Toshiba V Series User Manual
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Toshiba V Series User Manual

Toshiba V Series User Manual

Integrated controller
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6E8C0882
model 3000
Loop Controller L3 User's Manual Basic Hardware

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  • Page 1 6E8C0882 model 3000 Loop Controller L3 User’s Manual Basic Hardware...
  • Page 2 Important Information No patent liability is assumed by TOSHIBA Corporation with respect to use of information, illustrations, circuits, equipment or examples of application in this publication. TOSHIBA Corporation reserves the right to make changes and improvements to this publication and/or related products at any time without notice.
  • Page 3 Safety Precautions This manual contains important information for the operator to operate this product safely and correctly and avoid bodily injury and property damage. Grasp the meanings of the following marks and their descriptions before reading this manual. Hazard Classifications Indicates a potentially hazardous situation which, if not avoided, WARNING could result in serious injury or death.
  • Page 4 1. Checking the Warning Labels on the Main Unit Make sure warning markings are attached on the main unit. If any of them are missing or the wording is illegible, contact Toshiba's Service Department. 2. Precautions on Installation WARNING Mandatory Be sure to ground the equipment.
  • Page 5 3. Safety Precautions on Maintenance and inspection WARNING Mandatory Mandatory Turn off power removing or connecting any Turn off power removing any modules after modules, boards, or devices. installing. Otherwise, it can cause electrical shock, or Otherwise, exposed conductive parts of wire machine damage.
  • Page 6 User's manual. beyond normal range or if failure is occurred Otherwise, it can cause malfunction, machine in the equipment. damage or fire due to overheat. Contact Toshiba for repairing. Operation under such situation can cause fire or electrical shock. CAUTION Forbidden...
  • Page 7 Forbidden Forbidden Do not disassemble or modify the equipment. Do not enter wire scrapes or other foreign Otherwise, it can cause malfunction or failure. debris into the equipment. Also, do not insert metal parts into them. They can cause fire or accidents. 6.
  • Page 8 Toshiba is not liable for any incidental loss caused by the use or non-use of this product, such as loss of business profits, suspension of business, or loss or change of data on memory.
  • Page 9 Preface The Toshiba Integrated Controller V series is a new integrated control system suitable for the age of open and light-sizing. Based on the control and computer technologies long accumulated, it implements an easy-to-use open system by applying a standard multi-vendor network and simplified engineering package software.
  • Page 10 If the ambient temperature or the internal temperature of the equipment has arisen too high, or if the equipment has developed a fault, stop using it, switch power off, and contact the nearest Toshiba service station. Do not open the case of the equipment while it is in operation except when setting the switches.

  • Page 11: Table Of Contents

    CONTENTS 1 Overview of Loop Controller L3 ..1 1.1 L3 System Configuration ..... . . 2 1.2 Configuration of Main Unit .
  • Page 12 CONTENTS 3.2.3 Unpacking .......46 3.2.4 Carry-in Entrance and Passage ....46 3.2.5 Carrying-in .
  • Page 13 CONTENTS 6.3 Consumables ....... 82 6.3.1 Replacement of Battery ..... 82 6.3.2 Checking and Adjustment of Output Voltage .

  • Page 15: Overview Of Loop Controller L3

    Chapter 1 Overview of Loop Controller L3 The loop controller L3 is a Toshiba Integrated Controller V series control station which uses Ethernet control LAN. The L3 controller is composed of an L3 CPU module (L3PU11/L3PU21), an Ethernet module (EN7 module) and various IF modules (all of which constitute a main unit or basic unit), and I/O modules.

  • Page 16: L3 System Configuration

    Chapter 1 Overview of Loop Controller L3 1.1 L3 System Configuration The L3 controller is composed of a main unit and intelligent PI/O and G3 I/O modules which are connected via serial bus and G3 I/O bus, respectively, with the main unit. The main unit comprises a power supply module, an L3 CPU module, an EN7 module for connection with an Ethernet control LAN, and other IF modules.

  • Page 17: Configuration Of Main Unit

    1.2 Configuration of Main Unit 1.2 Configuration of Main Unit There are two types of basic base units for the L3 controller: one for single configuration and the other for duplex configuration. The L3 main unit (basic unit) comprises an L3 CPU module which is the core component of the L3 controller, an EN7 module for connection to the Ethernet, various other IF modules, and a power supply module which supplies power to each of these modules.

  • Page 18: Duplex Configuration

    Chapter 1 Overview of Loop Controller L3 1.2.2 Duplex Configuration Figure 1-4 shows an example of basic unit in duplex configuration (BU748) (implemented on two single-configuration basic base units). Figure 1-4 An Example of Basic Unit in Duplex Configuration (BU748) (on Two Single-configuration Basic Base Units) For the duplex-configuration basic unit on two single-configuration basic base units, install a duplexing interface module in slot [S0].

