Operation Manual for NJ

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 manual is intended for the following personnel, who must also have knowledge of electrical systems (an electrical engineer or the equivalent).
• Personnel in charge of introducing FA systems.
• Personnel in charge of designing FA systems.
• Personnel in charge of installing and maintaining FA systems.
• 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.
• CJ-series Temperature Control Units
• CJ1W-TC003
• CJ1W-TC004
• CJ1W-TC103
• 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 NJ-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 NJ-series CPU Unit.
NJ-series User’s Manuals
CJ-series Special Unit Operation
Manuals for NJ-series CPU Unit
NJ-series Troubleshooting Manual
NJ-series CPU Unit Built-in
EtherNet/IP Port User´s Manual
NJ-series Motion Control
Instructions Reference Manual
NJ-series CPU Unit Built-in
EtherCAT Port User´s Manual
NJ-series CPU Unit Motion
Control User´s Manual
NJ-series Instructions
Reference Manual
NJ-series CPU Unit
Software User´s Manual
NJ-series CPU Unit
Hardware User´s Manual
Basic information
Introduction to NJ-series Controllers
Setting devices and hardware
Using motion control
Using EtherCAT
Using EtherNet/IP
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
Using EtherNet/IP
Troubleshooting and managing
errors in an NJ-series Controller
Use the
relevant
manuals for
references
according to
any error that
occurs.
Maintenance
Using EtherCAT
Using EtherNet/IP
Using CJ-series Units
2
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Manual Configuration
Manual Configuration
NJ-series CPU Unit Hardware User’s Manual (Cat. No. W500)
Section
Description
Section 1
Introduction
This section provides an introduction to the NJ-series Controllers and their features,
and gives the NJ-series Controller specifications.
Section 2
System Configuration
This section describes the system configuration used for NJ-series Controllers.
Section 3
Configuration Units
This section describes the parts and functions of the configuration devices in the NJseries Controller configuration, including the CPU Unit and Configuration Units.
Section 4
Installation and Wiring
This section describes where and how to install the CPU Unit and Configuration Units
and how to wire them.
Section 5
Troubleshooting
This section describes the event codes, error confirmation methods, and corrections
for errors that can occur.
Section 6
Inspection and Maintenance
This section describes the contents of periodic inspections, the service life of the Battery and Power Supply Units, and replacement methods for the Battery and Power
Supply Units.
Appendices
The appendices provide the specifications of the Basic I/O Units, Unit dimensions,
load short-circuit protection detection, line disconnection detection, and measures for
EMC Directives.
NJ-series CPU Unit Software User’s Manual (Cat. No. W501)
Section
Description
Section 1
Introduction
This section provides an introduction to the NJ-series Controllers and their features,
and gives the NJ-series Controller specifications.
Section 2
CPU Unit Operation
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.
Section 3
I/O Ports, Slave Configuration, and
Unit Configuration
This section describes how to use I/O ports, how to create the slave configuration
and unit configuration and how to assign functions.
Section 4
Controller Setup
This section describes the initial settings of the function modules.
Section 5
Designing Tasks
This section describes the task system and types of tasks.
Section 6
Programming
This section describes programming, including the programming languages and the
variables and instructions that are used in programming.
Section 7
Checking Operation and Actual
Operation
This section describes the items and procedures for checking the operation of an NJseries Controller, including offline debugging procedures.
Section 8
CPU Unit Functions
This section describes the functionality provided by the CPU Unit.
Section 9
Communications Setup
This section describes how to go online with the CPU Unit and how to connect to
other devices.
Section 10
Example of Actual Application Procedures
This section describes the procedures that are used to actually operate an NJ-series
Controller.
Section 11
Troubleshooting
This section describes the event codes, error confirmation methods, and corrections
for errors that can occur.
Appendices
The appendices provide the CPU Unit specifications, task execution times, specifications of individual system-defined variables, data attribute lists, CJ-series Unit memory information, CJ-series Unit memory allocation methods, and version information.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
3
Manual Configuration
Sysmac Studio Version 1 Operation Manual (Cat. No. W504)
Section
Description
Section 1
Introduction
This section provides an overview and lists the specifications of the Sysmac Studio
and describes its features and components.
Section 2
Installation and Uninstallation
This section describes how to install and uninstall the Sysmac Studio.
Section 3
System Design
This section describes the basic concepts for designing an NJ-series System with the
Sysmac Studio and the basic operating procedures.
Section 4
Programming
This section describes how to create programs with the Sysmac Studio.
Section 5
Online Connections to a Controller
This section describes how to go online with a Controller.
Section 6
Debugging
This section describes how to debug the programs online on the Controller or debug
it offline with the Simulator.
Section 7
Other Functions
This section describes other functions that are supported by the Sysmac Studio,
including security functions and troubleshooting functions.
Section 8
Reusing Programming
This section describes how to reuse the programs that you create with the Sysmac
Studio.
Section 9
Support Software Provided with the
Sysmac Studio
This section describes the Support Software that is provided with the Sysmac Studio.
Section 10
Troubleshooting
This section describes the error messages that are displayed when you check a program on the Sysmac Studio and how to correct those errors.
Appendices
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 NJseries CPU Unit (Cat. No. W491) (This manual)
Section
4
Description
This section describes the features and the system configuration of the Temperature
Section 1
Features and System Configuration
Control Unit.
Section 2
Specifications and Functions
This section describes the specifications, the functionality, and the operating procedure for the Temperature Control Unit, and where and how to wire the Unit.
Section 3
Settings Required for Temperature
Control
This section explains the various settings required for temperature control of the
Temperature Control Unit.
Section 4
Optional Settings
This section explains the optional settings for the Temperature Control Unit.
Section 5
Error and Alarm Processing
This section describes the troubleshooting procedure for the Temperature Control
Unit.
Appendices
---
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
Features and System Configuration
This section describes the features of the Temperature Control Unit and its basic system configuration.
Section 2
Specifications and Functions
This section describes the functions and specifications of the Temperature Control
Unit, including technical specifications, Unit parts, wiring, and data allocations.
Section 3
Settings Required for Temperature
Control
This section explains the various settings required for temperature control.
Section 4
Optional Settings
This section explains how to use the input compensation value.
Section 5
Error and Alarm Processing
This section provides information on troubleshooting and error processing.
Appendices
---
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5
Manual Structure
Manual Structure
Page Structure
The following page structure is used in this manual.
Mounting Units
Level 1 heading
Level 2 heading
Level 3 heading
Connecting Controller Components
Gives the current
headings.
4 Installation and Wiring
Level 2 heading
4-3
Level 3 heading
4-3-1
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.
A step in a procedure
1
Join the Units so that the connectors fit exactly.
Hook
Indicates a procedure.
Hook holes
Connector
4-3 Mounting Units
4
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.
Lock
Release
Slider
Gives the number
of the main section.
Precautions for Correct Use
Special information
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.
Icons indicate
precautions, additional
information, or reference
information.
Manual name
4-3-1 Connecting Controller Components
2
Page tab
NJ-series CPU Unit Hardware User’s Manual (W500)
4-9
This illustration is provided only as a sample. It may not literally appear in this manual.
Special Information
Special information in this manual is classified as follows:
Precautions for Safe Use
Precautions on what to do and what not to do to ensure safe usage of the product.
Precautions for Correct Use
Precautions on what to do and what not to do to ensure proper operation and performance.
Additional 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.
