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PART 1 T1-16S Programmer Port Function

1.1 Computer link function
The T1-16S’s programmer port mendukung computer link function sama baiknya komunikasi dengan programming tool.
The programmer port dapat menerima T-series computer link commands. By preparing the communication software based on the protocol described in this manual in the master computer (computer, operator interface unit, etc.), the following functions become available by the master computer.
• Reading data (register/device value) from the T1-16S
• Writing data (register/device value) into the T1-16S
• Monitoring the T1-16S’s operation status (RUN/HALT/ERROR)
• Reading the error code from the T1-16S
• Reading the clock/calendar data from the T1-16S
• Writing the clock/calendar data into the T1-16S
• Controlling the T1-16S operation mode
• Program up-loading from the T1-16S
• Program down-loading into the T1-16S
Using the computer link function, you can connect a master computer or an operator interface unit with the T1-16S, and can configure a SCADA/MMI system.

1.2 System configuration
The interface of the T1-16S’s programmer port is RS-232C. Without using a conversion adapter, the RS-232C serial port of the master computer can be connected to the T1-16S’s programmer port directly. (One-to-one configuration)
One-to-one configuration:

On the other hand, when two or more T1-16S’s are connected with a master computer, the multi-drop adapters (CU111) can be used. (One-to-N configuration)
One-to-N configuration:

• The CU111 is the RS-232C/RS-485 converter dedicated for the T1-series PLC.
  
• If the master computer has RS-232C interface but not RS- 485, the RS-232C/RS-485 converter (ADP-6237B) can be used.

1.3 Communication overview
In the computer link system, the T1-16S waits for receiving a request message issued from the master computer. When a request message is issued, the T1-16S checks the station number contained in the request message. And when the station number designation matches the T1-16S’s station number setting, the T1-16S processes the request and returns the response. This is why each T1-16S must have a unique station number in the one-to-N configuration. Otherwise, more than one T1-16S may attempt to process the request, resulting in faulty response. The following figure illustrates the processing sequence executed when a request to station number 3 is issued.

1. The request message is sent from the master to all the connected T1-16S. (request for station #3 in this example)
2. The request message is interpreted and processed in the T1-16S which has the same station number as request. (station #3 T1-16S in this example)
3. Processing result is returned as response to the master.
Note: Available station number is 1 to 32. The station number is set in the special
register SW36. Refer to sections 4.1.

2.1 Transmission specifications

Note:
(1) The station number and parity (odd or none) can be set by user. Transmission speed, start bit, data bit, and stop bit settings are fixed as above. Refer to sections 4.1 and 4.2.
(2) The response delay time can be set by user. (0 to 300 ms, 10 ms units) Refer to section 4.3.
2.2 Optional computer link cable
The 2 m cable used to connect the T1-16S’s programmer port connector with a master computer is optionally available. (Type: PT16S)

Note: Wires of pins 1, 2 and 3 are not used for RS-232C transmission. Do not connect these wires.
3.1 One-to-one configuration
When one T1-16S is connected to a master computer, the cable connections should be as follows. The optional computer link cable (PT16S) is used for the connection.

• Wires of brown, red and orange should not be connected. These wires should be terminated without connecting each other.
• RTS signal of the T1-16S is always ON.
• The T1-16S can transmit data when CTS signal is ON.
Using the multi-drop adapter CU111, one-to-one connection via RS-485 is also available. In this case, the RS-232C/RS-485 converter ADP-6237B can be used.

• Short RXA and TERM (TRM) terminals at both the CU111 and the ADP-6237B.
• Use shielded twisted-pair cable for noise immunity. The cable shield should be connected to ground.
3.2 One-to-N configuration
By using the multi-drop adapter CU111, two or more T1-16S’s (up to 32) can be connected to a master computer. In this case, the RS-485 transmission line should be terminated at both ends.

Termination resistors (1/2 W - 220 Ω) should be connected between TXA and TXB, and RXA and RXB, at each end of the line (at both termination stations).

