address other than Class C, contact us. Though Class C address is torange from 192.0.0.1 to 223.255.255.255, DOPC default address in use starts from192.168.0.0. If an address is set by default, Field_4 of the IP address is determineddepending on the node address. This means that the IP address does not need to be set.For Field_3, set an address of system A. To set an address of system B, automaticallyincrement it by one.An arbitrary value can be set here, ranging from 0 to 253. Generally, however, it is set to 0.

Table 5-3. Relationships between Node Addresses and IP Addresses When IPAddresses Are Set by Default

Node addressLeft 192.168.0.1 192.168.1.1

Right 192.168.0.129 192.168.1.129Left 192.168.0.2 192.168.1.2

Right 192.168.0.130 192.168.1.1303 192.168.0.3 192.168.1.3

IP address of system BIP address of system A

Non-redundant Controller

Redundant Controller

Redundant Controller 1

2

Process Controller

3.5.2.3 Procedure for Setting IP AddressesEach field value of Field_1.Field_2.Field_3.Field_4 is generally given in decimal. At first,the value for each field is expressed converted into the hexadecimal value.

Examples Convert 192.168.0.0 (decimal) into hexadecimal.The value converted is C0.A8.00.xx (hexadecimal).

Using the rotary DIP switches on the rear side of the HD-ETM70 module, set this value.

Default setting C 0 A 8 0 0 0 0

Connector

Note: This figure shows the rear side of HD-ETM70.1 2 3 4 5 6 7 8

ADDRESS

Setting range Invalid

Settings unnecessary

Indication of printed circuit board

Figure 3-17. Rotary DIP Switches for IP Address Setting

During normal operation, use the default settings without changing the switches.

21

Section 4. Process Controller II /Process Manager EX Base Unit

The Process Controller II (DOPC II) adopts a redundant configuration only.

ETM200

POW

RUN

1

2

3

MSC

LINK

RX

ETM200

POW

RUN

1

2

3

MSC

LINK

RX

MSC200

POW

RUN

SYNC

MSC200

POW

RUN

SYNC

MSC200

POW

RUN

SYNC

XBM200

POW

RUN

PRIMARY

XBM200

POW

RUN

PRIMARY

TRM200 BPS200

POW

OK

CTRL

ETMA

ETMB

MSC1

MSC2

MSC3

XBML

XBMR

Figure 4-1. Main Base Unit

The DOPC II(PM-EX) main unit is divided into the following types, depending ondifferences in input/output equipment in connection is provided. Of these types, Figure 4-1shows HD-DCDD201.

HD-DCDD201(MJ-DCDD201)/HD-DCDD401(MJ-DCDD401)For FX-bus input/output equipment connection

HD-DCDD101(MJ-DCDD101)/HD-DCDD301(MJ-DCDD301)For X-bus input/output equipment connection

Section 4. Process Controller II / Process Manager EX Base Unit

22


Except for the differences above, HD-DCDD201/401 and 101/301 basically provide thesame functions.

FX-bus input/output equipment is divided into the following I/O modules. Distributed I/O module Signal unit I/O (SIO) Base unit mounted type I/O module

The FX-bus cable connection methods adopted by the distributed I/O module, signal unit I/O and base unit mounted type I/O are different from each other. For details on the methodfor connecting FX-bus input/output equipment, refer to the FX-bus Input/OutputEquipment Hardware Manual: MS2-SYS100-3004.

X-bus input/output equipment is divided into the following I/O modules. Signal unit I/O (SIO) Base unit mounted type I/O module

The X-bus cable connection methods adopted by the signal unit I/O and base unit mountedtype I/O are different from each other. For details, refer to the X-bus Input/OutputEquipment Hardware Manual: MS2-SYS100-3005.

Each main unit is comprised of the following. The J numbers in the parentheses are for PM-EX. HD-MBU200(J-MBU200) : Redundant main base plate (for connecting FX-bus

input/output equipment) HD-MBU100(J-MBU100) : Redundant main base plate (for connecting X-bus

input/output equipment) HD-MSC300/200(J-MSC300/200) : Control module HD-ETM200(J-ETM210) : Ethernet interface module HD-XBM200(J-XBM200) : X-bus interface module HD-BPS200(J-BPS200) : Backup battery module HD-TRM300/200(J-TRM300/200) : Terminal block interface module

When input/output equipment is installed remotely, the HD-DCDD401/201(MJ-DCDD401/201) use the HD-CEXT200(J-CEXT200) for slot 1/2 and the HD-DCDD301/101(MJ-DCDD301/101) use the HD-EXT102(J-EXT102) for slot 1/2.

Their components are described in Section 4.1, switch settings in Section 4.2, externalinput/output in Section 4.3, and Ethernet cable connection method in Section 4.4.

23

4.1 ComponentsThe components of DOPC II are shown below.

4.1.1 Redundant Main Base Plate(HD-MBU200/J-MBU200)

4.1.1.1 For Connecting FX-bus Input/Output Equipment (HD-MBU200/J-CEXT200)This is a base plate for mounting the DOPC II/PM-EX main body and adopts an 11SLOTconfiguration.FX-bus optical Extender(HD-CEXT200/J-CEXT200) is installed in SLOT1 and SLOT2.