6
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
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)
7
Manual Structure
8
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Sections in this Manual
Sections in this Manual
1
2
1
Features and System Configuration
3
2
Specifications and Functions
4
3
Settings Required for Temperature Control
4
Optional Settings
A
5
Error and Alarm Processing
I
A
Appendices
I
5
Index
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
9
CONTENTS
CONTENTS
Introduction ............................................................................................................... 1
Relevant Manuals ...................................................................................................... 2
Manual Configuration ............................................................................................... 3
Manual Structure ....................................................................................................... 6
Sections in this Manual ............................................................................................ 9
CONTENTS............................................................................................................... 10
Read and Understand this Manual ........................................................................ 13
Safety Precautions .................................................................................................. 16
Precautions for Safe Use........................................................................................ 21
Precautions for Correct Use................................................................................... 27
Regulations and Standards.................................................................................... 31
Unit Versions ........................................................................................................... 33
Related Manuals ...................................................................................................... 35
Revision History ...................................................................................................... 36
Section 1
1-1
Features and System Configuration
Introduction and Features ...................................................................................................... 1-2
1-1-1
1-1-2
1-2
System Configuration ............................................................................................................. 1-7
1-2-1
1-2-2
Section 2
2-1
2-3
Specifications .......................................................................................................................... 2-2
Specifications .............................................................................................................................. 2-2
Input Function Block Diagram ..................................................................................................... 2-5
Input Specifications ..................................................................................................................... 2-5
Application Procedure ............................................................................................................ 2-7
Part Names and Functions ................................................................................................... 2-11
2-3-1
2-3-2
2-3-3
2-3-4
2-3-5
10
Basic System Configuration ........................................................................................................ 1-7
Mounting the Unit ........................................................................................................................ 1-8
Specifications and Functions
2-1-1
2-1-2
2-1-3
2-2
Introduction ................................................................................................................................. 1-2
Features ...................................................................................................................................... 1-3
Part Names ............................................................................................................................... 2-11
Indicators................................................................................................................................... 2-11
Unit Number Switches............................................................................................................... 2-12
DIP Switch Setting Functions.................................................................................................... 2-13
Input Type Switch ...................................................................................................................... 2-15
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
CONTENTS
2-4
Wiring ..................................................................................................................................... 2-16
2-4-1
2-4-2
2-4-3
2-5
Data Exchange with the CPU Unit........................................................................................ 2-21
2-5-1
2-5-2
2-5-3
2-5-4
2-5-5
2-5-6
2-6
Terminal Wiring Examples ........................................................................................................ 2-16
Output Circuits .......................................................................................................................... 2-17
I/O Wiring Examples................................................................................................................. 2-18
Overview................................................................................................................................... 2-21
Accessing from the User Program............................................................................................ 2-22
Saving Set Value in the Non-volatile Memory........................................................................... 2-23
Operation Data ......................................................................................................................... 2-24
Initialization Data ...................................................................................................................... 2-30
Operating Parameters............................................................................................................... 2-32
Range of Set Values and Monitor Values ............................................................................ 2-35
2-6-1
2-6-2
Section 3
Set Values................................................................................................................................. 2-35
Monitor Values .......................................................................................................................... 2-37
Settings Required for Temperature Control
3-1
Setting the Input Type ............................................................................................................. 3-2
3-2
Selecting the Temperature Units............................................................................................ 3-4
3-3
Setting the Pin 3 of the DIP Switch ........................................................................................ 3-5
3-4
Selecting the Control Operation (Forward/Reverse) ............................................................ 3-6
3-5
Selecting PID Control or ON/OFF Control ............................................................................. 3-7
3-6
Setting the Control Period ...................................................................................................... 3-8
3-7
Setting the Set Points.............................................................................................................. 3-9
3-8
Using ON/OFF Control .......................................................................................................... 3-10
3-9
Setting the PID Constants .................................................................................................... 3-11
3-10 Using the Alarm Output Function ........................................................................................ 3-15
3-11 Using the Heater Burnout Alarm .......................................................................................... 3-19
3-12 Starting and Stopping Temperature Control....................................................................... 3-21
Section 4
Optional Settings
4-1
Shifting the Input Value (Input Compensation) .................................................................... 4-2
4-2
Recovering from Sensor Not Connected Errors................................................................... 4-3
Section 5
Error and Alarm Processing
5-1
Error and Alarm Processing ................................................................................................... 5-2
5-2
Troubleshooting..................................................................................................................... 5-10
5-3
Event Logs ............................................................................................................................. 5-16
5-3-1
5-3-2
5-3-3
Overview of the Event Logs...................................................................................................... 5-16
Error Table ................................................................................................................................ 5-17
Error Descriptions ..................................................................................................................... 5-18
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
11
CONTENTS
Appendices
A-1 Dimensions ..............................................................................................................................A-2
A-2 Functional Differences due to CPU Units (NJ/CJ-series) to be Connected .......................A-3
A-3 Correspondence Table of Device Variables for CJ-series Unit and Memory Used
for CJ-series Unit Addresses ...............................................................................................A-4
A-4 Sample Programming............................................................................................................A-10
Index
12
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 NONINFRINGEMENT, 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 any act exceed the individual price of the product on which
liability is asserted.
IN NO 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:
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or
uses not described in this manual.
• 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.
• 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.
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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.
It 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 your 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
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.
WARNING
Caution
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury. Additionally, 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.
Precautions for Safe Use
Indicates precautions on what to do and what not to do to ensure safe usage of the product.
Precautions for Correct Use
Indicates precautions on what to do and what not to do to ensure proper operation and performance.
16
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Safety Precautions
Symbols
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.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
17
Safety Precautions
WARNING
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.
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 countermeasure 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 following cases. The remote I/O slaves will operate according to the settings in the
slaves.
•
•
•
•
•
If an error occurs in the power supply
If the power supply connection becomes faulty
If a CPU watchdog timer error or CPU reset occurs
If a major fault level Controller error occurs
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 system operates safely in such a case.
18
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 problems, 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 communications or a major fault level error, and implement safety measures.
Correctly set all of the EtherCAT slaves.
The NJ-series Controller continues normal operation for a certain period of
time when a momentary power interruption occurs. This means that the NJseries 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 accidents due to incorrect operation.
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.
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
Caution
Application
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.
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.
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.
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.
20
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Precautions for Safe Use
Precautions for Safe Use
Disassembly and Dropping
• Do not attempt to disassemble, repair, or modify any Units. Doing so may result in malfunction or fire.
• Do not drop any Unit or subject it to abnormal vibration or shock. Doing so may result in Unit malfunction or burning.
Mounting
• 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.
Installation
• Always connect to a ground of 100 Ω or less when installing the Units. A ground of 100 Ω or less
must be installed when shorting the GR and LG terminals on the Power Supply Unit.
Wiring
• 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.
• 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.
• Mount terminal blocks and connectors only after checking the mounting location carefully.
• Be sure that the terminal blocks, expansion cables, and other items with locking devices are properly
locked into place.
• Always remove any dustproof 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.
• 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 polarity. If the polarity is reversed, current may flow in the reverse direction and damage the connected
devices regardless of the operation of the Controller.
Power Supply Design
• 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 NJ-series CPU Unit Hardware User’s 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 Control Units Operation Manual for NJ-series CPU Unit(W491)
21
Precautions for Safe Use
• Do not apply voltages or connect loads to the Output Units or slaves in excess of the maximum ratings.
• 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 NJ-series CPU Unit Hardware 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 generated impulse voltage may damage the Power Supply Unit. Use the adjustment on the tester to gradually increase and decrease the voltage.
• Apply the voltage between the Power Supply Unit's L1 or L2 terminal and the GR terminal when testing insulation and dielectric strength.
• Do not supply AC power from an inverter or other device with a square-wave output. Internal temperature 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.
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, outputs 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 supply 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.
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 builtin non-volatile memory. This data will not be backed up correctly if the power supply is turned OFF.
Also, a major fault level 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 Controller 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.
• Mounting or removing I/O Units or the CPU Unit
• Assembling the Units
• Setting DIP switches or rotary switches
22
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Precautions for Safe Use
• Connecting cables or wiring the system
• 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.
Operation
• Confirm that no adverse effect will occur in the system before you attempt any of the following.
• Changing the operating mode of the CPU Unit (including changing the setting of the Operating
Mode at Startup)
• Changing the user program or settings
• Changing set values or present values
• Forced refreshing
• Always sufficiently check the safety at the connected devices before you change the settings of an
EtherCAT slave or Special Unit.
• If 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.