  • Page 19: Connection With Intelligent Pi/O System

    1.3 Connection with Intelligent PI/O System 1.3 Connection with Intelligent PI/O System The L3 controller can be connected with an intelligent PI/O system via serial bus. Connection with an intelligent PI/O system requires the following components, for system construction: • Communication base unit (USCB1) •...
  • Page 20 Chapter 1 Overview of Loop Controller L3 Figure 1-6 shows example cable connections between the main unit and intelligent PI/O system for duplex configuration. Main unit (Duplex) 3 lines Relay cable (Max length: 3 m) Relay terminal Terminal unit Serial bus (Max. length: 30 m) resistor Provided with One SBIF1 module...
  • Page 21 1.3 Connection with Intelligent PI/O System Table 1-2 Terminal Unit Name Type Specification Terminal unit UTBA1 For 8-point analog or 4-point pulse I/O Two PI/O modules can be installed. UTBA2 For 4-point analog I/O Two PI/O modules can be installed. UTBA3 For 8-point non-insulated distributor module UTBA6...

  • Page 22: Connection With G3 I/O System

    Chapter 1 Overview of Loop Controller L3 1.4 Connection with G3 I/O System The L3 controller can be connected via direct bus (G3 I/O bus) to a G3 I/O system. Install a G3 I/O module in a direct-bus-connectable slot of the L3 basic base unit. Expansion of the G3 I/O system requires the components shown in Table 1-3.
  • Page 23 1.4 Connection with G3 I/O System Table 1-4 I/O Modules Name Type Specification DC input module DI334 32 points (8 points/common), 12 to 24 Vdc, 10 mA/point DI334H 32 points (8 points/common), 12 to 24 Vdc, 10 mA/point, High-speed response DI344 32 points (8 points/common), 48 Vdc, 5 mA/point DI335...

  • Page 24: Connection With Engineering Tool

    Chapter 1 Overview of Loop Controller L3 1.5 Connection with Engineering Tool The L3 controller is connectable with an engineering tool designed to create, register and document control programs, process I/O information, and various tag information. Since the engineering tool runs on the Windows NT platform, it is operable on a PC/AT- compatible personal computer or the OIS1200.

  • Page 25: Names And Functions Of Modules

    1.6 Names and Functions of Modules 1.6 Names and Functions of Modules The L3 controller is composed of a CPU module (S/L/C), an Ethernet EN7 module, expansion interface modules, and a power supply module which supplies power to these modules. This section describes the name and function of each module. Table 1-5 and table 1-6 list modules and basic base units, respectively, to be used for the L3 controller.
  • Page 26 Chapter 1 Overview of Loop Controller L3 Table 1-6 Basic Base Unit Name Type Description Station bus (4 slots) × 2 Basic base unit For duplex BU784 configuration For single BU748 Station bus (8 slots) + G3 I/O bus configuration BU746 Station bus (6 slots) + G3 I/O bus BU744...

  • Page 27: L3 Cpu Module

    1.6 Names and Functions of Modules 1.6.1 L3 CPU module L3PU11/L3PU21 The L3 CPU module executes process control (program). On the front panel, the module is provided with: • one RS-232C channel (D-sub male connector) for connection with the engineering tool, •...
  • Page 28 Chapter 1 Overview of Loop Controller L3 Figure 1-10 shows the front panel of L3 CPU module (L3PU21). 7-segment LED Status LED (RUN/HARD/SOFT/EXT) 7-segment display mode switch Mode switch (Key switch) (HALT/RUN/P-RUN) Engineering tool connector (TOOL: RS-232C) Maintenance connector (MAINT: RS-232C) Serial bus connector (SB: RS-485) Figure 1-10 Front Panel of L3 CPU Module (L3PU21)
  • Page 29 1.6 Names and Functions of Modules For the details of error, refer to the "model 2000/3000 Loop Controller S2/L3 User’s Manual - Functions" (6F8C0885). For each error that has occurred, the detail can be studied using the engineering tool. (2) 7-segment LED Indicates the operation status (RUN/HALT/ERROR mode) of the L3 controller by code.

  • Page 30: Power Supply Module

    Chapter 1 Overview of Loop Controller L3 (5) 7-segment display mode switch (Rotary switch) Used to switch 7-segment display modes. Table 1-11 Switch Position and Corresponding Display Mode Switch position 7-segment display mode Normal character display of operation mode Hexadecimal code display of operation mode Hexadecimal code display of error (Medium-category code) Hexadecimal code display of error (Small-category code) 4 to F...
  • Page 31 1.6 Names and Functions of Modules Figure 1-11 shows the front panel of power supply module (PS791/PS791S). Power LED Battery LED Fan stop LED Front cover Voltage check terminal (5 V) Voltage check terminal (3.3 V) Voltage check terminal (0 V) Voltage adjustment knob (5 V) Voltage adjustment knob (3.3 V) Reset detection voltage adjustment knob...
  • Page 32 Chapter 1 Overview of Loop Controller L3 IMPORTANT Absolutely do not touch the reset detection voltage adjustment knob during normal operation. This knob is used in the reset voltage test, and does not need adjustment during normal operation. (7) Fan power output terminals (FAN+, FAN-) Power supply terminal for a dedicated fan when connected.
  • Page 33 1.6 Names and Functions of Modules NOTE If the battery is abnormal or if no battery is installed, the battery LED (BATT) goes out or remains unlit, and the information is recorded in the error log. WARNING • The power supply module is a dedicated power source for the L3 controller. Be sure to install the power supply module on a dedicated basic base unit.