Figure 4-2. Redundant Main Base Plate (for FX-bus)

The following interfaces are provided.Table 4-1. Redundant Main Base Plate Functions (for FX-bus)

Key No. Name

CN33 Power connector +24 VDC power input

LED1 Power LED Comes on with +24 VDC supplied

TB1 Contact I/O terminal 1 (For details, see Section 4.3)TB2 Contact I/O terminal 2 (For details, see Section 4.3)

SW1-SW8 Address setting switch

1: ON - OFF-

Cold restartHot/warm restart

2: ON - When both HW Rev.0 and HW Rev.1 or laterare present

OFF- When both HW Rev.0 and HW Rev.1 or laterare not present

3: Always OFF4: ON - OFF-

To be set for enabling online upgradesNormal operation

1A, 1B2A, 2B3A, 3B4A, 4B

(FX-bus connector)

F1 Fuse Fuse for protecting contact output driving circuits

SW9 Function

Function

Channel 1Channel 2Channel 3Channel 4

Sets IP addresses and node numbers.(For details, see Section 4.2.1)

4.1 Components

24


4.1.1.2 For Connecting X-bus Input/Output Equipment (HD- MBU100/J-MBU100)This is a base plate for mounting the DOPC II/PM-EX main body and adopts an 11SLOTconfiguration.X-bus optical Extender(HD-EXT11/12, J-EXT12/22) is installed in SLOT1 and SLOT2.

Figure 4-3. Redundant Main Base Plate (for X-bus)

The following interfaces are provided.Table 4-2. Redundant Main Base Plate Functions (for X-bus)

Key No. Name





1: ON - OFF-






1A, 1B2A, 2B3A, 3B

(X-bus connector)


SW9 Function

Function

Channel 1Channel 2Channel 3


25

4.1.2 Control Module (HD-MSC300/200, J-MSC300/200)The control module performs control computation.

A triplex structure is adopted to achieve high reliability, and a set of DOPC II(PM-EX)requires three HD-MSC300/200(J-MSC300/200) modules. These are mounted in Slots 5 to7 from the main base plate. Simultaneously taking out two modules from these slots stopscontinuity of control.HD-MSC200(J-MSC200) is obsolete.HD-MSC300(J-MSC300) and HD-MSC200(J-MSC200) must not be installed together onthe same base unit.

MSC200

PWR

RUN

SYNC

Figure 4-4. Control Module (MSC200)

The control module provides the following functions as an interface.

Table 4-3. LED of Control ModuleKey No. Name Function

PWR PowerSupply Remains on when power is normally supplied within the module.

RUN Operation Remains on when the CPU operates normally.

SYNC Synchronization

Remains on when the module synchronizes with other controlmodules and is put in a controllable state.Blinks when the module synchronizes with other control modules.

In addition, the module is equipped with a three-digit 7 segment LED. For details on howthe LEDs come on, refer to the Maintenance Manual.

4.1 Components

26


4.1.3 Ethernet Interface Module (HD-ETM200, J-ETM200)The Ethernet communication interface module provides a 10Base-T interface.

A set of DOPC II(PM-EX) needs two HD-ETM200(J-ETM200) modules: one for system Aand the other for system B. The module for system A is mounted in Slot 3, and the modulefor system B, in Slot 4. Taking out these two modules simultaneously stops continuity ofcontrol.

ETM200

PWR

RUN

1

2

3

MSC

LINK

RX

Figure 4-5. Ethernet Interface Module (ETM200)


Table 4-4. LED of Ethernet Interface ModuleKey No. Name Function

PWR PowerSupply Remains on when power is supplied normally within the module.


1, 2, 3MSC

Internallink

Remains on when an internal link with each of MSC1, MSC2 andMSC3 is put in LINK state. Blinks when data is transmitted andreceived.

LINK link Comes on when link of a cable connected to the front connector isestablished.

RX Receive Comes on when data is entered via a cable connected to the frontconnector.


27

4.1.4 X-Bus Interface Module (HD-XBM200, J-XBM200)This is an X-Bus communication interface.

A set of DOPC II(PM-EX) requires two HD-XBM200(J-XBM200) modules: one is for themain system and one for the standby system. If a failure occurs in the main system, thestandby module is switched to the main system to continue controlling. These modules aremounted in Slots 8 and 9 in the main base unit. Taking out two modules simultaneouslystops continuity of control.

XBM200

PWR

RUN

PRIMARY

Figure 4-6. X-Bus Interface Module (XBM200)


Table 4-5. LED of X-Bus Interface ModuleKey No. Name Function



PRIMARY Mainsystem Remains on when the module operates as the main system.


4.1 Components

28


4.1.5 Terminal Block Interface Module (HD-TRM300/200,J-TRM300/TRM200)The Terminal Block Interface module, mounted in Slot 10 of the main base unit(HD-DCDD401/301/201/101, MJ-DCDD401/301/201/101), interfaces with external input/output terminals (see Section 4.3 for details) on the main base plate.HD-TRM200(J-TRM200) is obsolete.HD-TRM200(J-TRM200) cannot be used since software release 6.0.HD-TRM300(J-TRM300) is software independent and can be used with any software release.

TRM200

CTRL

ETMA

ETMB

MSC1

MSC2

MSC3

XBML

XBMR

CAUTION

REMOVING THIS MODULECAUSES ALL TERMINALCONTACTS TO BE OPEN

CAUTION


Figure 4-7. Terminal Block Interface Module (TRM200)

Caution Removing this module results in open connection of the externalinput/output terminals on the Main Base Plate.

The terminal board interface module has the following interface functions:

Table 4-6. LED of Terminal Block Interface ModuleFunction

Remains on when the board is controllable.

Remains on when the ETM200 module installed in the slot 3 is normal.


Remains on when the MSC300/200 module installed in the slot 5 is normal.



Remains on when the XBM200 module installed in the slot 8 is normal.

Remains on when the XBM200 module installed in the slot 9 is normal.XBMR

MSC1

MSC2

MSC3

XBML

Key No.

CTRL

ETMA

ETMB

29

4.1.6 Backup Battery Module (HD-BPS200, J-BPS200)The Backup Battery module, mounted in Slot 11 of the main base unit, supplies power forbackup of power supply in case of 24V power break or for saving data in nonvolatilememory from the main memory of the control module in case of power failure.

