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CJ-series Temperature Control Units Operation Manual for NJ

1. CO N o1 AI Wy DM Control period Control sensitivity Proportional band Integral time Derivative time Heater burnout current nim oOlO WwW YF CO N OD oO A wl rp o a or AJOIN O Not allocated When there are errors in two or more settings the setting error number with the highest priority will be stored CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 7 5 Error and Alarm Processing i ERC Indicator Lit and RUN Indicator Not Lit These alarms indicate that there is an error in the Unit s Initialization Data When one of these alarms occurs correct the cause of the alarm and then clear the alarm by restarting the Unit or resetting the controller including turning ON the power Error Control status Processing Hardware Check An error occurred in the Control operation Restart the Unit or reset the controller includ Error Unit s peripheral hardware will stop ing by turning ON the power e f the error is in non volatile memory turn ON pin 7 of the Unit s DIP Switch to initialize the settings If these steps do not clear the error repair or replace the Unit Cold Junction An error occurred in the Control operation Check the connections at the cold junction sen Sensor Error cold junction sensor will stop sor on the terminal block and restart the Unit or reset the controller including by turning ON the
2. Page Structure The following page structure is used in this manual Level 2 heading Level 3 heading A step in a procedure Indicates a procedure Special information Icons indicate precautions additional information or reference information LE Manual name 4 Installation and Wiring 4 3 Mounting Units 4 3 1 Connecting Controller Components The Units that make up an NJ series Controller can be connected simply by pressing the Units together and locking the sliders by moving them toward the back of the Units The End Cover is connected in the same way to the Unit on the far right side of the Controller 1 Join the Units so that the connectors fit exactly Hook Hook holes Connector T u H 2 The yellow sliders at the top and bottom of each Unit lock the Units together Move the sliders toward the back of the Units as shown below until they click into place Move the sliders toward the back until they lock into place Te A Precautions for Correct Use eee The sliders on the tops and bottoms of the Powe r Supply Unit CPU Unit I O Units Special I O Units and CPU Bus Units must be completely locked until they click into place after connecting the adjacent Unit connectors NJ series CPU Unit Hardware User s Manual W500 Special Information Special information in this manual is classified as follows a Fprecautions for Safe Use Precautions on what to do and what not to do to ensur
3. An overflow e The heater current exceeded U S page 20 occurred in the CT 55 0 A input 64860000 hex Heater Burn A heater burnout e The power supply to the heater U S page 21 out Alarm occurred is not ON e The heater is burned out or deteriorated 8Iqel 10113 c G CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 17 5 Error and Alarm Processing 5 3 3 Error Descriptions This section describes the information that is given for individual errors i Controller Error Descriptions The items that are used to describe individual errors events are described in the following copy of an error table Event name Gives the name of the error Gives the code of the error Meaning Gives a short description of the error Source Gives the source of the error Source details Gives details on Detection Tells when the Error attributes Tells the level of Recovery Gives the recov Log category Effects User program Tells what will hap Operation variables the source of the timing error is detected error Tells which log influence on con ery method 2 the error is saved trol 1 in 3 Provides special information on the operation that results pen to execution of from the error event the user pro gram 4 System defined Variable Data type Name Lists the variable names data types and meanings for system defined variables that provide direct error notifica
4. ose 2 5A Normal current control OFF current 5 0 5A Operation will be stable with difference 1 0 A Heaters ome output age EE ree 1 eaters are 0 o controlled through OUT2 l l l 1 000 x3 ii l 200 VAC Normal current a 15A 210A 1 2 a l Current with 1 burnout Bi SoA Ts 15 10 SV 12 5A 2 Normal current control OFF current 15 10 5A Operation will be stable with difference gt 2 5 A 3 20 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 Settings Required for Temperature Control 3 12 Starting and Stopping Temperature Control To start temperature control for a loop that has been stopped turn device variables for CJ series Unit Stop Bit _Ch1_StopCtiCmd and _Ch2_StopCtlCmd to OFF To stop temperature control for the loop turn ON the Stop Bit e The factory setting of the bits is OFF running Starting Loop 1 and Stopping Loop 2 Wd v g g a g a v g 3 j 3 i 6 A i e To start control in loop 1 and stop control in loop 2 turn OFF Loop 1 Stop Bit _Ch1_StopCtiCmd and turn ON Loop 2 Stop Bit _Ch2_StopCtlCmo CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 21 3 Settings Required for Temperature Control 3 22 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Optional Settings a This section explains how to use the input compensat
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6. CTinout2 A4 N C TF CT input2 Ise AS CT inp HB output 2 COMET Bl aa eave A4 T input 1 T input 1 B8 utput 1 e AO MB output T Platinum Resistance Thermometer Temperature Control Units CJ 1W TC 103 CJ 1W TC 104 2 loops NPN outputs HB alarm 2 loops PNP outputs HB alarm out gt B Input 1 B Input 1 B PSR A4 N C GTinput 2 __ 0 V COM B9 7 B9 When not using temperature input terminals e For a resistance thermometer connect a resistance of approximately 100 to 200 Q between ter minals A and B and establish a short between terminals B and B e Short the input terminals for thermocouples e Do not connect anything to terminals that are not being used H Precautions for Correct Use Do not connect any wiring to the N C terminals CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions 2 4 2 Output Circuits The following diagrams show the internal output circuits Output Circuits NPN Outputs CJ 1W 003 N S 5 3 a S ae eee a 7 24 V S 4n119 Nd NO Z v Z E XX Output indicator COM Internal circuits CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 17 2 Specifications and Functions PNP Outputs CJ 1W 104 Internal circuits wy NL Ts Output indicator 2 4 3 1 0 Wiring Examples
7. Ch1_AllnOfsSta Loop 1 Input Compensa INT tion Value for Monitor D m 33 00 15 Ch1_CtlPrdSta Loop 1 Control Period for UINT Monitor D m 34 00 15 Ch1_CtlHystrsSta Loop 1 Control Sensitivity UINT for Monitor D m 35 00 15 Ch1_ProportionalBandS Loop 1 Proportional Band UINT ta for Monitor D m 36 00 15 Ch1i_IntgImSta Loop 1 Integral Time for UINT Monitor D m 37 00 15 Ch1_DerivativeTmSta Loop1 Derivative Time for UINT Monitor D m 38 00 15 Chi_MV Loop 1 Manipulated Vari INT able Monitor D m 40 00 15 Ch2_AL1LviSta Loop 2 Alarm 1 SV for INT Monitor D m 41 00 15 Ch2_AL2LviSta Loop 2 Alarm 2 SV for INT Monitor D m 42 00 15 Ch2_AllnOfsSta Loop 2 Input Compensa INT tion Value for Monitor D m 43 00 15 Ch2_CtlPrdSta Loop 2 Control Period for UINT Monitor D m 44 00 15 Ch2_CtlHystrsSta Loop 2 Control Sensitivity UINT for Monitor D m 45 00 15 ore er uenencriass Loop 2 Proportional Band UINT for Monitor D m 46 00 15 Ch2_IntgTmSta Loop 2 Integral Time for UINT Monitor D m 47 00 15 Ch2_DerivativeTmSta Loop 2 Derivative Time for UINT Monitor D m 48 00 15 Ch2_ MV Loop 2 Manipulated Vari INT able Monitor gt 40 pos A1owmyy pue yun SeLIes gt 10 sojqeue 2AA JO B GeL 2U puods Uo y Ww 0 Q C 2 rF a j U CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 A 9 Appendices A 4 Sam
8. During Power Supply Do not touch any of the terminals or terminal blocks while the power is being supplied Doing so may result in electric shock Do not attempt to take any Unit apart In particular high voltage parts are present in the Power Supply Unit while power is supplied or immediately after power is turned OFF Touching any of these parts may result in electric shock There are sharp parts inside the Unit that may cause injury OD Fail safe Measures Provide safety measures in external circuits to ensure safety in the system if an abnormality occurs due to malfunction of the CPU Unit other Units or slaves or due to other external factors affecting operation Not doing so may result in serious accidents due to incorrect operation Emergency stop circuits interlock circuits limit circuits and similar safety measures must be provided in external control circuits The Controller outputs may remain ON or OFF due to deposition or burning of the output relays or destruction of the output transistors As a countermea sure for such problems external safety measures must be provided to ensure safe operation of the system The CPU Unit will turn OFF all outputs from Basic Output Units in the follow ing cases The remote I O slaves will operate according to the settings in the Slaves e If an error occurs in the power supply e If the power supply connection becomes faulty e If a CPU watchdog timer error or CPU reset oc
9. Thermocouple Temperature Control Units CJ1W TCO003 CJ1W TC004 2 loops HB alarm NPN 2 loops HB alarm PNP outputs outputs CJ1W TC003 CJ1W TC004 JRA QA Te Q TA Bwalwk e Do not touch or remove the cold junction sensor e Use the type of sensor selected on the Input Type Switch e The Temperature Control Unit and Terminal Block are a matched set so use the Temperature Control Unit and Terminal Block with matching serial numbers 2 18 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions e Do not connect anything to the N C terminals The N C terminals cannot even be used as junc tion terminals e Do not connect any Current Transformer to the CT input terminals other than an OMRON E54 CT1 or E54 CT3 Platinum Resistance Thermometer Temperature Control Units CJ1W TC103 CJ1W TC104 N 2 loops HB alarm NPN 2 loops HB alarm PNP outputs outputs l Ce CJ1W TC103 CJ1W TC104 D ao O m x A 3 jez D o Use the type of sensor selected on the Input Type Switch Do not connect anything to the N C terminals The N C terminals cannot even be used as junc tion terminals Do not connect any Current Transformer to the CT input terminals other than an OMRON E54 CT1 or E54 CT3 Always attach crimp terminals to th
10. x A gt D 5 fe 0 S g g 0 A U c c 2 rF slo awesed ueiado 9 9S Z 2 Specifications and Functions Device variable for CJ series Unit Data R W Function Ch1_IntglmSta Ch2_IntgTmSta UINT Loop 1 and The Temperature Control Loop 2 Integral Unit returns the set values Time for Moni that are actually used for tor temperature control Use these values to monitor operation Ch1_DerivativeTmCf Ch2_DerivativeT UINT RW Loop 1 and The values written here are g mCfg Loop 2 Deriva not written to RAM while tive Time Ch _PIDCalcFlg PID Constants Calculated Flag is setto 1 These settings are valid in PID control only Ch1_DerivativeTmSt Ch2_DerivativeT UINT Loop 1 and The Temperature Control a mSta Loop 2 Deriva Unit returns the set values tive Time for that are actually used for Monitor temperature control Use these values to monitor operation 2 34 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions 2 6 Range of Set Values and Monitor Values 2 6 1 Set Values Device variable for Default Non volatile i Data range CJ series Unit value memory save Ch1_SetPointCfg Set point Depends on the Input Type C 0 N A Ch2_SetPointCfg setting or or Refer to 2 1 3 Inout Specifica F 0 0 tions for details Ch1_HBLvICfg Heater 0 to 500 A Ch2_HBLvICfg Burnout 0 0 to 50 0 en Current 1 AlmMd Loop 1 2 O to 9999
11. 1 3 System ConfiguraBoN ssiri erissa inanan nai aaraa ara PEA in aa AA Aaaa SAATAN E aaan aiia 1 7 1 2 1 Basie System COnguUraO ei e a ant rate en a E EE 1 7 1 2 2 Mounting tne VAN eses a e e e t 1 8 Specifications and Functions Specificato S saioan aaa ANa a Aaaa aa a Aaa 2 2 2 1 1 SPECE AHON e i ee eee ene ee eee 2 2 2 1 2 INPULRUNGION BIOCKIDIA Gra Msgs detent auett el oes Bhat adhe atte label wees a 2 5 2 1 3 NADIE S DO CHICANO MS taecdets ace R sc aae ts orate eg aeons ona ec meaadaieas 2 5 Applicaton PFOC SQUIRE sisian aaa a 2 7 Part Names and FUNCHONS sicsiiccsniscccnsadansdsnscidecsssisiucvensresuvcuescueusdssieuundedcusesssianusaasniucdansventcess 2 11 2 3 1 PANAME S aori a e E A a 2 11 2 3 2 MACAO Sna E E a e eoeere en gedce 2 11 2 3 3 UTE NUMDEr SWIECIE S ena e a nce aueeeu saath daa eeceasadtuisaled aces 2 12 2 3 4 DIP SWwilch Seting FUNCIONS 2c csc sce ancorihag E E Wadanatsienacce 2 13 2 3 5 MOLINE SWO Siana acenente ac aecdedeatcae a ten uae ccus aeetaee fonetean E 2 15 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 CONTENTS 24 WINO aso a a 2 16 2 4 1 Terminal VVINING EXampla Sessi A N 2 16 2 4 2 OUDPUrE FEUI ech alee ts Sle etc Rae a e does stn Seen ae dhe Ace 2 17 2 4 3 OE NVAPING EX AIM OIC S assis soe corcccrtaces set cots caamwutineacen A dd aadaaaaateatertens 2 18 2 5 Data Exchange with the CPU UnNit s ssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn
12. 6 7 7 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 29 2 Specifications and Functions Setting error number Priority In the case there are multiple setting errors the setting error number with the highest priority is stored 2 5 5 Initialization Data The Temperature Control Unit is initialized If you are using the temperature alarm function the alarm mode setting and alarm hysteresis setting must be written to the appropriate device variables for CJ series Unit Initialization Data settings are set from the I O Port screen in Configurations and Setup of Sysmac Stu dio The data setup file will be reflected in the I O port Initialization Data Reset the Controller or restart the Unit after setting is complete The settings in the Initialization Data are reflected in the unit when the Controller is reset or when the unit restarts The Initialization Data is retained in the CPU Unit by the battery even during power interruptions Precautions for Safe Use When you change the unit settings and reset the Controller or restart the unit be sure to first properly check the safety of the devices at the connection destination Allocating Initialization Data to Device Variables for CJ series Unit Device variables for CJ series Unit for initialization that can be allocated with Initialization Data are shown below For the setting range and monitoring range of each value refer
13. CT is connected to the wrong channel Input the CT correctly The heater is being operating with another output Change the wiring to control output that corresponds to i e one from an Output Unit the CT input The connected CT is not an OMRON E54 CT1 or CTs other than the OMRON E54 CT1 and E54 CT3 E54 CT3 cannot be used Connect an E54 CT1 or E54 CTS3 Settings Temperature control has not been started Start temperature control The control output s ON time is less than 200 ms The heater burnout alarm will operate when the control output s ON time is longer than 200 ms T The heater s power supply was turned ON after Start temperature control after the heater s power sup F temperature control was started ply has been turned ON 5 The heater burnout current is set to 0 0 or 50 0 A Set the appropriate heater burnout current between 0 1 i and 49 9 A 8 The heater burnout current is based on the Take an actual measurement of the heater s current to a heater s rated current determine the appropriate heater burnout current The heater burnout current from the actual mea Consider the voltage range of the heater s power sup surement is not appropriate ply and current measurement error Set the heater burnout current again Usage The heater current exceeds 50 0 A Use a heater current of 50 0 A or less The heater current is DC The heater burnout alarm cannot be used with a DC heater A pure metallic heater is being used Take an actu
14. Control Unit is restarted or the controller is reset including when the power is turned ON Chi_CtlPrdCfg Control 1 to 99 S 20 e The Tempera Ch2_CtIPrdCtg Period 1 to 99 ture Control Unit s settings Ch1_CtlHystrsCfg Control 0 to 9999 are written to Ch2_CtlHystrsCfg Sensitivity 0 0 to 999 9 RAM When the F Save Settings Bit GAA Propor 0 to 9999 of the device ProportionalBandCfg tional Band 0 0 to 999 9 or variables for CJ Ch2 oF series Unit for ProportionalBandCfg operation Is turned to 1 the Ch1_IntgTmCfg Integral 0 to 9999 233 set values are Ch2_IntgTmCfg Time 0 to 9999 written to non Ch1_DerivativeTmC Derivative 0 to 9999 S 40 volatile memory fg Time 0 to 9999 e f DIP switch pin Ch2_DerivativeTmC 8 is ON the set fg tings are auto matically transferred from non volatile memory to the CPU Unit when the Temperature Control Unit is restarted or the controller is reset including when the power is turned ON 2 36 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions 1 Heater burnout is not detected when you set the value to 0 0 A or 50 0 A When the value is 0 0 Heater Burnout Alarm OFF When the value is 50 0 Heater Burnout Alarm ON 2 When Save Settings Bit of the operation data changes from 0 to 1 the set values of the corresponding loop are written in the non volatile memory of the
15. Function Module Source details CJ series Unit Detection Continuously for timing operating data and operation adjustment data or at power ON or Controller reset for initial setting data User program Continues Operation Operating data or operation adjustment data The set value that caused the error at the Unit will be ignored Operation will continue using the set value held in the Temperature Controller Unit Initial setting data Control operations of the Unit will stop g nT The set value is incorrect Check the content of the setting error Check and correct the settings number in the lower byte of device variable _DecPointSetErrSta and correct the settings If you correct the initial setting data cycle the power supply reset the Controller or restart the Unit Attached information 1 Loop number where error was detected You can change the event level to the minor fault level If you change the level to the minor fault level the Recovery col umn above will be changed to Error reset CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 19 q W m 6 A r amp uv suoduos q 10113 S G 5 Error and Alarm Processing Meaning An error occurred in the sensor input Source PLC Function Module Source details CJ series Unit Continuously timing User program Continues Operation Control operations will continue Control outputs for the loop of the Unit will s
16. Heating With forward operation cooling the manipulated variable is increased as the PV increases With reverse operation heating the manipulated variable is increased as the PV decreases Manipulated variable Manipulated variable 100 100 0 0 Low SV High Low SV High temperature temperature temperature temperature Forward operation Reverse operation For example when heating control is being performed and the process value PV is lower than the set point SP the manipulated variable is increased proportionally as the difference between the PV and SP increases Consequently heating control uses reverse operation and cooling control uses for ward operation The factory setting is reverse operation heating Set reverse operation or forward operation with loops 1 and 2 Setting the Control Operation Pins 4 and 5 Setting Loop 1 to Reverse Operation and Loop 2 to Forward Operation If pin 4 is turned OFF and pin 5 is turned ON loop 1 will be set for reverse operation heating and loop 2 will be set for forward operation cooling The following diagram shows pins 4 and 5 set to their factory settings OFF which sets reverse operation heating for all loops If this setting is changed the new setting will not become effective until the Unit is restarted or the controller is reset including when the power is turned ON Pins 4 and 5 Control Operation Setting e295 7 c c bl MODE The factory set
17. Locations close to power lines e Before touching a Unit be sure to first touch a grounded metallic object in order to discharge any Static build up e Install the Controller away from sources of heat and ensure proper ventilation Not doing so may result in malfunction in operation stopping or in burning e An I O bus check error will occur and the Controller will stop if an I O Connecting Cable s connector is disconnected from the Rack Be sure that the connectors are secure e Do not allow foreign matter to enter the openings in the Unit Doing so may result in Unit burning electric shock or failure e Do not allow wire clippings shavings or other foreign material to enter any Unit Otherwise Unit burning failure or malfunction may occur Cover the Units or take other suitable countermeasures especially during wiring work e For EtherCAT and EtherNet IP use the connection methods and cables that are specified in the NJ series CPU Unit Built in EtherCAT Port User s Manual Cat No W505 and the NJU series CPU Unit Built in EtherNet IP Port User s Manual Cat No W506 Otherwise communications may be faulty e Use the rated power supply voltage for the Power Supply Units Take appropriate measures to ensure that the specified power with the rated voltage and frequency is supplied in places where the power supply is unstable e Make sure that the current capacity of the wire is sufficient Otherwise excessive heat may be
18. Monitor Values The meaning of the row of R W in the table below is as follows RW Read Write R Read only Device variable for CJ series Unit Loop 1 Chi_PV Ch1_HtrCurVal Ch1_SetPointCfg Ch1_SetPointSta Ch1_HBLviCfg Chi_HBLvlSta Ch1_StartATCmd Loop 2 Ch2_PV Ch2_HtrCurVal Ch2_SetPointCfg U g af type INT UINT Ch2_SetPointSta Ch2_HBLvICfg Ch2_HBLvlSta Ch2_StartATCmd UINT UINT BOOL JJ S i R W a a Loop 1 and Loop 2 Process Value Loop 1 and Loop 2 Heater Current Loop 1 and Loop 2 Set point Loop 1 and Loop 2 Set point for Moni tor Loop 1 and Loop 2 Heater Burnout Cur rent Loop 1 and Loop 2 Heater Burnout Cur rent for Monitor Loop 1 and Loop 2 Start AT Bit CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Function If the process value exceeds the allowed indication range a sensor error will occur Ch _SensErr Sensor Error Flag will become 1 and the PV will contain the data 13 108 If the measured heater cur rent exceeds 55 0 A Ch _CTOVfFIg CT Overflow Flag will become 1 and the heater current will be stored as 13 108 Set the set point of loop 1 and loop 2 Indicate the current set point of loop 1 and loop 2 Set the heater burnout cur rent of loop 1 and loop 2 If the set value is set to 0 0 heater b
19. NJ series User s Manuals Basic information NJ series CPU Unit Hardware User s Manual NJ series CPU Unit Software User s Manual NJ series Instructions Reference Manual NJ series CPU Unit Motion Control User s Manual NJ series CPU Unit Built in EtherCAT Port User s Manual NJ series Motion Control Instructions Reference Manual NJ series CPU Unit Built in EtherNet IP Port User s Manual NJ series Troubleshooting Manual CuJ series Special Unit Operation Manuals for NJ series CPU Unit Introduction to NJ series Controllers Setting devices and hardware Using motion control Using EtherCAT Using EtherNet IP v Using CJ series Units Software settings Using motion control Using EtherCAT Using EtherNet IP Programming Using motion control Using EtherCAT Using CJ series Units Programming error processing Testing operation and debugging Using motion control Using EtherCAT i L l a a i Lo LS P lt gt o SS fl So fel SS fe gt eo oj a fe oa fe a a i CS E E L a L gt oe Ss p 5 E E oo gt e a aoe Ee alas ees ao ST a gt e a ese a 2 a aa gt o E EA See man 7 SE gt T l a I S gt eo fee zamn aa S gt o pean a ass eos so pS akea aasa y E E 7 Using EtherNet IP Troubleshooting and managing relevant errors in an NJ series Contro
20. NJ series general specifications 31 x 90 x 65 mm W x H x D 150 g max Bf Characteristics Item Model number Temperature sensor Number of loops Control output and heater burnout alarm output Temperature control method Control operation 2 2 Specification CJ1W TC003 TC004 CJ1W TC103 TC104 Thermocouple Types R S K J T L and B Platinum resistance thermometer Types Pt100 and JPt100 There are two types of Unit available Two loop Unit with heater burnout detection 1 NPN or PNP outputs both with short circuit protection 1 Externally supplied power supply voltage 24 VDC 10 15 Maximum switching capacity 100 mA per output Leakage current 0 3 mA max Residual voltage 3 V max ON OFF control or PID control with two degrees of freedom Set with pin 6 on the Unit s DIP switch Forward or reverse operation Set with pins 4 and 5 on the Unit s DIP switch CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions Item Specification RUN STOP control Supported Controlled from the CPU Unit through the device variable for CJ series Unit Operation with CPU The Temperature Control Unit can be set to continue operating or stop operating when the CPU Unit is in Unit in PROGRAM PROGRAM mode Set with pin 1 on the Unit s DIP switch mode N Auto Manual switch for None m operational output 3 Autotuning AT of PID Supported C
21. PV and SP increases Consequently heating control uses reverse operation and cooling control uses forward operation Input Compensation Function This function adjusts the PV by adding an input compensation value to the temperature measured by the sensor If you have an application where you want to control and display the temperature at a point that is offset from the sensor s measurement point use this function to control the temperature at a value near the desired point Heater Burnout Detection Single phase Operation Only A Current Transformer CT can be connected to each loop to detect a heater burnout CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 5 Features and System Configuration Two Internal Alarms for Each Loop There are two internal alarms per loop Alarms can be output to the device variables for CJ series Unit in the CPU Unit s memory areas and any one of the following 9 alarm modes can be used Upper and lower limit alarm upper limit alarm lower limit alarm upper and lower limit alarm with standby sequence upper limit alarm with standby sequence lower limit alarm with standby sequence absolute value upper limit alarm and absolute value lower limit alarm Store Set Values in Non volatile Memory Various Temperature Control Unit set values such as the alarm SVs and PID constants can be stored in the Unit s non volatile memory using device variables f
22. Temperature Control Unit Make sure that the number of times data is written to the non volatile memory does not exceed 100 000 times Note When you set a value outside the setting range the Setting Error Flag of the Operation Data turns ON and you are notified of the Setting Error Number In this case the set value becomes invalid and the Unit operates using the previous set value Y o a g gt Q 0 9 v R 5 m Q g gt Q g 5 f Q 2 6 2 Monitor Values Device variable for ESET oP Default CJ series Unit g value Ch1_PV Process Value Depends on the Input Type set Ch2_PV ting Refer to 2 1 3 Input Specifica tions for details S NJeA I0OPUON Z 9 g Ch1_HtrCurVal Heater Current 1 0 to 550 A _ Ch2_HtrCurVal 0 0 to 55 0 Chi_MV Manipulated Variable 0 to 1000 Ch2_MV Monitor 2 0 0 to 100 0 1 Ifthe heater current exceeds 55 0 A the monitor value will indicate 13 108 2 The Manipulated Variable Monitor indicates the manipulated variable that is presently being output When output is ON 100 0 When output is OFF 0 0 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 37 2 Specifications and Functions 2 38 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Settings Required for Temperature Control This section explains the various settings required for temperature control 3 1 Setting the
