Toshiba TOSDIC-CIE DS User manual

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Installation and Wiring
Manual
6F8C0764
Toshiba Integrated Control System
MENU

Third Edition Dec, 1999
The contents of this manual may be revised without notice.
Copyright 1998-1999 by Toshiba Corporation. All rights reserved.
No part of this manual may be reproduced in any form without permission.

Safety Precautions
i
Safety Precautions
The instruction manual and the labels affixed to the products or equipment give important
information for using products safely. It helps prevent damage to properties and hazard to people
who use them or work with them.
Make yourself familiar with the signal words and signs in this page, then read the safety
precautions that follow and always follow the instructions to avoid hazards.
Explanation of signal words
Signal word is a word that designates a degree or level of hazard seriousness.
The words WARNING and CAUTION are used for the products.
WARNING Indicates a potentially hazardous situation which could result
in death or serious injury, if you do not follow the
instructions.
CAUTION Indicates a potentially hazardous situation which may result
in minor or moderate injury and/or property damage, if you
do not follow the instructions.
Hazard alert shapes and symbols
Following shapes and symbols are used in the safety precaution labels affixed to the
products and in other places including operation manuals for giving safety instructions.
Filled circle means "Mandatory Action" or "Do as indicated."
Required action is shown in the circle or described near the circle.
Circle band with a diagonal slash means "Prohibition" or " You must not do."
Prohibited action is shown in the circle or described near the circle.
Triangle means "Hazard Alerting" or "Be alert agaist hazard."
The kind of hazard is shown in the triangle or described near the triangle.
Exclamation point with a triangle is a safety alert symbol which indicates a
potential hazard. It is used with a Signal Word.
Square or rectangle means "Information Messages" or "Notice."
Important precautions for system operation
System fault or data loss may occur in the event of power outage whether it is external or
internal of the system. Take precautions in advance to protect the system in order to prevent such
event to take place. Also back up your data regularly to minimize the possible damage by loss of
data as a result of such event.

Safety Precautions
ii
Confirmation of product safety label
Confirm that product safety labes are put on the front panel of the power supply module. If
the lavel is lost or soiled, inform TOSHIBA Corporation.

Safety Precautions
iii
1. Safety Precautions for Installation
WARNING
Grounding required:
To avoid the risk of electric shock or fire, be sure to ground the equipment.
CAUTION
Choose proper environment for installation:
Avoid installing and storing the equipment in the following environments:
zLocation with considerable dust
zLocation in which flammable or corrosive gases (such as SO2and H2S) are present
zLocation where vibration or shock exceeds allowable limits
zLocation where condensation may occur due to rapid change in temperature
zLocation where the temperature is not within the specified range for installation
zLocation where the humidity exceeds the specified limits for installation
zLocation in the direct sunlight
zLocation near a device that generates strong radio waves or magnetic fields
Considerations for maintenance and inspection:
Install the equipment in a place that facilitates maintenance and inspection. If not, in case of
malfunctioning, it may hinder the recovery of the system and result in serious accident.
Ensure proper ventilation:
Do not block vents, intake or exhaust openings of the equipment. Blocking them may cause
mulfunctioning or overheating which may result in fire.
Prohibit excessive voltage or current:
Avoid applying excessive voltage and current across the input/output terminals by keeping them
within the specified ratings. Otherwise it may result in equipment damage.
Avoid noise interference:
Place I/O and data transmission signal cables away from the power cables and the devices that
generate magnetic or electromagnetic fields. Interference noise may cause the equipment to
malfunction.