  • Page 34: Expansion Interface Module

    Chapter 1 Overview of Loop Controller L3 1.6.3 Expansion Interface Module Serial I/O Expansion Module (IF735) A serial I/O expansion module is used to expand the intelligent PI/O system for three additional lines. This module has serial bus connectors on the front panel. Figure 1-12 shows the front panel of serial I/O expansion module (IF735).
  • Page 35 1.6 Names and Functions of Modules (2) Serial bus connector (D-sub connector) Dedicated connector to connect serial bus. (RS-485 compliant) Direct I/O expansion module (IF741/IF721) A direct I/O expansion module is used to expand the G3 I/O bus for two or four additional lines.
  • Page 36 Chapter 1 Overview of Loop Controller L3 Figure 1-14 shows the front panel of direct I/O expansion module (IF721). Status LED Direct bus connector CH0: Channel 1 CH1: Channel 2 Figure 1-14 Front Panel of Direct I/O Expansion Module (IF721) Duplexing Interface Module (IF719) The module IF719 is used to exchange tracking data between the primary (P) and secondary (S) blocks of the L3 main unit in duplex configuration.
  • Page 37 1.6 Names and Functions of Modules Figure 1-15 shows the front panel of duplexing interface module (IF719) Status LED Tracking data (RUN) transmission/reception LED (TX/RX) Online/Standby LED (ONL/STBY) Primary/secondary switch (PRI/SEC) Tracking status/data connector (TS/TD) Figure 1-15 Front Panel of Duplexing Interface Module (IF719) 6F8C0882...
  • Page 38 Chapter 1 Overview of Loop Controller L3 (1) Status LED Indicates the operation status (RUN/ERROR mode) of the IF719. Table 1-13 Indication by Status LED Name of LED Indication ON: RUN mode OFF: ERROR mode (2) Online/Standby LED Indicates whether the L3 CPU module is online or standby. Table 1-14 LED Status for Online/Standby L3 CPU module Duplexing interface...
  • Page 39 1.6 Names and Functions of Modules Duplexing Interface Module (IF748/IF728) The IF748/IF728 is a duplexing interface module which provides direct I/O expansion function, as well as redundancy of transmission line. On its front panel, this module is provided with tracking status and data connectors, and direct bus connectors. Figure 1-16 shows the front panel of duplexing interface module (IF748).
  • Page 40 Chapter 1 Overview of Loop Controller L3 (1) Status LED Indicates the operation status (RUN/ERROR mode) of the IF748. Table 1-17 Indication by Status LED Name of LED Indication ON: RUN mode OFF: ERROR mode (2) Online/Standby LED Indicates whether the L3 CPU module is online or standby. Table 1-18 LED Status for Online/Standby L3 CPU module Duplexing interface...

  • Page 41: Basic Base Unit

    1.6 Names and Functions of Modules 1.6.4 Basic Base Unit BU748/BU746/BU744/BU742 The BU748/BU746/BU744/BU742 is a board unit for single configuration, which is equipped with a G3 I/O bus motherboard and a station bus motherboard. Fig. 1-17 is the front view of the BU748, along with standard module installation positions. PIF module installation slot Basic base unit G3 I/O access CPU module installation slot...

  • Page 42: Fan Unit

    Chapter 1 Overview of Loop Controller L3 BU784 The BU784 is a board unit for duplex configuration, which is equipped with a G3 I/O bus motherboard and a station bus motherboard. Fig. 1-19 is the front view of the BU784, along with standard module installation positions.

  • Page 43: Mounting, Dismounting & Cable Connection

    Chapter 2 Mounting, Dismounting & Cable Connection This chapter describes the methods for mounting/dismounting a base unit, a fan unit, and various modules, and for cable connection. Since the L3 controller is not dust-proof, it must be mounted in the control panel (console) that has incorporated dust-preventive measures.

  • Page 44: Mounting/Dismounting Of Base Unit And Fan Unit

    Chapter 2 Mounting, Dismounting & Cable Connection 2.1 Mounting/Dismounting of Base Unit and Fan Unit This section describes the method for mounting/dismounting a base unit and a fan unit. WARNING • Do not touch rotary parts when power is applied; injury can be caused. CAUTION •...

  • Page 45: Dismounting

    2.1 Mounting/Dismounting of Base Unit and Fan Unit 2.1.2 Dismounting Dismount the base unit/fan unit in the following procedure. (1) Loosen each of the four screws that fix the base unit/fan unit, by rotating it a few turns counterclockwise using a Phillips screwdriver. (2) Lift the base unit/fan unit so that the head of each fixing screw enters the larger section of each mounting hole, then remove the unit by pulling it to the operator side.