23. The ambient temperature where the Temperature Install the Temperature Control Unit in a location with Control Unit is installed exceeds the Unit s rat an ambient temperature between 0 and 55 C ings Wireless equipment is being used near the Tem Shield the Temperature Control Unit perature Control Unit The temperature around the Temperature Control Move the Temperature Control Unit to a location where Unit is not uniform because of heat generating it won t be affected by heat generating equipment equipment near the Unit There is a draft breeze on the Temperature Eliminate or block the draft Control Unit s terminal block CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 11 5 Error and Alarm Processing Step Possible Cause Remedy Settings The Input Type setting is incorrect Set the Input Type correctly The Temperature Units setting is incorrect Set the Temperature Units correctly The measured temperature appears to be shifted Set the Inout Compensation Value to 0 0 because of the Input Compensation Value set ting The data storage display format setting is incor e Check the data storage display format of pin 3 of rect the DIP switch and correct the user program The user program of the Host System is not cor Always set pin 3 of the DIP switch to ON when con rect nected with the NJ series Usage There is a thermocouple input and the input termi Conne
24. To use an NS series PT to check events connect the PT to the built in EtherNet IP port on the CPU Unit CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 Error and Alarm Processing 5 3 2 Error Table The errors that may occur for this Unit are listed below The following abbreviations and symbols are used in the event level column Abbreviation Name Maj Major fault level Prt Partial fault level Min Minor fault level Obs Observation Info Information Symbol Meaning S Event levels that are defined by the system U Event levels that can be changed by the user This symbol appears only for events for which the user can change the event level A version in parentheses in the Event code column is the unit version of the CPU Unit when the event q Ww m 6 A r amp uv was added Refer to the NJ series Troubleshooting Manual Cat No W503 for all of the event codes that may occur in an NJ series Controller p Level waits svomame twang smetce Pa jac 04680000 hex Cold Junction An error occurredin Faulty connection to the cold page 19 Sensor Error the cold junction junction sensor sensor e The cold junction sensor failed 34940000 hex Setting Error There is an illegal e The set value is incorrect U S page 19 setting 64840000 hex Sensor Error An error occurredin Error in input from the Sensor U S page 20 the sensor input 64850000 hex CT Overflow
25. Unit Loop 1 2 Alarm 1 Mode and Alarm 2 Mode _AlmMd to 16 F i e 16 FF A N Ps 6 i gt Q 3 5 N 0 a O a 9 A e gt i m 3 7 Bits te ee ee ee ee de oe os te toe e fe ce Alarm mode 1 Alarm mode 2 Alarm mode 1 Alarm mode 2 Example To disable loop 2 set Loop 1 2 Alarm 1 Mode and Alarm 2 Mode _A mMa to 16 FF In this case Alarm Mode 1 and Alarm Mode 2 of loop 1 are set to 0 DM Area address CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 4 3 4 Optional Settings 4 4 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Error and Alarm Processing SSS This section provides information on troubleshooting and error processing 5 1 Error and Alarm Processing cccceeeee eee n eee e eee eens 5 2 9 2 TYOUDICSNOOUNG c 3s fate rere eee eee ees 5 10 9 3 EVCNULOGS iden thine a2 eatin he dolar Sareea a cavenden a oe aes 5 16 5 3 1 Overview of the Event LogS 0 cece eee eee eee 5 16 Sore Enor lable 242 t8vastitackevausaste tga dekte toed weeds ees Bes 5 17 5 393 Eror DESENDIONS 2210 22eicetecatiadcctagacktohcteteah ton hoe dad 5 18 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 1 5 Error and Alarm Processing 5 1 Error and Alarm Processing f Identifying Errors with the Indicators The ERC Indicator or ERH Indicator will light if an alarm or
26. alarms are cleared automatically when the cause of the alarm is corrected If pin 1 of the Temperature Control Unit s DIP Switch is OFF stop operation when CPU Unit is in PRO GRAM mode the RUN Indicator will be OFF when the CPU Unit is in PROGRAM mode Ch1_SensErr Chl1_CTOvfFlig Ch1_SetErr Chl1_HBFlg Ch2_SensErr Ch2_CTOvfFlg Ch2_SetErr Ch2_HBFlg There is an error in a setting Cause An input error has occurred The heater current is above e a A heater circuit has burned 55 0 A out Control e Control operation contin Control operation continues The incorrect set value will Control operation continues status ues Output OFF be ignored and operation will e Alarm operates as if the continue with the set values temperature is out of retained in the Temperature range Control Unit y a m g Y 5 el D D 3 U rj A Q v 5 amp Processing Check for incorrect input wir The heater current value will Check the Setting Error Check the heater and repair ing disconnection short cir be correct when the current Number in the heater where the burnout cuit and incorrect input type is within range DecPointSetErrSta Cor occurred setting rect the indicated setting Setting Error Numbers Setting error n mber Setting name Priority No incorrect settings Alarm mode 1 Alarm mode 2 Alarm 1 hysteresis Alarm 2 hysteresis Set point Alarm 1 SV Alarm 2 SV Input compensation value
27. error occurs in the Temperature Control Unit Front of Temperature Control Unit RUN RUN Indicator Green Lit The Temperature Control Unit is operating normally it __ Te Temperature Control Unit is stopped ERC Temperature Control T An error occurred in the Temperature Control Unit itself Notit lit There is no error in the Temperature Control Unit ERH CPU Unit Error ka An error occurred in the CPU Unit Not Notlit There is no error in the CPU Unit 5 2 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 Error and Alarm Processing i Error Processing Flowchart Use the following flowchart to identify the error when an error has occurred in the Temperature Control Unit Error occurred An alarm occurred while the Unit was operating Yes p g Yes Is the RUN Indicator lit Is the ERC Indicator lit Refer to Alarms and Statuses Detected by the Temperature Control Unit No No Confirm that the Unit s Initialization Data is correct Refer to Alarms and Statuses Detected by the Temperature Control Unit An error occurred in the CPU Unit Yes Refer to Errors Originating in the CPU Unit y a m 3 f gt Q gt f 3 U O A R U gt Q Yes Is the ERH Indicator lit Is the RUN Indicator lit No No Confirm that the Unit s unit number setting is correct Refer to Errors Originating in the CPU Unit Refer to 5 2 Tro
28. heater burnout detection function CJ1W TC103 CJ1W 1C104 f Temperature Ranges Platinum resistance Thermocouple Item Tuner i 1800 fae 1600 1400 1200 1000 650 0 650 0 60 40 p 0 400 0 B 0 20 200 200 an 200 0 e 200 0 200 0 O O Usable temperature range C Settings 2 to 9 are not allowed K CA Chromel alumel R Platinum 13 Rhodium Platinum J IC lron constantan S Platinum 10 Rhodium Platinum T CC Copper constantan B Platinum 30 Rhodium Platinum 6 Rhodium L lron constantan 1 2 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 Features and System Configuration i Exchange Data with the CPU Unit Data can be exchanged between the CPU Unit and Temperature Control Unit through the I O port gen erated for the Temperature Control Unit To connect this Unit to the NJ series set pin 3 Data storage display format of the DIP switch to ON The factory setting is OFF J 3 d o 5 9 2 i f SW3 Data storage display format Settings Settings are not allowed 16 bit binary This change becomes effective when the Controller is reset or when the Unit is restarted soinyee4 Z 1 1 2 Features Use ON OFF Control or PID Control with 2 Control Loops The Temperature Control Unit can perform basic ON OFF control as wel
29. index 4 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Authorized Distributor
30. manual is intended for the following personnel who must also have knowledge of electrical sys tems an electrical engineer or the equivalent e Personnel in charge of introducing FA systems e Personnel in charge of designing FA systems e Personnel in charge of installing and maintaining FA systems e Personnel in charge of managing FA systems and facilities For programming this manual is intended for personnel who understand the programming language specifications in international standard IEC 61131 3 or Japanese standard JIS B3503 Applicable Products This manual covers the following products e CJ series Temperature Control Units e CJ1W TC003 e CJ1W TC004 e CJ1W TC103 e CJ1W TC104 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 Relevant Manuals Relevant Manuals There are three manuals that provide basic information on the NJ series CPU Units the NJU series CPU Unit Hardware User s Manual the NJ series CPU Unit Software User s Manual and the NJ series Instructions Reference Manual Most operations are performed from the Sysmac Studio Automation Software Refer to the Sysmac Studio Version 1 Operation Manual Cat No W504 for information on the Sysmac Studio Other manuals are necessary for specific system configurations and applications Read all of the manuals that are relevant to your system configuration and application to make the most of the NU series CPU Unit
31. not described in this manual e Nuclear energy control systems combustion systems railroad systems aviation systems medical equipment amusement machines vehicles safety equipment and installations subject to separate industry or government regulations e Systems machines and equipment that could present a risk to life or property Please know and observe all prohibitions of use applicable to the products NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS AND THAT THE OMRON PRODUCTS ARE PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM PROGRAMMABLE PRODUCTS OMRON shall not be responsible for the user s programming of a programmable product or any consequence thereof 14 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Read and Understand this Manual Disclaimers CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons lt is our practice to change model numbers when published ratings or features are changed or when significant construction changes are made However some specifications of the products may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on you
32. of connection for EtherCAT are within specifications Do not connect EtherCAT communications to EtherNet IP a standard in house LAN or other net works An overload may cause the network to fail or malfunction e Malfunctions or unexpected operation may occur for some combinations of EtherCAT revisions of the master and slaves If you disable the revision check in the network settings use the Sysmac Studio to check the slave revision settings in the master and the actual slave revisions and then make sure that functionality is compatible in the slave manuals or other references You can check the actual slave revisions from the Sysmac Studio or on slave nameplates e After you transfer the user program the CPU Unit is restarted and communications with the Ether CAT slaves are cut off During that period the slave outputs behave according to the slave settings The time that communications are cut off depends on the EtherCAT network configuration If the EtherCAT network configuration contains only OMRON EtherCAT slaves communications are cut off for a maximum of 45 seconds Before you transfer the user program confirm that the system will not be adversely affected CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Precautions for Safe Use e f the Fail soft Operation parameter is set to stop operation process data communications will stop for all slaves when an EtherCAT communications error is detected
33. of each loop J01_Ch _PV are stored in the data storage destination of the user defined variable 7emperature Each input value is read when the Sensor Error Flag of each loop is OFF 2 8 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions Variable Variable names Variable type Type J01_Ch1_PV Loop 1 Process Value INT J01_Ch2_PV Device vari Loop 2 Process Value INT able for Cu JO1_Ch1_SensErr series Unit 1 Loop 1 Sensor Error Flag BOOL JO1_Ch2_SensErr Loop 2 Sensor Error Flag BOOL Temperature1 User defined Loop 1 PV Data Storage Destination INT Temperature2 variable 2 Loop 2 PV Data Storage Destination INT 1 Device variables for CJ series Unit are created using the O map from the Sysmac Studio 2 Before you create the user program use Sysmac Studio to create user defined variables N N D ke E A ad fe gt V g A 8 c 0 Example of program JO1_Ch1_SensErr Loop 1 Sensor Error Flag JO1 Chi_ PV Temperature 1 JO1_Ch2_SensErr Loop 2 Sensor Error Flag JO1_Chi_ PV Temperature2 Settings 1 Set the Unit number referring to 2 3 3 Unit Number Switches If the unit number is set to 1 2 Set the input type referring to 2 3 5 Input Type Switch Set the switch on the front panel of the Unit to 1 for a K thermocouple 0 0 to 500 0 C CJ series Temperature Control Units Operation Manual for NJ series CPU Unit
34. of the OUT Area of Operating Parameters are not imported into the Temperature Control Unit When the bit is 0 PID constants of the OUT Area of Operating Parameters are imported into the Temperature Control Unit Loop 2 Standby The value becomes 1 when the Tempera Flag ture Control Unit is waiting for I O refreshing after the Controller is reset or the Unit is restarted 11 Ch2_StbyFlg BOOL 12 Ch2_CJErr BOOL 13 Ch2_CTOvfFlg BOOL Loop 2 Cold The value becomes 1 when Junction e Cold junction sensor error occurs Sensor Error Loop 2 CT The value becomes 1 when the heater cur Overflow Flag rent of the CT current detector exceeds 55 0 A Loop 2 Sensor The value becomes 1 when Error Flag e Sensor is not connected to loop 2 e Sensor of loop 2 disconnects e Input temperature exceeds the measure ment temperature range 14 Ch2_SensErr BOOL 15 Ch2_SaveFlg BOOL 5 6 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Loop 2 Save The value becomes 1 when you select save Completed loop2 change from 0 to 1 and data is writ Flag ten to the non volatile memory This flag initializes to 0 when Loop 2 Save changes from 1 to 0 however the value is 0 immediately after a controller reset 5 Error and Alarm Processing 7 ERC Indicator Litand RUN Indicator Lit These alarms indicate that an incorrect operation was performed while the Unit was operating normally These
35. power DM Setting Error There is an error in the Ini Control operation Check the location of the error correct the initial Initialization Data tialization Data settings will stop ization data alarm mode or alarm hysteresis and then restart the Unit or reset the controller including by turning ON the power i Errors Originating in the CPU Unit The ERH Indicator will light when the Temperature Control Unit cannot operate normally because I O refreshing is not being performed properly with Special I O Units An error in the CPU Unit or I O bus can interfere with I O refreshing ERH Indicator Lit and RUN Indicator Lit jee Lit HH Not lit The ERH and RUN Indicators will both be lit when I O refreshing is not being performed properly between the CPU Unit and the Temperature Control Unit due to an error in the I O bus or a WDT watchdog timer error in the CPU Unit Turn the Controller power supply OFF and ON For details refer to the NJU series CPU Unit Hardware Users Manual Cat No W500 Error Cause Control status Processing CPU Unit Monitor A response was not Control operation Check the I O refreshing interval Error returned from the CPU will continue Unit within the fixed inter val CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 Error and Alarm Processing i ERH Indicator Lit and RUN Indicator Not Lit mee T lit If there is an error in t
36. series CPU Unit W491 33 Unit Versions 2 Right click any open space in the Unit Editor and select Production Information The Production Information Dialog Box is displayed l Production information Ed Model information Lot number N7501 1500 Ver 1 00 30810 Hardware version DFDDD Software version SYSTEM 1 00 00 23327 BOOT 20110726 IOPFP B 3 0 ESS IOPRW 1 02 Production information Runtime 165 Model information Sm Rack 0 Slot 0 Unit 4 CILW SCU22 Ver 2 0 z 7 Trg NA Unit revision _ Rack 0 Slot 0 Unit 4 CJIW 5SCU22 Ver 2 0 110711 PEro T AO Rack 0 Slot 1 Unit 1 CIIW DAC4 Ver 031201 Rack 0 Slot 1 Unit 1 CJ1W DAD41 Ver 031201 Simple Display Detailed Display In this example Ver 1 00 is displayed next to the unit model The following items are displayed CPU Unit CJ series Units Unit model Unit model Unit version Unit version Lot number Lot number Rack number slot number and unit number EtherCAT Slaves 1 Double click EtherCAT under Configurations and Setup in the Multiview Explorer Or right click EtherCAT under Configurations and Setup and select Edit from the menu The EtherCAT Configuration Tab Page is displayed for the Controller Configurations and Setup layer 2 Right click the master in the EtherCAT Configurations Editing Pane and select Display Produc tion Information The Production Information Dialog Box is displayed 3 Production Information Eg Type
37. source of the problem try to isolate the problem from the symptoms using the tables on the following pages CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 Error and Alarm Processing i Troubleshooting from Symptoms Measurement Errors Incorrect Measurement or No Measurement Step Possible Cause Remedy Connection The temperature sensor is connected to the Wire temperature sensor correctly wrong terminals or polarity is reversed The temperature sensor connected to the Tem Replace the temperature sensor with one that is com perature Control Unit is not compatible with the patible with the Temperature Control Unit Unit The temperature sensor wires are broken short Replace the temperature sensor with a good one circuited or damaged No temperature sensor is connected Connect a temperature sensor Installation The compensating conductor being used is not e Directly connect a thermocouple with long lead wires compatible with the thermocouple e Use a compensating conductor that is compatible with the thermocouple Some equipment is connected between the ther The equipment used for connections must be made mocouple and Temperature Control Unit that specifically for use with thermocouples uses metal different than the metal in the com pensating conductor or thermocouple y S Ri ea i S 9 B 5 The terminal screws are loose so there is poor Tighte
38. storage display format Data storage display format format Set to ON for use Control operation for loop 1 Forward Reverse cooling heating suoioun 4 Bues YOUMS did v Z Control operation for loop 2 Forward Reverse cooling heating Control method ON OFF con PID control trol Initialize set values in Non vola Initialize Do not initial tile Memory ize Transfer set values in Non vola Transfer Do not trans ON tile Memory fer j Operation in PROGRAM mode Pin 1 The following table shows how the Temperature Control Unit will operate when the CPU Unit s oper ating mode is changed Temperature Control Unit Operation of Temperature Control Unit when settings CPU Unit s operating mode is changed OFF Stop Continue operation ON Continue Continue operation i Temperature Units Pin 2 Select either C display centigrade or F display fahrenheit When F is selected the temperature is converted using the following equation F C x 1 8 32 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 13 2 Specifications and Functions 2 14 i Data Storage Display Format Pin 3 Set this switch to ON for use i Control Operation for Loop 1 Pin 4 Pin 4 selects forward cooling operation ON or reverse heating operation OFF for control loop 1 E Control Operation for Loop 2 Pin 5 Pin 5 selects forward cooling operation ON or reverse heatin
39. to 2 6 Range of Set Values and Monitor Values 2 30 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions The meaning of the row of R W in the table below is as follows RW Read Write R Read only Device variable for CJ series Unit Data R W Function Loop 1 type Chi_AL1HystrsC _Ch2_AL1HystrsC UINT RW Loop 1 and Loop 2 Set the Alarm 1 hyster fg fg Alarm 1 Hysteresis esis Chi_AL2HystrsC _Ch2_AL2HystrsC UINT RW Loop 1 and Loop 2 Set the Alarm 2 hyster fg fg Alarm 1 Hysteresis esis AlmMd WORD RW Loop 1 2 Alarm 1 Alarm 1 Mode and Mode and Alarm 2 Alarm 2 Mode of Loop Mode 1 and Loop 2 16 0 No alarm 16 1 Upper and lower limit alarm 16 2 Upper limit alarm 16 3 Lower limit alarm 16 4 Upper and lower limit range alarm 16 5 Upper and lower limit alarm with standby sequence 16 6 Upper limit alarm with standby sequence 16 7 Lower limit alarm with standby sequence 16 8 Absolute value upper limit alarm 16 9 Absolute value lower limit alarm The values written are written to RAM Explanation of Alarm Modes Bits 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Alarm 1 Mode Alarm 1 Mode Alarm 2 Mode 2 22 at 20 28 22 21 20 22 ot 8 22 21 Note Setting Alarm 1 or Alarm 2 Mode to 16 FF will disable the corresponding loop Control operations will stop and ERC indicator w
40. version is given on the ID information label of the products for which unit versions are man aged as shown below Example for NJ series NJ501 LJLILIL CPU Unit lt ID information label Unit model Unit version Lot No DDMYYO a Lot number and serial number MAC address The following information is provided on the ID information label Item Description Unit model Gives the model of the Unit Unit version Gives the unit version of the Unit Lot number and Gives the lot number and serial number of the Unit serial number DDMYY Lot number LJ For use by OMRON xxxx Serial number M gives the month 1 to 9 January to September X October Y November Z December MAC address Gives the MAC address of the built in port on the Unit i Confirming Unit Versions with Sysmac Studio You can use the Unit Production Information on the Sysmac Studio to check the unit version of the CPU Unit CJ series Special I O Units CJ series CPU Bus Units and EtherCAT slaves The unit versions of CJ series Basic I O Units cannot be checked from the Sysmac Studio CPU Unit and Cj series Units 1 Double click CPU Expansion Racks under Configurations and Setup in the Multiview Explorer Or right click CPU Expansion Racks under Configurations and Setup and select Edit from the menu The Unit Editor is displayed for the Controller Configurations and Setup layer CJ series Temperature Control Units Operation Manual for NJ
41. you change anything else in the file the Controller may perform unexpected operation when you restore or automatically transfer the data Unit Replacement e If you replace a CPU Bus Unit or Special I O Unit refer to operation manual for the Unit for informa tion on the data required for individual Units and redo the necessary settings e The absolute encoder home offset is backed up with a Battery in the CPU Unit When you change the combination of the CPU Unit and Servomotor e g when you add or replace a Servomotor define home again To restore the information without changing the CPU Unit Servomotor combination remove the absolute encoder home offset from the data to restore i Task Settings e Ifa Task Period Exceeded error occurs shorten the programs to fit in the task period or increase the setting of the task period i Motion Control e Use the system defined variable in the user program to confirm that EtherCAT communications are established before you attempt to execute motion control instructions Motion control instructions are not executed normally if EtherCAT communications are not established e Use the system defined variables to monitor for errors in communications with the slaves that are controlled by the motion control function module Motion control instructions are not executed nor mally if an error occur in slave communications e Before you start an MC Test Run make sure that the operation parameters are
42. 0 If the factory settings are used the proportional band will produce a manipulated variable of 0 0 at the set point i Example PID Control Application Procedure In this example autotuning is executed for loop 1 and loop 1 operates using PID control with two degrees of freedom First execute Autotuning AT 1 Start autotuning by turning the device variable for CJ series Unit Loop 1 Start AT Bit _Ch1_StartATCmad from 0 to 1 Next perform PID constants calculation 2 When autotuning is completed the calculated PID constants will be stored in the Read PID Constants At the same time the Loop 1 PID Constants Calculated Flag _Ch1_P DCalcFlg will be turned ON Use this bit as an input condition in the CPU Unit s user program and transfer the Read PID Constants to Setting PID Constants 3 After the PID constants have been transferred to the output area by the user program turn the Loop 1 change PID Constants Bit _Ch1_ChgP IDCmd from 0 to 1 The Temperature Control Unit will read the Setting PID Constants The PID Constants Calculated Flag _Ch1_P DCalcFlg will be turned from 1 to 0 automatically when you turn the Change PID Constants Bit _Ch1_ChgP IDCmd from 0 to 1 Refer to A 4 Sample Programming for an example user program that performs the steps out lined above 3 12 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Timing Chart Start AT Bit PID Constants Calculate
43. 00 to D20099 D20100 to D20199 D20200 to D20299 D20300 to D20399 D20400 to D20499 D20500 to D20599 D20600 to D20699 D20700 to D20799 D20800 to D20899 D20900 to D20999 D20000 nx100 to D20000 nx100 99 D29400 to D29499 Appendices EN Additional Information e f the same unit number or Special I O Unit Area is set for more than one Special I O Unit a major fault level Duplicate Unit Number occurs and the Unit will not operate e After correcting the unit number setting turn the Controller power supply OFF and ON gt 405 p sn oway pue yun SeLes f 10 sajqeue A 22A JO B qeL B2UepUCdsaIOD Y 8 i Cc gt 3 i CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 A 5 Appendices Operation Data CJ series 1 O NJ series device variable for O memory address CJ series Unit er sem meone nme oe Output 00 15 Ch1_SetPointCfg Loop 1 Set point INT CPU Unitto A 00 15 Ch2 SetPointCf Loop 2 Set point INT this Unit t 00 15 _Ch2_ ae 0 Loop 1 Stop AT Bit BOOL 0 Loop 2 Stop Bit BOOL Loop 1 Stop Bit BOOL Ch2_ChgPIDCmd Loop 2 change PID Con BOOL stants Bit Ch1_ChgPIDCmd Loop 1 change PID Con BOOL stants Bit Ch2_SaveCmd Loop 2 Save Settings Bit BOOL Ch1_SaveCmd Loop 1 Save Settings Bit BOOL 3 4 12 13 14 15 A 6 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Appendices CJ series I O NJ
44. 01 is used when this Unit is registered in Unit Configuration Defined variable User defined variable Name Allocated address AT Comments type setting Device variable for CJ series Unit Name Dafa pecan Allocated address AT Comments type setting JO1_Chi_ATFlg BOOL False lOBus rack 0 slot 0 Ch1__ Loop 1 AT Flag StaWd Ch1_ATFlg J01_Ch1_PIDCalcFlg BOOL False lOBus rack 0 slot 0 Ch1_ Loop 1 PID Constants StaWd Ch1_PIDCalcFlg Calculated Flag J01_Ch1_SaveFlg BOOL False lOBus rack 0 slot 0 Ch1_ Loop 1 Save Completed StaWd Ch1_SaveFlg Flag J01_Ch1_ProportionalBa UINT lOBus rack 0 slot 0 Ch1_ Loop 1 Proportional Band ndSta ProportionalBandSta for Monitor J01_Ch1_ProportionalBa UINT lOBus rack 0 slot 0 Ch1_ Loop 1 Proportional Band ndCfg ProportionalBandCfg JO1_Ch1_IntgTmSta UINT l OBus rack 0 slot 0 Ch1__ Loop 1 Integral Time for IntgTmSta Monitor JO1_Ch1_IntgTmCfg UINT lOBus rack 0 slot 0 Ch1__ Loop 1 Integral Time IntgTmCfg J0O1_Ch1_DerivativeTmSt UINT lOBus rack 0 slot 0 Ch1__ Loop 1 Derivative Time for a DerivativeTmSta Monitor J01_Ch1_DerivativeTmCf UINT lOBus rack 0 slot 0 Ch1_ Loop 1 Derivative Time g Derivative TmCfg J01_Ch1_StartAT Cmd BOOL False lOBus rack 0 slot 0 Ch1_ Loop 1 Start AT Bit StartAT Cmd J01_Ch1_ChgPIDCmd BOOL False lOBus rack 0 slot 0 Ch1_ Loop 1 change PID Con ChgPIDCmd stants Bit J01_Ch1_SaveCmd BOOL False lOBus rack 0 slot 0 Ch1_ Loop 1 Sav