• Connect termination resistors (1/2 W - 220 Ω) between TXA and TXB, and RXA and RXB, at each end of the line (at both termination stations).
• Use shielded twisted-pair cable for noise immunity. Connect the cable shield each other, and connect it to ground. (Single point grounding)
• When a terminal block is used to branch off the line, the branch should not exceed 3 m cable length from the terminal block to the CU111 or the master computer.
• For RS-232C side connections, refer to section 3.1.
4.1 Station number setting
The station number is set by writing the data into the special register SW36. The valid station number data is 1 to 32 (decimal). Turn the T1-16S to HALT mode, and write the station number into SW36. After writing, execute the EEPROM write command. And cycle power off and on again. Then the setting will be effective.

Note:
(1) The default setting of the station number is 1.
(2) If the data is out of the valid range, the T1-16S works as station 1.
The SW36 setting is saved in the program storage module RM102 (ver. 2 or later). Therefore, when you save the T1-16S program into the RM102 then load it into another T1-16S, the original SW36 setting will be copied. However, in case of the T-PDS, the SW36 setting is not saved in the disk file. Therefore even when you load the T1-16S program by the T-PDS, you must set the SW36 data for the T1-16S manually as mentioned above.
4.2 Parity setting
Parity setting can be selected either odd or none. The even parity is not supported. The default is odd parity. The none parity is normally used for modem connection. The parity is set by writing the data into the special register SW37. The valid data is 1 or 2. Turn the T1-16S to HALT mode, and write the parity setting (0 = none, 1 = odd) into SW37. After writing, execute the EEPROM write command. And cycle power off and on again. Then the setting will be effective.

(1) The default setting of the parity is odd.
(2) If the data is out of the valid range, the T1-16S works as odd parity.
The SW37 setting is saved in the program storage module RM102 (ver. 2 or later). Therefore, when you save the T1-16S program into the RM102 then load it into another T1-16S, the original SW37 setting will be copied. However, in case of the T-PDS, the SW37 setting is not saved in the disk file. Therefore even when you load the T1-16S program by the T-PDS, you must set the SW37 data for the T1-16S manually as mentioned above.
4.3 Response delay time setting
The response time from the programmer port of the T1-16S can be changed. The possible setting is as follows.
Internal processing time + (0 to 300) ms (10 ms units)
This function is useful when a wire-less modem is used. To set the response delay time, turn the T1-16S to HALT mode, and write the delay time (0 to 30) into SW38. After writing, execute the EEPROM write command. And cycle power off and on again. Then the setting will be effective.

(1) The default setting is 0. (Minimum delay)
(2) If the set data is out of the valid range, it is limited by 30 (300 ms).
The SW38 setting is saved in the program storage module RM102 (ver. 2 or later). Therefore, when you save the T1-16S program into the RM102 then load it into another T1-16S, the original SW38 setting will be copied. However, in case of the T-PDS, the SW38 setting is not saved in the disk file. Therefore even when you load the T1-16S program by the T-PDS, you must set the SW38 data for the T1-16S manually as mentioned above.
4.4 Peripheral support priority mode
In the T1-16S, the peripheral support processing (computer link service) is executed at the bottom of each scan with the time limit of 2 ms to minimize the extension of the scan time. However the T1-16S can work with the peripheral support priority mode. In this mode, the computer link service is executed without a break. By using this mode, the communication response becomes quick although the scan time may be extended at the time.
To select the peripheral support priority mode, set the special relay S158 to ON by user program.

Cascade Control

Dalam beberapa aplikasi, 2 PID controllers digunakan dal kombinasi. Dalam konfigurasi ini, MV (manipulated variable) dari primary PID controller dihubungkan ke SV(set point) dari secondary PID controller. Ini disebut cascade control. Kelebihan dari cascade control is quicker suppression of disturbances or upsets. That is, the secondary PID loop is expected to suppress errors before their influence appears on the PV of the primary PID loop.

The figure below shows an example of cascade control.

