UMEI Norihiko1 MANO Shuuichi1
We have developed a new range of temperature controllers called the Green series. The whole series, which ranges from the low-end 300 series to the mid-range 500 series and high-end 700 series which is equipped with additional applications such as custom computation functions and dual-loop control capabilities, is developed based on common specifications.
This paper describes the pre-configured control strategy (UT mode) on the 500 series and 700 series and the communication protocols (PC link communication, ladder communication and coordinated operation) available over the entire series.
In order to meet user needs, the Green series of controllers has not only been equipped with control computation systems, "Super" overshoot suppressing function and generous alarm functions proven on existing models, but have also been fitted with a number of new functions. These include various pre- configured control functions or "UT modes" (500 and 700 series); versatile display functions with LCD (700 series only); custom- built control function capabilities –"custom computation" (700 series only); and three communication protocols – PC link communication, ladder communication and coordinated operation. This paper explains the characteristic functions of the series, such as control and communication functions.
The 500 and 700 series of controllers have more than one pre-configured control function to meet the demands of various applications. These control functions are called UT modes. The UT750, a 700 series controller, has 13 UT modes, while the 500 series controllers UT550/UT520 have 8 (as shown in Table 1). The UT mode is selected using the keys on the front panel. For example, when the UT mode parameter UTM is set at 4, the controller for the cascade control application is active.
Table 1 UT Mode
|2||Cascade primary loop control||○||○|
|3||Cascade secondary loop control||○||○|
|5||Loop control for backup||○||○|
|6||Loop control with PV switching||○||○|
|7||Loop control with PV auto-selector||○||○|
|8||Loop control with PV-hold function||○|
|12||Temperature & humidity control||○|
|13||Cascade control with 2 universal inputs||○|
|14||Loop control with PV switching and 2 universal inputs||○|
|15||Loop control with PV auto-selector and 2 universal inputs||○|
|21||Custom computation control||○|
1. UT Mode
The internal controls for each UT mode are divided into fixed components and variable components so that multiple control capabilities can be realized. Figure 1 illustrates the control computation concept applied in the UT750. Fixed components include an input hardware manager with linearizing temperature conversion computations (input processing section in the figure); a target setpoint calculator and PID control (PID control processing section in the figure); and an output hardware manager (output processing section in the figure). Variable components exist for each application which requires different input data and calculation data to compute the control output level (input block and output block in the figure).
Figure 1 Diagram for UT750 Control Computation Concept
The type of data displayed, the display sequence and the display conditions can also be selected (this information is called "operating display information"). The input and output block functions can be easily configured in order to perform functions by incorporating the supplied software computation modules.
Figure 2 shows the input block and the output block layout. In this example, the input data from AIN1 and AIN2 are converted to the same scale by an EU range conversion module and then transmitted to the 2-input selector module. The 2-input selector module selects either the AIN1 or AIN2 data according to the upper and lower selection limits or the selector signal. The selected data are processed by a 10-segment linearizer module and transmitted from the PVIN1 input block to the control computation section.
Figure 2 Input/Ooutput Block for UT Mode 6 (loop control with PV switching)
Thus, the information required by the selected UT mode is obtained at power-on by first configuring the input/output block information and the operating display information for each UT mode in the firmware.
2. Custom Computation Function
The custom computation function enables easy configuration of the control function by manipulating the UT mode structures. The function uses the LL200 PC-based Custom Computation Building Tool to rearrange the input/output block information and the operating display information to meet various application requirements and transmit this information to the controller for downloading. The controller carries out the input/output block processes according to the downloaded custom computation information. The 65 computation modules available for customization are shown in Table 2.