45. 3 TC004 TC103 TC104 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit This manual SYSMAC CJ Series Temperature Control Units Operation Manual CJ1W TCUOLILI Control Units CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Description An introduction to the entire NJ series system is provided along with the following information on the CPU Unit e Features and system configuration Introduction Part names and functions General specifications Installation and wiring Maintenance and inspection Use this manual together with the NJ series CPU Unit Software User s Manual Cat No W501 The following information is provided on a Con troller built with an NJ501 CPU Unit e CPU Unit operation e CPU Unit features e Initial settings e Programming based on IEC 61131 3 lan guage specifications Use this manual together with the NU series CPU Unit Hardware User s Manual Cat No W500 Describes the operating procedures of the Sys mac Studio Describes the application methods of the Cu series Temperature Control Units used in an NJ series configuration Describes the application methods of the Cu series Temperature Control Units 35 Revision History Revision History A manual revision code appears as a suffix to the catalog number on the front and back covers of the manual Cat No W491 E1 03 to Revision code Revi
46. 6 PATI NOOO 22s 2 c2o08so2e0 52s2ses2es R Seis 3 15 Alarm output function ic vecalacenel cee eee 3 15 Ala VS eticeton sass A eee atlas 3 16 Assumed CAUSO sis arr a E cee oe 5 17 Al AUTOUNO s x2ctcetsstscesveetecactentesssdseuncteeieeseteiees 1 5 3 11 PA CXS CUUIOM noren as cee eee A 11 Autotuning EXECUTION cccccceseeecceeeeeeeceesseeessnaeess A 11 C GE eet eases a ote aaa E 2 13 Cold junction Sensor error sssssssssrnrerrrrrrrrerreren 5 8 5 19 CONNECCION soreer aa skew shakceceocter bineciee cies 2 11 Contormethod taiaire e a S 3 7 Control operation x racviceacsssndurnieaceeiacsiaoaredeeivzassareeears 1 5 3 6 GS ONO sia et e a a aeaese 2 2 COMMO MSO G ec Sersinseach ec n RA 3 8 COnMOVSCNSIIVILY saisir an ad 3 10 Controller errors sariden e E manccsecarapeen 5 16 CPU UNICE ann AA aaaeern mea 5 2 CPU t MONITOR CI OF sarrin EE 5 8 CPUunt WDT GNO annn a 5 9 CT current transformer 0 cccccccceeeeeeeeeseeeeeees 2 4 3 19 CT OVErOW scura r 5 7 5 20 Current transformer CT cccccceeeeeeeeeeeeeeeeees 2 4 3 19 Current transformer CT ratings cccccssseeeeseeeeeeeeeees 2 4 D Data storage display format cceeeeeeeeeeeeeeeeees 2 14 Decimal POINT oe e 2 29 Derivative time cccccceccseceeceececeeeceeseeceeeeeeeeeneeees 3 7 3 14 Device variables for CJ series unit ccccceceeeeeeeeees 2 21 Dielectric strength cccccsseeceeccsseeeeccesseeeeseeeeesseaeeee
47. 6 2 EMI Electromagnetic Interference EN 61131 2 and EN 61000 6 4 Radiated emission 10 m regulations Low Voltage Directive Always ensure that devices operating at voltages of 50 to 1 000 VAC and 75 to 1 500 VDC meet the required safety standards The applicable directive is EN 61131 2 Conformance to EC Directives The NJ series Controllers comply with EC Directives To ensure that the machine or device in which the NJ series Controller is used complies with EC Directives the Controller must be installed as fol lows e The NJ series Controller must be installed within a control panel e You must use reinforced insulation or double insulation for the DC power supplies connected to DC Power Supply Units and I O Units e NJ series Controllers that comply with EC Directives also conform to the Common Emission Stan dard EN 61000 6 4 Radiated emission characteristics 10 m regulations may vary depending on the configuration of the control panel used other devices connected to the control panel wir ing and other conditions You must therefore confirm that the overall machine or equipment complies with EC Directives CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 31 Regulations and Standards Conformance to Shipbuilding Standards The Nu series Controllers comply with the following shipbuilding standards Applicability to the ship building standards is based on certain usage conditions
48. 8 of the DIP switch is ON the setting data stored in the non volatile memory will automatically be transferred to the device variables for CJ series Unit Operating Parameters when the Unit restarts or the Temperature Control Unit is reset including when the power is turned ON CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 23 Y a 4 A gt J 5 a 0 g g D A Y c 5 rF JOW W BIIVE OA UON OU Ul ONJA 18S Hules E G Z 2 Specifications and Functions Area allocated in CPU Transfer timing Unit from device vari ables for CJ series Unitin CPU Unit to RAM Device vari Operation Set point I O refresh period able for CJ Data Heater Burnout series Unit Current Alarm Mode Alarm Hysteresis When the control ler is reset or the Unit restart Initializa tion Data Alarm SVs Input Compensa tion Value Operating Parameters I O refresh period Control Period Control Sensitivity Proportional Band During I O refresh ing and PID Con stants Calculated Flag is O 1 Integral Time Derivative Time Transfer timing from RAM to non volatile memory Setting data in RAM is written to non volatile mem ory when you change the Save Settings Bits of the device variables for CJ series Unit for operation from 0 to 1 2 Transfer timing from non volatile memory to device variables for CJ series Unitin CPU Unit When the Unit r
49. AL1Flg BOOL Loop 1 and The value becomes 1 when Loop 2 AL1 the temperature is within the Flag alarm range set for the input value of loop 1 and loop 2 The value becomes 0 when the temperature is not within the alarm range set for the input value Ch1_AL2Flg Ch2_AL2Flg BOOL Loop 1 and The value becomes 1 when Loop 2 AL2 the temperature is within the Flag alarm range set for the input value of loop 1 and loop 2 The value becomes 0 when the temperature is not within the alarm range set for the input value Chi_HBFlg Ch2_HBFlg BOOL Loop 1 and The value becomes 1 if the Loop 2 HB Flag detected heater current does CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 27 Y a x A gt D 5 fe 0 S g g 0 A U c c 2 rF eyeq uoneiado S Z not exceeds the Heater Burn out Current 2 Specifications and Functions Device variable for CJ series Unit Loop 1 Chi_ATFlg Ch1_CtlOutFlg Ch1_StopFlg Ch1_SetErr Ch1_PIDCalcFlg Chi_StbyFlg Ch1_CJErr Ch1_CTOviFlg 2 28 Data R bee RW Nome Ch2_ ATFig BOOL i Ch2_CtlOutFlg Ch2 StopFlg Ch2_SetErr Ch2_PIDCalcFlg Ch2_StbyFlg Ch2_CJErr Ch2_CTOviFlg a a i i 7 E 7 i 7 7 k a Loop 1 and Loop 2 AT Flag Loop 1 and Loop 2 Control Output Flag Loop 1 and Loop 2 Stop Flag Loop 1 and Loop 2 Setting Error Flag Loop 1 and Loop 2 PID Co
50. Controller error will occur the next time you start operation and operation will stop Do not turn OFF the power supply or remove the SD Memory Card while SD Memory Card access is in progress i e while the SD BUSY indicator flashes Data may become corrupted and the Control ler will not operate correctly if it uses corrupted data To remove the SD Memory Card from the CPU Unit while the power supply is ON press the SD Memory Card power supply switch and wait for the SD BUSY indicator to turn OFF before you remove the SD Memory Card Do not disconnect the cable or turn OFF the power supply to the Controller when downloading data or the user program from Support Software Always turn OFF the power supply to the Controller before you attempt any of the following e Mounting or removing I O Units or the CPU Unit e Assembling the Units e Setting DIP switches or rotary switches CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Precautions for Safe Use e Connecting cables or wiring the system e Connecting or disconnecting the connectors The Power Supply Unit may continue to supply power to the rest of the Controller for a few seconds after the power supply turns OFF The PWR indicator is lit during this time Confirm that the PWR indicator is not lit before you perform any of the above g Operation e Confirm that no adverse effect will occur in the system before you attempt any of the following e Ch
51. ICfg to 20 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 17 i C Al 5 g D gt 3 TI c 5 A ch fe 5 3 Settings Required for Temperature Control i Summary of Alarm Output Function Settings Variable name AlmMd Ch1_AL1HystrsCfg Ch1_AL2HystrsCfg Ch2_AL1HystrsCfg Ch2_AL2HystrsCfg Ch1_ALiLvIiCfg Ch1_AL2LvIiCfg Ch2_ALiLvICfg Ch2_AL2LvICfg Function Loop 1 2 Alarm 1 Mode and Alarm 2 Set the Alarm 1 Mode and Alarm 2 Mode of loop 1 and loop 2 WORD 0 No alarm 1 Upper and lower limit alarm 2 Upper limit alarm 3 Lower limit alarm 4 Upper and lower limit range alarm 5 Upper and lower limit alarm with standby sequence 6 Upper limit alarm with standby sequence 7 Lower limit alarm with standby sequence 8 Absolute value upper limit alarm 9 Absolute value lower limit alarm UINT Set the loop 1 alarm hys UINT Set the loop 2 alarm hys INT Set the loop 1 detection INT Set the loop 2 detection xo D CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 Settings Required for Temperature Control 3 11 Using the Heater Burnout Alarm i Heater Burnout Detection Follow this procedure to detect heater burnout an open heating wire To the CT terminals 1 Pass the heater wire through the hole in the Current Transformer CT Refer to Current Trans former CT Rat
52. Input Type ccc eee 3 2 3 2 Selecting the Temperature Units ccc cece eee ees 3 4 3 3 Setting the Pin 3 of the DIP Switch ccc cence ees 3 5 3 4 Selecting the Control Operation Forward Reverse 0 00000caes 3 6 3 5 Selecting PID Control or ON OFF Control 0000 c cence eae 3 7 3 6 Setting the Control Period c cece eee 3 8 3 7 Setting the Set Points iv 8 since medina hee Oa wae eae eee bie ee 3 9 3 8 Using ON OFF Control 0cc cece eee eee eee eee 3 10 3 9 Setting the PID Constants oii ikoiiiiee er aie eee 3 11 3 10 Using the Alarm Output Function 0cc cece 3 15 3 11 Using the Heater Burnout Alarm 2 ccc 3 19 3 12 Starting and Stopping Temperature Control 00cceeaneeeees 3 21 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 1 3 Settings Required for Temperature Control 3 1 Setting the Input Type Set the input type of the temperature sensor being used There are two types of Temperature Control Units available One accepts thermocouple inputs and the other accepts platinum resistance thermom eter inputs Both types have an INPUT TYPE rotary switch on the front of the Unit to set the input type Set the Input Type Switch to the correct setting for sensor and temperature range being used The input type setting applies to all of the Unit s control loops It is not possible to set different input types for the different control loops i Sett
53. It may not be possible to use the product in some locations Contact your OMRON representative before attempting to use a Controller on a ship i Usage Conditions for NK and LR Shipbuilding Standards e The NJ series Controller must be installed within a control panel e Gaps in the door to the control panel must be completely filled or covered with gaskets or other material e The following noise filter must be connected to the power supply line Noise Filter Manufacturer Model Cosel Co Ltd TAH 06 683 Trademarks 32 e Sysmac and SYSMAC are trademarks or registered trademarks of OMRON Corporation in Japan and other countries for OMRON factory automation products e Windows Windows 98 Windows XP Windows Vista and Windows 7 are registered trademarks of Microsoft Corporation in the USA and other countries EtherCAT is registered trademark and patented technology licensed by Beckhoff Automation GmbH Germany The SD logo is a trademark of SD 3C LLC gt xP Other company names and product names in this document are the trademarks or registered trade marks of their respective companies CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Unit Versions Unit Versions Unit Versions A unit version has been introduced to manage CPU Units in the NJ Series according to differences in functionality accompanying Unit upgrades i Notation of Unit Versions on Products The unit
54. Loop 2 Alarm 2 Hysteresis UINT Operating Parameter CJ series I O NJ series device variable for I O memory address CJ series Unit DMNo BitNo Variablename Name Datatype Output D m 10 00 15 Chi_ALiLviCfg Loop 1 Alarm 1 SV INT CPU Unitto Dim 11 00 15 Ch1 AL2LvICt Loop 1 Alarm 2 SV INT this Unit Ometi 00 18 _Cht_ g p D m 12 00 15 Ch1_AllnOfsCfg Loop 1 Input Compensa INT tion Value D m 13 00 15 Ch1i_CtlPrdCfg Loop 1 Control Period UINT 00 15 Ch1_CtlHystrsCfg Loop 1 Control Sensitivity UINT D 2 D m 15 00 15 _Ch1_ProportionalBand Loop 1 Proportional Band UINT Cfg DTG UNT Loop 1 Derivative Time UINT Dm2 NT D m 22 00 15 Ch2_AllnOfsCfg Loop 2 Input Compensa INT tion Value i 00 15 Ch2 CtIPrdCfg Loop 2 Control Period UINT 00 15 Ch2_CtlHystrsCfg Loop 2 Control Sensitivity UINT 2 m 23 m 24 n Cfg m 26 a m 27 00 15 Ch2_IntgTmCtg Loop 2 Integral Time UINT 00 15 Ch2_DerivativeTmCfg Loop 2 Derivative Time UINT A 8 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 m 5 O Appendices CJ series 1 O NJ series device variable for I O memory address CJ series Unit omno eino Varabienane Name ate Input D m 30 00 15 Ch1_AL1LvISta Loop 1 Alarm 1 SV for This Unit to Monitor CPU Unit D m 31 00 15 Ch1_AL2LviSta Loop 1 Alarm 2 SV for Monitor D m 32 00 15
55. N A Alarm 1 0 No alarm Mode and eal Alarm 2 Upper and lower limit alarm Mode Upper limit alarm Lower limit alarm Upper and lower limit range alarm Upper and lower limit alarm with standby sequence Upper limit alarm with standby sequence Lower limit alarm with standby sequence Absolute value upper limit alarm Absolute value lower limit alarm Chi_AL1HystrsCfg Loop 1 and 0 to 9999 C Ch2_AL1HystrsCfg Loop 2 0 0 to 999 9 or _Ch1_AL2HystrsCig ao ano i _Ch2_AL2HystrsCfg Hysteresis Y o a g gt Q 0 9 v R 5 m Q g P Q g f Q SON EA 19S 1 9 2 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 35 2 Specifications and Functions Device variable for Default Non volatile f Data range CJ series Unit value memory save Ch1_AL1LvICfg Alarm 1 SV 999 to 9999 e The Tempera Ch2_AL1LvICfg 999 to 9999 ture Control T Unit s settings Chi_AL2LvICf Alarm 2 SV 999 to 9999 are written to tie j EAA RAM When the _Ch2_AL2LvICfg Save Settings Bit of the device Ch1_AllnOfsCfg Input Com 999 to 9999 variables torG i Ch2_AllnOfsCfg pensation 999 to 9999 series Unit for Value operation is turned to 1 the set values are written to non volatile mem ory 2 If DIP switch pin 8 is ON the set tings are auto matically transferred from non volatile memory to the CPU Unit when the Temperature
56. N Additional Information e ON OFF Control With ON OFF control the control output will be ON when the PV is below the SV The control output will be OFF when the PV is at or above the SV This control method is used when the Unit is set for reverse operation e PID Control with Two Degrees of Freedom In earlier versions of PID control the same controller section controlled both the response to the SV and the response to disturbances The weakness in this design was that both responses could not be satisfied at the same time If the disturbance response was emphasized i e P and were reduced and D was increased the SV response would oscillate and overshoot If the SV response was emphasized i e P and were increased and D was reduced the dis turbance response would be delayed To overcome these problems PID control with two degrees of freedom was used for this Tem perature Control Unit to take advantage of the strengths of PID control and improve both distur bance and target response as shown in 3 below Earlier PID Control Method 1 2 Not good Good Not good The disturbance response is good but The SV response is good but the the SV response is delayed disturbance response is not PID Control with Two Degrees of Freedom 3 Both the SV response and disturbance response are good CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 Features and System Configu
57. OMRON Machine Automation Controller CJ series Temperature Control Units Operation Manual for NJ series CPU Unit CJ1W TC003 CJ1W TC004 CJ1W TC103 CJ1W TC104 Temperature Control Units W491 E1 03 OMRON 2011 All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical electronic photocopying recording or otherwise without the prior written permission of OMRON No patent liability is assumed with respect to the use of the information contained herein Moreover because OMRON is constantly striving to improve its high quality products the information contained in this manual is subject to change without notice Every precaution has been taken in the preparation of this manual Nevertheless OMRON assumes no responsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained in this publication Introduction Introduction Thank you for purchasing an CJ series Temperature Control Units This manual contains information that is necessary to use with the NJ series CPU Unit Please read this manual and make sure you understand the functionality and performance of the NJ series CPU Unit before you attempt to use it in a control system Keep this manual in a safe place where it will be available for reference during operation Intended Audience This
58. PID 2 degrees of freedom with Autotuning AT Control output CJ1W TCL103 CJ1W TCL101 L103 Open collector NPN output pulse Open collector NPN output pulse External 24 VDC power supply External 24 VDC power supply CJ1W TCL104 CJ1W TCL102 _104 Open collector PNP output pulse Open collector PNP output pulse External 24 VDC power supply External 24 VDC power supply Setting accu Thermocouple 0 3 or 1 C whichever is larger 1 digit or less racy input Instruction Resistance ther 0 3 or 0 8 C whichever is larger 1 digit or less accuracy mometer input Data storage display format of data 16 bit binary only variable BCD or 16 bit binary selectable exchanged with CPU Unit Use with pin 3 of the DIP switch set to Set with pin 3 of the DIP switch ON OFF BCD ON Binary RUN STOP control Supported Operation during CPU Unit PRO Continue or stop operating selectable GRAM mode Autotuning AT of PID constant Can be started and stopped Sampling period 500 ms Input compensation value 99 9 to 999 9 C F Output wiring method Terminal block Heater Burnout Detection Available 2 loop type only CT heater detection current 0 0 to 50 0 A Setting write memory Non volatile Memory 100 000 writes or RAM CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 A 3 p gt N T c 5 A cr O 5 D g 6 5 A Q 2 C 6 g A U Cc Cc 2 7j 2 la n Q 5 8 g
59. PU Unit W491 Sections in this Manual Sections in this Manual Features and System Configuration specifications and Functions Settings Required for Temperature Control Optional Settings Error and Alarm Processing Appendices CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 9 CONTENTS CONTENTS PRE OCIUIG GIO ID seeesavemaceacesienucseieweneup da vauenseyetewanssavesasasnaenceasasnedescanrandacauameumeassnauenceare casey 1 Relevant Manuals soassa a 2 M ual C onfng urot Morana 3 Mani tal S Tuce 6 Secuons 1M MIS Mahuka aa 9 CONTENTS nana 10 Read and Understand this Manual sssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 13 Sae PEG AMO INS mon sacdeecsanmunsasnteoceusecanenuna 16 Precautions Tor Sale USC iiiisscssssisssssnetesssssasesavssececeasssasaraivvndecnsustusaisanvessessanasesaaanas 21 Precautions for Correct USC cs sss 27 Regulations and Standards ssssnsssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 31 UNIC VOVSIONS iaci 33 Related Mantas ire 35 REVISION HIS OIN ceira sea tinencccesswensuetisaacouannmuseuss 36 Section 1 Section 2 10 1 1 1 2 2 1 2 2 2 3 Features and System Configuration introduction and Features sis iiidiicdiediceasiccesteinwavacsuddniduntuarsianidstusavivinsiisivdadseniaruuauannacudiaveeariudanal 1 2 1 1 1 MOUCHO essan a aa aa 1 2 1 1 2 eS LU S ar a A E
60. Q O 5 5 Appendices A 3 Correspondence Table of Device Variables for CJ series Unit and Memory Used for CJ series Unit Addresses If this Unit is used with an NJ series CPU Unit the user program uses device variables for CJ series Unit that reference the memory used for CJ series Unit to use the functions The correspondence tables for word addresses bit positions and device variables for CJ series Unit between the I O memory of the CJU series CPU Unit and memory used for CJ series Unit of the NJ series CPU Unit are shown below Start address of special I O Unit area n 2000 words Unit number x 10 Unit number 0 to 94 Start address of special I O Unit DM area m D20000 Unit number x 100 Unit number O to 94 Set the ClO and DM area words allocated to the Unit by using the unit number switches on the front panel of the Unit Switch No 0 1 2 3 4 5 6 7 8 9 94 There are two unit numbers per Temperature Control Unit Hence the unit numbers 0 to 94 are avail Unite Special I O Unit area allocated CIO number Unit 6 CIO 2060 to CIO 2079 Unit 7 ClO 2070 to CIO 2089 CIO 2080 to CIO 2099 CIO 2090 to CIO 2109 Unit n CIO 2000 nx10 to CIO 2000 nx104 19 Unit 94 CIO 2940 to CIO 2959 able Please note that this is different from other Special I O Units CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Data Memory DM Area allo cated DM number D200
61. V is 50 0 A the heater burnout alarm will be ON Min detectable ON time 200 ms If the control output is ON for less than 200 ms the heater burnout detection function will not operate and heater current measurement will not be performed Current Transformer CT Ratings Item E54 CT1 E54 CT3 Max continuous heater current 120 A Dielectric strength 1 000 VAC 1 min Vibration resistance 50 Hz 98 m s2 Weight Approx 11 5 g Approx 50 g Accessories None Contacts 2 Plugs 2 The maximum continuous heater current that can be detected at a CU1W TCLILJL Temperature Control Unit is 50 A Note Do not use any Current Transformer CT other than the OMRON E54 CT1 or E54 CT3 Current Transformer CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions 2 1 2 Input Function Block Diagram Temperature Control Unit CPU Unit Special I O Controller hal Area Alarm 1 input Forward r everse Alarm 2 output switching Temperature Input 1 Control output 1 l CT CT input input 1 CT input Heater __ Heater alarm output 1 Pe Input 2 H Control Same as 1 output 1 CT input 2 Heater burnout alarm output 2 2 1 3 Input Specifications Pin 2 of the DIP switch selects whether the temperature is indicated in C or F The indicated range will be within 20 C or 20 F of the setting ranges shown
62. W491 2 9 2 Specifications and Functions 2 10 3 ezo9S Pe lt 2 li Set the Unit s functions referring to 2 3 4 DIP Switch Setting Functions Be sure that pin 2 is OFF to select centigrade and that pin 3 Data storage display format is ON to select BCD MODE 4 5 Mount and wire the Unit referring to 1 2 2 Mounting the Unit Turn ON the power supply to the controller Precautions for Safe Use EN 7 2 3 Always turn OFF the power supply to the Controller before attempting any of the following e Mounting or dismounting I O Units or CPU Unit e Assembling the Units e Setting DIP switches or rotary switches e Connecting cables or wiring the system After the power is turned OFF the Power Supply Unit may continue to supply power to the Con troller for a few seconds During that time the PWR indicator remains lit When performing any of the above operations check that the PWR indicator does not lit Additional Information An I O Setting Check Error occurs when there is a Unit Configuration in the CPU Unit which does not match the actual Unit Configuration In this case reset the Controller in step 2 of the follow ing Transfer a User Program to a CPU Unit process to cancel the error Transfer a User Program to a CPU Unit Connect Sysmac Studio to the Controller and transfer the created user program Reset the Controller Or restart this Unit Run with the created user program CJ ser
63. When the Controller i is reset or the Unit restarts Operating Parameters Device variables for Operating Parameters Constantly exchanges CJ series Unit for When the Controller is reset data necessary for operation adjustments a he Uaitrestalts TEE operation adjustments Device Variables for CJ series Unit These are variables used to exchange data between the user program and Special I O Unit Three types of device variables for CJ series Unit are available Operation Data Initialization Data and Operating Parameters For details refer to 2 5 2 Accessing from the User Program CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 21 2 Specifications and Functions i Unit Restart To resume operation after changing settings in the Initialization Data or removing the cause of errors first restart the Unit with one of the methods described below Initialization Data are updated after restart e Reset the Controller from Sysmac Studio e Reset the Controller from cycling the power supply to the controller e Restart using the ResetUnit instruction of the program e Restart using a system defined variable Variable name Type _CJB_S O Restart BOOL Unit number 00 to 94 in Precautions for Correct Use e f the error persists after the restart replace this Unit e During restart output is O V as the data immediately before restart is maintained for input 2 5 2 Accessing f
64. _Ch1_AL1HystrsCfg Ch2_AL1HysirsCfg and Alarm 2 Hysteresis _Chi1_AL2HystrsCfg _Ch2_AL2HysirsCfg inde pendently for each alarm The standard setting is 0 2 lf the alarm hysteresis settings are changed the new setting will not become effective until the control ler is reset or the Unit is restarted Always reset the controller or restart the Unit after changing these settings i Setting the Alarm SVs Operating Parameters The Alarm SVs are indicated by X in the Alarm Modes table in 3 10 Using the Alarm Output Function Set values in device variables for CJ series Unit Alarm 1 SV _Ch1_AL1LvICfg _Ch2_AL1LvICfg and Alarm 2 SV _Ch1_AL2LvICfg _Ch2_AL2LvICfqg EN Additional Information About the Standby Sequence The standby sequence disables the alarm output once the PV leaves the alarm range The alarm output will not function until the PV re enters the alarm range For example with the standard lower limit alarm mode the PV is usually lower than the set point when the power is turned ON so the PV is within the alarm range and the alarm output goes ON If Lower limit Alarm with Standby Sequence Mode is selected the alarm will not be output until after the PV rises above the alarm SP leaves the alarm range and then falls below the alarm SP again Restarting the Standby Sequence The standby sequence will be cleared once the PV leaves the alarm range but the standby sequence will restart reset in the follow
65. ad short circuit protection detection line disconnection detection and measures for EMC Directives i NJ series CPU Unit Software User s Manual Cat No W501 Section Section 1 Introduction Section 2 CPU Unit Operation Section 3 I O Ports Slave Configuration and Unit Configuration Section 4 Controller Setup Section 5 Designing Tasks Section 6 Programming Section 7 Checking Operation and Actual Operation Section 8 CPU Unit Functions Section 9 Communications Setup Section 10 Example of Actual Application Pro cedures Section 11 Troubleshooting Appendices CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Description This section provides an introduction to the NU series Controllers and their features and gives the NJ series Controller specifications This section provides information that is necessary to use the CPU Unit including how the CPU Unit works and the operations that it performs depending on the status of the CPU Unit This section describes how to use I O ports how to create the slave configuration and unit configuration and how to assign functions This section describes the initial settings of the function modules This section describes the task system and types of tasks This section describes programming including the programming languages and the variables and instructions that are used in programming This section describes the