• 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 Controller error with an event level of partial fault or higher (in which outputs are disabled) will go to Operational 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.
• Always confirm safety at the connected equipment before you reset Controller errors for a CJ-series
Special Unit. When a Controller error is reset, 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.
Battery Backup
• 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.
If 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.
Debugging
• Forced refreshing ignores the results of 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
• 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 Sysmac Studio to perform the operation for forced refreshing.
Depending on the difference in the forced status, the control system may operate unexpectedly.
• 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.
General Communications
• When you use data link communications, check the error information that is given in ErrSta (Controller 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.
• Unexpected operation 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 transferred.
• 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.
• 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.
EtherNet/IP Communications
• 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.
• If EtherNet/IP tag data links (cyclic communications) are used with a repeating hub, the communications load on the network will increase. This will increase collisions and may prevent stable communications. Do not use repeating hubs on networks where tag data links are used. Use an Ethernet
switch instead.
EtherCAT Communications
• Make sure that the communications distance, number of nodes connected, and method of connection
for EtherCAT are within specifications.
Do not connect EtherCAT communications to EtherNet/IP, a standard in-house LAN, or other networks. An overload may cause the network to fail or malfunction.
• 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.
• After you transfer the user program, the CPU Unit is restarted and communications with the EtherCAT 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.
24
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Precautions for Safe Use
• If 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 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.
• 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 established before attempting control operations.
• If frames sent to EtherCAT slaves are lost due to noise or other causes, slave I/O data is not communicated, and the intended operation is sometimes not achieved. If noise countermeasures are
required, use the _EC_InDataInvalid (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.
• 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.
• 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 operation is sometimes not achieved. Perform the following processing for a slave that
needs to be replaced.
Program the _EC_InDataInvalid (Input Data Disable) system-defined variable as an interlock condition.
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.
Motion Control
• Confirm the axis number carefully before you perform an MC Test Run.
• 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.
• Always execute the Save Cam Table instruction if you change any of the cam data from the user program 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 operation.
• 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 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.
Battery Replacement
• The Battery may leak, rupture, heat, or ignite. Never short-circuit, charge, disassemble, heat, or
incinerate the Battery or subject it to strong shock.
• 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.
• UL standards require that only an experienced engineer replace the Battery. Make sure that an experienced 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
• 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.
Unit Replacement
• 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 Battery 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 Studio and clear the Low Battery Voltage error.
• 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.
Disposal
• Dispose of the product and Batteries according to local ordinances as they apply.
• 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 California, USA.
Perchlorate Material - special handling may apply.
See www.dtsc.ca.gov/hazardouswaste/perchlorate.
• 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.
When Using the Temperature Control Unit
• 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.
• Set the parameters of the Temperature Control Unit so that they are appropriate for the system being
controlled. Inappropriate settings can lead to unexpected operation, which in turn can damage the
product or cause accidents.
• 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.
• Do not use the Unit in locations where it will be subject to direct radiant head from a heater.
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CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Precautions for Correct Use
Precautions for Correct Use
Storage, Mounting, and Wiring
• Do not operate or store the Controller in the following locations. Operation may stop or malfunctions
may occur.
• Locations subject to direct sunlight
• Locations subject to temperatures or humidity outside the range specified in the specifications
• Locations subject to condensation as the result of severe changes in temperature
• Locations subject to corrosive or flammable gases
• Locations subject to dust (especially iron dust) or salts
• Locations subject to exposure to water, oil, or chemicals
• Locations subject to shock or vibration
• Take appropriate and sufficient countermeasures when installing the Controller in the following locations.
• Locations subject to strong, high-frequency noise
• Locations subject to static electricity or other forms of noise
• Locations subject to strong electromagnetic fields
• Locations subject to possible exposure to radioactivity
• Locations close to power lines
• Before touching a Unit, be sure to first touch a grounded metallic object in order to discharge any
static build-up.
• 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.
• 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.
• Do not allow foreign matter to enter the openings in the Unit. Doing so may result in Unit burning,
electric shock, or failure.
• 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.
• For EtherCAT and EtherNet/IP, use the connection methods and cables that are specified in the NJseries CPU Unit Built-in EtherCAT Port User’s Manual (Cat. No. W505) and the NJ-series CPU Unit
Built-in EtherNet/IP Port User’s Manual (Cat. No. W506). Otherwise, communications may be faulty.
• 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.
• Make sure that the current capacity of the wire is sufficient. Otherwise, excessive heat may be generated. 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.
• Do not touch the terminals on the Power Supply Unit immediately after turning OFF the power supply. Residual voltage may cause electrical shock.
• If you use reed switches for the input contacts for AC Input Units, use switches with a current capacity 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
Error Processing
• 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.
• 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.
Restoring and Automatically Transferring Data
• When you edit the restore command file or the automatic transfer command file, do not change anything in the file except for the “yes” and “no” specifications for the selectable data groups. If you
change anything else in the file, the Controller may perform unexpected operation when you restore
or automatically transfer the data.
Unit Replacement
• If you replace a CPU Bus Unit or Special I/O Unit, refer to operation manual for the Unit for information on the data required for individual Units and redo the necessary settings.
• 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.
Task Settings
• If a Task Period Exceeded error occurs, shorten the programs to fit in the task period or increase the
setting of the task period.
Motion Control
• 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.
• 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 normally if an error occur in slave communications.
• Before you start an MC Test Run, make sure that the operation parameters are set correctly.
• Do not download motion control settings during an MC Test Run.
EtherCAT Communications
• Do not disconnect the EtherCAT slave cables during operation. The outputs will become unstable.
• Set the Servo Drives to stop operation if an error occurs in EtherCAT communications between the
Controller and a Servo Drive.
• Make sure that all of the slaves to be restored are participating in the network before you reset a Network 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 specified node address or the error may not be reset correctly.
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CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Precautions for Correct Use
Battery Replacement
• Be sure to install a replacement Battery within two years of the production date shown on the Battery
label.
• 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.
• 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 for Correct Use
SD Memory Cards
• Insert the SD Memory Card all the way.
• Do not turn OFF the power supply to the Controller during SD Memory Card access. The files may be
corrupted.
If 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.
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CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Regulations and Standards
Regulations and Standards
Conformance to EC Directives
Applicable Directives
• EMC Directives
• Low Voltage Directive
Concepts
z 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 61000-6-2
EMI (Electromagnetic Interference): EN 61131-2 and EN 61000-6-4 (Radiated emission: 10-m regulations)
z 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.
z 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 follows:
• The NJ-series Controller must be installed within a control panel.
• You must use reinforced insulation or double insulation for the DC power supplies connected to
DC Power Supply Units and I/O Units.
• NJ-series Controllers that comply with EC Directives also conform to the Common Emission Standard (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, wiring, 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 NJ-series Controllers comply with the following shipbuilding standards. Applicability to the shipbuilding standards is based on certain usage conditions. 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.
Usage Conditions for NK and LR Shipbuilding Standards
• The NJ-series Controller must be installed within a control panel.
• Gaps in the door to the control panel must be completely filled or covered with gaskets or other
material.
• The following noise filter must be connected to the power supply line.
Noise Filter
Manufacturer
Cosel Co., Ltd.
Model
TAH-06-683
Trademarks
• Sysmac and SYSMAC are trademarks or registered trademarks of OMRON Corporation in Japan
and other countries for OMRON factory automation products.
• 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.
Other company names and product names in this document are the trademarks or registered trademarks of their respective companies.
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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.
Notation of Unit Versions on Products
The unit version is given on the ID information label of the products for which unit versions are managed, as shown below.
Example for NJ-series NJ501-@@@@ CPU Unit:
ID information label
Unit model
NJ501 - 1500
Unit version
Ver.1.@@
PORT1 MAC ADDRESS: @@@@@@@@@@@@
PORT2 MAC ADDRESS: @@@@@@@@@@@@
Lot No. DDMYY@
xxxx
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
serial number
Gives the lot number and serial number of the Unit.