BPS200

PWR

OK

CHARGE

Figure 4-8. Backup Battery Module (BPS200)

The control module provides the following functions as an interface.Table 4-7. LED of Backup Battery Module

Key No. Name Function

PWR Power Supply Remains on when 24V power is supplied from outside.

OK Normal Comes on when backup power can be supplied.

CHARGE Charge Blinks during quick charging

Batteries are consumables. The level of deterioration depends heavily on serviceconditions.

Table 4-8. Recommended Battery Replacement Period

Service Condition Recommended batteryreplacement period

Cabinet ambient temperature of 0 to 28 degrees C is maintained andthe frequency of power outage is once per month or less. 4 years

Cabinet ambient temperature is 28 to 35 degrees C or the frequency ofpower outage is once per week or less. 2 years

Cabinet ambient temperature is 35 to 40 degrees C or the frequency ofpower outage is once per day or less. 1 year

Although the label attached on the front of the module at the time of first shipment shows areplacement date that is 4 years after the manufacturing date, set an appropriate batteryreplacement timing taking into account the actual service condition. The model number ofthe replacement battery is HD-BAT200/J-BAT200.

4.1 Components

30


4.2 Setting SwitchesThe DOPC II/PM-EX main unit is equipped with IP address setting switches, also used forsetting node numbers, on the Ethernet and mode setting switches of DOPC II/PM-EX.

4.2.1 Setting node numbers and setting IP addressesEight rotary switches (SW1 to SW8) on the base plate are used to set node numbers and IPaddresses (they need not be set in modules).

An IP address is given with four fields delimited by dots.

Each field consists of eight bits and is usually given in decimal form (0 to 255). In DOPC II/PM-EX, low-order eight bits of an IP address is a node number. A node number can be setto any value ranging from 1 to 126.

It is advisable to set IP addresses to class C in DOPC II/PM-EX.

Setting methodIn this example, an IP address is to be set to 192.168.0.25, a Class C local address.First, convert the decimal numbers in each of the fields into two-digit hexadecimal numbers.Set the high order of the first field (C in this example) to SW1 and set the low order (0 in thisexample) to SW2. Similarly, set SW3 to A, SW4, 8, SW5, 0, SW6, 0, SW7, 1, and SW8, 9.

Convert into hexadecimal number.192. 168. 0. 25

C0. A8. 00. 19

SW1

C

SW2

0

SW3A

SW48

SW5

0

SW6

0

SW89

SW7

1

ADDRESS


Caution 1. A standard network is duplicated. Setting addresses in system Aautomatically sets addresses in system B. For example, makingthe above settings (setting the address to 192.168.0.25 in systemA) automatically sets the address to 192.168.1.25 in system B.

2. Be careful not to set the IP address in duplicate. If set in that way,normal communications are not possible.

31

4.2.2 Function setting switchesFunctions can be selected using the four-bit DIP switch (SW9) on the base plate.

1st bit : Indicates the restart type (cold or other).ON : Cold restartOFF : Warm or hot restart (Note 1)

2nd bit : For H/W, sets whether or not both Rev.0 (Note 2) and Rev.1 or later are present.ON : When both of them are present (Note 3)OFF : When both of them are not present

3rd bit : System reservation

4th bit : System upgrade modeON : Set for online upgradeOFF : For normal operation

1 2 3 4

ON

SW9

FUNCTION

Figure 4-10. Function setting switches

Note 1 Warm or hot restart is selected depending on the status of externalcontact terminal with power turned on. When hot signal on (short) isentered, hot restart is selected. When hot signal off (open) is entered,warm restart is selected.

Note 2 H/W Rev.0 is used only for the DOPC II/PM-EX initial limitationshipment job. After commercial production, H/W Rev.1 or later isselected.

Note 3 Applicable H/W is ETM200, MSC300/200, XBM200, BPS200 and baseplate.If this setting is not made, warm restart or hot restart may not beperformed correctly.

4.2 Setting Switches

32


4.3 External inputs and outputsThe main base unit provides external inputs and outputs: nine outputs and one input.Internal and external power supplies are available to operate these signals. However,internal or external power supply is selected collectively in the whole.

To use internal power supply for the operation, connect the jumpers: No.1 and No.6 of TB1,and No.2 and No.7. To use external power supply for the operation, connect external 24V toNo.1 of TB1, and connect the external ground to No.2.

Caution When using external power supply, do not connect the No.1 andNo.6 jumpers of TB1, and No.2 and No.7 jumpers. Supplying 24Vpower with the jumpers connected causes damage.

Removing the HD-TRM200/300, J-TRM200/300 module from Slot10 of the base plate makes all the signals above invalid.

Signals are explained below.

Outputs: 9 signalsOutput signals isolate transistor outputs by a photo-coupler and each of them isconnected paired with an SRC terminal. Since an SRC terminal contains three terminalsas a whole, clamp them together.As the whole, the controller provides a signal for indicating control can be continued andeight signals for indicating respective modules are kept sound. When modules operatenormally, their transistor outputs are set to ON.

Specification Type : Transistor outputRating : 24 VDCOperating rage : 15 to 30 VDCLoad current : Maximum 0.2 ALoad peak current : 0.5 ALoad peak current at off time : 0.1 mA or lessOutput transistor ON voltage : 1.5V or less

Equivalent circuit TRM200/300

Photo-coupler

Back plane

EXT24V

SRC

CTLEXTCOM

External circuit

LOAD relay, lamp, etc.

External cabling

Terminal block

Figure 4-11. External output circuit

33

Input: 1 signalsThe input signal is isolated by a photo-coupler and connected paired with an RTNterminal. One input signal, which is a hot restart signal connected to the AC power downmonitor, is used.When the actual short break time of the AC power supply is less than or equal to the setvalue, the AC power down monitor sets ON. The AC power down monitor is turned onif the time for a short break of AC power supply is less than or equal to a set value.DOPC II/PM-EX monitors this signal and determines the restart mode when the +24VDC power supply is restored from power failure.