66. al measurement of the heater s current to determine the appropriate heater burnout current CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 15 5 Error and Alarm Processing 5 3 EventLogs 5 3 1 Overview of the Event Logs 5 16 You use the same methods to manage all of the events that occur on the NuU series Controller The events include errors and information You can use the Sysmac Studio or an NS series PT to confirm current Controller events and the logs of events that have occurred These logs are called event logs Controller errors that occur for this Unit are also reported as events in the NJ series CPU Unit Refer to the NJ series CPU Unit Software User s Manual Cat No W501 for details on the event logs in an NJ series CPU Unit Refer to the NJ series Troubleshooting Manual Cat No W503 for details on Controller errors confirmation methods and corrections Check current Controller events and the event log of past events syemae studio NuJ series CPU Unit PLC Function Motion Control EtherCAT Master EtherNet IP Fventsdurge Function Module Function Module Function Module ne User program Create User defined Error instruction Event logs SetAlarm NS series PT Create User defined Information instruction SetInfo Backup battery Check current Controller events and the event log of past events EtherCAT slave
67. and diagram show the data exchange method for each data type Y a 4 A gt J 5 a 0 S g g D A U c 5 rF Data exchange type How to access Unit data Bats Contents AT specification Fome Timing of data type destination program exchange M JA AO L G Z Operation Process value set point I O port Opera Device variable for I O refresh period Data start AT bit stop AT bit etc tion Data CJ series Unit I O port Initializa tion Data When the Controller is reset or the Unit restarts Initialization Alarm mode alarm hystere Data Sis etc Operating Alarm SVs control period I O port Operat I O refresh period Parameter proportional band integral ing Parameters time etc Unit Restart Unit Restart Flag etc None System defined Flag etc variable The Initialization Data and Operating Parameters are retained in the CPU Unit by the battery even during power interruptions NJ series CPU Unit Temperature Control Unit User program I O port CJ1W TCUOLL Operation Data Device variables Operation Data Constantly exchanges for CJ series Aana C oriiro Neris Tese data necessary for or the Unit restarts Unit for operation Oren oi retresn perio Initialization Data Device variables Initialization Data Transfers Initialization for CJ series When the Controller is reset Data such as Alarm Mode Unit for initialization Or CGA Alarm Hysteresis etc
68. anging the operating mode of the CPU Unit including changing the setting of the Operating Mode at Startup e Changing the user program or settings e Changing set values or present values e Forced refreshing e Always sufficiently check the safety at the connected devices before you change the settings of an EtherCAT slave or Special Unit e f two different function modules are used together such as when you use CJ series Basic Output Units and EtherCAT slave outputs take suitable measures in the user program and external controls to ensure that safety is maintained in the controlled system if one of the function modules stops The relevant outputs will stop if a partial fault level error occurs in one of the function modules e Always confirm safety at the connected equipment before you reset Controller errors with an event level of partial fault or higher for the EtherCAT Master Function Module When the error is reset all slaves that were in any state other than Operational state due to a Con troller error with an event level of partial fault or higher in which outputs are disabled will go to Oper ational state and the outputs will be enabled Before you reset all errors confirm that no Controller errors with an event level of partial fault have occurred for the EtherCAT Master Function Module e Always confirm safety at the connected equipment before you reset Controller errors for a CJ series Special Unit When a Controller error is r
69. any act exceed the individual price of the product on which liability is asserted INNO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY REPAIR OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED STORED INSTALLED AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION ABUSE MISUSE OR INAPPROPRIATE MODIFICATION OR REPAIR CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 13 Read and Understand this Manual Application Considerations SUITABILITY FOR USE OMRON shall not be responsible for conformity with any standards codes or regulations that apply to the combination of products in the customer s application or use of the products At the customer s request OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product machine system or other application or use The following are some examples of applications for which particular attention must be given This is not intended to be an exhaustive list of all possible uses of the products nor is it intended to imply that the uses listed may be suitable for the products e Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses
70. ar 3 9 3 8 USING ON OFF COntl sisiiiurceitetiniedecesuiasanvcddianviteucevestivaccvonssseei cuseduniuenvecdussselvasunuadedandennesuade 3 10 3 9 Setting the PID Constants ci caseccaiiscvacccatasetacicaaaseweccenssais rectesaaitasiasendadausnaeusantausievadecssisadedsadaais 3 11 3 10 Using the Alarm Output FUNCTION ssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna 3 15 3 11 Using the Heater Burnout Alarm icici anasa a a aaa Aaaa a aeaa aAa 3 19 3 12 Starting and Stopping Temperature Control ssssssssnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 3 21 Section 4 Optional Settings 4 1 Shifting the Input Value Input Compensation ssssssssnssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 4 2 4 2 Recovering from Sensor Not Connected Errors s ssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn Section 5 Error and Alarm Processing 5 1 Error and Alarm Processing sivisiesisseedisses isisddsccssiervescsesvedciecssnsssisnendasadaiveruscusiadevacedeiss 5 2 Troubles hoo UNG sirrin a a aaa 9 EVENT LOGS rie a 5 3 1 Overview of the Event LOOS csecsen e r a a aT a 5 3 2 Eron Veale e O 5 3 3 Emor DEScripIONnS esapi a eia A a AA aE CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 11 CONTENTS Index 12 Appendices DIMENSIONS srini A 2 Functional Differences due to CPU Units NJ CJ series to be Connected sssssccssssseeees A 3 Corre
71. arameters control period and PID con stants Operation Data RUN STOP control and starting CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 7 N N D A ad fe V g A g c 0 2 Specifications and Functions Precautions for Safe Use e When you change the unit settings and reset the Controller or restart the Unit be sure to first properly check the safety of the devices at the connection destination e Warm up the Unit for at least 30 minutes to ensure accurate operation The indicated temper ature error will be larger if the Unit is not warmed up i Example Operating Procedure The following settings are used in this example for a Two loop Temperature Control Unit Input tyoe Thermocouple Input K thermocouple 0 0 to 500 0 C In this example the device name J01 is used when this Unit is registered in Unit Configuration CJ1W TC003 CPU Unit K thermocouple 0 0 to 500 0 C Lopi gt gt gt J01 Chi PV Lop2 gt 5 gt J01 Ch2 PV Unit number 1 Create Unit Configuration Use Sysmac Studio to create Unit Configuration Place the Temperature Control Unit in slot O on the CPU Rack When this Unit is registered in the Unit Configuration the device name is entered as J01 For details on creation of Unit Configuration refer to the Sysmac Studio Version 1 Operation Manual Cat No W504 Creating User Programs The process value PV
72. asinek Meee ket ae ee eae A 10 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 A 1 Appendices A 1 Dimensions All dimensions are in mm CJ 1W TC OOO of ria Jo ms Iira JAI SO nl Sia ie LLI ea 1 O LLI o B AASA 90 2 Current Transformer Sold Separately E54 CT1 E54 CT3 2 36 dia 12dia R it td Two M3 holes Depth 4 pe a 30 A 2 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Appendices A 2 Functional Differences due to CPU Units NJ CJ series to be Connected This Unit can be used with NJ series CPU Units If this Unit is used with the NJ Series some functions become unavailable compared to when it is used with the CJ series The following explains how each function of this Unit changes when a CJ series CPU Unit is con nected compared when an NuJ series CPU Unit is connected Name Use with NJ series Use with CJ series Model CJ1W TC003 004 CJ1W TC001 002 003 004 CJ1W TC103 104 CJ1W TC101 102 103 104 Unit type SYSMAC Cu series Special I O Unit Applied PLC SYSMAC NJ Series SYSMAC CJ Series Number of control loops 2 loops with Heater Burnout Alarm 2 loops with Heater Burnout Alarm or 4 loops Control input Thermocouple R S K J T B L Resistance thermometer JPt100 Pt100 Control Mode PID or ON OFF
73. ble increases as the PV increases with reverse operation the manipulated vari able decreases as the PV increases i ON OFF Control Operation Pin 6 of the DIP switch on the front of the Unit selects whether the Temperature Control Unit uses ON OFF control or PID control with 2 degrees of freedom The Unit will use PID control if pin 6 is OFF it will use ON OFF control if pin 6 is ON The factory setting is PID control f Control Sensitivity In ON OFF control the ON and OFF switching creates a stable hysteresis loop The width of the hysteresis loop is called the control sensitivity Control sensitivity heating ON OFF A Set point Example Settings Set the control method set point and control sensitivity for the use of ON OFF control In this example ON OFF control is used for loop 1 The set point is 200 C and the control sensitivity is 2 C e Turn ON pin 6 of the DIP switch on the front of the Unit The new setting will be read when the Unit is restarted or the controller is reset including when the power is turned ON e Set device variable for CJ series Unit Loop 1 Set point _Ch1_SetPointCfg to 200 See 3 7 Setting the Set Points for details e Set device variable for CJ series Unit Loop 1 Control Sensitivity _Ch1_CtlHystrsCfg to 20 Ch1_CtlHystrsCfg UINT Loop 1 Control Sensitivity Enabled only during ON OFF control Ch2_CtlHystrsCfg UINT Loop 2 Control Sensitivity Enabled only during ON OFF co
74. can be mounted in a Rack if the Temperature Control Units are the only Units being used in the Rack Power Supply Unit CJ 1W TC LIL CJ1W PA205R 10 Units i Installation Procedure Use the following procedure to install the Temperature Control Unit The PLC must be removed from the DIN Track in order to connect a Temperature Control Unit 1 Align the Units and connect them together so that the connectors join smoothly and completely Hooks Openings for hooks Connector 2 Slide the yellow latches on the top and bottom of the Unit until you hear the latches click and lock the Units together Slide latches back until they lock The latches will click when they lock 1 8 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 Features and System Configuration 3 Install an End Cover on the rightmost Unit Precautions for Safe Use The Unit s functions may not be completely operational if the sliders are not locked securely i N lt i a S h j g 5 Precautions for Correct Use An End Cover is provided with the CPU Unit Always install this End Cover on the rightmost Unit in the PLC The NJ series PLC will not operate properly if the End Cover is not installed Pun y BununoN Z Z 4 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 9 1 Features and System Configuration i Handling Precautions e Always turn OFF the controller
75. ce name when this Unit is regis tered in the Unit Configuration By default a device name is assigned from J01 in the order of registration in the Unit Configuration This identifies the individual Unit For details on creation of device variables for CJ series Unit refer to the Sysmac Studio Version 1 Operation Manual Cat No W504 There are 3 types of device variables for CJ series Unit Operation Data Initialization Data and Operating Parameters In the explanations from here on the device name automatically created is used as the device vari ables for CJU series Unit for example _Ch1_PV 2 5 3 Saving Set Value in the Non volatile Memory A Caution Do not turn OFF the power supply while setting data is being written to the non volatile memory in the Temperature Control Unit Confirm that the Save Completed Flag turns ON after the data write operation has been Q completed before turning OFF the power supply If power is turned OFF during a write opera tion the data saved in the non volatile memory may be destroyed The Temperature Control Unit has two types of memory RAM and Non volatile Memory Device variables for CJ series Unit are written to the RAM in the Temperature Control Unit For Operat ing Parameters among the device variables for CJ series Unit some of this data can be written from the RAM to non volatile memory by turning ON the Save Settings Bits _Chi_SaveCmd and Ch2_SaveCmad If pin
76. cifications f General Specifications Item Unit classification Compatible Racks Max number of Units Methods of exchanging data with CPU Insulation resis tance Dielectric strength Internal current consumption Other Dimensions Weight Specification NJ series Special I O Unit NJ series CPU Rack or NJ series Expansion Rack 10 Units Rack max CPU Rack or Expansion Rack Data exchange by using I O ports Refer to 2 5 Data Exchange with the CPU Unit 20 MQ min at 500 VDC between the following points Output terminals NC terminals and external AC terminals Power Supply Unit e Input terminals and external AC terminals Power Supply Unit e Input terminals and output terminals e External DC terminals inputs outputs and NC and the FG plate e Between input terminals Sensor and CT inputs e Between the I O terminals and NC terminals 2 000 VAC 50 60 Hz for 1 min detected current 1 mA e Between the output terminals NC terminals and external AC terminals Power Supply Unit 1 000 VAC 50 60 Hz for 1 min detected current 1 mA e Input terminals and external AC terminals Power Supply Unit e Input terminals and output terminals e External DC terminals inputs outputs and NC and the FG plate 500 VAC 50 60 Hz for 1 min detected current 1 mA e Between input terminals Sensor and CT inputs e Between the I O terminals and NC terminals 250 mA max 5 VDC Other general specifications conform to the
77. ct a thermocouple nals are shorted The temperature sensor was replaced or switch Turn the power OFF and then ON again settings were changed while the power was ON EN Additional Information Here is a simple method to check the temperature sensor inputs With a resistance thermometer Unit connect a 100 Q resistor to the A B temperature sensor input terminals and short the B B terminals The Temperature Control Unit is operating normally if the measured temperature is at the 0 0 C or 32 0 F level With a thermocouple Unit short the temperature sensor input terminals The Temperature Con trol Unit is operating normally if the measured temperature is the temperature in the vicinity of the terminal block i Troubleshooting from Symptoms Temperature Control Errors Temperature Does Not Rise Step Possible Cause Remedy Connection The measured temperature is incorrect Refer to Troubleshooting from Symptoms Measurement Errors for troubleshooting directions There is no load connected to the control output termi Connect a load nals The load s polarity is reversed or the load is wired to the Wire the load correctly wrong terminals The terminal screws are loose so there is poor contact Tighten the terminal screws between the wires and terminals The heater s power supply is not ON Turn ON the heater s power supply The heater circuit is burned out or damaged Replace the heater with a good one The heat
78. culated flag ccccecccceeeseeeeeeeeeees 3 11 PUD COMMON a2iuk cee et ait ole tea ete eek 1 4 3 7 PID control with two degrees of freedom 1 4 3 7 Pin 1 of the DIP switch operation in PROGRAM mode 0sseeeeeeeeees 2 13 Pin 2 of the DIP switch C F ee eeeeeee 2 5 2 13 3 4 Pin 3 of the DIP switch ce cccceceeeeetteeeeeeeeees 2 14 3 5 Pin 4 of the DIP switch control operation for loop 1 0 0 eee 2 14 3 6 Pin 5 of the DIP switch control operation for loop 2 eee 2 14 3 6 Pin 6 of the DIP switch control method 2 14 3 7 Pin 7 of the DIP switch initialize non volatile memory set values 2 14 Pin 8 of the DIP switch transfer non volatile memory set values 2 14 2 23 Platinum resistance thermometer input setting ranges 2 6 Process value PV Import ccccecesseeeeeeeeeeeeseeees A 10 Proportional band ccccccceeeecececeeeeeeeseeeeeeeaeees 3 7 3 13 PV process value cccccccsssseceececceeseeceeeeceesseeeeeeseaaeees 1 5 R RAM Saeeedetetct icant hoc te ecnes coeds ace sanoetececeneeesyaciaemeageeune 2 23 Se ter gee pero oe a eae PE Ose eater mee ee ee ee pan 2 22 PROVOIS eczecssodesstertegz 2 525e8 sos ensk ore iesee a geacemeess acseoteaecn ace 3 6 PRUINGINGICALON ficckce ie ek ee otek ooh Sie ad 2 11 5 2 S OPISE DONE aust xtotes eed co besgel i eadstsstieasteaceiemeteley 1 5 3 9 Sampli
79. curs e If a major fault level Controller error occurs e While the CPU Unit is on standby until RUN mode is entered after the power is turned ON External safety measures must be provided to ensure safe operation of the system in such cases If external power supplies for slaves or other devices are overloaded or short circuited the voltage will drop outputs will turn OFF and the system may be unable to read inputs Provide external safety measures in controls with monitoring of external power supply voltage as required so that the sys tem operates safely in such a case 000S CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Safety Precautions WARNING Fail safe Measures Unintended outputs may occur when an error occurs in variable memory or in memory used for CJ series Units As a countermeasure for such prob lems external safety measures must be provided to ensure safe operation of the system Provide measures in the communications system and user program to ensure safety in the overall system even if errors or malfunctions occur in data link communications or remote I O communications If there is interference in remote I O communications or if a major fault level error occurs Output status will depend on the products that are used Confirm the operation that will occur when there is interference in communi cations or a major fault level error and implement safety m
80. d Flag System controlled Change PID Constants Bit User controlled Setting PID Constant Setting PID Constant 0 0 3 Settings Required for Temperature Control AT in progress The PID constants haven t been refreshed from the Automatic CPU Unit if this bit is ON calculations Set to 1 by the system completed after calculations are completed When this bit goes ON the PID Con stants Calculated Flag is unlatched and goes OFF Reflects Setting PID Constant Contains the PID transferred PID constants calcu this starts operation a eal calculated by fated automatically by AT This EAk MNS starts operation Use the PID Constants Calculated Flag as an input condition to trigger the transfer of the read PID constant in the Operating Parameters automatically calculated with AT to the setting PID constant in the Operating Parame PID constants user settings PID constants automatically calculated by autotuning ae she ie read to the Nothing is read to the Output area data read to the Unit s RAM by Unit s RAM during this CJ1W TCLILILI Unit s RAM by 10 M interval I O refreshing EN Additional Information Effects of Changes to the PID Constants The following tables show the effects on the PV when each PID constant is changed increased or decreased e Changing P The Proportional Band Increasing P Decreasing P It take
81. d and Ch2_SaveCmd of the device variables for CJ series Unit Refer to 2 5 3 Saving Set Value in the Non volatile Memory for details on the settings CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions 2 3 5 Input Type Switch Y Ww Ki rt a y 5 2 T 5 A ch O 5 7 Thermocouple Temperature Control Units Input type Temperature ranges setting Pe Fahrenheit 0 0 to 900 0 F 0 0 to 750 0 F 300 0 to 700 0 F 100 to 850 C 100 to 1 500 F 0 0 to 400 0 C 0 0 to 750 0 F 0 to 1 700 C 0 to 3 000 F 0 to 1 700 C 0 to 3 000 F B 100 to 1 800 C 300 to 3 200 F Platinum Resistance Thermometer Temperature Control Units YoUMS adA jndu G Z OO CO N oO BW NM O Input type Temperature ranges Type setting uF Centigrade Fahrenheit 0 Pt100 200 0 to 650 0 C 300 0 to 1 200 0 F 1 JPt100 200 0 to 650 0 C 300 0 to 1 200 0 F 2 to9 Do not set 2 through 9 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 15 2 Specifications and Functions 2 4 Wiring 2 4 1 Terminal Wiring Examples 2 16 Thermocouple Temperature Control Units CJ 1W TC003 CJ 1W TC 004 2 loops NPN outputs HB alarm 2 loops PNP outputs HB alarm Cold junction comp put 1 junction comp Bates Cola juncton comp BS Ae putt PCole junction comp B4 e he
82. dio and clear the Low Battery Voltage error e Make sure that the required data including the user program configurations settings variables and memory used for CJ series Units is transferred to a CPU Unit that was replaced and to externally connected devices before restarting operation Be sure to include the routing tables network parameters and other CPU Bus Unit data which are stored in the CPU Unit f Disposal e Dispose of the product and Batteries according to local ordinances as they apply 1 G9 ie E th iA Elk e The following information must be displayed for all products that contain primary lithium batteries with a perchlorate content of 6 ppb or higher when shipped to or transported through the State of Califor nia USA Perchlorate Material special handling may apply See www dtsc ca gov hazardouswaste perchlorate e The CPU Unit contains a primary lithium battery with a perchlorate content of 6 ppb or higher Place the above information on the individual boxes and shipping boxes when shipping finished products that contain a CPU Unit to the State of California USA i When Using the Temperature Control Unit e To prevent blocking heat distribution do not block the exterior of the Temperature Control Unit with other object or block the ventilation holes on the Unit e Set the parameters of the Temperature Control Unit so that they are appropriate for the system being controlled Inappropriate settings can lead to un
83. e Settings Bit SaveCmd gt A v 9 3 5 0 U rj te z te CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 A 11 Appendices Programming Example Start AT Bit ATrun J01_Ch1_ATFlg J0O1_Ch1_StartATCmd JO1_Ch1_StartATCmd After the Autotuning AT calculations are complete the read PID constants are transferred to the setting PID constants updated and saved to the non volatile memory J01_Ch1_PIDCalcFlg 1 J01_Ch1_DerivativeTmCfg J0O1_Ch1_ChgPIDCmd 1 J0O1_Ch1_SaveCmd 2 After saving to the non volatile memory is complete the save instruction is switched OFF J0O1_Ch1_SaveFlg 2 J0O1_Ch1_SaveCmd 2 1 Change of Change PID Constants Bit JO1_Ch1_ChgP DCmd from OFF to ON changes the PID Constants Calculated Flag JO1_Ch1_PI DCalcFlg from ON to OFF 2 With pin 8 of the DIP switch set to ON transfer settings within non volatile memory be sure to write to the non volatile memory of the Temperature Control Unit change the Save Settings Bit from OFF to ON A 12 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Index CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Iindex 1 Index Index A AT MOTI ie ake acer eal ellis ea 1 5 3 11 PIa eames a aces tte enna ates ene eee ean 5 2 Alarmi BySteresSiS si pict nad occa lcdaet nna anda ctaeat sect 3 1
84. e safe usage of the product l Precautions for Correct Use Precautions on what to do and what not to do to ensure proper operation and performance E SR Information Additional information to read as required This information is provided to increase understanding or make operation easier Note References are provided to more detailed or related information CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 spun 6Bugunow 7 sjuauodwod J9 O4JU0D Buydauu0D L S y Level 1 heading Level 2 heading Level 3 heading Gives the current headings Page tab Gives the number of the main section This illustration is provided only as a sample It may not literally appear in this manual Manual Structure Precaution on Terminology In this manual download refers to transferring data from the Sysmac Studio to the physical Controller and upload refers to transferring data from the physical Controller to the Sysmac Studio For the Sysmac Studio synchronization is used to both upload and download data Here synchronize means to automatically compare the data for the Sysmac Studio on the computer with the data in the physical Controller and transfer the data in the direction that is specified by the user CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Manual Structure CJ series Temperature Control Units Operation Manual for NJ series C
85. e wiring that connects to the terminal block and tighten the ter minal screws securely The terminal screws are M3 screws and need to be tightened to a torque of 0 5 N m Use wire that is AWG 22 to AWG 18 0 32 to 0 82mm2 Fork terminal Round terminal 6 0 mm max DH 6 0 mm ra OL Observe the following precautions when wiring to minimize noise and optimize the Temperature Control Unit s operation e Use twisted pair shielded wire for the output wiring e Keep the I O lines away from power lines including AC power supply lines and high power lines Do not run the I O lines in the same duct or conduit as power lines CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 19 2 Specifications and Functions e Noise from the power supply line may be superimposed on I O signals if equipment that generates high frequency noise is used nearby or the Temperature Control Unit s power line is shared with elec trical welding equipment or discharging equipment In this case install a noise filter at the power sup ply inputs 2 20 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions 2 5 Data Exchange with the CPU Unit 2 5 1 Overview The Temperature Control Unit exchanges data with the CPU Unit through the I O port generated for the Temperature Control Unit e Operation Data e Initialization Data e Operating Parameters The table
86. easures Correctly set all of the EtherCAT slaves The Nu series Controller continues normal operation for a certain period of time when a momentary power interruption occurs This means that the NJ series Controller may receive incorrect signals from external devices that are also affected by the power interruption Accordingly take suitable actions such as external fail safe measures and interlock conditions to monitor the power supply voltage of the external device as required You must take fail safe measures to ensure safety in the event of incorrect missing or abnormal signals caused by broken signal lines momentary power interruptions or other causes Not doing so may result in serious acci dents due to incorrect operation eS Oooo Voltage and Current Inputs Make sure that the voltages and currents that are input to the Units and slaves are within the specified ranges Inputting voltages or currents that are outside of the specified ranges may cause accidents or fire B Downloading Always confirm safety at the destination before you transfer a user program configuration data setup data device variables or values in memory used for CJ series Units from the Sysmac Studio The devices or machines may perform unexpected operation regardless of the operating mode of the CPU Unit CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 19 Safety Precautions Applica
87. ensation Value for Moni tor Loop 1 and Loop 2 Control Period Loop 1 and Loop 2 Control Period for Mon itor Loop 1 and Loop 2 Control Sensitivity Loop 1 and Loop 2 Control Sensitivity for Monitor Loop 1 and Loop 2 Propor tional Band Loop 1 and Loop 2 Propor tional Band for Monitor Loop 1 and Loop 2 Integral Time CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Function The Temperature Control Unit returns the set values that are actually used for temperature control Use these values to monitor operation Set the control period The Temperature Control Unit returns the set values that are actually used for temperature control Use these values to monitor operation This setting is valid in ON OFF control only The Temperature Control Unit returns the set values that are actually used for temperature control Use these values to monitor operation The values written here are not written to RAM while Ch _PlDCalcFlg PID Constants Calculated Flag is set to 1 These settings are valid in PID control only The Temperature Control Unit returns the set values that are actually used for temperature control Use these values to monitor operation The values written here are not written to RAM while Ch _PlDCalcFlg PID Constants Calculated Flag is set to 1 These settings are valid in PID control only 2 33 Y a