Cascade control is effective only when the response of the secondary process is much faster than the primary process. In the above example, the primary loop is for temperature and the secondary loop is for flow rate. Normally, response of temperature control loop is far slower than the flow loop. In this example configuration, cascade control can be effective.
In cascade control, the MV tracking function in the primary PID is required. This function provides bumpless transfer when the secondary PID changes from the local auto mode to the cascade mode. Then, the MV of the primary PID tracks the local SV of the secondary PID when the secondary PID is in local mode.

NOTE: The PID3 instruction supports the cascade mode and MV tracking.

PID control system

Normally the PID function is used to control process variables such as temperature, pressure, liquid level, or flow rate. The PID controller receives the process variable (PV) and controls the manipulation variable (MV) in order to adjust the PV to match the set value (SV). The figure below shows a typical configuration for a PID control system.

In the above figure:
Process: A reaction which is controlled by physical values such as temperature, pressure, flow rate, etc.
Sensor: A detector that detects the controlled physical values. It can be a thermocouple, RTD, pressure gage, flow meter, etc.
Signal Converter: A device that transmits a weak sensor signal to the PID controller by converting it into the signal suited for the environment such as 4 - 20 mA, 1 - 5 Vdc, pulse train, etc.
Actuator: A device that regulates fluid or electric power to the process according to the signal generated by the PID controller. It can be a control valve, thyristor, variable speed drive, etc.
PV: Process variable ... normally 4 - 20 mA or 1 - 5 Vdc analog signals
MV: Manipulation variable ... normally 4 - 20 mA, 1 - 5 Vdc or a time-proportional pulse.
SV: Set value.
PID Equation: Controls the MV based on the magnitude of e and De and the PID tuning parameters. These parameters may be more or less aggressive based on system time responses and operator preferences.

PID Basics

1. Direct action and reverse action
   There are two basic actions of PID with respect to the control direction of MV. These are direct action and reverse action.
   · Direct action will lead the MV to increase when the PV is larger than the SV.
   (For example, cooling application)
   · Reverse action will lead the MV to decrease when the PV is larger than the SV.
   (For example, heating application)
   
2. PID Parameters

• Proportional (P) control action
  Proportional (P) control generates the MV in proportion to the error (E). Here, the error (E) is the difference between the SV and the PV, and defined as follows:
  E = SV-PV
  In the P control action, the MV is calculated as follows.
  MV=KP×E
  KP is called proportional gain.
  Generally, P control action works as follows:
  
  With just P control, an offset (residual error) will remain. Therefore, P control is used with I control (PI control) to eliminate the offset.
  
• Integral (I) control action
  Integral (I) control will generate the MV in proportion to the time-integral of the error (E). While the error (E) exists, the I control will modulate the MV to eliminate the error (E). Generally the MV with I control is calculated as follows:
  
  TI is called integral time, the unit of measure is ‘seconds per repeat’
  When TI is large, the MV will change slowly. When TI is small, the MV will change rapidly. That is, the smaller the TI, the larger the integral gain. When TI is too small, oscillation of PV will appear as figure below.
  
  The I control is not used by itself. It is used with P (PI control) or P and D (PID control).
  NOTE: When the SV is changed, E may remain for a relatively long time, and the MV may reach either its minimum or maximum value. If I continues to integrate beyond this point there will be a significant lag time in response to an overshoot (a change in the direction of E). This problem is called ‘reset windup’, the name originating with pneumatic controls and their ‘gain, reset and rate’ tuning parameters. To prevent this, the PID3 instruction has a feature called anti-reset windup, which stops the I control action when the MV reaches its limit.
  
• Derivative (D) control action
  Derivative (D) control will generate the MV in proportion to the rate of change in the error (E). By adding the D control, quick corrective action can be obtained at the beginning of an upset condition. Generally the MV by the D control is written as follows.
  
  TD is called derivative time, the unit of measure is ‘repeats per second’.
  When TD is large, MV is relatively large for any E. That is, the larger the TD, the larger the derivative gain. If TD is 0 (zero), the D control does not function. When TD is too large, short periodic oscillations of PV will appear:
  
  The D control is not used by itself. It is used with P and I (PID control). D control is poorly suited for processes which oscillate rapidly and is seldom used in processes which have a fast response time (most pressure or flow loops). For processes with long lag times (many temperature and some level loops), D control can reduce both the magnitude of e and the potential for large overshoots caused by a given upset condition. Note that these same processes often act as mechanical integrators and the I tuning parameter can actually stimulate a worsening of the overshoot or oscillationproblem.