Specification ON current : 3mA minOFF current : 0.7mA max

Equivalent circuit

RTN

EXTCOM

HOT

TRM200/300

Photo-coupler

Back plane

EXT24V

Relay or transistor

External cabling

Terminal block

External circuit

Figure 4-12. External input circuit

These are connected via two sets of terminal blocks having ten terminals located at the rightside of the base plate. The meanings of the terminals are as follows. Their specificationsand connecting procedures are described later.

4.3 External inputs and outputs

34


TB1Table 4-9. TB1 Functions

TerminalNo Name Meaning

1 EXT24V I/O 24V power supplyTo use internal +24 VDC, connect to No.6 terminal.

2 EXTCOM I/O groundTo use internal +24VDC, connect to No.7 terminal.

3 RTN Used as a return, paired with the 8: FAN input terminal.

4 RTN Used as a return, paired with the 9: HOT input terminal.

5 SRC Used as a source, paired with the 10: CTL output terminal.

6 24VInternal +24 VDC power supplied from DCPDU to the base plate.To use internal +24 VDC, connect to No.1 terminal.To use external power supply, disconnect from No.1 terminal.

7 SGInternal groundTo use internal +24 VDC, connect to No.2 terminal.To use external power supply, disconnect from No.2 terminal.

8 FAN Not used.

Hot restart inputClosing the terminal, paired with 4: RTN, between No.9 and No.4terminals identifies hot restart to be allowable.When the +24 VDC power supply is restored from power failure, thecontroller monitors this signal and determines the restart mode.

10 CTLControllable state outputIs used paired with 5: SRC. If the terminal is controllable as acontroller, the transistor is set to "ON".

9 HOT

Note To use external power supply, remove jumpers from between No.1 andNo.6 terminals on TB1 and between No.2 and No.7 terminals.

Note Short breaking of the AC power supply, results in open of CTL functionsignal.

35

TB2Output signals are connected, indicating modules are kept sound.

Table 4-10. TB2 FunctionsTerminal

No Name Meaning

1 SRC A source of output terminal. Equivalent to No.5 terminal on TB1 andNo.2 terminal on TB2.


3 MSC 1Output of MSC 1 state.Used paired with SRC. When MSC300/200 into which Slot5 has beeninserted is normal, the transistor is set to "ON".



6 ETM AOutput of ETM state in system A.Used paired with SRC. When ETM200 into which Slot3 has beeninserted is normal, the transistor is set to "ON".

7 ETM BOutput of ETM state in system B.Used paired with SRC. When ETM200 into which Slot4 has beeninserted is normal, the transistor is set to "ON".

8 XBM LOutput of XBM state on the left side.Used paired with SRC. When XBM200 into which Slot8 has beeninserted is normal, the transistor is set to "ON".

9 XMB ROutput of XBM state on the right side.Used paired with SRC. When XBM200 into which Slot9 has beeninserted is normal, the transistor is set to "ON".

10 BPSOutput of BPS state on the left side.Used paired with SRC. When BPS200 into which Slot11 has beeninserted is normal, the transistor is set to "ON".

Connecting TB2 requires power to be supplied to TB1.

To prevent output failures when MSC300/200 restarts, output is not turned OFF until twominutes passes after the stop of MSC300/200. Immediately after the insertion of MSC300/200, output may be turned ON for about two minutes regardless of the state. However,when internal 24 VDC power failure occurs, the output is immediately turned OFF.

Note Short breaking of the AC power supply, results in open of External outputsfunction signals.


36


4.4 Ethernet Cable ConnectionThis section provides Ethernet cabling procedures. For setting node numbers and IPaddresses, see Section 4.2

DOPC II(PM-EX) adopts 10Base-T for Ethernet interfaces.From the connector on the front face of the HD-ETM200(J-ETM200) module, connect the10M hub (HD-HUB5T8) or switching hub (eight ports: HD-SWHUBX30/31, 24 port: HD-SWHUBX16) via a UTP cable. The PM-EX is connected to the switching hub (eight ports:MJ-SWHUBX31). When this is the case, connect system A to HD-ETM200(J-ETM200)inserted into Slot3 and system B to HD-ETM200(J-ETM200) inserted into Slot4.

The switching hub supports both 100Mbps and 10Mbps and the bit transmission rate of theswitching hub connected to DOPC II is automatically set to 10Mbps.

MSC200ETM200 ETM200 MSC200MSC200 XBM200 XBM200 TRM200 BPS200

Boot color of cable A:white or gray

Boot color of cable B:blue

Cable A Cable B

Redundant DOPCII node

10M HUB (HD-HUB5T8)or

switching hub(HD-SWHUBX32/31/16)

Figure 4-13. Connection Using 10Base-T (Redundant DOPC II/PM-EX)

37

Use a 10M hub to connect 10Base-5 (coaxial cable) or 10Base-FL (fiber optics).Existing redundant DOPC needs to connect cables A and B to both sets of right and leftsides, i.e., a total of four cables need to be connected. In DOPC II, however, one cable needsto be connected to each of systems A and B.

If the switching hub includes spare ports, it is recommended that DOPC II be connected tothe switching hub.

Switching Hub

DOPCII DOPCIIDOPCIIDOPCII

Connections can be made up to the number of ports in the switching hub. If more ports than those provided in the hub are required, cascade connections can be made in the switching hub.

Figure 4-14.Configuration Example 1: Direct Connection with Switching Hub

If a switching hub is not used, or if a switching hub is used but ports are expanded by usinga 10M hub, the restrictions on the number of controllers connectable to the 10M Ethernet ofone system are different from those of existing DOPC. For 10M Ethernet of one system, theconfiguration for a guideline should be less than 8,000pps in total of controllers inconnection. Exceeding 8,000pps should adopt a switching hub in the configuration.