88. er s heat output is insufficient e Replace the heater with one that has a higher output e When using two or more heaters check whether one is burned out Replace if necessary An overheating protection device is operating Increase the overheating protection device s temperature set ting so it is higher than the Temperature Controller Unit s set point Settings The forward operation reverse operation setting is Correct the setting incorrect The PID constant settings are not correct e Perform autotuning e Make the correct PID constant settings manually Temperature control has not been started Start temperature control A cooling fan is operating Turn OFF the cooling fan 5 12 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 Error and Alarm Processing Measured Temperature Higher than Control Temperature Step Possible Cause Remedy Connection The measured temperature is incorrect Refer to Troubleshooting from Symptoms Measurement Errors for troubleshooting directions The load is connected to the wrong control loop so the Wire the load correctly heater is being controlled by another loop s control out put The contacts are fused in the relay operated by the con Replace the relay with a good one trol output There is a short circuit in the relay operated by the con Replace the relay with a good one trol output Current is flowing to the heater because of leakage c
89. eset the Unit where the Controller error with an event level of observation or higher will be restarted Before you reset all errors confirm that no Controller errors with an event level of observation or higher have occurred for the CJ series Special Unit Observation level events do not appear on the Controller Error Tab Page so it is possible that you may restart the CJ series Special Unit without intending to do so You can check the status of the _CJB_UnitErrSta 0 0 to _CJB_UnitErrSta 3 9 error status variables on a Watch Tab Page to see if an observation level Controller error has occurred i Battery Backup e The user program and initial values for the variables are stored in non volatile memory in the CPU Unit The present values of variables with the Retain attribute and the values of the Holding DM and EM Areas in the memory used for CJ series Units are backed up by a Battery If the Battery is not connected or the Battery is exhausted the CPU Unit detects a Battery backup Memory Check Error lf that error is detected variables with a Retain attribute are set to their initial values and the Holding DM and EM Areas in memory used for CJ series Units are cleared to all zeros Perform thorough verifications and provide sufficient measures to ensure that the devices perform safe operation for the initial values of the variables with Retain attributes and the resulting operation il Debugging e Forced refreshing ignores the results of
90. estarts or the con troller is reset including when the power is turned ON with pin 8 of the DIP switch set to ON 1 The PID constants resulting from autotuning are automatically written to RAM at the end of autotuning 2 Non volatile memory can be written up to 100 000 times Temperature Control Unit CPU Unit backup area Non volatile Memory I O refresh Operation Data BoncrON or Unt Operation Data aa L e Initialization Data Initialization Data Save Settings Bit Operating E I O refresh Operating 0 OFF gt 1 ON Parameters Parameters lend When the power turns ON or the Unit restarts with pin 8 of the DIP switch set to ON 2 5 4 Operation Data Operating Parameters Temperature Control Unit The Operation Data includes the Process Value Set Points Stop Bits Start AT Bits Stop AT Bits and other basic data Operation data is exchanged each cycle time during the I O refresh period Input data is transferred from the Temperature Control Unit to the CPU Unit and output data is trans ferred from the CPU Unit to the Temperature Control Unit 2 24 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions Allocating Operation Data to Device Variables for CJ series Unit Device variables for CJ series Unit are shown below For the setting range and monitoring range of each value refer to 2 6 Range of Set Values and
91. expected operation which in turn can damage the product or cause accidents e Turn ON the power supply to the load e g heater at the same time or before turn ON the power supply to the Temperature Control Unit Optimum control may not be achieved if power is turned ON in the wrong order e Do not use the Unit in locations where it will be subject to direct radiant head from a heater CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Precautions for Correct Use Precautions for Correct Use i Storage Mounting and Wiring e Do not operate or store the Controller in the following locations Operation may stop or malfunctions may Occur e Locations subject to direct sunlight e Locations subject to temperatures or humidity outside the range specified in the specifications e Locations subject to condensation as the result of severe changes in temperature e Locations subject to corrosive or flammable gases e Locations subject to dust especially iron dust or salts e Locations subject to exposure to water oil or chemicals e Locations subject to shock or vibration e Take appropriate and sufficient countermeasures when installing the Controller in the following loca tions e Locations subject to strong high frequency noise e Locations subject to static electricity or other forms of noise e Locations subject to strong electromagnetic fields e Locations subject to possible exposure to radioactivity e
92. g Source Error attributes Effects System defined variables Cause and correction Attached information Precautions Remarks 5 Error and Alarm Processing Heater Burnout Alarm 6486 0000 hex A heater burnout occurred PLC Function Module Source details Continuously timing The power supply to the heater is not Turn ON the power supply to the When you use the Temperature Con ON heater troller Unit turn ON the power supply to the connected heater The heater is burned out or deterio If the above causes does not apply None rated replace the heater Attached information 1 Loop number where error was detected You can change the event level to the minor fault level If you change the level to the minor fault level the Recovery col umn above will be changed to Error reset CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 21 q W m 6 A r amp uv suoduos q 10113 S G 5 Error and Alarm Processing 5 22 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Appendices A 1 A 2 A 3 A 4 DIMENSIONS a 646 s5id dae bd eed aaa a Re alae a se ae A 2 Functional Differences due to CPU Units NJ CJ series to be CONNCCES wineries eer a ae ee A 3 Correspondence Table of Device Variables for CJ series Unit and Memory Used for CJ series UnitAddresses 00ccceaeeeaeenaes A 4 Sample Programmi g 446 08iviw
93. g operation OFF for control loop 2 Control Method Pin 6 Pin 6 selects either ON OFF control ON or PID control OFF e If ON OFF control is being used the width of the hysteresis loop hysteresis can be set to adjust the control sensitivity e If PID control PID control with two degrees of freedom is being used the PID constants can be set automatically with the autotuning function i Initialize Non volatile Memory Set Values Pin 7 If pin 7 is ON the setting data in non volatile memory will be initialized to their default settings when the Temperature Control Unit restarts or the Controller is reset including when the power is turned ON Initialize non volatile memory only when a Hardware Check Error has occurred Refer to ERC Indicator Lit and RUN Indicator Not Lit in 5 1 Error and Alarm Processing for details i Transfer Set Values in Non volatile Memory Pin 8 If pin 8 is ON the setting data in the Temperature Control Unit s non volatile memory will be trans ferred to the corresponding device variable for CJ series Unit of the CPU Unit when the Tempera ture Control Unit restarts or the Controller is reset including when the power is turned ON Turn ON pin 8 if you want the Temperature Control Unit to operate with setting data stored in non volatile memory The set values in the Temperature Control Unit s RAM can be saved to non volatile memory by turn ing ON the corresponding Save Settings Bits _Ch1_SaveCm
94. gener ated When cross wiring terminals the total current for all the terminals will flow in the wire When wiring cross overs make sure that the current capacity of each of the wires is not exceeded e Do not touch the terminals on the Power Supply Unit immediately after turning OFF the power sup ply Residual voltage may cause electrical shock e If you use reed switches for the input contacts for AC Input Units use switches with a current capac ity of 1 A or greater If the capacity of the reed switches is too low surge current may fuse the contacts CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 27 Precautions for Correct Use i Error Processing e In applications that use the results of instructions that read the error status consider the affect on the system when errors are detected and program error processing accordingly For example even the detection of a minor error such as Battery replacement during operation can affect the system depending on how the user program is written e If you change the event level of a Controller error the output status when the error occurs may also change Confirm safety before you change an event level i Restoring and Automatically Transferring Data e When you edit the restore command file or the automatic transfer command file do not change any thing in the file except for the yes and no specifications for the selectable data groups If
95. he Controller is reset or the Unit is restarted 12 Ch1_CJErr BOOL Loop 1 Cold The value becomes 1 when 13 Ch1_CTOvfFlg BOOL 14 Ch1_SensErr BOOL 15 Ch1i_SaveFlg BOOL changes from 1 to 0 however the value is 0 immediately after a controller reset Ch2_StaWd WORD Loop 2 Status Bits serve the functions described below Each bit is defined with a BOOL data type variable Bit 00 Loop 2 AL2 Flag Bit 01 Loop 2 AL1 Flag Bit 02 Loop 2 HB Flag Bit 03 Loop 2 AT Flag Bit 04 Loop 2 Control Output Flag Bit 05 Bit 06 Bit 07 Bit 08 Loop 2 Stop Flag Bit 09 Loop 2 Setting Error Flag Bit 10 Loop 2 PID Constants Calculated Flag Bit 11 Loop 2 Standby Flag Bit 12 Loop 2 Cold Junction Sensor Error Bit 13 Loop 2 CT Overflow Flag Bit 14 Loop 2 Sensor Error Flag Bit 15 Loop 2 Save Completed Flag CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 5 Junction Sen e Cold junction sensor error occurs sor Error Loop 1 CT The value becomes 1 when the heater cur Overflow Flag rent of the CT current detector exceeds 55 0 A y a m 3 f gt Q gt f 3 U O A R U gt Q Loop 1 Sensor The value becomes 1 when Error Flag Sensor is not connected to loop 1 e Sensor of loop 1 disconnects e Input temperature exceeds the measure ment temperature range Loop 1 Save The value becomes 1 when you select save Completed loop 1 change fro
96. he Temperature Control Unit s unit number setting or if I O refreshing cannot be performed properly with the Temperature Control Unit because of an I O bus error or WDT watchdog timer error in the CPU Unit only the EHR Indicator will light Eror Cause Control status Processing Duplicate Unit Num The Temperature Control Unit s unit number Control operation Correct the unit number set ber is duplicated on another Special I O Unit or is will stop tings Turn the Controller not within the allowed range 00 to 94 power supply OFF and ON The Temperature Control Unit occupies two unit numbers for one unit I O Setting Check The Special I O Units registered in the Unit Error Configuration in the CPU Unit are different from the ones actually mounted I O Bus Check Error An error occurred in the transfer of data between the CPU Unit and another Unit CPU Unit An error occurred in the CPU Unit WDT Error i Unit Restart To resume operation after changing settings in the Initialization Data or removing the cause of errors restart the Unit with one of the methods described below Check that the sliders con nect all of the Units securely and the End Cover is locked Turn the Controller power supply OFF and ON Initialization Data will be updated after restart e Reset the Controller from Sysmac Studio e Reset the Controller by turning the Controller power supply OFF and ON e Restart using the ResetUnit instr
97. ies Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions 2 3 PartNames and Functions 2 3 1 Part Names Status Output Indicators Indicators Unit Number Switches Di wac ae Qin To LLI O co n a IO LLI r er e a NO LLI a Wei as ei OS za Ios INPUT 77 gt LIS he a E gt IB we _ me ee iF e7 yt Tr LEZ e D gt Connector DIP Switch Input Type Switch DIN Track Mounting Pin Terminal Block Sliding Latch Lock Lever Sliding Latch 2 3 2 Indicators i Status Indicators The Status Indicators indicate the operating status of the Temperature Control Unit as explained in the following table RUN Indicator Green Lit Normal operating status lit Temperature control is stopped Temperature Con mes error occurred in the Temperature Control Unit itself trol Unit Error re ane as a Sensor Error or Initialization Error Notit lit Normal operating status CPU Unit Error a An error occurred in the CPU Unit Notit lit Normal operating status i Output Indicators The Output Indicators light to indicate when the corresponding Temperature Control Unit output is ON CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 11 Y Ww Ki rt a y 5 2 T 5 A ch O 5 7 SOWEN Hed L E Z 2 Specifications and Functions 2 3 3 Unit Number Swi
98. ifications and Functions Device variable for CJ series Unit Data R W Function Ch1_SensErr Ch2_SensErr BOOL Loop 1 and The value becomes 1 for the Loop 2 Sensor following Error Flag e A sensor is not connected to loop 1 e The connection to sensor of loop 1 is broken e A temperature exceeding the measurable input range is input Chi_SaveFlg Ch2_SaveFlg BOOL Loop 1 and The value becomes 1 when Loop 2 Save writing data to non volatile Completed memory is completed after Flag setting _Ch _SaveCma Save Settings Bit of loop 1 and loop 2 from 0 to 1 The Save Completed Flag initial izes to 0 when Ch _SaveCma Save Settings Bit of loop 1 and loop 2 is set from 1 to O It is 0 immediately after the con troller is reset DecPointSetErrSta WORD Loop 1 2 Deci Specify the decimal point mal Point and position of the PV SP for loop Loop 1 2 Set 1 and loop 2 The number of ting Error Num loop 1 and loop 2 settings in ber which a setting error exists is stored in hexadecimal Explanation of Decimal Point and Setting Error Numbers Y a x A gt D 5 fe 0 S g g 0 A U c c 2 rF eyeq uoneiado S Z Bit 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 DecPointSetErrSta Setting Error Numbers Loop 1 0 1 Loop 2 0 1 Loop 1 0 to F Loop 2 0 to F Setting Error Numbers Setting error number Priority i z 2 s s A 5 5
99. ill not light by alarms Example To disable loop 2 set AlmMd Loop 1 2 Alarm 1 Mode and Alarm 2 Mode to 16 00FF CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 31 Y a x A gt D 5 fe 0 S g g 0 A U c c 2 rF eByeq uonezieu 9 9 Z 2 Specifications and Functions 2 5 6 Operating Parameters 2 32 The Temperature Control Unit s Operating Parameters exchange the Temperature Control Units Alarm SVs control periods and other Operating Parameters with the CPU Unit Operating Parameters are exchanged each cycle during the I O refresh period Input data is transferred from the Temperature Control Unit to the CPU Unit and output data is transferred from the CPU Unit to the Temperature Control Unit The Operating Parameters are retained in the CPU Unit by the battery even during power interruptions Allocating Operating Parameters to Device Variables for CJ series Unit Device variables for CJ series Unit Operation Parameters that can be allocated with Operating Parameters are shown below For the setting range and monitoring range of each value refer to 2 6 Range of Set Values and Monitor Values The meaning of the row of R W in the table below is as follows RW Read Write R Read only Device variable for CJ series Unit Data R W Function Loop 1 Loop 2 type Chi_MV Ch2_ MV Loop 1 and When ON OFF control is Loop 2 Manipu used this value will be 100
100. in a slave For this reason if Servo Drives are connected the Servos for all axes will be turned OFF Make sure that the Fail soft Operation parameter setting results in safe operation when a device error occurs e EtherCAT communications are not always established immediately after the power supply is turned ON Use the system defined variables in the user program to confirm that communications are estab lished before attempting control operations e If frames sent to EtherCAT slaves are lost due to noise or other causes slave I O data is not commu nicated and the intended operation is sometimes not achieved If noise countermeasures are required use the _ EC _ nDatalnvalid Input Data Disable system defined variable as an interlock condition in the user program Refer to the NJ series CPU Unit Built in EtherCAT Port User s Manual Cat No W505 for details The slave outputs behave according to the slave settings Refer to the manuals for the slaves for details e When an EtherCAT slave is disconnected communications will stop and control of the outputs will be lost not only for the disconnected slave but for all slaves connected after it Confirm that the system will not be adversely affected before you disconnect a slave e If you disconnect the cable from an EtherCAT slave to disconnect it from the network any current communications frames may be lost If frames are lost slave I O data is not communicated and the intended operat
101. in the following table If the allowed indication range is exceeded a sensor error will occur The corresponding sensor error bit will be turned ON and the PV process value will contain the data 13108 When a sensor error occurs that control loop s control output will be turned OFF The alarm function will operate because the PV indicates an abnormally high temperature i Thermocouple Input Setting Ranges Sensor Set value Input type Temperature range Thermocouple o K 200 to 1300 C 300 to 2300 F 0 0 to 500 0 C 0 0 to 900 0 F eS J 100 to 850 C 100 to 1500 F ae 0 0 to 400 0 C 0 0 to 750 0 F O4 fT 200 0 to 400 0 C 300 0 to 700 0 F L 100 to 850 C 100 to 1500 F 0 0 to 400 0 C 0 0 to 750 0 F 7 R Oto 1700 C 0 to 3000 F 8 s 0 to 1700 C 0 to 3000 F O9 fl BF 100 to 1800 C 300 to 3200 F The lower limit indication for B type thermocouples is 0 C or O F AJOJN e Note When the Input Type Switch has been changed the SV and input compensation values will change as follows e f the SV exceeds the setting range it will be fixed at the lower limit or upper limit of the setting range e The position of the decimal point will change if necessary CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 5 i h A 7 wesbeig y20jg uonouny Indu Z L zZ 2 Specifications and Functions For example when the temperature range
102. information Serial number Node RSSD KNO1L ECT Rev 2 1 OMRON Corporation Ox00000000 The following items are displayed Node address Type information Serial number If the model number cannot be determined such as when there is no ESI file the vendor ID product code and revision number are displayed 34 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Related Manuals Related Manuals The following manuals are related to the NJ series Controllers Use these manuals for reference Manual name NJ series CPU Unit Hardware User s Manual Cat No Model numbers Application NJ501 UULIL I NJ301 UULL I W500 W501 W504 W491 W396 Learning the basic specifi cations of the NJ series CPU Units including intro ductory information designing installation and maintenance Mainly hard ware information is pro vided NJ series CPU Unit Soft ware User s Manual NJ501 UOULLI NJ301 UULL I Learning how to program and set up an Nu series CPU Unit Mainly software information is provided SYSMAC SE2ULLI Sysmac Studio Version 1 Operation Manual Learning about the operat ing procedures and func tions of the Sysmac Studio Leaning the functions and application methods of the CJ series Temperature Control Units used in an NJ series configuration Leaning the functions and application methods of the CJ series Temperature CJ1W TC00
103. ing situations e At the start of operation when the controller is restarted or reset including when the power is turned ON when the alarm SV input compensation values or set point is changed e When the alarm SV input calculated values or set point is changed e When the Output OFF Flag turns OFF 3 16 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 Settings Required for Temperature Control Summary of Alarm Operation The following timing chart shows the operation of alarms with a standby sequence In this exam ple the alarm mode is Upper and Lower limit Alarm with Standby Sequence Alarm mode Upper and Lower limit Alarm with Standby Sequence Alarm SV upper Alarm goes OFF by hysteresis Standby sequence cleared Alarm goes OFF by hysteresis Alarm SV lower Output disabled by standby sequence Alarm output 4 i Example Alarm Settings Alarm Mode and Alarm Hysteresis The alarm mode and alarm hysteresis for loops 1 and 2 are set as shown in the following table Set Loop 1 2 Alarm 1 Mode and Alarm 2 Mode _AlmMa to 16 3218 2 Set hysteresis values in Alarm Hysteresis _Ch1_AL1HystrsCfg Ch2_AL1HystrsCfog Ch1_AL2HystrsCfg and _Ch2_AL2HystrsCfg 3 To enable the new settings reset the controller or restart the Unit Setting Alarm 1 SV of Loop 2 to 20 C Set Loop 2 Alarm 1 SV _Ch2_AL1Lv
104. ing the Input Type Switch Set the input type with the Input Type Switch on the front of the Unit If this set value is changed the new setting will not become effective until the Unit is restarted or the controller is reset including when the power is turned ON The diagram above shows the input type set for a K type thermocouple with a temperature range of 0 0 to 500 0 C i Input Type Settings Thermocouple Input Types Input type Temperature ranges sensor TYP Setting Fahrenheit Thermocouple K 0 200t01 300 C 300 to 2 300 F 4 200 0 to 400 0 C 300 0 to 700 0 F 100 to 850 C 100 to 1 500 F Lo Booo i ora 0 0 to 750 0 F a a Bo KR WwW hm gt O1 O to 1 700 C 0 to 3 000 F 8 0 to 1 700 C 0 to 3 000 F 100 to 1 800 C 300 to 3 200 F The factory setting is 0 3 2 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 Settings Required for Temperature Control Platinum Resistance Thermometer Input Types Temperature ranges Sensor Type BUN De z 2 setting Centigrade Fahrenheit Platinum Pt100 200 0 to 650 0 C 300 0 to resistance 1 200 0 F thermometer JPt100 200 0 to 650 0 C 300 0 to 1 200 0 F ff 2to9 Do not set 2 through 9 The factory setting is 0 W a Wn 0 5 S g CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 3 3 Settings Required for Temperatu
105. ings in 2 1 Specifications and A 1 Dimensions for details on the specifications model numbers and dimensions 2 When current flows through the heater wire it induces an AC current in the Current Transformer CT that is proportional to the current in the heater wire The current flowing through the heater can be determined from the current induced in the CT 3 The current will drop if there is a heater burnout and the heater burnout alarm HB output will be turned ON if the current falls below the preset heater burnout current 4 The HB output is a latched output To release the latch i e turn OFF the HB output either set the heater burnout current to 0 0 reset the controller or restart the Temperature Control Unit Note 1 Do not use any CT other than the OMRON E54 CT1 or E54 CT3 Current Transformer 2 Set the desired heater burnout detection current in the Heater Burnout Current word The value in the Heater Current Monitor word can be used to check the CT s current 3 Set the heater burnout current to 0 0 if you are not using the heater burnout detection function 4 The heater burnout current is set independently for each loop i Operating Conditions Connect the CT and pass the heater wire through the CT in advance Turn ON the heater s power supply before the Temperature Control Unit or turn ON both at the same time The heater burnout alarm will be output if the heater s power supply is turned ON after the Tem perature Con
106. ion is sometimes not achieved Perform the following processing for a slave that needs to be replaced Program the _EC_ nDatalnvalid Input Data Disable system defined variable as an interlock con dition Set the Impermissible Number of Continuous Timeouts setting in the EtherCAT master to at least 2 Refer to the NJ series CPU Unit Built in EtherCAT Port User s Manual Cat No W505 for details f Motion Control e Confirm the axis number carefully before you perform an MC Test Run e The motor is stopped if communications are interrupted between the Sysmac Studio and the CPU Unit during an MC Test Run Connect the communications cable between the computer and CPU Unit securely and confirm that the system will not be adversely affected before you perform an MC Test Run e Always execute the Save Cam Table instruction if you change any of the cam data from the user pro gram in the CPU Unit or from the Sysmac Studio If the cam data is not saved the previous condition will be restored when the power is turned ON again possibly causing unexpected machine opera tion e The positive drive prohibit input POT negative drive prohibit input NOT and home proximity input DEC of the Servo Drive are used by the MC Function Module as the positive limit input negative limit input and home proximity input Make sure that the signal widths for all of these input signals are longer than the control period of the MC Function Module If the input
107. ion value 4 1 Shifting the Input Value Input Compensation 0000ceeaeeee 4 2 4 2 Recovering from Sensor Not Connected Errors 00ecueencanees 4 3 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 4 1 4 Optional Settings 4 1 Shifting the Input Value Input Compensation e The input value is shifted by the input compensation value for all points in the sensor s range For example if the input compensation value is set to 1 2 C and the original process value is 200 C the value after compensation will be 201 2 C Temperature Before compen Input sation compensation value Inout a p 100 FS e The factory setting of the input compensation value is 0 0 for all loops Example Application 1 In Figure 1 the temperature sensor is some distance from the workpiece that is being controlled and the reading from the temperature sensor must be adjusted to reflect the actual temperature at the workpiece The reading from thermometer B shows the true temperature at the work piece C 2 The input compensation value is just the difference between the workpiece s temperature B and the Temperature Control Unit s reading A Figure 2 shows the process values before and after compensation Input Compensation Value Workpiece s temp B Unit s reading A 3 After setting the input compensation value compare the temperature displayed on the Unit A w