  • Page 46: Mounting/Dismounting Of Modules

    Chapter 2 Mounting, Dismounting & Cable Connection 2.2 Mounting/Dismounting of Modules This section describes the method for mounting each module on and dismounting it from the base unit. WARNING • Confirm that cable is not connected to the module to be mounted/dismounted. •...
  • Page 47 2.2 Mounting/Dismounting of Modules (4) Tighten each of two fixing screws (M4) at top and bottom of the module by rotating it clockwise with a Phillips screwdriver, to securely fix the module on the base unit. Figure 2-4 Fixing of Module CAUTION After inserting each module in the female connector, tighten the fixing screws immediately.

  • Page 48: Dismounting

    Chapter 2 Mounting, Dismounting & Cable Connection 2.2.2 Dismounting All modules, including the power supply module, can be dismounted from the base unit by the same method. Dismount each module in the following procedure. (1) Remove each of two fixing screws (M4) at top and bottom of the module by rotating it counterclockwise with a Phillips screwdriver.

  • Page 49: Mounting/Dismounting Of Line I/O Terminal Unit

    2.3 Mounting/Dismounting of Line I/O Terminal Unit 2.3 Mounting/Dismounting of Line I/O Terminal Unit The following paragraphs describe the method for mounting/dismounting the line I/O terminal unit of power supply module. WARNING Before work, check visually or with a tester that no external cable is connected to the line I/O terminal unit and that the unit is not in live state, i.e., no power is supplied to the unit.

  • Page 50: Connection Of External Cables To Line I/O Terminal Unit

    Chapter 2 Mounting, Dismounting & Cable Connection 2.4 Connection of External Cables to Line I/O Terminal Unit This section describes the method for connecting external cables to the line I/O terminal unit on the power supply module. WARNING • Before connecting external cable, make sure that power is not supplied to the cable. Other- wise, electrical shock can be caused.
  • Page 51 2.4 Connection of External Cables to Line I/O Terminal Unit (Red) (Yellow) Fan/Alarm input (Black) RUN relay output Exclusive Class-D grounding Figure 2-8 Cable Connection of Power Supply Module WARNING • Be sure to close the terminal unit cover after cable connection. Exposure of conducting parts after cable connection can cause electrical shock.

  • Page 52: Connection With Serial Bus

    Chapter 2 Mounting, Dismounting & Cable Connection 2.5 Connection with Serial Bus For connection between the L3 CPU module (or serial I/O expansion module) of the main unit and each communication base unit, connect the module with the serial bus, via a relay terminal unit, using relay cable.

  • Page 53: Connection With Engineering Tool

    2.6 Connection with Engineering Tool 2.6 Connection with Engineering Tool For connection between the L3 CPU module and the engineering tool, use dedicated cable with an RS-232C-compliant connector. Cable connection method is described below. CAUTION • Use a screwdriver suitable to connector-fastening screws. Otherwise, the screws can be damaged.

  • Page 55: Installation & Wiring

    Chapter 3 Installation & Wiring This chapter describes the required installation environment and grounding of the L3 controller. 6F8C0882...

  • Page 56: Installation Environment

    Chapter 3 Installation & Wiring 3.1 Installation Environment Regarding the system to which the L3 controller is to be introduced, the following paragraphs describe the requirements of control room in which equipment is to be installed, environmental conditions, and power supply equipment. Carefully study these requirements before making a plan.

  • Page 57: Environmental Conditions

    3.1 Installation Environment 3.1.2 Environmental Conditions Avoid installing the L3 controller in any location where: • the ambient temperature can fall out of the range between 0 C and 55 • the relative humidity can fall out of the range between 20% and 90%; •...
  • Page 58 Chapter 3 Installation & Wiring • If the L3 controller is to be used under power conditions other than the above, it is necessary to install an insulating transformer to adjust the voltage. In such a case, contact our sales department. •...

  • Page 59: Carrying-In & Installation

    3.2 Carrying-in & Installation 3.2 Carrying-in & Installation Since the equipment is considerably large in both weight and size, prepare a plan to carry the equipment to the installation site, in advance. To carry and install the equipment in a short time without any problem or accident, check the transportation passage, the parking space for trucks, etc.

  • Page 60: Unpacking

    Chapter 3 Installation & Wiring (5) Carefully handle each package, paying attention to the handling mark on it (Figure 3- Indicating vertical orientation Indicating sling points Indicating that the content is Indicating the fragile and center of balance must be handled carefully Indicating that the cargo...

  • Page 61: Carrying-In

    3.2 Carrying-in & Installation 1800mm 800mm 800mm 600mm Required height: Required height: Height of console + Height of Height of console + Height 1000 mm min. carrying device of carrying device 1500 mm min. For train of three consoles For a single console Figure 3-4 Dimensions of Carry-in Entrance and Passage (Example) 3.2.5 Carrying-in...

  • Page 62: Installation

    Chapter 3 Installation & Wiring 3.2.6 Installation Prior to installing equipment, check that the location, anchor bolt positions, and cable through-hole positions comply with the drawing. Confirm that anchor bolt positions of each equipment are proper relative to the channel base. It is recommended to fix the equipment by the following method.
  • Page 63 3.2 Carrying-in & Installation Fixing of peripheral equipment Peripheral equipment need not be fixed as a rule. If necessary, fix peripheral equipment using the same method as for the console. Checking after installation Upon completion of installation, confirm the following items: •...