DDMYY: Lot number, @: 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.
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.
z 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-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.
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
z EtherCAT Slaves
1
Double-click EtherCAT under Configurations and Setup in the Multiview Explorer. Or, rightclick 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 Production Information.
The Production Information Dialog Box is displayed.
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.
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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.
W500
Model numbers
NJ501-@@@@
NJ301-@@@@
Application
Description
Learning the basic specifications of the NJ-series
CPU Units, including introductory information,
designing, installation, and
maintenance. Mainly hardware information is provided.
An introduction to the entire NJ-series system is
provided along with the following information on
the CPU Unit.
• 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).
NJ-series CPU Unit Software User’s Manual
W501
NJ501-@@@@
NJ301-@@@@
Learning how to program
and set up an NJ-series
CPU Unit. Mainly software
information is provided.
The following information is provided on a Controller built with an NJ501 CPU Unit.
• CPU Unit operation
• CPU Unit features
• Initial settings
• Programming based on IEC 61131-3 language specifications
Use this manual together with the NJ-series
CPU Unit Hardware User’s Manual (Cat. No.
W500).
Sysmac Studio Version 1
Operation Manual
W504
SYSMACSE2@@@
Learning about the operating procedures and functions of the Sysmac Studio.
Describes the operating procedures of the Sysmac Studio.
CJ-series Temperature
Control Units Operation
Manual for NJ-series
CPU Unit (This manual)
W491
CJ1W-TC003/TC004/-TC103/TC104
Leaning the functions and
application methods of the
CJ-series Temperature
Control Units used in an
NJ-series configuration.
Describes the application methods of the CJseries
SYSMAC CJ Series
Temperature Control
Units Operation Manual
W396
CJ1W-TC@@@
Leaning the functions and
application methods of the
CJ-series Temperature
Control Units.
Describes the application methods of the CJseries
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Temperature Control Units used in an NJ-series
configuration.
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
Revision code
Revision code
01
02
03
36
Date
July 2011
March 2012
August 2012
Revised content
Original production
Corrected errors.
Made changes accompanying release of unit version 1.03 of
the CPU Unit.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1
Features and System
Configuration
This section describes the features of the Temperature Control Unit and its basic system configuration.
1-1 Introduction and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-1-1
1-1-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-2-1
1-2-2
Basic System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Mounting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1-1
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 thermometers (JPt100 and Pt100), and two types of outputs: NPN and PNP.
The Unit also performs Autotuning (AT) of PID constants.
Available Units
Output type
I/O type
Two control loops
(with heater burnout detection function)
NPN outputs
PNP outputs
Thermocouple
CJ1W-TC003
CJ1W-TC004
Platinum resistance thermometer
CJ1W-TC103
CJ1W-TC104
Temperature Ranges
K(CA)
1800
1600
1400
1200
1000
800
600
400
200
0
-200
Input Type Switch
Minimum Units
K(CA)
J(IC)
J(IC)
T(CC)
L
L
R
S
B
1700
650.0
650.0
−200.0
−200.0
1300
850
500.0
850
400.0
400.0
400.0
100
0.0
−200
0
1°C
1
0.1°C
0.0
−100
2
1°C
−200.0
3
4
0.1°C
0.1°C
−100
5
1°C
0.0
6
0.1°C
0
0
7
8
9
1°C
1°C
1°C
0
0.1°C
R: Platinum 13% Rhodium-Platinum
J (IC): Iron-constantan
S: Platinum 10% Rhodium-Platinum
T (CC): Copper-constantan
B: Platinum 30% Rhodium-Platinum 6% Rhodium
1-2
JPt100
---
1700
K (CA): Chromel-alumel
L:
Pt100
1800
1
0.1°C
Settings 2 to 9 are not allowed.
Usable temperature range (°C)
Platinum resistance
thermometer
Thermocouple
Item
2 to 9
---
Iron-constantan
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1 Features and System Configuration
Data can be exchanged between the CPU Unit and Temperature Control Unit through the I/O port generated 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)
O
N
1
1 2 3 4 5 6 7 8
SW3
1-1-2 Features
Data storage/display format Settings
Settings are not allowed. OFF
16-bit binary
ON
This change becomes effective when the Controller is reset, or when the Unit is restarted.
1-1-2
1-1 Introduction and Features
Exchange Data with the CPU Unit
Features
z Use ON/OFF Control or PID Control with 2 Control Loops
The Temperature Control Unit can perform basic ON/OFF control as well as PID control of two control loops. The PID control function has two degrees of freedom and an autotuning function that can
be used to autotune the PID value.
z 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.
z 500-ms Sampling Cycle
PID control is performed with a sampling cycle of 500 ms.
z 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.
z 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.
z Terminal Block Connections
Both inputs and outputs are connected through a terminal block.
z 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 setting is PID control.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1-3
1 Features and System Configuration
Additional Information
• 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.)
• 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.
1
2
If the disturbance response was emphasized (i.e., P and I were reduced and D was increased),
the SV response would oscillate and overshoot.
If the SV response was emphasized (i.e., P and I were increased and D was reduced), the disturbance response would be delayed.
To overcome these problems, PID control with two degrees of freedom was used for this Temperature Control Unit to take advantage of the strengths of PID control and improve both disturbance and target response as shown in 3 below.
Earlier PID Control Method
2
1
Not good
Good
The disturbance response is good, but
the SV response is delayed.
Good
Not good
The SV response is good, but the
disturbance response is not.
PID Control with Two Degrees of Freedom
3
Good
Good
Both the SV response and disturbance
response are good.
1-4
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1 Features and System Configuration
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.)
Hunting period
1-1 Introduction and Features
Autotuning (AT) Function
Amplitude
SV
1
1-1-2 Features
AT starts.
AT stops.
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.
z 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
temperature
SV
High
temperature
Forward operation
SV
Low
temperature
High
temperature
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 PV and SP
increases. Consequently, heating control uses "reverse operation" and cooling control uses "forward
operation."
z 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.
z 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
1 Features and System Configuration
z 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
z 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 for 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 automatic 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 settings can be used at their factory settings. (Refer to 2-6 Range of Set Values and Monitor Values for
the default settings.)
1-6
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1 Features and System Configuration
1-2 System Configuration
1-2
System Configuration
Caution
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.
1-2-1 Basic System Configuration
1-2-1
1
Basic System Configuration
CJ1W-TC103
two-loop heater burnout alarm
Platinum resistance thermometer, NPN
outputs
Power supply
for outputs
(24 VDC)
Control output
Heater
1 kW
Temperature Sensor
Platinum resistance
thermometer
Current
Transformer
200 VAC
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 (CJ1W-TC103) mounted.
2 An OMRON E54-CT1 or E54-CT3 Current Transformer must be used as the Current Transformer (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 performance 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-TC@@@ Temperature Control Units that can
be mounted in a Rack if the Temperature Control Units are the only Units being used in the Rack.
Power Supply Unit
CJ1W-PA205R
CJ1W-TC@@@
10 Units
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
2
Connector
Openings for hooks
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.)
Lock
Sliding
latch
Release
1-8
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1 Features and System Configuration
1-2 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.
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.
1
1-2-2 Mounting the Unit
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1-9
1 Features and System Configuration
Handling Precautions
• Always turn OFF the controller's power supply before connecting or disconnecting wiring to the Unit.
• 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.
• 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 measures such as covering with a cover.
• If 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.
81
TC0 RUCN
ER
ERH
ADJ
H
MAC
No. 1
x10
0
x10
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
A cold junction sensor is attached to the terminal block for Temperature Control Units with thermocouples. The accuracy ratings are given for the Temperature Control Unit used in a set with
the cold 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.
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.