108. is changed by changing the Input Type Switch from 0 K type thermocouple with a temperature range of 200 to 1 300 C to 1 K type thermocouple with a temperature range of 0 0 to 500 0 C an SV of 200 C will be changed to 20 0 C f Platinum Resistance Thermometer Input Setting Ranges Sensor Set value Input type Temperature range Platinum Resis ima Pt100 200 0 to 650 0 C 300 0 to 1200 0 F ples Thermom JPt100 200 0 to 650 0 C 300 0 to 1200 0 F 2t09 Do not set 2 through 9 2 6 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions 2 2 Application Procedure The procedure for installing and setting up the Temperature Control Unit is illustrated below Use Sysmac Studio to create and set programs For operations of Sysmac Studio refer to the Sysmac Studio Version 1 Operation Manual Cat No W504 Create POU and global variables Create Unit Configuration Programs and software settings Set the unit number Set the input type Set DIP switch 3 to ON Set the function of the Temperature Control Unit Mount and wire to the Rack gt Fo D v v x O am pe c D D v L Turn ON the power to the controller Transfer the user program Create Initialization Data of the Unit Reset the Controller or restart the Unit Warm up the Unit Program transfer and opera
109. items and procedures for checking the operation of an NJ series Controller including offline debugging procedures This section describes the functionality provided by the CPU Unit This section describes how to go online with the CPU Unit and how to connect to other devices This section describes the procedures that are used to actually operate an NJ series Controller This section describes the event codes error confirmation methods and corrections for errors that can occur The appendices provide the CPU Unit specifications task execution times specifica tions of individual system defined variables data attribute lists CJ series Unit mem ory information CJ series Unit memory allocation methods and version information Manual Configuration Sysmac Studio Version 1 Operation Manual Cat No W504 Section Section 1 Introduction Section 2 Installation and Uninstallation Section 3 System Design Section 4 Programming Section 5 Online Connections to a Controller Section 6 Debugging Section 7 Other Functions Section 8 Reusing Programming Section 9 Support Software Provided with the Sysmac Studio Section 10 Troubleshooting Appendices Description This section provides an overview and lists the specifications of the Sysmac Studio and describes its features and components This section describes how to install and uninstall the Sysmac Studio This section describes the basic concepts f
110. ith the temperature indicated by thermometer B The input compensation value is correct if the two readings are approximately equal D Temperature sensor A Thermometer Figure 1 Input Compensation Configuration Unit s temperature A Temperature reading A Control Unit After compensation Temperature after i g 120 compensation 29k 120 Input compensation value e g 10 C Temperature before compensation e g 110 C Before compensation Lower limit input compensation value e g 10 C Thermometer reading B SP region e g 120 C Figure 2 Compensation Graph of 1 point Compensation 4 2 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 4 Optional Settings 4 2 Recovering from Sensor Not Connected Errors If a sensor is not connected for any loop a sensor error will occur and the ERC indicator on the front panel of the Unit will light When necessary the control and alarm functions for any loop can be dis abled The status will be as follows e The ERC indicator will not light to indicate sensor errors for the loop Refer to 5 7 Error and Alarm Processing e Control will not be performed for the loop e Alarms will not be given for the loop e Temperatures will be input for the loop To disable the control and alarm functions of a certain loop set both Alarm Mode 1 and Alarm Mode 2 of each loop of device variables for CJ series
111. junction sensor Always use the Unit and terminal block in a set There are labels with serial numbers attached to the terminal blocks and Units to help keep track of the sets i N lt i a S h j g 5 When returning a thermocouple type Temperature Control Unit for repair always return the Unit and the terminal block with the cold junction sensor as a set j R k Ee al ie RE Pun y BuunoN Z Z 4 e HA ARA H RI NS WE a F E A CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 11 1 Features and System Configuration 1 12 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Specifications and Functions This section describes the functions and specifications of the Temperature Control Unit including technical specifications Unit parts wiring and data allocations 2 1 2 2 2 3 2 4 2 5 2 6 SPCCHICAUONS fia wen Foe SW a as Oe ee a a 2 2 2 1 1 SDE CINICATONS 4 44 00 den kn dee a a a A a ee de Oke gh one he 2 2 2 1 2 Input Function Block Diagram 0 eee 2 5 2 123 INDULSDECIICAHONS 3 0046 920 666 eis eo tt ROR sieeve ds 2 5 Application Procedure sai ee wind saw Pee el Be eee ee 2 7 Part Names and FUNCUONS sssassssnsssnsnsnnnnsnnnnnnnnnnnn 2 11 2 3 1 Par NAMES oaae Sore ade te GAO AG eR a aren ath
112. l as PID control of two con trol loops The PID control function has two degrees of freedom and an autotuning function that can be used to autotune the PID value Connect Temperature Sensors Directly Temperature sensors can be connected directly to the Temperature Control Unit two inputs There are two models that support thermocouples R S K J T B and L thermocouples and two models that support platinum resistance thermometers 500 ms Sampling Cycle PID control is performed with a sampling cycle of 500 ms RUN STOP Control from CPU Unit Commands can be sent from the CPU Unit to switch the Temperature Control Unit s PID control between RUN and STOP Independent Operation in PROGRAM Mode A switch on the front of the Unit pin 1 of the DIP switch selects whether the Temperature Control Unit will continue operation or stop when the CPU Unit is in PROGRAM mode Terminal Block Connections Both inputs and outputs are connected through a terminal block Select ON OFF Control or PID Control A switch on the front of the Unit pin 6 of the DIP switch selects whether the Temperature Control Unit operates with ON OFF control or PID control with 2 degrees of freedom Note The setting on pin 6 sets the control method for all of the Unit s control loops The factory set ting is PID control CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 3 Features and System Configuration E
113. lated Variable for ON and 0 for OFF Monitor Ch1_AL1LvICfg Ch2_AL1LviCfg Loop 1 and Set the alarm 1 detection Loop 2 Alarm 1 level SV Loop 1 and The Temperature Control Loop 2 Alarm 1 Unit returns the set values SV for Monitor that are actually used for temperature control Chi_AL1LvlSta Ch2_AL1LviSta Use these values to monitor operation Ch1_AL2LvIiCfg Ch2_AL2LvICfg Loop 1 and Set the alarm 2 detection Loop 2 Alarm 2 level SV Loop 1 and The Temperature Control Loop 2 Alarm 2 Unit returns the set values SV for Monitor that are actually used for temperature control Chi_AL2LviSta Ch2_AL2LviSta Use these values to monitor operation Ch1_AllnOfsCfg Ch2_AllnOfsCfg Loop 1 and Set the input compensation Loop 2 Input value Compensation Value CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Device variable for CJ series Unit Loop 1 Ch1_ AllnOfsSta Ch1_CtlPrdCfg Ch1_CtlPrdSta Ch1_CtlHystrsCfg Ch1_CtlHystrsSta Ch1i_ProportionalBan dCfg Chi_ProportionalBan dSta Ch1_IntgTmCfg Ch2_AllnOfsSta Ch2_CtlPrdCfg Ch2_CtlPrdSta Ch2_CtlHystrsCfg Ch2_CtlHystrsSta Ch2_Proportional BandCfg Ch2_Proportional BandSta Ch2_IntgTmCfg Data R Bee RW mame UINT UINT UINT UINT UINT UINT UINT RW 2 Specifications and Functions Loop 1 and Loop 2 Input Comp
114. ller manuals for references according to any error that Maintenance Using EtherCAT Using EtherNet IP Using CJ series Units gt 2 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Manual Configuration Manual Configuration i NJ series CPU Unit Hardware User s Manual Cat No W500 Section Section 1 Introduction Section 2 System Configuration Section 3 Configuration Units Section 4 Installation and Wiring Section 5 Troubleshooting Section 6 Inspection and Maintenance Appendices Description This section provides an introduction to the NU series Controllers and their features and gives the NJ series Controller specifications This section describes the system configuration used for NJ series Controllers This section describes the parts and functions of the configuration devices in the NJ series Controller configuration including the CPU Unit and Configuration Units This section describes where and how to install the CPU Unit and Configuration Units and how to wire them This section describes the event codes error confirmation methods and corrections for errors that can occur This section describes the contents of periodic inspections the service life of the Bat tery and Power Supply Units and replacement methods for the Battery and Power Supply Units The appendices provide the specifications of the Basic I O Units Unit dimensions lo
115. m 0 to 1 and data is writ Flag ten to the non volatile memory This flag initializes to 0 when Loop 1 Save 5 Error and Alarm Processing Name of device variable for 00 Ch2_AL2Flg BOOL Loop 2 AL2 The value becomes 1 when the temperature Flag is within the alarm range set with the input value of loop 2 The value becomes 0 when outside the alarm range 01 Ch2_AL1Flg BOOL Loop 2 AL1 The value becomes 1 when the temperature Flag is within the alarm range set with the input value of loop 2 The value becomes 0 when outside the alarm range 02 Ch2_HBFlg BOOL Loop 2 HB Flag The value becomes 1 when the heater cur rent detection value falls below the Heater Burnout Current 03 Ch2_ATFlg BOOL Loop 2 AT Flag The value becomes 1 during Autotuning AT of loop 2 The value becomes 0 when Autotuning AT stops or finishes 04 Ch2_CtlOutFlg BOOL Loop 2 Control The value becomes 1 during output of loop 2 Output Flag Control Output 08 Ch2_StopFlg BOOL Loop 2 Stop The value becomes 0 when temperature Flag control of loop 2 executes and 1 when con 09 Ch2_SetErr BOOL trol stops Loop 2 Setting The value becomes 1 when there is an error 10 Ch2_PIDCalcFlg BOOL Error Flag in the setting value set as a device variable for CJ series Unit Loop 2 PID The value becomes 1 when PID constants Constants Cal calculated by the Temperature Control Unit culated Flag with AT are updated When this bit is 1 PID constants
116. n the terminal screws contact between the wires and terminals The thermocouple s lead wires or the compensat Use thicker compensating conductors ing conductors are too long so the resistance in e Change the wiring location to reduce the length of the wires is affecting operation the wiring The conductors between the temperature sensor Use conductors with the same resistance for the A B and the Temperature Control Unit s terminals and B terminals have three different conductive resistances Noise from electric equipment around the Tem Move the Temperature Control Unit away from the perature Control Unit is affecting operation equipment that is generating the noise Install surge protectors or noise filters on the equip ment that is generating the noise The temperature sensor s leads run close to Separate the temperature sensor s leads from the power lines So noise is being induced from the power lines power lines Run the temperature sensor s leads in a conduit or duct separate from the one carrying the power lines Do not run the temperature sensor s leads parallel to the power lines Reduce the length of the temperature sensor s leads Use shielded wire for the temperature sensor s leads The temperature sensor is installed too far from Install the temperature sensor in a protective tube the point being controlled so the response to closer to the point being controlled temperature changes is delayed
117. nally there may be severe property damage Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or property damage D recautions for Safe Use Indicates precautions on what to do and what not to do to ensure safe usage of the product H Precautions for Correct Use Indicates precautions on what to do and what not to do to ensure proper operation and performance CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Symbols CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 o eB Safety Precautions The circle and slash symbol indicates operations that you must not do The specific operation is shown in the circle and explained in text This example indicates prohibiting disassembly The triangle symbol indicates precautions including warnings The specific operation is shown in the triangle and explained in text This example indicates a precaution for electric shock The triangle symbol indicates precautions including warnings The specific operation is shown in the triangle and explained in text This example indicates a general precaution The filled circle symbol indicates operations that you must do The specific operation is shown in the circle and explained in text This example shows a general precaution for something that you must do 17 Safety Precautions 18 WARNING
118. ng DEMO verses seat ern eeSteeetenedes i 2 3 SENSOR aior er anea a a 5 7 5 20 SEL DOM ass A A N AAi 1 5 3 9 DE HINGCS MOM eiers n aE 5 7 5 19 Setting error NUMDESS ssannnonnnnnnnnnnnnnnnsnnnnnnnnnnenene 2 29 5 7 Simple method to check the temperature sensor MAUS ireann a a 5 12 Special VO UNIT Ala riir e a a A 4 Special I O unit DM area ceeeeeeeeeeeeeeeeeeeeeeaasaeeeeeees A 4 SlaNnGDy SEQUENCES kc5icinduhedeanicess Havixtebeteesserlictaiess 3 16 SATUS MAINGICAIONS sosea a ee seebtieetd 2 11 SOD 6 ON Nee ee Cece eee eee eee ae oer ee 3 21 SyS MaC SIC Ore ceeccute setts EEEE 2 7 System defined variable ccccseeeeeeccceeeeeeeeeseeeeeseees 2 21 T Temperature control errors ceceeceseeeeseeeeeeeeneeeeeeees 5 12 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Index Temperature control method cccccesseeeeeeeeeeeeeeeneees 2 2 Temperature control unit error eccecesseeeeeeeneeeeeeeeeees 5 2 Temperature units cccceccsesecececeeeeeecsesseeeceeeeeesesseees 3 4 Thermocouple input setting ranges ccccseeeeeeeeeees 2 5 U Undershoolihg rosserie oae i ae oteneceetee ee 5 13 UNIE COMIGUIATION eeina 2 7 Unit number switches ce cee eeeceeeceeceeeeeeeeeeeeeees 2 12 A 4 IAIE RE SUNG eecaccceceseczcccaneetaashactscnsedecoueacshentocmenesoeaee 2 22 W Warmup IMC 223 5 suetcna tia Cusseta Baa eal cas 2 3 Index 3 Index
119. nnnnnna 2 21 2 5 1 OWE OW arna ni ee ne ec eer Ree ee ee ene a eee eer ae eee ern ee eee ee eee 2 21 2 5 2 Accessing from the User Program avataic24eiccte xd vede ws wattindAdwvectivlde seeded ae 2 22 2 5 3 Saving Set Value in the Non volatile MEMOLY cccccssseeeeeeeeeceeeeeeeeeeeseeeeseeeeeeeeeesesssaaaeaeeeeeess 2 23 2 5 4 Operation D aleiais ee ccsi usecase en E tons eeudasae dec 2 24 2 5 5 VATA AO ML tel 2a stracaeasnrettt dns acestetedeernsend N 2 30 2 5 6 Operating Parameters iorri e a e E 2 32 2 6 Range of Set Values and Monitor Values sssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna 2 35 2 6 1 oeb VAES ear A S 2 35 2 6 2 Montor yale Sostener EAA E 2 37 Section 3 Settings Required for Temperature Control 3 1 Seting h Input Typene a aa aa aaia 3 2 3 2 Selecting the Temperature Units sissrisreininiiis sainia aaan anaana aaa aaa annaa E anaa 3 4 3 3 Setting the Pin 3 Of the DIP S WIte Wh iiisaas sicesi ccctsiandeiead siaveldessasasiecentcandsiecemsssuriseccdesaasavedseucansvads 3 5 3 4 Selecting the Control Operation Forward ReverSe sssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 3 6 3 5 Selecting PID Control or ON OFF Control ssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna 3 7 3 6 Setting the Control Period si ii ivccscsacasaanceacedia sas cuctcesensadcussansdsiancewsaacdasavacewensanssecedueansesedescendies 3 8 3 7 SEUNG THES CL POUAUS sisisi aaa a aa aa
120. nstants Cal culated Flag Loop 1 and Loop 2 Standby Flag Loop 1 and Loop 2 Cold Junction Sen sor Error Loop 1 and Loop 2 CT Overflow Flag Function The value becomes 1 during autotuning of loop 1 and loop 2 The value becomes 0 when autotuning stops or fin ishes The value becomes 1 when the control output of loop 1 and loop 2 is ON The value becomes 0 when the Temperature Control Unit is controlling the temperature of loop 1 and loop 2 The value becomes 1 when the Temperature Control Unit is not controlling the tempera ture of loop 1 and loop 2 The value becomes 1 when there is an error in the set values in the device variable for CJ series Unit The value becomes 1 when the PID constants calculated by the Temperature Control Unit for autotuning are updated When this value is 1 the PID constants in the Operating Parameters are not output to the Temperature Control Unit When this value is 0 the PID constants in the Operating Parameters are output to the Temperature Control Unit The value becomes 1 when the Temperature Control Unit is waiting for I O refreshing after the Controller is reset or the Unit is restarted The value becomes 1 for the following e Cold junction sensor error The value becomes 1 if the heater current detected by the CT Current Transformer exceeds 55 0 A CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Spec
121. ntrol CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 Settings Required for Temperature Control 3 9 Setting the PID Constants Setting PID Constants with Autotuning The autotuning AT function can be used to automatically calculate the optimal PID constants for the set point during operation This Temperature Control Unit uses the limit cycle method which deter mines the controlled system s characteristics by forcibly changing the manipulated variable Autotuning cannot be started if the Unit is stopped or using ON OFF control operation Starting Autotuning e To start autotuning turn the device variables for CJ series Unit Loop 1 and 2 Start AT Bit _Ch1_StartATCmd _Ch2_StartATCmd from 0 to 1 e When autotuning is completed you must replace the current PID constants with the calculated PID constants in order for the Unit to operate with the calculated PID constants The Unit stores the calculated PID constants in the Read PID Constants in the Operating Parameters and turns ON the PID Constants Calculated Flag at the same time Use this flag as an input condition in the CPU Unit s user program and transfer the read PID constants from the Operating Parameters to the word in the Operating Parameters where the Setting PID constants are stored After the PID constants have been transferred turn the Change PID Constants Bit from 0 to 1 Toggling this control bit causes the Temperature Con
122. ntrol Units Operation Manual for NJ series CPU Unit W491 Precautions for Safe Use Precautions for Safe Use i Disassembly and Dropping e Do not attempt to disassemble repair or modify any Units Doing so may result in malfunction or fire e Do not drop any Unit or subject it to abnormal vibration or shock Doing so may result in Unit malfunc tion or burning i Mounting e The sliders on the tops and bottoms of the Power Supply Unit CPU Unit I O Units and other Units must be completely locked until they click into place after connecting the adjacent Unit connectors i Installation e Always connect to a ground of 100 Q or less when installing the Units A ground of 100 Q or less must be installed when shorting the GR and LG terminals on the Power Supply Unit i Wiring e Follow the instructions in this manual to correctly perform wiring Double check all wiring and switch settings before turning ON the power supply Use crimp terminals for wiring Do not connect bare stranded wires directly to terminals e Do not pull on the cables or bend the cables beyond their natural limit Do not place heavy objects on top of the cables or other wiring lines Doing so may break the cables e Mount terminal blocks and connectors only after checking the mounting location carefully e Be sure that the terminal blocks expansion cables and other items with locking devices are properly locked into place e Always remove any dustp
123. oint mode External terminal con Removable terminal block with 18 points M3 screws nections 1 The last three digits of the model number indicate the Unit s features CJiw TC LJ o L L Output type 3 NPN outputs two loop control outputs and heater burnout alarm output 4 PNP outputs two loop control outputs and heater burnout alarm output Always 0 Input type 0 Thermocouple input 1 Platinum resistance thermometer input 2 Indication accuracy of thermocouples e Accuracy ratings are given for the Temperature Control Unit used in a set with a cold junction sensor on the terminal block Always use the Unit and terminal block in a set There are labels with serial numbers attached to the terminal blocks and Units to help keep track of the sets e When returning a thermocouple type Temperature Control Unit for repair always return the Unit and the ter minal block with the cold junction sensor as a Set CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 3 2 Specifications and Functions i Heater Burnout HB Alarm Item Specification Maximum heater current Single phase AC 50 A Indication accuracy of input cur 5 of full scale 1 digit max rent Heater burnout alarm setting 0 1 to 49 9 A 0 1 A units range The heater burnout detection function will not operate if the set value is set to 0 0 A or 50 0 A When the SV is 0 0 A the heather burnout alarm will be OFF When the S
124. ontrolled from the CPU Unit through the device variable for CJ series Unit constant A Indication accuracy Centigrade 0 3 PV or 1 C whichever is larger Centigrade 0 3 PV or 0 8 C whichever is larger 9 1 digit max 1 digit max i Fahrenheit 0 3 PV or 2 F whichever is larger 1 Fahrenheit 0 3 PV or 1 6 F whichever is larger digit max 1 digit max e The accuracy will be 2 C 1 digit max when using an L type thermocouple or using a K or T type thermocouple below 100 C e The accuracy will be 3 C 1 digit max when using an R or S type thermocouple below 200 C e The B type thermocouples may not be accurate S below 400 C 2 zi Warmup time 30 min Y O Sensitivity when using 0 0 to 999 9 C or F 0 1 C or F units F ON OFF control Proportional band 0 1 to 999 9 C or F 0 1 C or F units Integral reset time 0 to 9 999 s one second units Derivative rate time 0 to 9 999 s one second units Control period 1 to 99 s one second units Sampling period 500 ms 2 loops Output refresh period 500 ms 2 loops Display refresh period 500 ms 2 loops Input compensation 99 9 to 999 9 C or F 0 1 C or F units value Alarm output setting 999 to 9 999 C or F 1 C or F units range The setting range will be 99 9 to 999 9 C or F 0 1 C or F units when using a platinum resistance ther mometer or using a K or J type thermocouple in decimal p
125. or CJ series Unit Also it is possible to set the Temperature Control Unit so that the set values stored in non volatile memory are automatically written to the device variables for CJ series Units when the power is turned ON or the Unit is restarted pin 8 of the DIP switch on the front panel of the Temperature Control Unit Once the set values have been stored in the Temperature Control Unit and the Unit is set for auto matic transfer the Unit will always start with those settings whether the power has been turned OFF or not The set values can be changed after startup if necessary To simplify Temperature Control Unit operation pin 8 of the DIP switch can be turned ON to enable operation by merely turning ON the power supply and setting Operation Data the SP All other set tings can be used at their factory settings Refer to 2 6 Range of Set Values and Monitor Values for the default settings CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 Features and System Configuration 1 2 System Configuration i N lt i a S h j 5 A Caution To provide for safe operation even in the event of Temperature Control Unit malfunctions provide Q safety measures to prevent abnormal temperature rise in a separate system outside the PLC system If proper safety measures are not taken serious accidents could result from Unit failure resulting in loss of control 1 2 1 Basic Sys
126. or designing an NU series System with the Sysmac Studio and the basic operating procedures This section describes how to create programs with the Sysmac Studio This section describes how to go online with a Controller This section describes how to debug the programs online on the Controller or debug it offline with the Simulator This section describes other functions that are supported by the Sysmac Studio including security functions and troubleshooting functions This section describes how to reuse the programs that you create with the Sysmac Studio This section describes the Support Software that is provided with the Sysmac Studio This section describes the error messages that are displayed when you check a pro gram on the Sysmac Studio and how to correct those errors The appendices describe the following Driver Installation for Direct USB Cable Connection Specifying One of Multiple Ethernet Interface Cards Online Help Simulation Instructions CJ series Temperature Control Units Operation Manual for NJ series CPU Unit Cat No W491 This manual Section Section 1 Features and System Configuration Section 2 Specifications and Functions Section 3 Settings Required for Temperature Control Section 4 Optional Settings Section 5 Error and Alarm Processing Appendices Description This section describes the features and the system configuration of the Temperature Control Unit This section de
127. otuning ON OFF control is being used Use P proportional control or PID control A long control period has been set in a system Reduce the control period with a very fast heating response Autotuning was performed but the Temperature Refresh the Temperature Control Unit s PID constants y S Ri g i S 9 8 5 Control Unit s PID constants were not refreshed with the calculated PID constants Refer to 3 9 Setting with the calculated PID constants the PID Constants for details CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 13 5 Error and Alarm Processing i Excessive Hunting The same connection and settings problems can cause overshooting undershooting and hunting Refer to Excessive Overshooting or Undershooting for details on possible connection and settings prob lems Step Possible Cause Remedy Usage The heater s output is too large for the controlled Use a heater that is suitable for the controlled system system Something disturbs the system periodically and Arrange the controlled system to minimize external dis changes it s heating requirement turbances Autotuning is in progress The hunting will stop when autotuning is completed f Troubleshooting from Symptoms Output Errors No Control Output or No Alarm Output Step Possible Cause Remedy Connection The measured temperature is incorrect Refer to Troubleshooting from Symptoms Meas
128. ple Programming ff Process Value PV Import Outline Store process value PV data of each loop Ch _PV in the user defined variable Temperature which is the data storage destination Each input value is read when the Sensor Error Flag of each loop is OFF In this example the device name J01 is used when this Unit is registered in Unit Configuration Defined variable User defined variable Name 2an acon Allocated address AT Comments type setting Temperature1 BOOL False Loop 1 PV Data Storage Destination Temperature2 BOOL False Loop 2 PV Data Storage Destination Device variable for CJ series Unit Name Dana Taco Allocated address AT Comments ame setting J01_Ch1_PV lOBus rack 0 slot 0 Ch1_ Loop 1 Process Value PV J01_Ch2 PV INT lOBus rack 0 slot 0 Ch2_ Loop 2 Process Value PV JO1_Chi_SensErr BOOL lOBus rack 0 slot 0 Ch1_ Loop 1 Sensor Error Flag StaWd Ch1_SensErr JO1_Ch2_SensErr BOOL lOBus rack 0 slot 0 Ch2_ Loop 2 Sensor Error Flag StaWd Ch2_SensErr Programming Example JO1_Ch1_SensErr Loop 1 Sensor Error Flag JO1_Ch1_ PV Temperature 1 JO1_Ch2_SensErr Loop 2 Sensor Error Flag J01 Ch2_ PV Temperature2 A 10 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Appendices AT Execution and PID Constants Calculation Outline The program from AT execution of loop 1 to PID constants calculation is shown below In this example the device name J