NOTE: The above equation for the D control is the complete derivative. However, for the actual process, such complete derivative action is harmful. Therefore, in the PID3, an incomplete derivative action is used. Also, in the PID3, derivative is applied only for a change in PV, not for the error. This is called pre-derivative PID. This method is used to prevent the unnecessary large changing of the MV for the SV is being changed.

Operation Mode
Generally a PID controller has two operation modes, Auto mode and Manual mode. Auto mode is the mode in which the MV is controlled by the PID equation. Manual mode is the mode in which the MV is changed by operator.
When the operation mode is changed from Manual to Auto, and vice versa, the MV should not be changed rapidly (bumped). Normally a PID controller has a function that enables it to hold the current MV during mode changes. This function is called bumpless transfer.
Some PID algorithms have a function called SV(Set point) tracking. When the SV tracking function is enabled, the SV is automatically over-written by the current PV during Manual mode. As the result, when the mode is changed from Manual to Auto, the control operation continues smoothly, since the SV and the PV are identical. A frequent operator complaint about SV tracking is that the SV must always be re-entered after each change from manual to auto mode. Therefore when SV tracking is implemented in a PID algorithm a manual switch is normally provided to allow operators the option of disabling it.
NOTE: In the PID3 instruction, a bumpless transfer function is available. The PID3 does not have the SV tracking function. However, this function can be easily programmed into preceding circuits in the PLC. See section 4.4, “Adding SV Tracking”

References :

• PROGRAMMABLE CONTROLLER PROSEC T-series. APPLICATION GUIDE - PID Function - . TOSHIBA CORPORATION
  
• Balchen, Jens G. and Kenneth I. Mumme. Process Control, Structures and Applications. New York: Van Nostrand Reinhold Company, 1988.
  
• Anderson, Norman A. Instrumentation for Process Measurement and Control. 3rd ed.
  Rednor, PA: Chilton Company, 1980. Intech December 1994, Controller Tuning and Control Loop Performance by David W. St. Clair of Straight-Line Control Company at 302-731-4699.
  
• Corripio, Armando B. Tuning of Industrial Control Systems. Instrumentation Society of America, 1990.
  
• Shinskey, F.G. Process Control Systems. 3rd ed. New York, NY. McGraw-Hill Book Company, 1988.

PLC - Inverter Connection

The Inverter connection mode is provided to communicate with the Toshiba Inverters (ASDs) VF-A7, G7, and/or S9 through the RS-485 line. By using this mode, the T1-16S(PLC) can monitor/control the Inverters connected on the RS-485 line without any special communication program. Jumlah maksimal Inverter yang bisa dihubungkan pada T!-16S adalah 64. Dengan catatan jumlah maksimal titik pada line RS-485 adalah 32. However the RS-485 adapter that is the peripheral device of Toshiba Inverter supports 2 communication ports to Inverters. Therefore more than 32 Inverters can be connected to the T1-16S when using the RS-485 adapters. This Inverter connection mode is using the standard serial communication function of the Inverters in order to configure monitor/control system inexpensively. For tightly integrated speed and sequence control, Toshiba recommends use of a T2 or T3 PLC with a DeviceNet or with a TOSLINE network module in the PLC and in the Inverters.

In the Inverter connection mode, tersedia 5 mode operasi sebagai berikut:

1. Data exchange mode
   This mode is used to control and monitor the Inverters. The T1-16S cyclically scans all the connected Inverters. The communication commands for Inverters are automatically generated by the T1-16S. This is the basic operation mode of this Inverter connection mode. The following functions are available for the each Inverter.
   