In the following configuration example, only one system is shown to simplify the drawing.Actually, however, another set of networks having the same configuration is required.

Switching Hub

10M hub


10M hub


Up to 8000pps in total Up to 8000pps in total

DOPCII connectable to 10M Ethernet of one system is up to 8,000pps in total.

Figure 4-15.Configuration Example 2: Combination of Switching Hub and Hub

For details on the network configuration procedures, refer to MS2-SYS100-3003.

4.4 Ethernet Cable Connection

38


4.5 I/O Address Setting RangeProcess Controller II (DOPC II) or PM-EX can set I/O configuration numbers in thefollowing range.

Table 4-11. Range of I/O Configuration Numbers Settable in PM-EX and DOPCIIBase (Card) NumbersBlock (File)

Numbers

12345678

: Non-redundant I/O modules and redundant I/O modules can be configured.: Only non-redundant modules can be configured.: I/O modules cannot be configured.

Note: Base unit type I/O is not configurable for card Nos. 13 to 16.

However, the following restrictions are put on analog input modules. Card Nos. 1 to 12 can be set in HD-CHAM and SIO HAM modes. Card Nos. 1 to 11 can be set in HD-CRAM and HD-CLAM.

39

Section 5. Process Controller III /Process Manager EX Base Unit

The Process Controller III (DOPC III) adopts a redundant configuration and a non-redundant configuration.

DOPC III/PM-EX redundant main unit

ETM210

POW

RUN

1

2

3

MSC

LINK

RX

ETM210

POW

RUN

1

2

3

MSC

LINK

RX

MSC300

MSC300

POW

RUN

SYNC

MSC300

POW

RUN

SYNC

MSC300

POW

RUN

SYNC

XBM200

POW

RUN

PRIMARY

XBM200

POW

RUN

PRIMARY

TRM200 BPS200

POW

OK

CTRL

ETMA

ETMB

MSC1

MSC2

MSC3

XBML

XBMR

Figure 5-1. Main Base Unit

The DOPC III(PM-EX) main unit is divided into the following types, depending ondifferences in input/output equipment in connection is provided. Of these types, Figure 5-1shows HD-DCDDA00.

HD-DCDDA00(MJ-DCDDA00) For FX-bus input/output equipment connection HD-DCDDA01(MJ-DCDDA01) For X-bus input/output equipment connection

Except for the differences above, HD-DCDDA00(MJ-DCDDA00) and HD-DCDDA01(MJ-DCDDA01) basically provide the same functions.

Section 5. Process Controller III / Process Manager EX Base Unit

40


DOPC III non-redundant main unitThe DOPC III non-redundant main unit is available in two types: a long type and a shorttype.

1) Long type

Figure 5-2. Non-redundant Main Unit - Long Type

The long-type DOPC III non-redundant main unit is divided into the following types,depending on differences in input/output equipment in connection and whether or not anexternal input/output is provided. Of these types, Figure 5-2 shows HD-DCSDA001.

HD-DCSDA001 For FX-bus input/output equipment connection HD-DCSDA011 For X-bus input/output equipment connection

Except for the difference above, HD-DCSDA001 and 011 basically provide the samefunctions.

2) Short type

Figure 5-3. Non-redundant Main Unit - Short Type

41

The short-type DOPC III non-redundant main unit comes only with the type for FX-businput/output equipment connection. HD-DCSDA000 For FX-bus input/output equipment connection

FX-bus input/output equipment is divided into the following I/O modules. Distributed I/O module Signal unit I/O (SIO) Base unit mounted type I/O module

The FX-bus cable connection methods adopted by the distributed I/O module, signal unit I/O, and base unit mounted type I/O module are different from each other. For details on themethod for connecting FX-bus input/output equipment, refer to the FX-bus Input/OutputEquipment Hardware Manual: MS2-SYS100-3004.

X-bus input/output equipment is divided into the following I/O modules. Signal unit I/O (SIO) Base unit mounted type I/O module

The X-bus cable connection methods adopted by the signal unit I/O and base unit mountedtype I/O module are different from each other. For details, refer to the X-bus Input/OutputEquipment Hardware Manual: MS2-SYS100-3005.

Each main unit is comprised of the following. The model number J in parentheses is for PM-EX HD-MBU200 (J-MBU200) : Redundant main base plate (for connecting FX-bus input/

output equipment) HD-MBU100 (J-MBU100) : Redundant main base plate (for connecting X-bus input/

output equipment) HD-MBU400L : Non-redundant main base plate - long type (for connecting

FX-bus input/output equipment) HD-MBU400S : Non-redundant main base plate - short type (for connecting FX-bus

input/output equipment) HD-MBU300L : Non-redundant main base plate - long type (for connecting X-bus

input/output equipment) HD-MSC300 (J-MSC300) : Control module HD-ETM210 (J-ETM210) : Ethernet interface module HD-XBM200 (J-XBM200) : X-bus interface module HD-BPS200 (J-BPS200) : Backup battery module HD-TRM300 (J-TRM300) : Terminal block interface module

When input/output equipment is installed remotely, the HD-DCDDA00 (MJ-DCDDA00)/HD-DCSDA001 use HD-CEXT200(J-CEXT200) for slot 1/2, HD-DCDDA01 (MJ-DCDDA01)/HD-DCSDA011 use HD-EXT11/12(J-EXT11/12) for slot 1/2, and HD-DCSDA000 uses HD-CEXT200 for slot 7/8.

Their components are described in Section 5.1, switch settings in Section 5.2, externalinput/output in Section 5.3, and Ethernet cable connection method in Section 5.4.