129. puts will be OFF or will be the values specified in the Unit or slave settings and external communications cannot be performed Use the RUN output on the Power Supply Unit for example to implement fail safe circuits so that external devices do not operate incorrectly Configure the external circuits so that the power supply to the control system turns ON only after the power supply to the Controller has turned ON If the power supply to the Controller is turned ON after the control power supply temporary errors may result in incorrect control system signals because the output terminals on Output Units may momentarily turn ON when power supply is turned ON to the Controller If you transfer data from a backup file on an SD Memory Card to the Controller when the power sup ply is turned ON properly select the data groups to transfer If the data for an unintended data group is transferred to the Controller it may cause the equipment to operate unpredictably Actual Operation Check the user program data and parameter settings for proper execution before you use them for actual operation Bf Turning OFF the Power Supply Never turn OFF the power supply to the Controller when the BUSY indicator is flashing While the BUSY indicator is lit the user program and settings in the CPU Unit are being backed up in the built in non volatile memory This data will not be backed up correctly if the power supply is turned OFF Also a major fault level
130. r CJ series Unit Set the Alarm Mode for each loop Ms C a 5 G i D gt 3 Tl c 5 A ch fe 5 lf the alarm mode setting is changed the new setting will not become effective until the controller is reset or the Unit is restarted Always reset the controller or restart the Unit after changing the alarm mode Alarm Modes In the following diagrams the X indicates the alarm SV The factory setting is 0 Setting Alarm mode Alarm output function Alarm SV X is positive Alarm SV X is negative 1 Upper and lower limit alarm Always ON 2 Upper limit alarm 3 Lower limit alarm 4 Upper and lower limit Always OFF range alarm 5 Upper and lower limit alarm TEN Always OFF with standby sequence 6 Upper limit alarm with standby sequence 7 Lower limit alarm with standby sequence 8 Absolute value upper limit alarm 9 Absolute value lower limit alarm CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 15 3 Settings Required for Temperature Control Setting the Alarm Hysteresis Initialization Data The hysteresis setting controls the ON OFF switching of the alarm output as shown in the following diagram This setting can be changed in the Initialization Data words allocated in the DM Area to the Temperature Control Unit Upper limit lll hysteresis aa hysteresis OFF OFF A A Alarm SV Alarm SV Set device variables for CuJ series Unit Alarm 1 Hysteresis
131. r Correct Use i SD Memory Cards e Insert the SD Memory Card all the way e Do not turn OFF the power supply to the Controller during SD Memory Card access The files may be corrupted lf there is a corrupted file in the SD Memory Card the file is automatically deleted by the restoration function when the power supply is turned ON 30 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Regulations and Standards Regulations and Standards Conformance to EC Directives i Applicable Directives e EMC Directives e Low Voltage Directive i Concepts EMC Directive OMRON devices that comply with EC Directives also conform to the related EMC standards so that they can be more easily built into other devices or the overall machine The actual products have been checked for conformity to EMC standards Whether the products conform to the standards in the system used by the customer however must be checked by the customer EMC related performance of the OMRON devices that comply with EC Directives will vary depending on the configuration wiring and other conditions of the equipment or control panel on which the OMRON devices are installed The customer must therefore perform the final check to confirm that devices and the overall machine conform to EMC standards Applicable EMC Electromagnetic Compatibility standards are as follows EMS Electromagnetic Susceptibility EN 61131 2 and EN 61000
132. r request Please consult with your OMRON representative at any time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes even when tolerances are shown PERFORMANCE DATA Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty It may represent the result of OMRON s test conditions and the users must correlate it to actual application requirements Actual performance is subject to the OMRON Warranty and Limitations of Liability ERRORS AND OMISSIONS The information in this manual has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 15 Safety Precautions Safety Precautions Definition of Precautionary Information 16 The following notation is used in this manual to provide precautions required to ensure safe usage of a CJ series Temperature Control Unit The safety precautions that are provided are extremely important to safety Always read and heed the information provided in all safety precautions The following notation is used Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Additio
133. ration Autotuning AT Function The Temperature Control Unit is equipped with an autotuning AT function that uses the limit cycle method to calculate the optimum PID constant for the controlled system The SV cannot be written for a loop if the loop is being autotuned i Q S A ch fe g Q i Hunting period AT starts AT stops soinjes4 Z Note The limit cycle method uses ON OFF operation to cause hunting around the SV measures the amplitude and hunting period and calculates the optimum PID constants Control Operation Forward and Reverse The Temperature Control Unit s control can be set to reverse operation or forward operation with pins 4 and 5 of the Unit s DIP switch The factory setting is for reverse operation heating One forward reverse setting controls the operation of loop 1 and the other forward reverse setting controls the operation of loop 2 Note With forward operation cooling the manipulated variable is increased as the PV increases With reverse operation heating the manipulated variable is increased as the PV decreases Manipulated variable Manipulated variable 100 100 0 0 Low SV High Low SV High temperature temperature temperature temperature Forward operation Reverse operation For example when heating control is being performed and the process value PV is lower than the set point SP the manipulated variable is increased as the difference between the
134. re Control 3 2 Selecting the Temperature Units The Temperature Control Unit can operate in C or F Select the desired temperature units with pin 2 of the DIP switch on the front of the Unit The temperature unit setting applies to all of the Unit s control loops It is not possible to set different temperature unit settings for the different control loops Pin 2 Temperature unit Setting The factory setting is OFF C as shown by the shading in the diagram above If this setting is changed the new setting will not become effective until the Unit is restarted or the con troller is reset including when the power is turned ON 3 4 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 Settings Required for Temperature Control 3 3 Setting the Pin 3 of the DIP Switch Set pin 3 Data storage display format of the DIP switch to ON The factory setting is OFF Data storage display Orga 16 bit binary W w i te g 0 a 5 Ww S g 0 z v V S al s If this setting is changed the new setting will not become effective until the Unit is restarted or the con troller is reset including when the power is turned ON CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 5 3 Settings Required for Temperature Control 3 4 Selecting the Control Operation Forward Reverse i Forward Cooling Reverse
135. rnout Current in normal operation current after heater burnout 2 SV e f more than one heater is connected through the CT set the heater burnout current to the current induced when the heater with the smallest current consumption is burned out If the heaters all con sume the same current set the heater burnout current to the current induced when one of the heat ers is burned out e The difference between the normal current and the heater burnout current must meet the following minimum levels Heaters drawing less than 10 0 A Normal current current with heater burnout 1 0 A Operation will be unstable with a difference less than 1 0 A Heaters drawing 10 0 A or more Normal current current with heater burnout 2 5 A Operation will be unstable with a difference less than 2 5 A e The set value range for the heater burnout current is 0 1 to 49 9 A Heater burnout will not be detected if the heater burnout current is set to 0 0 or 50 0 A The heater burnout alarm will be OFF if the heater burnout current is set to 0 0 it will be ON if the heater burnout current is set to 50 0 e The total heater current during normal operation must not exceed 50 0 A Example Applications Heater Control output Example 1 A single 1 kW 200 VAC heater is maa os controlled through OUT1 1 kW i 200 VAC Normal current aa 5A lt 10A l CT l Current when control output is OFF 0 A O O SV
136. rogram will continue Stops Execution of the user program stops Starts Execution of the user program starts 5 18 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 Error and Alarm Processing 7 Error Descriptions Event name Meaning Source Error attributes Effects System defined variables Cause and correction Attached information Precautions Remarks Event name Meaning Source Error attributes Effects System defined variables Cause and correction Attached information Precautions Remarks Cold Junction Sensor Error 04680000 hex An error occurred in the cold junction sensor PLC Function Module Source details CJ series Unit Continuously eo a Control operations a the Unit will stop Faulty connection to the cold junction Check the connections to the cold Securely connect the cold junction sensor junction sensor i e terminal block sensor i e terminal block reconnect it if the connection is faulty and then cycle the power supply or restart the Unit The cold junction sensor failed If the cause is not a faulty connection None replace the Temperature Control Unit Attached information 1 Loop number where error was detected You can change the event level to the minor fault level If you change the level to the minor fault level the Recovery col umn above will be changed to Error reset There is an illegal setting PLC
137. rol Output BOOL oO eh 2 3 4 oO Ch2_StopFlg Ch2_SetErr Ch2_PIDCalcFlg Loop 2 Stop Bit BOOL Loop 2 Setting Error Flag BOOL Loop 2 PID Constants BOOL Calculated Flag Loop 2 Standby Flag BOOL Loop 2 Cold Junction BOOL Sensor Error Loop 2 CT Overflow Flag BOOL Loop 2 Sensor Error Flag BOOL Loop 2 Save Completed BOOL 0 Ch2_StbyFlg Ch2_CJErr Ch2_CTOvfFlg Ch2_SensErr Ch2_SaveFlg 0015 C C C 12 05 C o oo Co aai C CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 A 7 Appendices CJ series 1 O NJ series device variable for O memory address CJ series Unit Output n 10 00 15 Ch1_HBLvICfg Loop 1 Heater Burnout UINT CPU Unit to Current this Unit n 11 00 15 Ch2_HBLvICfg Loop 2 Heater Burnout UINT Current Input 00 15 Ch1_HtrCurVal Loop 1 Heater Current UINT This Unitto n414 00 15 Ch2_HtrCurVal Loop 2 Heater Current UINT eUu ore oe iene p n 15 00 15 Chi_HBLviSta Loop 1 Heater Burnout UINT Current for Monitor n 16 00 15 Ch2_HBLvliSta Loop 2 Heater Burnout UINT Current for Monitor Initialization Data CJ series 1 0 memory address DMNo BitNo Varablename Name Damy D m 0 00 15 AlmMd Loop 1 2 Alarm 1 Mode and Alarm 2 WORD Mode Tare JNT m3 UNT m 4 m 5 NJ series device variable for CJ series Unit m 4 00 15 Ch2_AL1HystrsCfg Loop 2 Alarm 1 Hysteresis UINT 00 15 Ch2_AL2HystrsCfg
138. rol Units Operation Manual for NJ series CPU Unit W491 21 22 Precautions for Safe Use Do not apply voltages or connect loads to the Output Units or slaves in excess of the maximum rat Ings Surge current occurs when the power supply is turned ON When selecting fuses or breakers for external circuits consider the above precaution and allow sufficient margin in shut off performance Refer to the relevant manuals for surge current specifications Refer to the NJU series CPU Unit Hard ware User s Manual Cat No W500 for surge current specifications If the full dielectric strength voltage is applied or turned OFF using the switch on the tester the gener ated impulse voltage may damage the Power Supply Unit Use the adjustment on the tester to grad ually increase and decrease the voltage Apply the voltage between the Power Supply Unit s L1 or L2 terminal and the GR terminal when test ing insulation and dielectric strength Do not supply AC power from an inverter or other device with a square wave output Internal temper ature rise may result in smoking or burning Always input a sinusoidal wave with the frequency that is given in the NJ series CPU Unit Hardware User s Manual Cat No W500 Install external breakers and take other safety measures against short circuiting in external wiring i Turning ON the Power Supply It takes up to approximately 10 to 20 s to enter RUN mode after the power is turned ON During that time out
139. rom the User Program The user program controls the Temperature Control Unit using the device variables for CJ series Unit Allocate variables for CJ series Units to the I O port which is explained below 1 0 port An I O port is a logical interface to enable the CPU Unit to exchange data with configuration units such as the Temperature Control Unit An I O port has a unique predefined name for each unit model and function An I O port is automatically created by preparing the Unit Configuration with Sysmac Studio How to Specify Device Variables for CJ series Unit Allocate variables for CJ series Units to an I O port with VO map in the Sysmac Studio Specify the variable name for the AT specification with the following method 1 Select a variable already registered in the variable table 2 Input a new variable name 3 Automatically create a variable name with Device variable creation When a device variable name for CJ series Unit is assigned with the method in 2 or 3 the variable input by Sysmac Studio is automatically registered in the variable table 2 22 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions The following is the configuration of variable names created with 3 Automatic creation Name of device variable for CJ series Unit Chi_PV This is an I O port name The name indicates the Unit functions statuses and parameters This is the devi
140. roof labels that are on the top of the Units when they are shipped before you turn ON the power supply If the labels are not removed heat will accumulate and malfunctions may occur e Before you connect a computer to the CPU Unit disconnect the power supply plug of the computer from the AC outlet Also if the computer has an FG terminal make the connections so that the FG terminal has the same electrical potential as the GR terminal on the Power Supply Unit A difference in electric potential between the computer and Controller may cause failure or malfunction If the external power supply to an Output Unit or slave has polarity connect it with the correct polar ity If the polarity is reversed current may flow in the reverse direction and damage the connected devices regardless of the operation of the Controller i Power Supply Design e Do not exceed the rated supply capacity of the Power Supply Units in the NJ series Controller The rated supply capacities are given in the NJU series CPU Unit Hardware Users Manual Cat No W500 If the capacity is exceeded operation may stop malfunctions may occur or data may not be backed up normally for power interruptions Use NJ series Power Supply Units for both the NJ series CPU Rack and Expansion Racks Operation is not possible if a CJ series Power Supply Unit is used with an NJ series CPU Unit or an NJ series Power Supply Unit is used with a CJ series CPU Unit CJ series Temperature Cont
141. s 2 2 DIP switch setting functions sssesessseeesennrereeenrneeeee 2 13 DISADIED M010 0 MANTENEN 4 3 DM setting error initialization data eeeeeeeeeeeees 5 8 Duplicate unit number nnnnsnonennnnennnnnnnnnnsnnnnenenennnnnene 5 9 E ERC MAdCatO P cienia na tee cas heeks 2 11 5 2 ERH indicator aaoseesnnennenenenserenenenenrnnennrrnrereree 2 11 5 2 Error processing flowchart ccccccssseeeeeeeeeeeeeeaneeeees 5 3 EVENtCOQE saen r T E R 5 17 Event name eai e e 5 17 EVONIS croira Aa a 5 16 Index 2 F FONAN cit are tei ie Ue eh oe eel 3 6 H Hardware check error cccccsseeeeeceesseeeceneeeessanseeeeseees 5 8 HB heater burnout alarm ccceececesssseeeeeeeeeeeaeseeeeees 2 4 AB al IM ENO S enn a Rita cis 5 15 HEAtEr DOAOUT seinan a E edocs 1 5 Heater burnout HB icc iceeetucst axbnedewonssecddnssaxsencdvediuvedens 3 19 Heater burnout alarm cssoesenneseneesneneneenennne 2 4 5 7 5 21 Heater burnout current ceeeeeeeeeeeeeeees 3 19 3 20 5 15 Heater burnout detection cccccecccceeeeeeeeeeeeeeeseeeeees 3 19 PUNUNG cornea a us se uatennsbeeteeh Gc aed 5 14 VO DUSCHECkEmNor sesine ea 5 9 VOMA aaa ieee eecedoteieeitc eesti aes 2 22 VODOU mesde a SE cent xe esac 2 22 VO setting CHECK EnO orsta E 5 9 VOWinng examples ssion 2 18 OIC ATOM ACCUNACY ecenin ar era a E 2 3 ninalization data niei a TE 2 21 2 30 Input compensation function
142. s Unit Loop 1 and 2 Set point _Ch1_SetPointCfg _Ch2_SetPointCfg See the following table Ch1_SetPointCfg Loop 1 Set point Set the set point of loop 1 Ch2_SetPointCfg Loop 2 Set point Set the set point of loop 2 Example To change the loop 1 Set point from 0 C to 200 C set Chi_SetPointCfg to 200 W N n g g D T R g a Changing the set point is not enough to start temperature control it is also necessary for the Stop Bit for that loop to be OFF Refer to 3 12 Starting and Stopping Temperature Control for details CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 9 3 Settings Required for Temperature Control 3 8 Using ON OFF Control 3 10 With ON OFF control you set a set point in advance During reverse operation the Temperature Con troller will turn OFF the control output when the set point is reached When the control output goes OFF the system temperature will begin to drop and the control output will be turned ON again when the system temperature falls below the set point This ON OFF operation is repeated around the set point The control sensitivity setting determines how far the system temperature has to fall below the set point before the control output is turned ON again Also the control operation setting determines whether the Unit operates with forward operation cooling or reverse operation heating With forward operation the manipulated varia
143. s longer to reach the set point SP but the process value PV does not overshoot The PV overshoots and there is hunting but the PV reaches the SP quickly e Changing The Integral Time Increasing Decreasing It takes longer to reach the SP but hunting overshooting and undershooting are reduced Overshooting and undershoot ing occur Hunting occurs The PV rises quickly CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 13 W O g amp g 0 2 0 A e a F G 3 Settings Required for Temperature Control e Changing D The Derivative Time Increasing D Overshooting undershooting and the set time are reduced but hunting will occur from small changes in the system itself Decreasing D Overshooting and undershoot ing are increased It takes time to return to the SP 3 14 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 Settings Required for Temperature Control 3 10 Using the Alarm Output Function This section explains the alarm modes standby sequence and alarm values i Setting the Alarm Mode Initialization Data There are two alarm outputs for each loop and any of the following nine alarm modes can be selected for each alarm s operation To use the alarm output function set a value in the Loop 1 2 Alarm 1 Mode and Alarm 2 Mode _AlmMad of the device variable fo
144. s power supply before connecting or disconnecting wiring to the Unit e To avoid problems with noise route the I O wiring in a separate duct or conduit that does not carry any high voltage lines or power lines e Prevent wire clippings cutting chips or other materials from getting inside the Unit They could cause scorching failure and malfunction Pay particular attention to this during installation and take mea sures such as covering with a cover e f the Unit was shipped from the factory with the dust protection label on top of the unit be sure to remove that label before switching ON the power The label prevents heat dissipation and could cause a malfunction Remove the protective label after wiring is completed g A ct Ye NS al a A i Q _ Hi Te 4 f D Precautions on Removable Terminal Blocks The terminal block can be removed by pressing down on the lever at the bottom of the terminal block Always confirm that this lever is up in the locked position before starting operation 1 10 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 Features and System Configuration H Precautions for Correct Use A cold junction sensor is attached to the terminal block for Temperature Control Units with ther mocouples The accuracy ratings are given for the Temperature Control Unit used in a set with the cold
145. scribes the specifications the functionality and the operating proce dure for the Temperature Control Unit and where and how to wire the Unit This section explains the various settings required for temperature control of the Temperature Control Unit This section explains the optional settings for the Temperature Control Unit This section describes the troubleshooting procedure for the Temperature Control Unit CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Manual Configuration CJ Series Temperature Control Units OPERATION MANUAL Cat No W396 Section Description Section 1 This section describes the features of the Temperature Control Unit and its basic sys Features and System Configuration tem configuration Section 2 This section describes the functions and specifications of the Temperature Control Specifications and Functions Unit including technical specifications Unit parts wiring and data allocations Section 3 This section explains the various settings required for temperature control Settings Required for Temperature Control Section 4 This section explains how to use the input compensation value Optional Settings Section 5 This section provides information on troubleshooting and error processing Error and Alarm Processing Appendices CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 Manual Structure Manual Structure
146. series device variable for memory address CJ series Unit CE Tome wenn me Om Input 00 15 Ch1_ PV Loop 1 Process Value INT This Unitto n44 00 15 Ch2 PV Loop 2 Process Value INT SPU Unity Lett 00 18 _ch2_ p u n 5 00 15 Ch1_SetPointSta Loop 1 Set point for Moni INT tor n 6 INT 00 15 Ch2_SetPointSta Loop 2 Set point for Moni tor Loop 1 2 Decimal Point WORD and Loop 1 2 Setting Error Number Loop 1 Status WORD Loop 1 AL2 Flag BOOL Loop 1 AL1 Flag BOOL Loop 1 HB Flag BOOL Loop 1 AT Flag BOOL Loop 1 Control Output BOOL I O DecPointSetErrSta n 00 15 n 8 00 15 Chi_StaWd Ch1_AL2Flg Ch1_AL1Flg Ch1_HBFlg Ch1_ATFlg Ch1_CtlOutFlg Ww N 04 Ch1_StopFlg Ch1_SetErr Chi_PIDCalcFlg Loop 1 Stop Flag BOOL Loop 1 Setting Error Flag BOOL Loop 1 PID Constants BOOL Calculated Flag Loop 1 Standby Flag BOOL Loop 1 Cold Junction BOOL Sensor Error Loop 1 CT Overflow Flag BOOL Loop 1 Sensor Error Flag BOOL Loop 1 Save Completed BOOL gt 40 p sn A1owmyy pue yun SeLIes gt 10 Sojqeue D21AA JO B GeL BDUepUOdSe IOD y v Q Q C 2 rF a i N 0 Ch1i_StbyFlg Ch1_CJErr Chi_CTOvfFlg Ch1_SensErr Chi_SaveFlg n 9 00 15 Ch2_StaWd Ch2_AL2Fig Ch2_AL1Flg Ch2_HBFlg Ch2_ATFlg Ch2_CtlOutFlg Loop 2 Status WORD Loop 2 AL2 Flag BOOL Loop 2 AL1 Flag BOOL Loop 2 HB Flag BOOL Loop 2 AT Flag BOOL Loop 2 Cont
147. set correctly e Do not download motion control settings during an MC Test Run i EtherCAT Communications e Do not disconnect the EtherCAT slave cables during operation The outputs will become unstable e Set the Servo Drives to stop operation if an error occurs in EtherCAT communications between the Controller and a Servo Drive e Make sure that all of the slaves to be restored are participating in the network before you reset a Net work Configuration Verification Error Process Data Communications Error or Link OFF Error in the EtherCAT Master Function Module If any slave is not participating when any of these errors is reset the EtherCAT Master Function Module may access slave with a different node address than the spec ified node address or the error may not be reset correctly 28 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Precautions for Correct Use i Battery Replacement e Be sure to install a replacement Battery within two years of the production date shown on the Battery label e Turn ON the power after replacing the Battery for a CPU Unit that has been unused for a long time Leaving the CPU Unit unused again without turning ON the power even once after the Battery is replaced may result in a shorter Battery life e When you replace the Battery use the CJ1W BAT01 Battery Set CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 29 Precautions fo
148. set from 1 to 0 and the PID constants stored as Operating Parameters will be retransferred to RAM in the Temperature Control Unit The set values of the applica ble loop are written from RAM to non volatile memory in the Temperature Control Units when a Save Settings Bit is set from 0 to 1 DO NOT turn OFF the power supply when data is being written from RAM to non vol atile memory Confirm that Ch _SaveFlg Save Completed Flag is set to 1 data is written to memory before turning OFF the power supply CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions Device variable for CJ series Unit Data R W Function Chi_StaWd Ch2_StaWd WORD Loop 1 and Bits serve the functions Loop 2 Status described below Each bit is defined with a BOOL data type variable Bit 00 Loop 1 and Loop 2 AL1 Flag Bit 01 Loop 1 and Loop 2 AL1 Flag Bit 02 Loop 1 and Loop 2 HB Flag Bit 03 Loop 1 and Loop 2 AT Flag Bit 04 Loop 1 and Loop 2 Control Output Flag Bit 05 Bit 06 Bit 07 Bit 08 Loop 1 and Loop 2 Stop Flag Bit 09 Loop 1 and Loop 2 Setting Error Flag Bit 10 Loop 1 and Loop 2 PID Constants Calculated Flag Bit 11 Loop 1 and Loop 2 Standby Flag Bit 12 Loop 1 and Loop 2 Cold Junction Sensor Error Bit 13 Loop 1 and Loop 2 CT Overflow Flag Bit 14 Loop 1 and Loop 2 Sensor Error Flag Bit 15 Loop 1 and Loop 2 Save Completed Flag Ch1_AL1Flg Ch2_
149. signal widths are shorter than the control period the MC Function Module may not be able to detect the input signals resulting in incorrect operation i Battery Replacement e The Battery may leak rupture heat or ignite Never short circuit charge disassemble heat or incinerate the Battery or subject it to strong shock e Dispose of any Battery that has been dropped on the floor or otherwise subjected to excessive shock Batteries that have been subjected to shock may leak if they are used e UL standards require that only an experienced engineer replace the Battery Make sure that an expe rienced engineer is in charge of Battery replacement CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 25 Precautions for Safe Use e Apply power for at least five minutes before changing the Battery Install a new Battery within five minutes at 25 C of turning OFF the power supply If power is not supplied for at least 5 minutes the saved data may be lost i Unit Replacement e We recommend replacing the Battery with the power turned OFF to prevent the CPU Unit s sensitive internal components from being damaged by static electricity and to prevent malfunctions The Bat tery can be replaced without turning OFF the power supply To do so always touch a grounded piece of metal to discharge static electricity from your body before you start the procedure After you replace the Battery connect the Sysmac Stu