Safety Precautions
iv
2. Safety Precautions for Inspection and Maintenance
WARNING
Turn off power:
Turn off power before attaching or detaching modules or before connecting devices. Failure to do
so may result in electric shock or equipment fault.
Make sure that power is off:
Always check and make sure that the external power is turned off before installing or removing
modules. Bare metals appear on the back of external terminal block of the module. To avoid
electric shock, take precautions against touching them.
CAUTION
Clean filters:
If the equipment has filters, clean them periodically. If it has fans, clean grilles and screens also.
Clogged filter may cause the equipment to overheat, resulting in malfunction, failure or fire.
Avoid shock:
Do not drop, bump or give strong shocks to the equipment or modules to avoid fault. Shocks may
cause malfunction.
Discharge static electricity:
Before handling equipment or modules, discharge static electricity from your body by touching a
metal that is grounded. Static electricity may cause equipment to malfunction or fail.
Use a conductive sheet or bag to avoid static:
When cards and modules are taken out of base-unit, they should be placed on an electrically
conductive sheet (the bag that comes with spare module in it is made of conductive sheet), which
is put on a grounded work bench. Static electricity may damage electrical parts.
Wipe off dirt:
Wipe off dirt and dust from equipment or modules, using a soft cloth. In case the dirt is persistant,
wet a cloth and wring it dry, then use it on the dirt. Dirt on the parts may result in faulty actions and
operations.
Do not use paint thinner for cleaning:
Do not use benzene, paint thinner for cleaning equipment or modules. These chemicals will distort
or discolor panels and modules.

Safety Precautions
v
3. Safety Precautions for Part Replacement
WARNING
Ensure to stop fans:
When replacing fan unit, make sure to stop the fan by switching off the fan unit at the distribution
panel (or circuit breaker), before detaching the power cord. Failure to do so may result in electric
shock or injury due to the fan blades in motion.
CAUTION
Turn power off before replacing fuses:
Before replacing power fuses or alarm fuse, be sure to turn off power of the unit. Failure to do this
may result in electric shock or fire.
Use lithium batteries properly:
Do not insert lithium battery with the polarity in reverse. Do not short the battery nor charge it.
Otherwise it may explode.
Use right lithium battery for the module:
Do not use the lithium battery in one module for another. Ratings of lithium battery differs by the
module and the use of improper battery may damage the equipment.
4. Safety Precautions for Daily Use
WARNING
Check specifications:
Before using the equipment, make sure that the capacity, frequency, voltage and regulation of the
power supply meet the specifications of the equipment. In case they don't, the equipment may not
only work adequately but may suffer a breakdown or cause overheat that may result in fire.
Turn off power in the event of a problem:
If the temperature in or around the equipment becomes abnormally high or an unusual fault occurs
in the equipment, stop using it and turn off power, then contact your Toshiba representative. If left
alone, overheat may result in fire.

Safety Precautions
vi
Avoid touching hot components:
Some components inside the modules become very hot after the power is turned on. To avoid
burns, do not touch them.
CAUTION
Do not touch components:
Do not touch pins, connectors or soldered surfaces in modules with any part of your body. Static
electricity may damage IC's or LSI's and cause equipment to fail. Also the pointed end of
component lead may hurt your body.
Do not disassemble the equipment:
Do not disassemble or modify the equipment or modules. Doing so may lesson equipment safety
or result in equipment malfunction or failure.
Handle cords and cables properly:
Do not force to pull, twist or bend cords and cables of power supply. Otherwise cables may break
or become hot.
Be careful of operations when the system is running:
Do not change function settings of switches on modules while the equipment is running. Otherwise
equipment may malfunction or fail.
Keep off metals:
Keep metals such as paper clips from going into the openings in the modules, units, and drives,
among others. Otherwise fire may result.

Safety Precautions
vii
5. Safety Precautions for Disposal
WARNING
Keep lithium batteries out of fire:
To avoid risk of explosion, do not throw lithium batteries into fire when you dispose of them.
CAUTION
Disposal of batteries:
Dispose lithium or Ni-Cad batteries according to the ordinance or regulations.
Full Compliance with the Following Precautions is a Must
A full compliance with the following precautions is a must in operating your equipment to
safeguard the safety of the operators and to maintain the equipment in the normal operating
condition:
(Note 1) Read the reference manual carefully before operating your equipment.
(Note 2) Avoid installing or storing your equipment in the following environment:
zDusty place
zPlace where corrosive gases generate, such as SO2and H2S.
zPlace subjected to vibration and shocks.
zPlace in a low- or a high-temperature environment deviating from the installation conditions specified
in this manual.
zA high-humidity place.
(Note 3) In case the ambient or internal temperature of the equipment rises abnormally high or
the equipment develops a failure, stop operating the equipment and turn the power off
the equipment. Contact the Toshiba service window in your area.
(Note 4) Do not open the equipment case or remodel the equipment.
(Note 5) Plug in or out the module after turning the power OFF.
(Note 6) The equipment taken out from the base unit must be placed on a conducting mattress
or conducting bag (bag containing a spare card) placed on a grounded desk.