ERH
ER
ADJ
A1
B1
H
MAC
No. 1
×10
0
×10
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1
1-2-2 Mounting the Unit
01
TC0 RUCN
1-2 System Configuration
Precautions for Correct Use
1-11
1 Features and System Configuration
1-12
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2
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 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-1-1
2-1-2
2-1-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Input Function Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-2 Application Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-3 Part Names and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-3-1
2-3-2
2-3-3
2-3-4
2-3-5
Part Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Number Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIP Switch Setting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Type Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11
2-11
2-12
2-13
2-15
2-4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-4-1
2-4-2
2-4-3
Terminal Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Output Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-5 Data Exchange with the CPU Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2-5-1
2-5-2
2-5-3
2-5-4
2-5-5
2-5-6
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing from the User Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Saving Set Value in the Non-volatile Memory . . . . . . . . . . . . . . . . . . . . . . . .
Operation Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initialization Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-21
2-22
2-23
2-24
2-30
2-32
2-6 Range of Set Values and Monitor Values . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2-6-1
2-6-2
Set Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Monitor Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Specifications
General Specifications
Item
Unit classification
Specification
NJ-series Special I/O Unit
Compatible Racks
NJ-series CPU Rack or NJ-series Expansion Rack
Max. number of
Units
10 Units/Rack max. (CPU Rack or Expansion Rack)
Methods of
exchanging data
with CPU
Data exchange by using I/O ports
Insulation resistance
20 MΩ min. (at 500 VDC) between the following points:
Refer to 2-5 Data Exchange with the CPU Unit
• Output terminals/NC terminals and external AC terminals (Power Supply Unit)
• Input terminals and external AC terminals (Power Supply Unit)
• Input terminals and output terminals
• External DC terminals (inputs, outputs, and NC) and the FG plate
• Between input terminals (sensor and CT inputs)
• Between the I/O terminals and NC terminals
Dielectric strength
2,000 VAC 50/60 Hz for 1 min., detected current: 1 mA
• 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
• Input terminals and external AC terminals (Power Supply Unit)
• Input terminals and output terminals
• External DC terminals (inputs, outputs, and NC) and the FG plate
500 VAC 50/60 Hz for 1 min., detected current: 1 mA
• Between input terminals (sensor and CT inputs)
• Between the I/O terminals and NC terminals
Internal current
consumption
250 mA max., 5 VDC
Other
Other general specifications conform to the NJ-series general specifications.
Dimensions
31 × 90 × 65 mm (W × H × D)
Weight
150 g max.
Characteristics
Item
Specification
Model number
CJ1W-TC003/TC004
CJ1W-TC103/TC104
Temperature sensor
Thermocouple: Types R, S, K, J, T, L, and B
Platinum resistance thermometer: Types Pt100 and
JPt100
Number of loops
There are two types of Unit available: Two-loop Unit with heater burnout detection. *1
Control output and
heater burnout alarm
output
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.
Temperature control
method
ON/OFF control or PID control with two degrees of freedom (Set with pin 6 on the Unit's DIP switch.)
Control operation
Forward or reverse operation (Set with pins 4 and 5 on the Unit's DIP switch.)
2-2
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
Item
Specification
Supported (Controlled from the CPU Unit through the device variable for CJ-series Unit.)
Operation with CPU
Unit in PROGRAM
mode
The Temperature Control Unit can be set to continue operating or stop operating when the CPU Unit is in
PROGRAM mode. (Set with pin 1 on the Unit's DIP switch.)
Auto/Manual switch for
operational output
None
Autotuning (AT) of PID
constant
Supported (Controlled from the CPU Unit through the device variable for CJ-series Unit.)
Indication accuracy
Centigrade: ±0.3% PV or ±1°C (whichever is larger) ±
1 digit max.
Fahrenheit: ±0.3% PV or ±2°F (whichever is larger) ± 1
digit max.
2-1 Specifications
RUN/STOP control
Centigrade: ±0.3% PV or ±0.8°C (whichever is larger)
± 1 digit max.
Fahrenheit: ±0.3% PV or ±1.6°F (whichever is larger)
± 1 digit max.
2
2-1-1 Specifications
• 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.
• The accuracy will be ±3°C ± 1 digit max. when
using an R or S-type thermocouple below 200°C.
• The B-type thermocouples may not be accurate
below 400°C.*2
Warmup time
30 min
Sensitivity (when using
ON/OFF control)
0.0 to 999.9 °C or °F (0.1 °C or °F units)
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
value
−99.9 to 999.9 °C or °F (0.1 °C or °F units)
Alarm output setting
range
−999 to 9,999 °C or °F (1 °C or °F units)
External terminal connections
Removable terminal block with 18 points (M3 screws)
The setting range will be −99.9 to 999.9 °C or °F (0.1 °C or °F units) when using a platinum resistance thermometer or using a K or J-type thermocouple in decimal-point mode.
*1 The last three digits of the model number indicate the Unit's features:
CJ1W-TC @ 0
@
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
*2
0: Thermocouple input
1: Platinum resistance thermometer input
Indication accuracy of thermocouples
• 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.
• 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.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2-3
2 Specifications and Functions
Heater Burnout (HB) Alarm
Item
Specification
Maximum heater current
Single-phase AC, 50 A
Indication accuracy of input current
±5% of full scale ± 1 digit max.
Heater burnout alarm setting
range
0.1 to 49.9 A (0.1 A units)
Min. detectable ON time*
200 ms
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 SV is 50.0 A, the heater
burnout alarm will be ON.)
* 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
50 A
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 CJ1W-TC@@@ 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.
2-4
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
2-1-2
Input Function Block Diagram
CPU Unit
Temperature Control Unit
ON/OFF control
Loop 1
Special I/O
Unit Area
°C
°F
2-1 Specifications
Controller
PV/SP,
etc.
PID control
Input 1
Temperature
input
Control
output
CT
input 1
CT input
Heater
burnout
alarm
output 1
Heater
burnout alarm
Alarm 2
2
2-1-2 Input Function Block Diagram
Control
output 1
Alarm 1
Forward/r
everse
switching
Loop 2
Input 2
Control
output 1
CT input 2
Same as 1.
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 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.
Thermocouple Input Setting Ranges
Sensor
Thermocouple
Set value
Input type
0
K
1
2
Temperature range
-200 to 1300°C/-300 to 2300°F
0.0 to 500.0°C/0.0 to 900.0°F
J
3
-100 to 850°C/-100 to 1500°F
0.0 to 400.0°C/0.0 to 750.0°F
4
T
-200.0 to 400.0°C/-300.0 to 700.0°F
5
L
-100 to 850°C/-100 to 1500°F
6
7
0.0 to 400.0°C/0.0 to 750.0°F
R
0 to 1700°C/0 to 3000°F
8
S
0 to 1700°C/0 to 3000°F
9
B*
100 to 1800°C/300 to 3200°F
* The lower-limit indication for B-type thermocouples is 0°C or 0°F.
Note When the Input Type Switch has been changed, the SV and input compensation values will
change as follows:
• If the SV exceeds the setting range, it will be fixed at the lower limit or upper limit of the setting
range.
• 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
2 Specifications and Functions
For example, when the temperature range 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.
Platinum Resistance Thermometer Input Setting Ranges
Sensor
Set value
Platinum Resistance Thermometer
0
Pt100
-200.0 to 650.0°C/-300.0 to 1200.0°F
1
JPt100
-200.0 to 650.0°C/-300.0 to 1200.0°F
2 to 9
2-6
Input type
Temperature range
Do not set 2 through 9.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
2-2
Application Procedure
Programs and software settings
Create POU and global
variables
Create Unit Configuration
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
I/O map.
Set the unit number.
Hardware setting and Rack assembly
Set the input type.
• Set the unit number switches on the front panel of
the Temperature Control Unit.
Set the same unit number as in the Unit Configuration settings.
• Set the Input Type Switches on the front panel of
the Temperature Control Unit.
Set DIP switch 3 to ON.
• Set the DIP switch on the front panel of the Temperature Control Unit.
Set the function of the Temperature Control Unit.
• Set the DIP switch on the front panel of the Temperature Control Unit.
Forward/reverse operation switching
Control method: ON/OFF control or PID control
°C/°F switching
Mount and wire to the Rack.
Turn ON the power to the controller.
Transfer the user program.