   • Control: Sends commands (Run, Stop, Jog, etc.) and changes the frequency (Inverter commands FA00 and FA01 are used)
     
   • Monitor: Monitors the operating frequency and the output terminal status (Inverter commands FD00 and FE07 are used)
   
   
2. Monitor mode:
   This mode is used to monitor the Inverters. The T1-16S cyclically scans all the connected Inverters. The communication commands for Inverters are automatically generated by the T1-16S. Different from the above Data exchange mode, only monitoring is available in this mode. The following functions are available for the each Inverter.
   
   • Monitor: Monitors the operating frequency and the output terminal status (Inverter commands FD00 and FE07 are used)
   
   
3. Read command mode:
   This mode is provided to read some data or parameters from the specified Inverter. User should specify the Inverter command and the target Inverter number. This mode is used to read the output voltage, current, etc. from the Inverter.
   
4. Write command mode:
   This mode is provided to write some data or parameters into the specified Inverter. User should specify the Inverter command with the data and the target Inverter number. This mode is used to write some parameters to the Inverter.
   
5. Broadcast mode:
   This mode is provided to send a command to all the connected Inverters simultanously. User should specify the Inverter command with the data. This mode is used to send Run, Stop command, etc. to all the Inverters at the same time. In this mode, only the number 0 Inverter will return the response.
   

In the Inverter connection mode, the 16-bit binary protocol specified for the VF-A7 is used to communicate with the Inverters.

System configuration
The following figure shows the system configuration. In case of the VF-S9, use its serial (logic) port through the RS-485 adapter to connect to the RS-485 line. On the other hand, in case of the VF-A7/G7, use of either its built-in RS-485 port or its serial (logic) port through the RS-485 adapter is possible.The maximum number of the Inverters connecable to the T1-16S is 64. (Available Inverter number is 0 through 63)

Refer to the Inverter (VF-A7, G7, or S9) manual for details of the RS-485 connection configuraion and the RS-485 adapter (Type: RS4001Z).

Setup procedure
The following chart shows the setup procedure of the Inverter connection function.

Cable connection

• Maximum cable length is 1 km.
  
• Short between RXA and TRM for termination at the T1-16S.
  
• Connect termination resistor 1/2 W - 120 Ω between RXA and RXB at the Inverter
  side.
  
• Use shielded twisted-pair cable for data communication suited to RS-485
  standard. The cable shield should be connected to ground.

• Maximum total cable length is 1 km.
  
• Connect termination resistor 1/2 W - 220 Ω between RXA and RXB, and between TXA and TXB at the both terminal stations.
  
• The length of the branch line should be less than 3 m.
  
• Use shielded twisted-pair cable for data communication suited to RS-485
  standard. The cable shield should be connected each other and connected to
  ground.

Mode setting
Mode operasi dari port RS-485 ditentukan oleh data dari special register SW56. Data ini disimpan dalam EEPROM dengan mengeksekusi command write EEPROM. T1-16S membaca data ini at power-on initialization, and decides the mode.To select the Inverter connection mode, follow the procedure below.
(1) Turn the T1-16S to HALT mode
(2) Write 3 into SW56 by using the programmer
(3) Execute the EEPROM write command
(4) Turn off power
(5) Turn on power again
Then the T1-16S’s RS-485 port functions as the Inverter connection mode.
catatan:
The SW56 setting is saved in the program storage module RM102 (ver. 2 or later). Therefore, when you save the T1-16S program into the RM102 then load it into another T1-16S, the original SW56 setting will be copied. However, in case of the T-PDS, the SW56 setting is not saved in the disk file. Therefore even when you load the T1-16S program by the T-PDS, you must set the SW56 data for the T1-16S manually as mentioned above.

Communication parameter setting
The transmission parameters are set by writing it into the system information memory of the T1-16S. Turn the T1-16S to HALT mode, then set the communication parameter in the system information.

Baudrate ... 9600 or 19200 bps is recommended.
Data bit length ... It must be 8 bits.
Stop bit ... 1 bit is recommended.
After the communication parameter setting, write it into the T1-16S’s built-in EEPROM before turning off power.