  • Page 64: Example Of Console-Mounted L3

    Chapter 3 Installation & Wiring 3.3 Example of Console-mounted L3 Figure 3-8 shows an example of the L3 controller mounted on a console. In this example, a main unit, an incoming/distributing unit, a terminal unit, etc. have been mounted in the console. I/O system power supply unit External power supply unit Fan unit...

  • Page 65: Mounting Of External Power Supply Unit And I/O System Power Supply Unit

    3.3 Example of Console-mounted L3 3.3.2 Mounting of External Power Supply Unit and I/O System Power Supply Unit In mounting an external power supply unit and an I/O system power supply unit, meet the conditions specified in figure 3-9. 15 mm min. External power supply unit or I/O system power supply unit 10 mm...

  • Page 66: Grounding Of L3 Controller

    Chapter 3 Installation & Wiring 3.4 Grounding of L3 Controller Grounding is important to ensure safe and stable system operation. Ground the L3 controller properly, taking account of the requirements specified in the following paragraphs. To ground the L3 controller, connect the ground terminals of each cubicle, console, line filter, I/O power supply, etc., as well as the shield of external signal cable, all together to the ground terminal of the incoming/distributing unit or peripheral equipment.
  • Page 67 3.4 Grounding of L3 Controller Separation from other equipment To avoid influence of grounding current of other equipment, separate the L3 controller from other equipment so that the grounding current does not flow through the controller. Separate the grounding conductor of the L3 controller from that of a power system that contains high-frequency equipment.

  • Page 68: Grounding Electrode

    Chapter 3 Installation & Wiring 3.4.2 Grounding Electrode Prepare grounding electrodes exclusive for the L3 controller. Ground resistance must be 100 Ω or less (equivalent to Class-D grounding). 3.4.3 Ground Bus The following paragraphs describe the ground bus. INSTRUCTIONS • Use 8 mm (AWG #8) or thicker cable for ground bus.
  • Page 69 3.4 Grounding of L3 Controller • Frame ground (FG) terminal The FG terminal is a ground terminal of the L3 controller. The metal portion of base unit has the same potential as the FG terminal. To prevent static electrification and ensure safe operation, be sure to connect the FG terminal to one ground point.

  • Page 70: Example Grounding Work

    Chapter 3 Installation & Wiring 3.4.4 Example Grounding Work Figure 3-15 shows example grounding work. Serial-grounding cable must be laid along the transmission line, as isolated from power supply line and cable that can electromagnetic induction. Where these cables are in parallel, each cable must be spaced from others.

  • Page 71: After Wiring Work

    3.5 After Wiring Work 3.5 After Wiring Work Upon completion of wiring work, confirm the following, and take necessary dust- preventive measures. • Cable numbers and connector numbers conform to the drawing. • Connectors or terminal screws are not loose. •...

  • Page 73: Startup & Shutdown

    Chapter 4 Startup & Shutdown This chapter describes the methods for confirming switch settings before startup, and LED status after startup, as well as the startup and shutdown procedures for L3 controller. NOTE • After installation or replacement of the L3 controller, clear the memory of the L3 controller. For the method, refer to Section 5.3 "Memory Clear"...

  • Page 74: Confirmation Of Switch Settings

    Chapter 4 Startup & Shutdown 4.1 Confirmation of Switch Settings 4.1.1 L3 CPU Module The L3 CPU module is provided with three kinds of switches: default setting switch, 7- segment display mode switch, and mode switch. The settings of these switches are the same regardless of whether the L3 controller is used in single or duplex configuration.

  • Page 75: Duplexing Interface Module (If719/If728/If748)

    4.1 Confirmation of Switch Settings Mode switch The mode switch is a key switch with three positions: "HALT", "RUN", and "P-RUN". To start the L3 controller normally, i.e., by turning on the power switch, position this switch to "HALT". Figure 4-3 Mode Switch This switch is used to select the operation mode of the L3 CPU module.

  • Page 76: Startup

    Chapter 4 Startup & Shutdown 4.2 Startup For safer operation of the L3 controller, configure the external power supply circuitry so that power is ON in the following sequence. Has L3 controller been replaced or installed? [1] Power ON of L3 controller [2] Power ON of I/O module external Clear the memory of L3 controller.
  • Page 77 4.2 Startup (3) The primary L3 CPU module and the secondary L3 CPU module are booted as online and standby modules, respectively, in the following sequence. Table 4-3 Operation Sequence and 7-segment LED Indication Primary Secondary Operation 7-segment LED Operation 7-segment LED Set the mode switch Set the mode switch to...
  • Page 78 Chapter 4 Startup & Shutdown CAUTION • Configure the external power supply circuitry so that power is ON in the following sequence: Power ON of L3 controller Power ON of I/O module external power supply and load power • Power on in other sequence can cause system malfunction, possibly resulting in equipment damage or accident.

  • Page 79: Shutdown

    4.3 Shutdown 4.3 Shutdown For safer operation of the L3 controller, configure the external power supply circuitry so that power is off in the following sequence. [1] Power OFF of I/O module external power supply and load power supply [2] Power OFF of L3 controller First, change the operation mode of the L3 CPU module to be turned off.