42


5.1 ComponentsThe components of DOPC III/PM-EX are shown below.

5.1.1 Redundant Main Base Plate

5.1.1.1 For Connecting FX-bus Input/Output Equipment (HD-MBU200/J-MBU200)This is a base plate for mounting the DOPC III/PM-EX main body and adopts an 11SLOTconfiguration.FX-bus optical Extender(HD-CEXT200/J-CEXT200) is installed in SLOT1 and SLOT2.

Figure 5-4. Redundant Main Base Plate (for FX-bus)

The following interfaces are provided.Table 5-1. Redundant Main Base Plate Functions (for FX-bus)

Key No. Name





1: ON - OFF-






1A, 1B2A, 2B3A, 3B4A, 4B

(FX-bus connector)


Function



SW9 Function

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5.1.1.2 For Connecting X-bus Input/Output Equipment (HD- MBU100/J-MBU100)This is a base plate for mounting the DOPC III/PM-EX main body and adopts an 11SLOTconfiguration.X-bus optical Extender(HD-EXT12/22, J-EXT12/22) is installed in SLOT1 and SLOT2.

Figure 5-5. Redundant Main Base Plate (for X-bus)

The following interfaces are provided.Table 5-2. Redundant Main Base Plate Functions (for X-bus)

Key No. Name





1: ON - OFF-






1A, 1B2A, 2B3A, 3B

(X-bus connector)


SW9 Function

Function



5.1 Components

44


5.1.2 Non-redundant Main Base Plate

5.1.2.1 For Connecting FX-bus Input/Output Equipment - Long Type (HD-MBU400L)This is a base plate for mounting the DOPC III main body and adopts an 11SLOTconfiguration.FX-bus optical Extender (HD-CEXT200) or FX-bus IOM is installed in SLOT1 andSLOT2.FX-bus IOM is installed in SLOT3 to SLOT8.

Figure 5-6. Non-redundant Main Base Plate - Long Type (for FX-bus)

The following interfaces are provided.Table 5-3. Non-redundant Main Base Plate - Long Type Functions (for FX-bus)

Key No. Name



TB1 Contact I/O terminal 1 (For details, see Section 5.3)


1: ON - OFF-


3: Always OFF

1A, 1B2A, 2B3A, 3B4A, 4B

(FX-bus connector)


Function


SW9


2: Always OFF

4: Always OFF

Function

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5.1.2.2 For Connecting FX-bus Input/Output Equipment - Short Type(HD-MBU400S)This is a base plate for mounting the DOPC III main body and adopts a 5SLOTconfiguration.FX-bus optical Extender (HD-CEXT200) is installed in SLOT7 and SLOT8.SLOT7 and SLOT8 cannot be used for IOM use.

Figure 5-7. Non-redundant Main Base Plate - Short Type (for FX-bus)

The following interfaces are provided.Table 5-4. Non-redundant Main Base Plate - Short Type Functions (for FX-bus)

Key No. Name





1: ON - OFF-


3: Always OFF

1A, 1B2A, 2B3A, 3B4A, 4B

(FX-bus connector)


Function

Function


SW9


4: Always OFF

2: Always OFF

5.1 Components

46


5.1.2.3 For Connecting X-bus Input/Output Equipment - Long Type (HD-MBU300L)This is a base plate for mounting the DOPC III main body and adopts an 11SLOTconfiguration.FX-bus optical Extender (HD-EXT12) or X-bus IOM is installed in SLOT1 and SLOT2.X-bus IOM is installed in SLOT3 to SLOT8.

Figure 5-8. Non-redundant Main Base Plate - Long Type (for X-bus)

The following interfaces are provided.Table 5-5. Non-redundant Main Base Plate - Long Type Functions (for X-bus)Key No. Name





1: ON - OFF-


3: Always OFF

1A, 1B2A, 2B3A, 3B

(FX-bus connector)



Function


SW9 Function 2: Always OFF

4: Always OFF

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5.1.3 Control Module (HD-MSC300, J-MSC300)The control module performs control computation.

The redundant main unit adopts a triplex structure to achieve high reliability, and a set ofDOPC III(PM-EX) stations requires three HD-MSC300(J-MSC300) modules. These aremounted in Slots 5 to 7 of the main base plate.In the non-redundant main unit of a DOPC III, one HD-MSC300 module is mounted in Slot 9.

MSC300

PWR

RUN

SYNC

Figure 5-9. Control Module (MSC300)


Table 5-6. LED of Control ModuleKey No. Name Function



SYNC Synchronization

Remains on when the module synchronizes with other controlmodules and is put in a controllable state.Blinks when the module synchronizes with other control modules.


5.1 Components

48


5.1.4 Ethernet Interface Module (HD-ETM210, J-ETM210)The Ethernet communication interface module provides a 10Base-T interface.

In the redundant main unit, a set of DOPC III(PM-EX) stations needs two HD-ETM210(J-ETM210) modules: one for system A and the other for System B. The module for system Ais mounted in Slot 3 of the main base unit, and the module for system B, in Slot 4 of the unit.It is not used in the non-redundant main unit of a DOPC III.

ETM210

PWR

RUN

1

2

3

MSC

LINK

RX

Figure 5-10. Ethernet Interface Module (ETM210)


Table 5-7. LED of Ethernet Interface ModuleKey No. Name Function

PWR PowerSupply Remains on when power is supplied normally within the module.


1, 2, 3MSC

Internallink

Remains on when an internal link with each of MSC1, MSC2 andMSC3 is put in LINK state. Blinks when data is transmitted andreceived.

LINK link Comes on when link of a cable connected to the front connector isestablished.

RX Receive Comes on when data is entered via a cable connected to the frontconnector.


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5.1.5 X-Bus Interface Module (HD-XBM200, J-XBM200)This is an X-Bus communication interface.