Access delay time setting
The access delay time is the interval from receiving #n Inverter response to sending #n+1 Inverter request command. This access delay time can be changed within the range of 0 to 300 ms. The shorter the setting, the faster the communication cycle.
Normally 1 (10 ms) setting is recommended. To set the access delay time, turn the T1-16S to HALT mode, and write the delay time (0 to 30) into SW57. After writing, execute the EEPROM write command. And cycle power off and on again. Then the setting will be effective.
catatan:
If the data is out of the valid range, it is regarded as 0.

Inverter setting
At the each Inverter, set the following communication parameters. For how to set the
parameters, refer to your Inverter (VF-A7/G7/S9) serial communication manual.

• Baudrate ... Same as the T1-16S’s setting
  
• RS-485 2-wire or 4-wire ... Set 4-wire system
  
• Parity ... Same as the T1-16S’s setting
  
• Inverter number ... Set consecutive number starting from 0

catatan:
In the Data exchange mode and the Monitor mode (see page 126), the T1-16S scans Inverters from #0 through #n (n: user setting). Therefore, if the Inverter number is skipped, unnecessary access will take place. It results in longer scan cycle.

Related instruction
Expanded data transfer (XFER)

Function
Function ini disediakan unt mengontrol Toshiba Inverters VF-A7/G7/S9 yang dihubungkan pada the RS-485 line. Ketika mode operasi RS-485 port diseting menjadi mode inverter (SW56 = 3), the T1-16S can perform the following functions for up to 64 Inverters.

1. Cyclically scans the Inverters and sends/receives the following data to/from each Inverter.
   
   • Send to Inverter: Frequency reference write and Operation command write (Run, Stop, Jog, etc.)
     
   • Receive from Inverter: Operating frequency monitor and Output terminal status monitor
   
   
2. Cyclically scans the Inverters and receives the following data from each Inverter.
   • Receive from Inverter: Operating frequency monitor and Output terminal status monitor
   
3. Sends a specified Read command to a specified Inverter and stores the response data.
   
4. Sends a specified Write command with the command data to a specified Inverter.
   
5. Sends a specified Write command with the command data to all the connected inverters as broadcast.

Inverter number (B):
Untuk operasi mode 0 and 1:
Mode ini menentukan the maximum Inverter number. For example, jika jumlahnya adalah 5, maka T1-16S scans dari #0 sampai #5 Inverters and mengulanginya. range setting 0 to 63.
Untuk operasi mode 2 and 3:
Mode ini menentukan target jumlah Inverter untuk sending commands. range setting 0 to 63.
Untuk operasi mode 4:
setting ini diabaikan. The broadcast address (HFF) is used as Inverter number.

Execution status (B+2):
Register ini menunjukkan the scan count. Selama operasi normal, meningkat dari 0 to 32767 and repeats. When the following error is detected, the bit-F of this register comes 1.

• RS-485 port busy (communication with Inverter is executing)
  
• Parameter data error

Communication error code (B+3):
Kode communication error merespon dari Inverter yang ditunjukkan disini. Jika 2 ato lbh inverter eror, the smallest Inverter number's error is stored. Refer to Inverter's manual for the error code.

Inverter communication status map (B+4 to B+7):
This table shows the communication status map of each Inverter. (1: Normal / 0: Error or No answer)

< Data exchange mode (Mode 0) >
When the instruction input comes ON with the operand B+1 is 0, the Data exchange mode (mode 0) is selected. In this mode, the T1-16S sends the following commands to the Inverters starting from #0 through the Inverter number specified by the operand B, and repeats.

The maximum Inverter number #n is specified by the operand B.
The scan execution status and the Inverter communication status are stored in the operand B+2 to B+7. The command data table is specified by the operand A and A+1. If A is 4 and A+1 is 1000, the register D1000 is specified as the table leading address.
Command data table (if D1000 is specified):

When the instruction input is reset to OFF, the operation is stopped after receiving the response from the Inverter currently communicating.
Note) Inverter communication command and monitor data format

• The data format for the operating frequency and the frequency reference registers are 0.01 Hz units. For example, if it is 60 Hz, the corresponding register data is 6000.
  
• The bit assignment of the operation command register is as follows. (VF-A7)

For the Inverter communication function details, refer to your Inverter ’s serial communication manual.