  • Page 80: Confirmation Of Led Status

    Chapter 4 Startup & Shutdown 4.4 Confirmation of LED Status After starting the L3 controller, confirm the status of status LED and 7-segment LED on the L3 CPU module. 4.4.1 LED Status on L3 CPU Module in Single Configuration When the L3 CPU module has booted normaly, all status LEDs (RUN/HARD/SOFT) light, and the 7-segment LED indicates [On].
  • Page 81 4.4 Confirmation of LED Status • When the online L3 CPU module is transmitting control data to the standby module to equalize control data, all status LEDs (RUN/HARD/SOFT) are lit, and the 7-segment LED indicates [EL]. On the duplexing interface module, "ONL" LED blinks, and "STBY"...

  • Page 83: Troubleshooting

    Chapter 5 Troubleshooting If an error or failure occurs in the L3 controller, the status LED, the 7-segment LED, and the trace function show the error. To check the detail of the error, connect the engineering tool with the L3 controller. If the error can not be eliminated on the customer side, contact our service staff.

  • Page 84: Status Led Indication

    Chapter 5 Troubleshooting 5.1 Status LED Indication Table 5-1 shows the condition under which each status LED on the L3 CPU module front panel lights. To confirm the detail of each error, connect the engineering tool to the L3 controller. Table 5-1 Status LED Indication on L3 CPU Module Status Indication...

  • Page 85: Trace Function

    5.2 Trace Function 5.2 Trace Function The L3 controller incorporates the function for self-diagnosis by hardware and software. If an error occurs, the detail of the error is recorded in the internal log, so that it can be read by the engineering tool when required. It is also possible to record the performance of the L3 controller, as well as the contents of operation and data transmission.

  • Page 86: Memory Clear

    Chapter 5 Troubleshooting 5.3 Memory Clear This section describes the method for clearing all memory area of the L3 CPU module. Clearing of all memory area is necessary after replacement or installation of the L3 CPU module, or for initialization after error rundown. Normally, do not carry out this memory clear operation.

  • Page 87: Formatting Of E2Prom

    5.4 Formatting of E2PROM 5.4 Formatting of E PROM If an error attributed to the E PROM of the L3 CPU module has occurred, it is necessary to format the E PROM, for initialization. Do not format the E PROM during ordinary operation.

  • Page 88: Error Reset

    Chapter 5 Troubleshooting 5.5 Error Reset When an error occurs in the L3 CPU module, it must be analyzed to remove the cause, and error reset operation must be conducted before rebooting of the CPU module. There are two error reset methods: •...

  • Page 89: Forced Startup

    5.6 Forced Startup 5.6 Forced Startup RUN execution with tracking cable broken If the L3 controller in duplex configuration executes RUN with the tracking cable disconnected, an error occurs due to abnormality of disconnected tracking cable. If either primary or secondary L3 main unit is mounted in the L3 controller duplex configuration, it is not possible to execute RUN, since tracking cable cannot be connected.

  • Page 91: Maintenance & Inspection

    Chapter 6 Maintenance & Inspection To ensure safe and proper operation of the L3 controller, be sure to carry out routine and periodical inspections. 6F8C0882...

  • Page 92: Routine Inspection

    Chapter 6 Maintenance & Inspection 6.1 Routine Inspection For routine inspection, check the following items with the L3 controller in operation. (1) Power supply module (PS791/PS791S) • Check that "POWER" LED is lit. If it is not lit, measure output voltage at voltage check terminals (5 and 3.3 V), to confirm that the voltage values are 5.1 ±...

  • Page 93: Periodical Inspection

    6.2 Periodical Inspection 6.2 Periodical Inspection Check the following items periodically (once every six months or so). (1) Reading of error trace record Connect the engineering tool to the L3 CPU module, to read error trace record. If any error has been recorded, check if the same erroneous phenomenon can occur repeatedly.
  • Page 94 Chapter 6 Maintenance & Inspection CAUTION • Take great care when measuring voltage at an AC power input terminal with power supplied. There is a danger of electrical shock. (10) Measurement of output voltage Measure output voltage at voltage check terminals (5 and 3.3 V), to confirm that the voltage values are 5.1 ±...
  • Page 95 6.2 Periodical Inspection Table 6-1 specifies the service life of some typical components of the L3 controller. Table 6-1 Service Life Recommended Deteriorating Model Maintenance Recommended No. Part name Symptom Nominal life replacement part name method measure cycle Lithium Discharge Consumed PS791/ Periodical Replace...

  • Page 96: Consumables

    Dispose of used batteries properly in accordance with the local government's ordinance or regulation. Part name: Lithium battery Model: ER6-CF (manufactured by Toshiba) WARNING • Absolutely do not charge, disassemble, convert or heat the lithium battery, nor put it in fire.