Safety Precautions
viii
Limitations on Use
zThis product has not been developed or manufactured for use in a system containing equipment
which directly involves human life. (Please see NOTE 1.) This product must not be used for
such uses.
zIn case this product is to be used in a system (see NOTE 2) containing equipment which
involves human safety and may potentially cause serious impacts on the maintenance of public
functions, special considerations (see NOTE 3) will be needed for system operation,
maintenance and management. Consult the Toshiba sales representative in your area.
(Note 1) Equipment which directly involves human life is as follows:
zMedical equipment such as life sustaining equipment and equipment in surgical operation rooms.
(Note 2) Systems containing equipment which involves human safety and may potentially cause
serious impacts on the maintenance of public functions are as follows:
zReactor control systems in nuclear power plants, safety protection systems of nuclear power facilities
and other systems which are important in safety.
zOperation control systems of cargo collection and delivery transport systems and aviation control
systems.
(Note 3) Special considerations are the construction of a safety system to incorporate foolproof,
fail-safe, redundancy and other designs after fully consulting a TOSHIBA engineer.
Non-Liability Clauses
zToshiba will not be responsible for damage caused by a fire, earthquake or a third party, or by
use under abnormal conditions such as an accident, intention, error or abuse by the user.
zToshiba will not be responsible for incidental damage due to the use of or inability to use this
product, including losses of business profits, suspension of business and mutilation or erasure of
stored data.
zToshiba will not be responsible for damage caused due to a failure in complying with the content
of this reference manual.
zToshiba will not be responsible for damage caused by malfunctioning due to combination with
equipment connected.
zToshiba will not be responsible for damage caused by malfunctioning due to combination with an
application program created by the customer.

Introduction
ix
Introduction
Toshiba integrated control system "TOSDIC-CIE DS" is a integrated control system with the
new concept to meet the open technology age. An easy-to-use open system is realized by
adopting the standard multi-vendor network and the package software of simple engineering
in addition to the control and computer technologies fostered over long years.
This manual explains the TOSDIC-CIE DS system constructed by using the server station
SVR-DS, the operator interface station OIS-DS and control station PCS-DS, and Ethernet
control LAN as the network to connect these stations, especially wiring of PCS-DS and process
I/O sub systems, connections OIS-DS main unit and peripheral devices, two redundant SVR-
DS stations.
In order for you to use the server station of the "TOSDIC-CIE DS" system and the units
correctly and safely, you are requested to read "Safety Precautions" prior to use.
The Structure of This Manual
This manual includes the following chapters.
Chapter 1 System Configuration
This chapter outlines the TOSDIC-CIE DS system and PCS-DS, process I/O sub
system, and also the euipment plan and carry-in/installation when the PCS-DS
system is introduced.
Chapter 2 Wiring of PCS-DS
This chapter explains the wiring of PCS-DS system power supply system and signal
systems including Ethernet, serial bus and I/O bus of Intelligent I/O sub system,
and parallel I/O bus of P5 series PI/O sub system.
Chapter 3 Connection of OIS-DS and SVR-DS
This chapter explains the connection of OIS-DS main unit and its peripheral devices,
and the duplex connection between two SVR-DS main units.
Chapter 4 Wiring of DPCS
This chapter explains the wiring of DPCS.

Introduction
x
Chapter 5 Network Configuration of Ethernet LAN
This chapter explains the network configuration and the wiring and earthing
methods of Ethernet2 control and information LAN.
Chapter 6 Earthing
This chapter explainsthe earthing methods and earthing work examples of PCS-DS,
OIS-DS and SVR-DS.
Chapter 7 End of Wiring Work
This chapter explains check items after the wiring work is completed.
TOSDIC-CIE is the registered trademark of Toshiba Corporation.
Ethernet is the registered trademark of Xerox Corporation.