Program transfer and operation
• Create and register global variables and each POU.
• 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.
• 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.
Create Initialization Data of the Unit.
Set the alarm mode and alarm hysteresis.
Reset the Controller or restart the Unit.
(The data setup file is reflected in the I/O port
(Initialization Data).)
• Reflect the settings for the Unit, in the Temperature
Control Unit.
Warm up the Unit.
Main operation
• At least 30 minutes after the controller power is
turned ON
• Read or write process values and set values from the
user program.
Operating Parameters (control period and PID constants)
Operation Data (RUN/STOP control and starting/
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2-7
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).
2
2 Specifications and Functions
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.
• Warm up the Unit for at least 30 minutes to ensure accurate operation. The indicated temperature error will be larger if the Unit is not warmed up.
Example Operating Procedure
The following settings are used in this example for a Two-loop Temperature Control Unit.
Input type: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
K thermocouple
(0.0 to 500.0 °C)
CPU Unit
Loop 1
User program
J01_Ch1_PV
Loop 2
J01_Ch2_PV
Unit number: 1
z Create Unit Configuration
Use Sysmac Studio to create Unit Configuration. Place the Temperature Control Unit in slot 0 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).
z Creating User Programs
The process value (PV) of each loop (J01_Ch#_PV) are stored in the data storage destination of the
user-defined variable (Temperature#).
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
z Variable
Variable type
J01_Ch1_PV
Device variable for CJseries Unit *1
J01_Ch2_PV
J01_Ch1_SensErr
J01_Ch2_SensErr
Temperature1
User-defined
variable *2
Temperature2
Description
2-2 Application Procedure
Variable names
Type
Loop 1 Process Value
INT
Loop 2 Process Value
INT
Loop 1 Sensor Error Flag
BOOL
Loop 2 Sensor Error Flag
BOOL
Loop 1 PV Data Storage Destination
INT
Loop 2 PV Data Storage Destination
INT
*1 Device variables for CJ-series Unit are created using the I/O map from the Sysmac Studio.
2
*2 Before you create the user program, use Sysmac Studio to create user-defined variables.
z Example of program
J01_Ch1_SensErr
(Loop 1 Sensor Error Flag)
MOVE
EN
J01_Ch1_ PV
In
ENO
Out
Temperature1
ENO
Out
Temperature2
J01_Ch2_SensErr
(Loop 2 Sensor Error Flag)
MOVE
EN
J01_Ch1_ PV
In
z Settings
1
2
Set the Unit number referring to 2-3-3 Unit Number Switches.
If the unit number is set to 1.
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(W491)
2-9
2 Specifications and Functions
3
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.
O
N
1 2 3 4 5 6 7 8
4
Mount and wire the Unit, referring to 1-2-2 Mounting the Unit.
5
Turn ON the power supply to the controller.
Precautions for Safe Use
Always turn OFF the power supply to the Controller before attempting any of the following.
• Mounting or dismounting I/O Units or CPU Unit.
• Assembling the Units.
• Setting DIP switches or rotary switches.
• Connecting cables or wiring the system.
After the power is turned OFF, the Power Supply Unit may continue to supply power to the Controller 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 following Transfer a User Program to a CPU Unit process to cancel the error.
z Transfer a User Program to a CPU Unit
2-10
1
Connect Sysmac Studio to the Controller and transfer the created user program.
2
Reset the Controller. (Or restart this Unit.)
3
Run with the created user program.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
Part Names and Functions
2-3-1
2-3 Part Names and Functions
2-3
Part Names
Output Indicators
Status
Indicators
Unit Number
Switches
7 8
4
0 1
5 6
9
Terminal
Block
2 3
7 8
4
0 1
5 6
9
2
2 3
2-3-1 Part Names
Connector
DIP Switch
7 8
4
0 1
5 6
9
2 3
Input Type
Switch
DIN Track
Mounting Pin
Terminal Block
Lock Lever
Sliding Latch
2-3-2
Sliding Latch
Indicators
Status Indicators
The Status Indicators indicate the operating status of the Temperature Control Unit, as explained in
the following table.
Indicator
Name
Color
Status
Meaning
RUN
RUN Indicator
Green
Lit
Not lit
Temperature control is stopped.
ERC
Temperature Control Unit Error
Red
Lit
An error occurred in the Temperature Control Unit itself,
such as a Sensor Error or Initialization Error.
Not lit
Normal operating status
ERH
CPU Unit Error
Red
Normal operating status
Lit
An error occurred in the CPU Unit.
Not lit
Normal operating status
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
2 Specifications and Functions
2-3-3
Unit Number Switches
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 number and allocated memory, refer to A-3 Correspondence Table of Device Variables for CJ-series Unit
and Memory Used for CJ-series Unit Addresses.
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.
2-12
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
DIP Switch Setting Functions
O
N
2-3 Part Names and Functions
2-3-4
1 2 3 4 5 6 7 8
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.
Function
ON
OFF
1
Operation when CPU Unit is in
PROGRAM mode
Continue
Stop
2
Temperature units (°C/°F)
°F
°C
3
Data storage/display format
Set to ON for use.
4
Control operation (for loop 1)
Forward
(cooling)
Reverse
(heating)
5
Control operation (for loop 2)
Forward
(cooling)
Reverse
(heating)
6
Control method
ON/OFF control
PID control
7
Initialize set values in Non-volatile Memory
Initialize
Do not initialize
8
Transfer set values in Non-volatile Memory
Transfer
Do not transfer
2-3-4 DIP Switch Setting Functions
Pin
Factory
setting
OFF
ON
Operation in PROGRAM mode (Pin 1)
The following table shows how the Temperature Control Unit will operate when the CPU Unit's operating mode is changed.
Temperature Control Unit
settings
Pin 1
OFF (Stop)
Stop Bit
Operation of Temperature Control Unit when
CPU Unit's operating mode is changed
From RUN to
PROGRAM
From PROGRAM to
RUN
Run
Stop operation
Continue operation
Stop
Stop operation
Stop operation
Continue operation
Continue operation
Stop operation
Stop operation
ON (Continue) Run
Stop
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 × 1.8) + 32
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2
2-13
2 Specifications and Functions
Data Storage/Display Format (Pin 3)
Set this switch to ON for use.
Control Operation for Loop 1 (Pin 4)
Pin 4 selects forward (cooling) operation (ON) or reverse (heating) operation (OFF) for control loop
1.
Control Operation for Loop 2 (Pin 5)
Pin 5 selects forward (cooling) operation (ON) or reverse (heating) operation (OFF) for control loop
2.
Control Method (Pin 6)
Pin 6 selects either ON/OFF control (ON) or PID control (OFF).
• If ON/OFF control is being used, the width of the hysteresis loop (hysteresis) can be set to adjust
the control sensitivity.
• If PID control (PID control with two degrees of freedom) is being used, the PID constants can be
set automatically with the autotuning function.
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.)
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 transferred to the corresponding device variable for CJ-series Unit of the CPU Unit when the Temperature 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 turning ON the corresponding Save Settings Bits (*_Ch1_SaveCmd 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.
2-14
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
Input Type Switch
2-3 Part Names and Functions
2-3-5
z Thermocouple Temperature Control Units
Input type
setting
Type
2
Temperature ranges
Centigrade
Fahrenheit
K
−200 to 1,300°C
−300 to 2,300°F
1
K
0.0 to 500.0°C
0.0 to 900.0°F
2
J
−100 to 850°C
−100 to 1,500°F
3
J
0.0 to 400.0°C
0.0 to 750.0°F
4
T
−200.0 to 400.0°C
−300.0 to 700.0°F
5
L
−100 to 850°C
−100 to 1,500°F
6
L
0.0 to 400.0 °C
0.0 to 750.0°F
7
R
0 to 1,700°C
0 to 3,000°F
8
S
0 to 1,700°C
0 to 3,000°F
9
B
100 to 1,800°C
300 to 3,200°F
2-3-5 Input Type Switch
0
z Platinum Resistance Thermometer Temperature Control Units
Input type
setting
Type
Temperature ranges
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 to 9
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
2-4-1
Wiring
Terminal Wiring Examples
z Thermocouple Temperature Control Units
CJ1W-TC003
(2 loops, NPN outputs, HB alarm)
Input 2 −
Input 2 +
B1 A1 Input 1 −
B2 A2 Input 1 +
Cold-junction comp. B3
Cold-junction comp. B4 A3 N.C.