In the redundant main unit, a set of DOPC III(PM-EX) stations requires two HD-XBM200(J-XBM200) modules: one is for the main system and the one for the standbysystem. If a failure occurs in the main system, the standby module is switched to the mainsystem to continue controlling. These modules are mounted in Slots 8 and 9 of the mainbase unit. Taking out two modules simultaneously stops continuity of control.In the non-redundant main unit of a DOPC III, one HD-XBM200 module is mounted in Slot 10.

XBM200

PWR

RUN

PRIMARY

Figure 5-11. X-Bus Interface Module (XBM200)


Table 5-8. LED of X-Bus Interface ModuleKey No. Name Function



PRIMARY Mainsystem Remains on when the module operates as the main system.


5.1 Components

50


5.1.6 Terminal Block Interface Module (HD-TRM300, J-TRM300)The Terminal Block Interface module, mounted in Slot 10 of the main base unit (HD-DCDDA00/01, MJ-DCDDA00/01), interfaces with external input/output terminals (seeSection 5.3 for details) on the redundant main base plate.This module is not used in the non-redundant main unit.

TRM300

CTRL

ETMA

ETMB

MSC1

MSC2

MSC3

XBML

XBMR

CAUTION


CAUTION


Figure 5-12. Terminal Block Interface Module (TRM300)

Caution Removing this module results in open connection of the externalinput/output terminals on the Main Base Plate.

The terminal board interface module has the following interface functions:

Table 5-9. LED of Terminal Block Interface ModuleFunction

Remains on when the board is controllable.



Remains on when the MSC300 module installed in the slot 5 is normal.



Remains on when the XBM200 module installed in the slot 8 is normal.

Remains on when the XBM200 module installed in the slot 9 is normal.XBMR

MSC1

MSC2

MSC3

XBML

Key No.

CTRL

ETMA

ETMB

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5.1.7 Backup Battery Module (HD-BPS200, J-BPS200)The Backup Battery module, mounted in Slot 11 of the main base unit, supplies power forbackup of power supply in case of 24V power break or for saving data in nonvolatilememory from the main memory of the control module in case of power failure.

BPS200

PWR

OK

CHARGE

Figure 5-13. Backup Battery Module (BPS200)

The control module provides the following functions as an interface.Table 5-10. LED of Backup Battery Module

Key No. Name Function

PWR Power Supply Remains on when 24V power is supplied from outside.

OK Normal Comes on when backup power can be supplied.

CHARGE Charge Blinks during quick charging

Batteries are consumables. The level of deterioration depends heavily on serviceconditions.

Table 5-11. Recommended Battery Replacement Period

Service Condition Recommended batteryreplacement period

Cabinet ambient temperature of 0 to 28 degrees C is maintained andthe frequency of power outage is once per month or less. 4 years

Cabinet ambient temperature is 28 to 35 degrees C or the frequency ofpower outage is once per week or less. 2 years

Cabinet ambient temperature is 35 to 40 degrees C or the frequency ofpower outage is once per day or less. 1 year

Although the label attached on the front of the module at the time of first shipment shows areplacement date that is 4 years after the manufacturing date, set an appropriate batteryreplacement timing taking into account the actual service condition. The model number ofthe replacement battery is HD-BAT200/J-BAT200.

5.1 Components

52


5.2 Setting SwitchesThe DOPC III/PM-EX main unit is equipped with IP address setting switches, also used forsetting node numbers, on the Ethernet and mode setting switches of DOPC III/PM-EX.

5.2.1 Setting node numbers and setting IP addressesEight rotary switches (SW1 to SW8) on the base plate are used to set node numbers and IPaddresses (they need not be set in modules).

An IP address is given with four fields delimited by dots.

Each field consists of eight bits and is usually given in decimal form (0 to 255). In DOPCIII/PM-EX, low-order eight bits of an IP address is a node number. A node number can beset to any value ranging from 1 to 126.

It is advisable to set IP addresses to class C in DOPC III/PM-EX.

Setting methodIn this example, an IP address is to be set to 192.168.0.25, a Class C local address.First, convert the decimal numbers in each of the fields into two-digit hexadecimal numbers.Set the high order of the first field (C in this example) to SW1 and set the low order (0 in thisexample) to SW2. Similarly, set SW3 to A, SW4, 8, SW5, 0, SW6, 0, SW7, 1, and SW8, 9.

Convert into hexadecimal number.192. 168. 0. 25

C0. A8. 00. 19

SW1

C

SW2

0

SW3A

SW48

SW5

0

SW6

0

SW89

SW7

1

ADDRESS


Caution 1 A standard network is duplicated. Setting addresses in system Aautomatically sets addresses in system B. For example, makingthe above settings (setting the address to 192.168.0.25 in systemA) automatically sets the address to 192.168.1.25 in system B.

Caution 2 Be careful not to set the IP address in duplicate. If set in that way,normal communications are not possible.

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5.2.2 Function setting switchesFunctions can be selected using the four-bit DIP switch (SW9) on the base plate.

1st bit : Indicates the restart type (cold or other).ON : Cold restartOFF : Warm or hot restart (Note 1)

2nd bit : For H/W, sets whether or not both Rev.0 (Note 2) and Rev.1 or later are present.ON : When both of them are present (Note 3)OFF : When both of them are not present

(Always OFF for the non-redundant unit)

3rd bit : System reservation

4th bit : System upgrade modeON : Set for online upgradeOFF : For normal operation

(Always OFF for the non-redundant unit)

1 2 3 4

ON

SW9

FUNCTION

Figure 5-15. Function setting switches

Note 1 Warm or hot restart is selected depending on the status of externalcontact terminal with power turned on. When hot signal on (short) isentered, hot restart is selected. When hot signal off (open) is entered,warm restart is selected.