Contents
xi
Contents
Safety Precautions i
Introduction ix
1. System Configuration 1
TOSDIC-CIE System Configuration 2
PCS-DS System Configuration 2
Equipment Plan 4
Control Room 4
Environmental Conditions 5
Power Supply Equipment 6
Carry-In/Installation 7
Transporting Passage/Truck Parking Lot 8
Unloading Transporting Work 8
Unpacking Work 9
Entrance/Access Passage 10
Carrying-In Work 10
Installation Work 11
PCS-DS Cabinet Panel-to-Panel Linking Procedure 13
PCS-DS Cabinet Mounting Example 15
Caution in Mounting 16
Installation of External Power Supply Unit and I/O Power Supply Unit 16
2. Wiring of PCS-DS51 17
Wiring of Power Supply Cable 17
Selecting Main Power Supply Cable 18
Connection to Units 18
Wiring of Ethernet cables 26
Cautions on installing Ethernet transmission lines 27
Components 31
Interior Wiring of PCS-DS51 38
Wiring of Ethernet Cable 41
Work Conditions 41

Contents
xii
Work Procedure 41
Connection of Ethernet Board 42
Connection of Transceiver 47
Installation of Transceiver 48
Installation of Optical Repeater 50
Installation of Electric Repeater 51
Installation of Hub 52
Installation of Optical Transceiver 54
Wiring of Serial Bus Cable 56
Configuration of Communication Base Unit 56
Wiring of Serial Bus Cable 58
Connection to Main Processor Board (FMDS1) 61
Connection to Serial Bus Cable for FMDS1B or Later (FMDS21/FMDS22) 64
Connection to Communication Base Unit 65
Wiring of I/O Bus Cable 67
Cautions on Installation of PI/O Module 67
Connection to Communication Base Unit and Terminal Board Unit 69
Wiring of Process Signal Cable 70
Wiring of Signal Cable 71
Connection to Terminal Board Unit 71
Exterior Wiring 73
Wiring outside Board 73
Isolation from Other Wiring 75
3. Connection of OIS-DS and SVR-DS 77
Outline of Connection 78
Connection between OIS-DS and its Peripheral Devices 79
Connecting to the Ethernet Control and Information LAN 79
Connecting between OIS-DS and its Peripheral Devices 81
Connection of Server Station 86
Connecting to the Ethernet Control and Information LAN 86
Redundant System Configuration 88
Cautions in Wiring 89
Power Supply 89
Wiring 89

Contents
xiii
4. Wiring of DPCS 91
Wiring of Ethernet Cables 91
Precautions for Ethernet communication line wiring 91
Wiring Inside the DPCS Cabinet 93
100BASE-TX/10BASE-T connection 93
10BASE5 connection 95
Connecting Ethernet Cables 97
Connection to the Ethernet board 97
5. Network Configuration of Ethernet 101
Ethernet System Configuration 101
Restrictions for Expanding the Transmission Line 101
Cable Segment and Link Segment 102
Maximum Network Configuration 103
Example of TOSDIC-CIE DS System Configuration 105
Grounding of Coaxial Cable 106
6. Earthing 107
Earthing of PCS-DS 107
Cautions in Earthing 108
Grounding Electrode 108
Ground Bus 108
Earthing Work Example 110
Earthing of OIS-DS 111
Cautions in Earthing 111
Grounding Electrode 111
Ground Bus 111
Earthing of SVR-DS 114
Cautions in Earthing 115
Grounding Electrode 115
Grounding Bus 115

Contents
xiv
7. End of Wiring Work 117
Appendix1 100M-Ethernet Control LAN Network Configuration 119
Basic Configuration 120
System Configuration 121
Transmission Path Specification 122
NetworkCofiguration 123
Network Equipment 123
Network Articles 124
Outline of Network Components 125
Network Restrictions 126
Configuration Example 132