CT input 2
CT input 2
Output 2
HB output 2
0 V COM (−)
B5
B6
B7
B8
B9
A4
A5
A6
A7
A8
A9
N.C.
CT input 1
CT input 1
Output 1
HB output 1
24 V
CJ1W-TC004
(2 loops, PNP outputs, HB alarm)
Input 2 −
Input 2 +
B1 A1 Input 1 −
B2 A2 Input 1 +
Cold-junction comp. B3
Cold-junction comp. B4 A3 N.C.
CT input 2
CT input 2
Output 2
HB output 2
0V
B5
B6
B7
B8
B9
A4
A5
A6
A7
A8
A9
N.C.
CT input 1
CT input 1
Output 1
HB output 1
24 V COM (+)
z Platinum Resistance Thermometer Temperature Control Units
CJ1W-TC103
(2 loops, NPN outputs, HB alarm)
Input 2 B'
Input 2 B
Input 2 A
N.C.
CT input 2
CT input 2
Output 2
HB output 2
0 V COM (−)
B1
B2
B3
B4
B5
B6
B7
B8
B9
A1
A2
A3
A4
A5
A6
A7
A8
A9
Input 1 B'
Input 1 B
Input 1 A
N.C.
CT input 1
CT input 1
Output 1
HB output 1
24 V
CJ1W-TC104
(2 loops, PNP outputs, HB alarm)
Input 2 B'
Input 2 B
Input 2 A
N.C.
CT input 2
CT input 2
Output 2
HB output 2
0V
B1
B2
B3
B4
B5
B6
B7
B8
B9
A1
A2
A3
A4
A5
A6
A7
A8
A9
Input 1 B'
Input 1 B
Input 1 A
N.C.
CT input 1
CT input 1
Output 1
HB output 1
24 V COM (+)
When not using temperature input terminals:
• For a resistance thermometer, connect a resistance of approximately 100 to 200 Ω between terminals A and B, and establish a short between terminals B and B'.
• Short the input terminals for thermocouples.
• Do not connect anything to terminals that are not being used.
Precautions for Correct Use
Do not connect any wiring to the N.C. terminals.
2-16
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
2-4 Wiring
z NPN Outputs (CJ1W-@03)
24 V
2
L
Internal circuits
2-4-2 Output Circuits
L
Output indicator
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
COM
2-17
2 Specifications and Functions
z PNP Outputs (CJ1W-@04)
COM
24V
Internal circuits
L
L
0V
Output indicator
2-4-3
I/O Wiring Examples
z Thermocouple Temperature Control Units
CJ1W-TC003
(2 loops, HB alarm, NPN
outputs)
CJ1W-TC004
(2 loops, HB alarm, PNP
outputs)
CJ1W-TC003
CJ1W-TC004
Loop 2
Loop 2
Coldjunction
Loop 1
Coldjunction
Loop 1
• Do not touch or remove the cold junction sensor.
• Use the type of sensor selected on the Input Type Switch.
• 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
• Do not connect anything to the N.C. terminals. (The N.C. terminals cannot even be used as junction terminals.)
• Do not connect any Current Transformer to the CT input terminals other than an OMRON E54CT1 or E54-CT3.
z Platinum Resistance Thermometer Temperature Control Units
CJ1W-TC104
Loop 1
Loop 2
2
2-4-3 I/O Wiring Examples
Loop 1
CJ1W-TC103
Loop 2
CJ1W-TC104
(2 loops, HB alarm, PNP
outputs)
2-4 Wiring
CJ1W-TC103
(2 loops, HB alarm, NPN
outputs)
• 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 junction terminals.)
• Do not connect any Current Transformer to the CT input terminals other than an OMRON E54CT1 or E54-CT3.
• Always attach crimp terminals to the wiring that connects to the terminal block and tighten the terminal 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).
M3
Fork terminal
6.0 mm max.
Round terminal
6.0 mm max.
Observe the following precautions when wiring to minimize noise and optimize the Temperature Control
Unit's operation.
• Use twisted-pair shielded wire for the output wiring.
• 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
• 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 electrical welding equipment or discharging equipment. In this case, install a noise filter at the power supply inputs.
2-20
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
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.
• Operation Data
• Initialization Data
• Operating Parameters
2-5 Data Exchange with the CPU Unit
2-5
2
The table and diagram show the data exchange method for each data type.
Data exchange type
AT specification
destination
Data contents
How to access
from user
program
2-5-1 Overview
Unit data
type
Timing of data
exchange
Operation
Data
Process value, set point,
start AT bit, stop AT bit, etc.
I/O port (Operation Data)
Device variable for
CJ-series Unit
I/O refresh period
Initialization
Data
Alarm mode, alarm hysteresis, etc.
I/O port (Initialization Data) (*)
When the Controller is
reset or the Unit
restarts
Operating
Parameter
Alarm SVs, control period,
proportional band, integral
time, etc.
I/O port (Operating Parameters)
(*)
I/O refresh period
Unit Restart
Flag, etc.
Unit Restart Flag, etc.
None
System-defined
variable
* The Initialization Data and Operating Parameters are retained in the CPU Unit by the battery even during power
interruptions.
NJ-series CPU Unit
User program
Temperature Control Unit
CJ1W-TC@@@
I/O port
[Operation Data]
Device variables
for CJ-series
Unit (for operation)
AT
specification
Constantly exchanges
data necessary for
operation
Operation Data
When the Controller is reset
or the Unit restarts
I/O refresh period
[Initialization Data]
Device variables
for CJ-series
Unit (for initialization)
AT
specification
Device variables for
CJ-series Unit (for
operation adjustments)
AT
specification
Initialization Data
When the Controller is reset
or the Unit restarts
When the Controller
is reset or the Unit
restarts
Operating Parameters
When the Controller is reset
or the Unit restarts
I/O refresh period
Transfers Initialization
Data such as Alarm Mode,
Alarm Hysteresis, etc.
[Operating Parameters]
Constantly exchanges
data necessary for
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
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.
• Reset the Controller from Sysmac Studio.
• Reset the Controller from cycling the power supply to the controller
• Restart using the ResetUnit instruction of the program
• Restart using a system-defined variable.
Variable name
Type
_CJB_SIO**Restart
BOOL
Unit number 00 to 94 in **
Precautions for Correct Use
• If the error persists after the restart, replace this Unit.
• During restart, output is 0 V as the data immediately before restart is maintained for input.
2-5-2
Accessing from 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.
z I/O 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.
z How to Specify Device Variables for CJ-series Unit
Allocate variables for CJ-series Units to an I/O port with I/O 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
2-5 Data Exchange with the CPU Unit
The following is the configuration of variable names created with 3. Automatic creation.
Name of device variable for CJ-series Unit
*_ Ch1_PV
This is an I/O port name. The name indicates the
Unit functions, statuses and parameters.
This is the device name when this Unit is registered 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.
2
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 variables for CJ-series Unit, for example *_Ch1_PV.
2-5-3
Saving Set Value in the Non-volatile Memory
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
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.
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 Operating 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 (*_Ch1_SaveCmd and
*_Ch2_SaveCmd).
If pin 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
2-5-3 Saving Set Value in the Non-volatile Memory
For details on creation of device variables for CJ-series Unit, refer to the Sysmac Studio Version 1
Operation Manual (Cat. No. W504).