150. sion code Date Revised content 01 Original production 02 March 2012 Corrected errors 03 August 2012 Made changes accompanying release of unit version 1 03 of the CPU Unit 36 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Features and System Configuration SSS This section describes the features of the Temperature Control Unit and its basic sys tem configuration 1 1 Introduction and Features 00000cuuuuunaaaaasa 1 1 1 INMFOCUCHOM i c4e cdn04442400844enn8eeg aie AEE 1 1 2 FeatureS 0 00 ce ee ee ee ee ee eae 1 2 System Configuration ccc cece ees 1 2 1 Basic System Configuration 000000 1 2 2 Mounting the Unit 0 0 cee eee CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 Features and System Configuration 1 1 Introduction and Features 1 1 1 Introduction This Unit receives inputs directly from thermocouple or platinum resistance thermometers performs PID control with two degrees of freedom and outputs results through open collector outputs This Unit has two types of inputs thermocouples R S K J T B and L and platinum resistance ther mometers JPt100 and Pt100 and two types of outputs NPN and PNP The Unit also performs Autotuning AT of PID constants i Available Units Output type I O type NPN outputs PNP outputs Two control loops PTOS CJ1W TC003 CJ1W TC004 with
151. spondence Table of Device Variables for CJ series Unit and Memory Used for CJ series Unit AGGreSSES sssiiicsssicscstssiscavedcrissccnntiscedarsiennstdansecenevansessnviisuedsinceisndsiinnsanei s A 4 Sample Program MINO sirsa a aaa a aaa A 10 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Read and Understand this Manual Read and Understand this Manual Please read and understand this manual before using the products Please consult your OMRON representative if you have any questions or comments Warranty and Limitations of Liability WARRANTY OMRON s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year or other period if specified from date of sale by OMRON OMRON MAKES NO WARRANTY OR REPRESENTATION EXPRESS OR IMPLIED REGARDING NON INFRINGEMENT MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE OMRON DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED LIMITATIONS OF LIABILITY OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS WHETHER SUCH CLAIM IS BASED ON CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY In no event shall the responsibility of OMRON for
152. tches 2 12 Use the unit number switches to set the specific unit number for each Special I O Unit mounted in a CPU Rack or Expansion Rack The unit number must be the one registered in Unit Configurations Set the unit number between 0 and 94 One Temperature Control Unit occupies two unit numbers and consecutive unit numbers cannot be set for Temperature Control Units Turn OFF the Controller before setting the unit number For details on the correlation of the unit num ber and allocated memory refer to A 3 Correspondence Table of Device Variables for CJ series Unit and Memory Used for CJ series Unit Addresses H Precautions for Correct Use If two or more Special I O Units are assigned the same unit number a major fault level Controller error Duplicate Unit Number will be generated and the PLC will not operate After correcting the unit number setting cycle the power to the controller CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 Specifications and Functions 2 3 4 DIP Switch Setting Functions eLUSredc ti Y Ww Ki rt a 9 5 2 T 5 A ch O 5 7 ON is to the right Turn OFF the Controller before setting the unit number Unit settings are reflected when the Unit restarts or the Controller is reset including when the power is turned ON Factory setting Operation when CPU Unitisin Continue Stop OFF PROGRAM mode Temperature units C F Data
153. tem Configuration CJ1W TC103 two loop heater burnout alarm Platinum resistance thermometer NPN outputs uoleinbyuoy Walsks o1Iseg L Z 4 Power supply for outputs 24 VDC Control output Heater 1 kW Current 200 VAC Transformer Temperature Sensor Platinum resistance thermometer E54 CT1 or E54 CT3 Note 1 The above diagram shows an example of the platinum resistance thermometer with two loop heater burnout alarm and NPN outputs CJU1W TC103 mounted 2 An OMRON E54 CT1 or E54 CT3 Current Transformer must be used as the Current Trans former CT Do not use any other Current Transformer 3 Turn ON the Stop Bit for the loop to stop temperature control If PID control is being used and the heater is turned OFF using an operation switch input to the heater PID control perfor mance will be adversely affected CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 1 7 1 Features and System Configuration 1 2 2 Mounting the Unit This Unit is a Special I O Unit of the NJ series You can mount the Unit to a CPU Rack or expansion Rack of the NJ series The number of Units that can be mounted in a CPU Rack or Expansion Rack depends on the capacity of the Rack s Power Supply Unit and the current consumption of the other Units in the Rack The following table shows the maximum number of CJ1W TCLILIL Temperature Control Units that
154. ting is OFF 3 6 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 Settings Required for Temperature Control 3 5 Selecting PID Control or ON OFF Control A switch on the front of the Unit pin 6 of the DIP switch selects whether the Temperature Control Unit uses ON OFF control or PID control with 2 degrees of freedom The control method setting applies to all of the Unit s control loops It is not possible to set different con trol method settings for the different control loops lf the control method setting is changed during operation the new setting will not become effective until the power is turned OFF and ON again t Ul v Q R ch gt Q 2 0 A 0 i o 5 z O T a A Pin 6 Control method Setting ON OFF contro The factory setting is OFF PID control as shown in the diagram above If this setting is changed the new setting will not become effective until the Unit is restarted or the con troller is reset including when the power is turned ON j Setting the Control Method Pin 6 PID Control with Two Degrees of Freedom With PID control it is necessary to set the proportional band P integral time I and derivative time D These settings can be made automatically with autotuning or manually Refer to 3 9 Setting the PID Constants for more details on the PID constants ON OFF Control With ON OFF control the control output will be ON
155. tion Do not touch any Unit when power is being supplied or immediately after the power supply is turned OFF Doing so may result in burn injury i Wiring Be sure that all terminal screws and cable connector screws are tightened to the torque specified in the relevant manuals The loose screws may result in fire or malfunction gt e Online Editing Execute online editing only after confirming that no adverse effects will be caused by deviations in the timing of I O If you perform online editing the task execution time may exceed the task period I O may not be refreshed with external devices input signals may not be read and output timing may change gt When Using the Temperature Control Unit To provide for safe operation even in the event of Temperature Control Unit malfunctions provide safety measures to prevent abnormal temperature rise in a separate system outside the PLC system If proper safety measures are not taken serious accidents could result from Unit failure resulting in loss of control Do not turn OFF the power supply while set value data is being written to the non volatile memory in the Temperature Control Unit Confirm that the Save Completed Flag turns ON after the data write operation has been completed before turning OFF the power supply If power is turned OFF during a write operation the data saved in the non volatile memory may be destroyed gt gt 20 CJ series Temperature Co
156. tion Main operation e Create and register global variables and each POU e Create algorithms for each POU and register local variables of each POU Register the Unit in the Configurations and Setup on the CPU Expansion Racks screen in Configuration and Setup At this time set both the device name and the unit number of the unit to be registered Create device variables for CJ series Unit by using VO map Set the unit number switches on the front panel of the Temperature Control Unit Set the same unit number as in the Unit Configu ration settings Set the Input Type Switches on the front panel of the Temperature Control Unit Set the DIP switch on the front panel of the Tem perature Control Unit Set the DIP switch on the front panel of the Tem perature Control Unit Forward reverse operation switching Control method ON OFF control or PID control C F switching Reflect the settings for the switches on the front panel of the Temperature Control Unit in the Unit Transfer user programs Unit Configuration and Setup and variable information Create the Unit settings with the I O port Set the alarm mode and alarm hysteresis The data setup file is reflected in the I O port Initialization Data Reflect the settings for the Unit in the Temperature Control Unit At least 30 minutes after the controller power is turned ON Read or write process values and set values from the user program Operating P
157. tion that are directly affected by the error or that contain settings that cause the error Cause and cor Assumed cause Correction Prevention rection Lists the possible causes corrections and preventive measures for the error Attached This is the attached information that is displayed by the Sysmac Studio or an NS series PT information Precautions Provides precautions restrictions and supplemental information If the user can set the event level the event levels Remarks that can be set the recovery method operational information and other information are also provided 1 One of the following 2 3 4 Major fault Major fault level Partial fault Partial fault level Minor fault Minor fault level Observation Information One of the following Automatic recovery Normal status is restored automatically when the cause of the error is removed Error reset Normal status is restored when the error is reset after the cause of the error is removed Cycle the power supply Normal status is restored when the power supply to the Controller is turned OFF and then back ON after the cause of the error is removed Controller reset Normal status is restored when the Controller is reset after the cause of the error is removed Depends on cause The recovery method depends on the cause of the error One of the following System System event log Access Access event log One of the following Continues Execution of the user p
158. tion may result if inappropriate data link tables are set Even if appropriate data link tables have been set confirm that the controlled system will not be adversely affected before you transfer the data link tables The data links start automatically after the data link tables are trans ferred e All CPU Bus Units are restarted when routing tables are transferred from Support Software to the CPU Unit Confirm that the system will not be adversely affected by restarting before you transfer the routing tables e Tag data links will stop between related nodes while tag data link parameters are transferred during Controller operation Confirm that the system will not be adversely affected before you transfer the tag data link parameters i EtherNet IP Communications e All related EtherNet IP nodes are reset when you transfer settings for the built in EtherNet IP port including IP addresses and tag data links settings Confirm that the system will not be adversely affected by resetting nodes before you transfer the settings e If EtherNet IP tag data links cyclic communications are used with a repeating hub the communica tions load on the network will increase This will increase collisions and may prevent stable communi cations Do not use repeating hubs on networks where tag data links are used Use an Ethernet switch instead ff EtherCAT Communications e Make sure that the communications distance number of nodes connected and method
159. toed bene sem hand 2 11 2a INCIIG ALORS i aos cece ci cas etre wd aero whist he Se tbe ee ie Dv ae ea gee ete 2 11 2 3 3 Unit Number Switches 0 0 0 0 0 2 12 2 3 4 DIP Switch Setting Functions nanana aaa cc ees 2 13 23 9 INDUCTVOe SWICK 2 2ii2 sieatuicusvien eaatelocieieee thedt Ries 2 15 WING 665505668 nin an aaa ca ee inate ene eeu So cesta ean 2 16 2 4 1 Terminal Wiring Examples 0 0000 e eee ee ee eee eens 2 16 262 OUUVCIRCUIS 255 oie SS bow ce feb yale ee ee ee 8 eae Ate Bee 2 17 2 4 3 I O Wiring Examples 0 0 ccc ees 2 18 Data Exchange with the CPU Unit ccc cece eee eee es 2 21 2 5 1 COVCRVIOW asese ere eede Se ee Gee ot ee es Se oe Be 2 21 2 5 2 Accessing from the User Program 0 00 c cee eee eee 2 22 2 5 3 Saving Set Value in the Non volatile Memory 000 eee ee 2 23 2 5 4 Operation Dala irasan oer su tiee eee ees e a bee Stee ae eee be tees 2 24 2 5 5 Initialization Dala i c66 d2cnedeten ieeadduracietaadedcuedwrandeeie 2 30 2 5 6 Operating Parameters 0 ccc ee eens 2 32 Range of Set Values and Monitor Values 00c0ceeeueeeeanenes 2 35 2 6 1 DE VAISS 3 ac hed Seg nth Doan tee ete ty teeth oi Pots he Leet bats 2 35 2 6 2 JNIONRNOMVAIWUCS ti hut ott oe tla eka he Sede oad dee 2 37 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 2 1 2 Specifications and Functions 2 1 Specifications 2 1 1 Spe
160. top The present temperature reaches the measurement upper limit and so the alarm cee will be performed due to the high temperature Error attributes Effects System defined eas C E Sousan Error in input from the Sensor Check the input for incorrect wiring Check for incorrect wiring broken disconnection or short circuits and wires and short circuits correct any problems Or correct the input type setting if the input type set ting is incorrect Attached Attached information 1 Loop number where error was detected information Precautions You can change the event level to the minor fault level If you change the level to the minor fault level the Recovery col Remarks umn above will be changed to Error reset Event name CT Overflow 64850000 hex Meaning An overflow occurred in the CT input Source PLC Function Module Source details CJ series Unit Continuously pee Error attributes eee Nome fe comzan The heater current exceeded 55 0 A Set the CT input so that it does not Set the CT input so that it does not exceed 55 0 A exceed 55 0 A Attached Attached information 1 Loop number where error was detected information Precautions You can change the event level to the minor fault level If you change the level to the minor fault level the Recovery col Remarks umn above will be changed to Error reset 5 20 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 Event name Meanin
161. trol Unit Temperature control will continue even if a heater burnout is detected so that the Unit can continue controlling heaters that have not burned out Heater burnout detection will operate when the control output has been ON continuously for more than 200 ms Sometimes the heater s rated current does not match the current that actually flows through the heater Use the heater current monitor to check the current during actual use Heater burnout detection will be unstable if there is only a small difference between the normal cur rent and heater burnout current For stable operation set a minimum difference of 1 0 A with heaters drawing less than 10 0 A or a minimum difference of 2 5 A with heaters drawing 10 0 A or more CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 19 W k i g D f k c 3 9 a gt Q 3 3 Settings Required for Temperature Control e The heater burnout detection function cannot be used if the heater is being controlled with the posi tion control method or cycle control method Also the heater burnout detection function cannot be used with three phase heaters Note To detect heater burnout in a three phase heater use a K2ZCU FL_LILIA LIGS with gate input ter minals Refer to the catalog for more details i Determining the Heater Burnout Current e Use the following equation to calculate the average of the normal current and the current with a heater bu
162. troller s PID constants to be refreshed with the new Setting PID constants W v g a g 0 y g A e a g i Read PID Constant Ch1_ProportionalBandSta Ch2_ProportionalBandSta Setting PID Constant Stopping Autotuning e To stop autotuning change device variables for CJ series Unit Loop 1 and 2 Stop AT Bit _Ch1_StopATCmd _Ch2_StopATCmd from 0 to 1 e Only the Stop Bit and Stop AT Bit settings can be changed while autotuning is being executed Settings changed during autotuning will be enabled when autotuning is completed e f the Stop Bit is turned ON while autotuning is being executed autotuning will be interrupted and operation will stop Autotuning will not restart when operation is restarted with the Stop Bit CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 11 3 Settings Required for Temperature Control i Setting PID Constants Manually Set Proportional Band P Integral Time 1 and Derivative Time D of the Setting PID Constants for the use of manually set PID constants EN Additional Information e When you already know the system s control characteristics set the PID constants directly to adjust the control characteristics Set the three PID constants The proportional band P inte gral time I and derivative time D e The Unit will operate with basic proportional operation if the integral time I and derivative time D are set to
163. ubleshooting CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 3 5 Error and Alarm Processing Bits Ch1_StaWd 00 01 02 03 04 08 09 Alarms and Statuses Detected by the Temperature Control Unit ERC indicator lights when an alarm occurs detected by the Temperature Control Unit itself At this time an alarm flag of the device variable for CJ series Unit for operation is stored Name of device variable for CJ series Unit Chi_AL2Flg Ch1_AL1Flg Ch1_HBFlg Chi_ATFlg Ch1_CtlOutFlg Ch1_StopFlg Ch1_SetErr om on te WORD Loop 1 Status BOOL Loop 1 AL2 Flag Loop 1 AL1 Flag i Loop 1 HB Flag BOOL BOOL BOOL Loop 1 AT Flag BOOL Loop 1 Control Output Flag Loop 1 Stop Flag BOOL BOOL Loop 1 Setting Error Flag Function Bits serve the functions described below Each bit is defined with a BOOL data type variable Bit 00 Loop 1 AL2 Flag Bit 01 Loop 1 AL1 Flag Bit 02 Loop 1 HB Flag Bit 03 Loop 1 AT Flag Bit 04 Loop 1 Control Output Flag Bit 05 Bit 06 Bit 07 Bit 08 Bit 09 Bit 10 Flag Bit 11 Bit 12 Bit 13 Bit 14 Bit 15 The value becomes 1 when the temperature is within the alarm range set with the input value of loop 1 Loop 1 Stop Flag Loop 1 Setting Error Flag Loop 1 PID Constants Calculated Loop 1 Standby Flag Loop 1 Cold Junction Sensor Error Loop 1 CT Overflo
164. uction of the program e Restart using a system defined variable Variable name Type _CJB_S O Restart BOOL Unit number 00 to 94 in Precautions for Correct Use e f the error persists after the restart replace this Unit e During restart output is O V as the data immediately before restart is maintained for input CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 9 q j m g g Q gt g 3 y g A Q D gt Q 5 Error and Alarm Processing 5 2 Troubleshooting 5 10 If some problem develops with the Temperature Control Unit use the following procedure to isolate and correct the problem Check Indicators Check switch settings and wiring Troubleshoot from symptoms Check the Temperature Controller Unit s operating status with the Indicators Follow the procedures described in 5 7 Error and Alarm Processing to isolate and correct any problems indicated by the LED Indicators Check the switch settings and wiring e Power Supply 1 Is the power supply ON 2 Is the voltage at the terminals within the allowed range e Switches Are the switch settings correct for the system you are using e Wiring 1 Is the terminal block wiring correct 2 Is the polarity correct not reversed 3 Are any power lines disconnected 4 Are any of the systems wires and cables broken or shorted If the system checks did not reveal the
165. ur Connect a bleeder resistor to prevent operation due to the rent through the relay operated by the control output leakage current Settings The forward operation reverse operation setting is Correct the setting incorrect The PID constant settings are not correct e Perform autotuning e When autotuning is completed refresh the PID constants properly so that the Unit operates with the calculated PID constants e Make the correct PID constant settings manually Usage There is excessive overshooting Refer to Excessive Overshooting or Undershooting for trouble shooting directions fl Excessive Overshooting or Undershooting Step Possible Cause Remedy Connection The measured temperature is incorrect Refer to Troubleshooting from Symptoms Measure ment Errors for troubleshooting directions A general purpose temperature sensor is being Change to a sheathed sensor used in a system with a very fast heating response Settings The proportional band is narrow because PID e Increase the P constant to a level that produces an constant P is too small acceptable response delay e Perform autotuning The integral time is short because PID constant Increase the constant to a level that produces an is too small acceptable response delay e Perform autotuning The derivative time is short because PID constant Increase the D constant to a level that produces D is too small acceptable stability e Perform aut
166. ure ment Errors for troubleshooting directions The load s polarity is reversed or the load is wired Wire the load correctly to the wrong terminals The connected load exceeds the output ratings e Use a load within the output s ratings e Repair the load if it is malfunctioning A load power supply is not connected to the tran Provide a power supply that is suitable for the output sistor output ratings and load The polarity is reversed to the transistor output s Wire the power supply correctly load power supply Settings Temperature control has not been started Turn OFF the Stop Bit The wrong loop number is specified Make settings for the correct loop number The loop is disabled Alarm mode 1 and alarm Set an alarm mode Refer to 3 70 Using the Alarm Out mode 2 are set to FF put Function for details The set point is incorrect Set the correct set point The alarm mode is set to 0 no alarm Set the correct alarm mode An alarm with a standby sequence has been set Set an alarm mode without a standby sequence A deviation alarm or absolute value alarm has Set the correct alarm mode been set incorrectly 5 14 CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 Error and Alarm Processing i Troubleshooting from Symptoms HB Alarm Errors Heater Burnout Not Detected Step Possible Cause Remedy Connection A Current Transformer CT is not connected Connect a CT The
167. urnouts will not be detected If the set value is set to 50 0 the heater burnout output will always be ON This can be used to check wiring Indicate the current set heater burnout current of loop 1 and loop 2 Turn ON the Start AT to start autotuning for loop 1 and loop 2 The status of the Stop AT is ignored if Ch _StopATCma Stop AT Bit is set to 1 2 25 Y a x A gt D 5 fe 0 S g g 0 A U c c 2 rF eyeq uoneiado S Z 2 Specifications and Functions 2 26 Device variable for CJ series Unit Loop 1 Chi_StopATCmd Chi_StopCtlCmd Ch1_ChgPIDCmd Ch1_SaveCmd Data R nope bpe MW Nane Ch2 StopATCmd BOOL Ch2_StopCtICmd BOOL Ch2_ChgPIDCmd BOOL Ch2 SaveCmd BOOL Loop 1 and Loop 2 Stop AT Bit Loop 1 and Loop 2 Stop Bit Loop 1 and Loop 2 change PID Constants Bit Loop 1 and Loop 2 Save Settings Bit Function Turn ON the Stop AT to stop autotuning for loop 1 and loop 2 The status of the Stop AT is ignored if autotuning is not being performed Set the Stop Bit to 0 to per form temperature control for loop 1 and loop 2 and set it to 1 to stop temperature control for loop 1 and loop 2 The Stop Bit will not function if pin 1 of the DIP switch is OFF and the CPU Unit is in PRO GRAM mode When a Change PID Con stants Bit is set from 0 to 1 the corresponding Ch _PIDCalcFlg PID Constants Calculated Flag will be
168. user program execution and refreshes I O with the specified values If forced refreshing is used for inputs for which I O refreshing is not supported the inputs will first take the specified values but they will then be overwritten by the user program This operation differs from the force set reset functionality of the CJ series PLCs CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 23 Precautions for Safe Use e You cannot upload or download information for forced refreshing with the Sysmac Studio After downloading data that contains forced refreshing change to RUN mode and then use the Sys mac Studio to perform the operation for forced refreshing Depending on the difference in the forced status the control system may operate unexpectedly e Do not specify the same address for the AT specification for more than one variable Doing so would allow the same entity to be accessed with different variable names which would make the user program more difficult to understand and possibly cause programming mistakes f General Communications e When you use data link communications check the error information that is given in ErrSta Control ler Error Status to make sure that no error has occurred in the source device Write the user program to use the received data only if there is no error If there is an error in the source device the data for the data link may contain incorrect values e Unexpected opera
169. w Flag Loop 1 Sensor Error Flag Loop 1 Save Completed Flag The value becomes 0 when outside the alarm range The value becomes 1 when the temperature is within the alarm range set with the input value of loop 1 The value becomes 0 when outside the alarm range The value becomes 1 when the heater cur rent detection value falls below the Heater Burnout Current The value becomes 1 during Autotuning AT of loop 1 The value becomes 0 when Autotuning AT stops or finishes The value becomes 1 during output of loop 1 Control Output The value becomes 0 when temperature control of loop 1 executes and 1 when con trol stops The value becomes 1 when there is an error in the set value set as a device variable for CJ series Unit CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 5 Error and Alarm Processing Name of device variable for 10 Ch1_PIDCalcFlg BOOL Loop 1 PID The value becomes 1 when PID constants Constants Cal calculated by the Temperature Control Unit culated Flag with AT are updated When this bit is 1 PID constants of the OUT Area of Operating Parameters are not imported into the Temperature Control Unit When the bit is 0 PID constants of the OUT Area of Operating Parameters are imported into the Temperature Control Unit 11 Ch1i_StbyFlg BOOL Loop 1 Standby The value becomes 1 when the Tempera Flag ture Control Unit is waiting for I O refreshing after t
170. when the PV is below the SV The control output will be OFF when the PV is at or above the SV This is the operation when the Unit is set for reverse operation This operation will work in the opposite way for forward operation CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 7 3 Settings Required for Temperature Control 3 6 Setting the Control Period This setting determines the output period control period for PID control System control will improve with a shorter control period but if you are using relays for heater control we recommend setting a control period of at least 20 s to increase the relay s lifetime If necessary the control period can be adjusted during trial operation Set the control period in the device variables for CJ series Unit Loop 1 and Loop 2 Control Period _Ch1_CtlPrdCfg _Ch2_CtlPrdCfg See the following table The standard setting is 2 s but the factory setting is 20 s e Each control loop has a separate control period setting e Setting the Loop 1 Control Period to 2 s Set _Ch1_CtlPrdCfg to 2 Ch1_CtlPrdCfg UINT Loop 1 Control Period Output Period in PID Control Ch2_CtlPrdCfg UINT Loop 2 Control Period Output Period in PID Control CJ series Temperature Control Units Operation Manual for NJ series CPU Unit W491 3 Settings Required for Temperature Control 3 7 Setting the Set Points Set the set point SP in the device variables for CJ serie

CJ-series Temperature Control Units Operation Manual for NJ

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