  • Page 97: Checking And Adjustment Of Output Voltage

    6.3 Consumables CAUTION Connect the battery in correct orientation. Reverse connection causes failure and malfunction. (5) Confirm that the "BATT" LED is lit. (6) Mount the front cover. NOTE When the battery is removed, the "BATT" lamp may light momentarily, the information being recorded in the log of the L3 CPU module.
  • Page 98 Chapter 6 Maintenance & Inspection Adjustment of output voltage Output voltage can be adjusted with the voltage adjustment knobs. Turn an appropriate voltage adjustment knob using a precision minus screwdriver. Clockwise turning increases voltage; counterclockwise turning decreases voltage. CAUTION Do not move the voltage adjustment knobs (5 V and 3.3 V) or the reset detection voltage adjustment knob while the L3 controller is operating.

  • Page 99: A Table Of Specifications

    Appendix A Table of Specifications The following pages give the general specifications, functional specifications, hardware specifications, and transmission-related specifications of the L3 controller. 6F8C0882...

  • Page 100: General Specifications

    Appendix A Table of Specifications A.1 General Specifications Table A-1 General Specifications Item Specification Rated voltage & frequency 100/200 Vac, 50/60 Hz 24 Vdc Allowable voltage & 85 to 132 Vac, 170 to 264 Vac, 47 to 63 Hz 20.4 to 28.8 Vdc frequency Current input (Primary side) 100 Vac - 1.8 A, 200 Vac - 0.9 A 24 Vdc - 6.3 A...

  • Page 101: Functional Specifications

    A.2 Functional Specifications A.2 Functional Specifications Table A-2 Functional Specifications Item Specification Control mode RUN/HALT/ERROR Program language IEC61131-3 compliant languages: • Instruction List (IL), • Structured Text (ST), • Ladder Diagram (LD), • Function Block Diagram (FBD), • Sequential Function Chart (SFC) Program capacity 2048 POU Program...
  • Page 102 Appendix A Table of Specifications Table A-2 Functional Specifications Item Specification Diagnosis function • Parity check • Memory diagnosis (Parity, R/W check) • Memory response check • ROM BCC check • I/O diagnosis • Legal instruction check • Program information check •...

  • Page 103: Hardware Specifications

    A.3 Hardware Specifications A.3 Hardware Specifications A.3.1 L3 CPU Module (L3PU11/L3PU21) Table A-3 L3 CPU Module Hardware Specifications Item Specification Processor General-purpose 32-bit processor Memory ROM 2 MB 8 MB (DRAM) 2 MB (SRAM with battery backup) Serial bus One line for standard specification Expandable with three additional lines (by using IF735) Direct bus One line for standard specification...

  • Page 104: Duplexing Interface Module (If719)

    Appendix A Table of Specifications A.3.3 Duplexing Interface Module (IF719) Table A-5 Duplexing Interface Module Hardware Specifications Item Specification Tracking method Serial tracking Cable length TS cable 6 m max. TD cable 6 m max. Tracking data transfer TS data 128 kbps max.
  • Page 105 A.3 Hardware Specifications Table A-7 Power Supply Module Hardware Specifications (Functional) Item Specification Status indicator POWER (5 Vdc output, green) BATT (Battery, green) FAN (Fan stop, red) RUN relay Dry A contact (240 Vac/24 Vdc - 0.2 A max) Cooling fan Applicable fan: FA714 To be externally mounted (Cooling by air-blowing from underside)

  • Page 106: Cables

    Appendix A Table of Specifications A.4 Cables The cables used in the L3 controller are shown in the following. A.4.1 Special Cable for Engineering Tool Type: ZCDEYAA***1 Figure A-1 Special Cable for Engineering Tool A.4.2 Serial Bus Relay Cable Type: ZCS010A***1 Figure A-2 Serial Bus Relay Cable model 3000 Loop Controller L3 User’s Manual - Basic Hardware -...

  • Page 107: Tracking Data Cable (Td)

    A.4 Cables A.4.3 Tracking Data Cable (TD) Type: GCY7** A.4.4 Tracking Status Cable (TS) Type: GCX7** 6F8C0882...

  • Page 109: B Outline Drawing

    Appendix B Outline Drawing B.1 Basic Base Unit (BU748) Figure B-1 Dimensional Outline Drawing of Basic Base Unit (BU748) 6F8C0882...

  • Page 110: L3 Cpu Module (L3Pu11/L3Pu21)

    Appendix B Outline Drawing B.2 L3 CPU Module (L3PU11/L3PU21) Ｌ３ＰＵ１１ Ｌ３ＰＵ２１ HARD HARD SOFT SOFT HALT RUN P-RUN HALT RUN P-RUN TooL TooL MAINT MAINT Figure B-2 Dimensional Outline Drawing of L3 CPU Module (L3PU11/L3PU21) model 3000 Loop Controller L3 User’s Manual - Basic Hardware -...

  • Page 111: Power Supply Module (Ps791/Ps791S/Ps735)

    B.3 Power Supply Module (PS791/PS791S/PS735) B.3 Power Supply Module (PS791/PS791S/PS735) PS791/791S PS735 ＰＳ７９１ ＰＳ７９１ ＰＳ７９１ ＰＳ７９１ P S 7 3 5 P S 7 3 5 P S 7 3 5 P S 7 3 5 POWER POWER BATT BATT 5 5 5 5 5 5 5 5 0 0 0 0...