Table 2 Computation Modules
|1||Addition||23||Equal||45||Detection of change|
|2||Subtraction||24||Not equal||46||Loop1 control output select 1|
|3||Multiplication||25||Range||47||Loop1 control output select 11|
|4||Division||26||Delay||48||Loop1 control output select 12|
|5||Absolute||27||AND (double word)||49||Loop1 control output select 13|
|6||Reciprocal||28||OR (double word)||50||Loop1 control output select 14|
|7||Min/max/average/difference||29||Word shift||51||Loop2 control output select 2|
|8||Hold maximum value||30||Totalization||52||Loop2 control output select 21|
|9||Hold minimum value||31||Timer||53||Loop2 control output select 22|
|10||Hold||32||Rate-of-change limiter||54||Loop2 control output select 23|
|11||Switch||33||10-segment linearizer 1||55||Display data unit conversion|
|12||Limiter||34||10-segment linearizer 2||56||Parameter setting|
|13||Constant||35||Inverse 10-segment linearizer 1||57||Data display 1|
|14||AND||36||Inverse 10-segment linearizer 2||58||Data display 2|
|15||OR||37||Curve linearizer 1||59||Special contact output setting|
|16||Exclusive OR||38||Curve linearizer 2||60||Output 1 configuration|
|17||NOT||39||Ratio||61||Output 2 configuration|
|18||Latch||40||First-order-lag filter||62||Fluid temperature compensation factor|
|19||Greater||41||EU range conversion||63||Fluid pressure compensation factor|
|20||Lesser||42||2-input selector||64||10-segment linearizer 3|
|21||Decrement counter||43||Temperature/humidity calculation||65||10-segment linearizer 4|
The Green series of controllers are equipped with three communication protocols: two general-purpose communication functions — PC link communication and ladder communication — and a specific function for communication between the various controllers, or coordinated operation.
1. Data Register Structure
The multitude of control parameters, such as the target setpoint, PID parameters and input types and others, which must be defined, are arranged in the data registers and managed by numbers; for example, No. D301 represents the target setpoint and No. D306 the proportional band. These data register numbers are common among the entire range of the Green series, that is, common from high-end models through to low-end models.
2. PC Link Communication
|Figure 3 Example of PC Link|
The PC link communication is a protocol which is used to communicate with a personal computer (abbreviated as PC) or a graphic panel. It is compatible with the PC link protocol used in Yokogawa's programmable logic controller (PLC) FA-M3/ FA500 series and assorts the read/write command data into register numbers. ASCII code (ex. 21 is taken as 3231hex) is used as send/receive data format. An example of communication is shown in Figure 3.
Communication to a graphic panel (Yokogawa TOP series and others) can be made by simply selecting the register number, without having to refer to the specific protocol.
Generally, PLCs use the ladder communication protocol discussed in section 3.3 below; however, the FA-M3 UT link module can also be used to monitor data by simply setting the actuating relay to "on" with a ladder program.
3. Ladder Communication
Ladder communication is a protocol used to communicate with PLCs. It employs PLC communication modules (Yokogawa ladder communication module and others) to communicate with simple ladder programs. In general, ladder programs do not use ASCII codes, but opt for simple BCD codes (e.g. 21 refers to 21hex) to change the ladders between send/receive data formats. Specification of send/receive data is also carried out using the register numbers.
4. Coordinated Operation
|Figure 4 Example of Coordinated Operation|
Coordinated operation involves linking a number of slave controllers to one master controller via communication terminals and running the slave controllers the same way as the master controller. An example is shown in Figure 4. Features of coordinated operation:
All of the digital indicating controllers (UT) and program controllers (UP) in the Green series can operate as master controllers, while all the UTs can operate as slave controllers. The existing UP27 and UT37 models can also be connected in the coordinated operation.
The UT mode function in the high-end and mid-range models, allows a number of control applications to be performed easily. In addition, the merits of standardizing specifications in communication protocols and register numbers will be revealed in engineering load reductions in communication applications, et cetera. This is the first time a UT mode function has been applied to the controller market. Our aim is to not only keep ahead of market trends by incorporating highly versatile control applications but, more so to develop controllers with advanced functions and user-friendly operations.
The UP27 Program Controller was discontinued on 1/01/1997.
The UTAdvanced UP55A is a replacement product.
The UT520 Digital Indicating Controller was discontinued on 1/01/2010. The UTAdvanced UT52A is a replacement product.
UT550 Digital Indicating Controller
Highly functional 1/4 DIN sized Controller comes with Custom Computing and 12 powerful control functions including dual-loop control. It also features easy-to-see large PV display and LCD display for interactive setting and programming. The universal I/O, auto-tuning, "SUPER" and "SUPER2" functions are standard. Two ports of RS-485 communication are option.
The UM33A provides up to 9 alarms outputs and input correction function (PV bias, Polygonal line approximation, polygonal line bias). Also, 24 VDC sensor power supply is available as an option.