Note 2 H/W Rev.0 is used only for the DOPC III/PM-EX initial limitationshipment job. After commercial production, H/W Rev.1 or later isselected.

Note 3 Applicable H/W is ETM210, MSC300, XBM200, BPS200 and baseplate.If this setting is not made, warm restart or hot restart may not beperformed correctly.

5.2 Setting Switches

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5.3 External inputs and outputsThe main base unit provides external inputs and outputs: nine outputs and one input.Internal and external power supplies are available to operate these signals. However,internal or external power supply is selected collectively in the whole.

To use internal power supply for the operation, connect the jumpers: No.1 and No.6 of TB1,and No.2 and No.7. To use external power supply for the operation, connect external 24V toNo.1 of TB1, and connect the external ground to No.2.

Caution When using external power supply, do not connect the No.1 andNo.6 jumpers of TB1, and No.2 and No.7 jumpers. Supplying 24Vpower with the jumpers connected causes damage.

Removing the HD-TRM300/J-TRM300 module from Slot 10 of thebase plate makes all the signals above invalid.

The circuits for external inputs and outputs are integrated into the TRM300 if the main baseunit is redundant, and are integrated into the MCS300 if the base unit is non-redundant.Signals are explained below.

Outputs: 9 signals(One signal for the non-redundant unit)Output signals isolate transistor outputs by a photo-coupler and each of them isconnected paired with an SRC terminal. Since an SRC terminal contains three terminalsas a whole, clamp them together.As the whole, the controller provides a signal for indicating control can be continued andeight signals for indicating respective modules are kept sound. When modules operatenormally, their transistor outputs are set to ON.

Specification Type : Transistor outputRating : 24 VDCOperating rage : 15 to 30 VDCLoad current : Maximum 0.2 ALoad peak current : 0.5 ALoad peak current at off time : 0.1 mA or lessOutput transistor ON voltage : 1.5V or less

Equivalent circuit TRM300(Redundant)MSC300(Non-redundant)

Photo-coupler

Back plane

EXT24V

SRC

CTLEXTCOM

External circuit

LOAD relay, lamp, etc.

External cabling

Terminal block

Figure 5-16. External output circuit

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Input: 1 signalsThe input signal is isolated by a photo-coupler and connected paired with an RTNterminal. One input signal, which is a hot restart signal connected to the AC power downmonitor, is used.The AC power down monitor is turned on if the time for a short break of AC powersupply is less than or equal to a set value. DOPC III/PM-EX monitors this signal anddetermines the restart mode when the +24 VDC power supply is restored from powerfailure.

Specification ON current : 3mA minOFF current : 0.7mA max

Equivalent circuit

RTN

EXTCOM

HOT

Photo-coupler

Back plane

EXT24V

Relay or transistor

External cabling

Terminal block

External circuit

TRM300(Redundant)MSC300(Non-redundant)

Figure 5-17. External input circuit

These are connected via two sets of terminal blocks having ten terminals located at the rightside of the base plate. The meanings of the terminals are as follows. Their specificationsand connecting procedures are described later.


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TB1Table 5-12. TB1 Functions

TerminalNo Name Meaning

1 EXT24V I/O 24V power supplyTo use internal +24 VDC, connect to No.6 terminal.

2 EXTCOM I/O groundTo use internal +24VDC, connect to No.7 terminal.

3 RTN Used as a return, paired with the 8: FAN input terminal.

4 RTN Used as a return, paired with the 9: HOT input terminal.

5 SRC Used as a source, paired with the 10: CTL output terminal.

6 24VInternal +24 VDC power supplied from DCPDU to the base plate.To use internal +24 VDC, connect to No.1 terminal.To use external power supply, disconnect from No.1 terminal.

7 SGInternal groundTo use internal +24 VDC, connect to No.2 terminal.To use external power supply, disconnect from No.2 terminal.

8 FAN Not used.

Hot restart inputClosing the terminal, paired with 4: RTN, between No.9 and No.4terminals identifies hot restart to be allowable.When the +24 VDC power supply is restored from power failure, thecontroller monitors this signal and determines the restart mode.

10 CTLControllable state outputIs used paired with 5: SRC. If the terminal is controllable as acontroller, the transistor is set to "ON".

9 HOT

Note To use external power supply, remove jumpers from between No.1 andNo.6 terminals on TB1 and between No.2 and No.7 terminals.

Note Short breaking of the AC power supply, results in open of CTL functionsignal.

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TB2Output signals are connected, indicating modules are kept sound.

Table 5-13. TB2 FunctionsTerminal

No Name Meaning



3 MSC 1Output of MSC 1 state.Used paired with SRC. When MSC300 into which Slot5 has beeninserted is normal, the transistor is set to "ON".



6 ETM AOutput of ETM state in system A.Used paired with SRC. When ETM into which Slot3 has been insertedis normal, the transistor is set to "ON".

7 ETM BOutput of ETM state in system B.Used paired with SRC. When ETM into which Slot4 has been insertedis normal, the transistor is set to "ON".

8 XBM LOutput of XBM state on the left side.Used paired with SRC. When XBM into which Slot8 has been insertedis normal, the transistor is set to "ON".

9 XMB ROutput of XBM state on the right side.Used paired with SRC. When XBM into which Slot9 has been insertedis normal, the transistor is set to "ON".

10 BPSOutput of BPS state on the left side.Used paired with SRC. When BPS into which Slot11 has been insertedis normal, the transistor is set to "ON".

Connecting TB2 requires power to be supplied to TB1.

To prevent output failures when MSC300 restarts, output is not turned OFF until twominutes passes after the stop of MSC300. Immediately after the insertion of MSC300,output may be turned ON for about two minutes regardless of the state. However, wheninternal 24 VDC power failure occurs, the output is immediately turned OFF.

Note Short breaking of the

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