  • Page 112: Serial I/O Expansion Module (If735)

    Appendix B Outline Drawing B.4 Serial I/O Expansion Module (IF735) ＩＦ７３５ ACK1 ACK2 ACK3 Figure B-4 Dimensional Outline Drawing of Serial I/O Expansion Module (IF735) model 3000 Loop Controller L3 User’s Manual - Basic Hardware -...

  • Page 113: Duplexing Interface Module (If719)

    B.5 Duplexing Interface Module (IF719) B.5 Duplexing Interface Module (IF719) IF719 STBY TS TS TD TD Figure B-5 Dimensional Outline Drawing of Duplexing Interface Module (IF719) 6F8C0882...

  • Page 115: C Table Of Trace Information

    Appendix C Table of Trace Information C.1 Error Trace Execution Event Level Timing Diagnosis Task Address Aux1 Aux2 Aux3 Cause Actions to be taken status C000 Hardware Major Initialization Error rundown Abnormal Failure of peripheral Replace module. initialization failure diagnosis hardware has error been detected...
  • Page 116 Appendix C Table of Trace Information Execution Event Level Timing Diagnosis Task Address Aux1 Aux2 Aux3 Cause Actions to be taken status C00D Daughter Major Periodical Error rundown Status Status Number of For CPU card with Replace and reboot CPU board failure diagnosis...
  • Page 117 C.1 Error Trace Execution Event Level Timing Diagnosis Task Address Aux1 Aux2 Aux3 Cause Actions to be taken status C118 Major Error rundown Write error has Status Replace and reboot CPU PROM Failure of E PROM failure occurred when module, or contact our service packing write code memory is staff.
  • Page 118 Appendix C Table of Trace Information Execution Event Level Timing Diagnosis Task Address Aux1 Aux2 Aux3 Cause Actions to be taken status 0E05 Temperature Recovery Periodical Continued Temperature abnormality from diagnosis abnormality corrected failure around CPU has been corrected. Registration 7000 Packing Caution...
  • Page 119 C.1 Error Trace Execution Event Level Timing Diagnosis Task Address Aux1 Aux2 Aux3 Cause Actions to be taken status 7113 User task Caution During user Continued Arithmetic IP (Absolute) IP By INT type addition Correct user task so that the limit overflow error task operation result...
  • Page 120 Appendix C Table of Trace Information Execution Event Level Timing Diagnosis Task Address Aux1 Aux2 Aux3 Cause Actions to be taken status 3206 User task Minor During user Task fallback Number of IP (Absolute) IP Compilation is not After completing compilation fallback failure task...

  • Page 121: Event Trace

    C.2 Event Trace C.2 Event Trace Execution Event Timing Description Aux1 Aux2 Aux3 status Power supply 0000 Power ON Power ON/ reset 0001 Reset Power ON/ reset 0002 Power OFF Power ON/ reset Operation mode transition 0101 Error rundown 0102 Initialize Only at the time of starting after long-term shutdown...
  • Page 122 Appendix C Table of Trace Information Execution Event Timing Description Aux1 Aux2 Aux3 status 0128 (EQL-H2W) Preparing for transmission of equalizing PHASE signal 012A (RCV-R1) Receiving equalizing signal PHASE 012B (RCV-R2) Receiving equalizing signal PHASE 012C (RCV-R3) Receiving equalizing signal PHASE 012D (RCV-H1)
  • Page 123 C.2 Event Trace Execution Event Timing Description Aux1 Aux2 Aux3 status 1110 Task execution permit 1111 Sub-schedule change 1112 Grouping change 1113 Intervention trace clear 1114 Error trace clear 1115 Event trace clear 1116 Transmission trace clear 1117 Connection management information register 1118 Connection table information...

  • Page 125: Index

    INDEX Index Ethernet control LAN 2, 55 NUMBER Expansion unit 10BASE2 10BASE5 7-segment LED Fan unit 18, 55 Frame ground 53, 55 Frame ground terminal Basic base unit 2, 3, 30 Battery IEC61131-3 Class-D grounding CPU module L3 controller 1, 2 L3 CPU module L3PU11 L3PU21...
  • Page 126 INDEX Maintenance 15, 16, 60 23, 24, 25, 26 Mode 14, 15 Mode switch 15, 16, 60, 61 Module Temperature sensor Motherboard Test program run Multi-controller Tracking 22, 24, 26 Voltage adjustment knobs Voltage check terminals Online 24, 26 Power input terminals Primary 24, 26 Primary/secondary...
  • Page 127 3000 Loop Controller L3 User’s Manual - Basic Hardware - 1st edition 14th Feb 2001 0882.0.0102 TOSHIBA CORPORATION INFORMATION AND INDUSTRIAL SYSTEMS & SERVICE COMPANY SYSTEM COMPONENTS DIVISION 1-1, Shibaura 1-chome, Minato-ku, Tokyo 105-8001, Japan Tel.:+81-3-3457-4900 Fax.:+81-3-5444-9268  TOSHIBA Corporation 2000 All Right Reserved.
  • Page 130 6E8C0882...

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