1. System Configuration
1
1. System Configuration
This chapter is described outline of TOSDIC-CIE DSand transmission system configuration and
installation example.
SVR-DS
Ethernet Control LAN
Ethernet Information LAN
PCS-DS PCS-DS
PLC SERVER
T3H PLC
T3H PLC
DPCS-DS
PC/WS
OIS-DS
Figure 1.1 TOSDIC-CIE System Configuration

1. System Configuration
2
TOSDIC-CIE System Configuration
TOSDIC-CIE DS is a control system of server station SVR-DS, operator interface station OIS-
DS, control station PCS-DS and other kinds of stations like a printer server station connected
with Ethernet control LAN. TOSDIC-CIE DS also has the other channel Ethernet LAN as
information network. The information system Ethernet LAN is connected to server station,
operator interface station and the printer server station. With the Ethernet control LAN, the
transmission line is made duplex.
With the PCS-DS, the main unit and PI/O sub systems are connected with the dedicated I/O bus.
For the main unit, the duplex configuration of redundant system is possible.
The PI/O sub system can be two types of the system architecture for a customer purpose. One of
them has a serial I/O bus. The serial bus is made by the duplex configuration. This type of I/O
sub system is used for the process instrumentation system like a petro-chemical plant.
The other PI/O sub system has a parallel I/O bus. The transmission data can be transferred
between the main unit and I/O sub systemwith a high speed via parallel I/O bus. This type of I/O
sub system is used for the electric control system like a iron or non-ferrous metal plant.
PCS-DS System Configuration
The Ethernet control LAN connected to OIS-DS51 or SVR-DS51 is connected to the
transmission card (FETH1) of the PCS-DS51 main unit via the transceiver.
The main unit and the communication module of the intelligent I/O system are connected with
the serial bus. The communication module and each PI/O module are connected with the I/O
bus.
The main unit and the bus interface of the parallel PI/O system, as well as units of the parallel
PI/O, are connected with the parallel bus.
Figure 1.2 is the system configuration of PCS-DS51.

1. System Configuration
3
P
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TR TR
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TR
TR
OIS-DS51 SVR-DS51
Control
room
TR : Transceiver
SBIF: Communication
module
PBIF: Bus interface
PI/O : Process I/O
: Terminating
resistor
Process signal
(to field devices)
Ethernet control LAN
(twisted pair)
Operator
room Ethernet
control
LAN
(10BASE5)
Hub
Ethernet
control
LAN(yellow
cable)
Hub
Ethernet
control
LAN
(10BASE5)
Main unit
Serial bus Parallel bus
I/O
bus
Serial bus Parallel bus
PCS-DS51 PCS-DS51
Figure 1.2 PCS-DS51 System Configuration

1. System Configuration
4
Equipment Plan
Concerning the equipment for introducing the MCS1000/1000H system, the control room for
installing the equipment, environmental conditions, and power supply equipment are explained.
The plan should be made after thorough investigation.
z
Control Room
Floor of Control Room
•Floor strength
The floor strength is about 2.94 ×107N/m2or higher. Sufficient strength should be considered
in accordance with the mass and dimensions of the equipment to be installed.
•Floor structure
Because the cables are laid, we recommend the wiring pit system with grooves in the floor or
on-floor (free access floor) system for the floor structure. If the floor surface is not processed,
cables exposed must be provided with covers for protection.
•Prevention of water entry, dust proofing of floor
For protecting the cables and equipment, water entry must be prevented. Also due
consideration should be taken to prevent dust from under the floor.
Windows and Doors of Control Room
If there is a fear of entry of dust, salty wind, or corrosive gas, closed windows should be adopted
and dust from the doors must be prevented.
The equipment must not be exposed to direct sunlight.
A sufficiently large entrance should be provided for bringing in the equipment.
Space of Control Room
•Minimum necessary space for operation and maintenance must be secured.
•PCS-DS51 is provided on the top with a fan to discharge air. The ceiling should be 500 mm or
more higher than the height of the cabinet of PCS-DS51. For PCS-DS51 of width 600 or width
800, the service area of minimum 800 mm or 1000 mm is required at the front and back,
respectively.