2 Specifications and Functions
Area allocated in CPU
Unit
Set value
Transfer timing
from device variables for CJseries Unit in
CPU Unit to RAM
Transfer timing
from RAM to nonvolatile memory
Transfer timing
from non-volatile
memory to device
variables for CJseries Unit in
CPU Unit
Device variable for CJseries Unit
Operation
Data
Set point
I/O refresh period
---
---
Initialization Data
Alarm Mode
When the controller is reset or the
Unit restart
---
---
Alarm Hysteresis
Operating
Parameters
Alarm SVs
I/O refresh period
Setting data in
RAM is written to
non-volatile memory when you
change the Save
Settings Bits of the
device variables for
CJ-series Unit (for
operation) from 0
to 1.*2
When the Unit
restarts or the controller is reset,
including when the
power is turned
ON, with pin 8 of
the DIP switch set
to ON.
Heater Burnout
Current
Input Compensation Value
Control Period
Control Sensitivity
Proportional Band
Integral Time
Derivative Time
During I/O refreshing and PID Constants Calculated
Flag is 0 *1
*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
RAM
Temperature Control Unit
backup area
Non-volatile Memory
I/O refresh
Operation Data
Power ON or Unit
restart
Initialization Data
Operating
Parameters
Operation Data
Initialization Data
I/O refresh
Operating
Parameters
Save Settings Bit
0(OFF)→1(ON)
Operating
Parameters
When the power turns ON or the Unit restarts with
pin 8 of the DIP switch set to ON
2-5-4
Operation Data
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 transferred 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
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 Monitor
Values.
The meaning of the row of "R/W" in the table below is as follows:
RW: Read/Write
2-5 Data Exchange with the CPU Unit
Allocating Operation Data to Device Variables for CJ-series Unit
R: Read only
Device variable for CJ-series Unit
Loop 1
Loop 2
Data
type
R/W
Name
Function
2
*_Ch2_PV
INT
R
Loop 1 and
Loop 2 Process
Value
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".
*_Ch1_HtrCurVal
*_Ch2_HtrCurVal
UINT
R
Loop 1 and
Loop 2 Heater
Current
If the measured heater current exceeds 55.0 A,
"*_Ch#_CTOvfFlg" (CT
Overflow Flag) will become 1
and the heater current will be
stored as "-13,108".
*_Ch1_SetPointCfg
*_Ch2_SetPointCfg
INT
RW
Loop 1 and
Loop 2 Set
point
Set the set point of loop 1
and loop 2.
*_Ch1_SetPointSta
*_Ch2_SetPointSta
INT
R
Loop 1 and
Loop 2 Set
point for Monitor
Indicate the current set point
of loop 1 and loop 2.
*_Ch1_HBLvlCfg
*_Ch2_HBLvlCfg
UINT
RW
Loop 1 and
Loop 2 Heater
Burnout Current
Set the heater burnout current of loop 1 and loop 2.
If the set value is set to 0.0,
heater burnouts 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.)
*_Ch1_HBLvlSta
*_Ch2_HBLvlSta
UINT
R
Loop 1 and
Loop 2 Heater
Burnout Current for Monitor
Indicate the current set
heater burnout current of
loop 1 and loop 2.
*_Ch1_StartATCmd
*_Ch2_StartATCmd
BOOL
RW
Loop 1 and
Loop 2 Start AT
Bit
Turn ON the Start AT to start
autotuning for loop 1 and
loop 2. The status of the Stop
AT is ignored if
"*_Ch#_StopATCmd"(Stop
AT Bit) is set to 1.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2-25
2-5-4 Operation Data
*_Ch1_PV
2 Specifications and Functions
Device variable for CJ-series Unit
Loop 1
Loop 2
Data
type
R/W
Name
Function
*_Ch1_StopATCmd
*_Ch2_StopATCmd
BOOL
RW
Loop 1 and
Loop 2 Stop AT
Bit
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.
*_Ch1_StopCtlCmd
*_Ch2_StopCtlCmd
BOOL
RW
Loop 1 and
Loop 2 Stop Bit
Set the Stop Bit to 0 to perform 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 PROGRAM mode.
*_Ch1_ChgPIDCmd
*_Ch2_ChgPIDCmd BOOL
RW
Loop 1 and
Loop 2 change
PID Constants
Bit
When a Change PID Constants Bit is set from 0 to 1,
the corresponding
"*_Ch#_PIDCalcFlg" (PID
Constants Calculated Flag)
will be set from 1 to 0 and the
PID constants stored as
Operating Parameters will be
retransferred to RAM in the
Temperature Control Unit.
*_Ch1_SaveCmd
*_Ch2_SaveCmd
RW
Loop 1 and
Loop 2 Save
Settings Bit
The set values of the applicable 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.
BOOL
DO NOT turn OFF the power
supply when data is being
written from RAM to non-volatile memory. Confirm that
"*_Ch#_SaveFlg" (Save
Completed Flag) is set to 1
(data is written to memory)
before turning OFF the
power supply.
2-26
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
Loop 1
*_Ch1_StaWd
Loop 2
*_Ch2_StaWd
Data
type
WORD
R/W
R
Name
Loop 1 and
Loop 2 Status
Function
Bits serve the functions
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 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_AL1Flg
BOOL
R
Loop 1 and
Loop 2 AL1
Flag
The value becomes 1 when
the temperature is within the
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
R
Loop 1 and
Loop 2 AL2
Flag
The value becomes 1 when
the temperature is within the
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_HBFlg
*_Ch2_HBFlg
BOOL
R
Loop 1 and
The value becomes 1 if the
Loop 2 HB Flag detected heater current does
not exceeds the Heater Burnout Current.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2-27
2
2-5-4 Operation Data
Bit 04: Loop 1 and Loop 2
Control Output Flag
2-5 Data Exchange with the CPU Unit
Device variable for CJ-series Unit
2 Specifications and Functions
Device variable for CJ-series Unit
Loop 2
Data
type
*_Ch1_ATFlg
*_Ch2_ATFlg
BOOL
*_Ch1_CtlOutFlg
*_Ch2_CtlOutFlg
*_Ch1_StopFlg
Name
Function
R
Loop 1 and
Loop 2 AT Flag
The value becomes 1 during
autotuning of loop 1 and loop
2. The value becomes 0
when autotuning stops or finishes.
BOOL
R
Loop 1 and
Loop 2 Control
Output Flag
The value becomes 1 when
the control output of loop 1
and loop 2 is ON.
*_Ch2_StopFlg
BOOL
R
Loop 1 and
Loop 2 Stop
Flag
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 temperature of loop 1 and loop 2.
*_Ch1_SetErr
*_Ch2_SetErr
BOOL
R
Loop 1 and
Loop 2 Setting
Error Flag
The value becomes 1 when
there is an error in the set
values in the device variable
for CJ-series Unit.
*_Ch1_PIDCalcFlg
*_Ch2_PIDCalcFlg
BOOL
R
Loop 1 and
Loop 2 PID
Constants Calculated Flag
The value becomes 1 when
the PID constants calculated
by the Temperature Control
Unit for autotuning are
updated.
Loop 1
R/W
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.
*_Ch1_StbyFlg
*_Ch2_StbyFlg
BOOL
R
Loop 1 and
Loop 2 Standby
Flag
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.
*_Ch1_CJErr
*_Ch2_CJErr
BOOL
R
Loop 1 and
Loop 2 Cold
Junction Sensor Error
The value becomes 1 for the
following:
Loop 1 and
Loop 2 CT
Overflow Flag
The value becomes 1 if the
heater current detected by
the CT (Current Transformer)
exceeds 55.0 A.
*_Ch1_CTOvfFlg
2-28
*_Ch2_CTOvfFlg
BOOL
R
• Cold junction sensor error
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
Loop 1
*_Ch1_SensErr
*_Ch1_SaveFlg
Data
type
Loop 2
*_Ch2_SensErr
R/W
BOOL
*_Ch2_SaveFlg
Function
Loop 1 and
Loop 2 Sensor
Error Flag
The value becomes 1 for the
following:
• A sensor is not connected
to loop 1.
• The connection to sensor
of loop 1 is broken.
• A temperature exceeding
the measurable input
range is input.
BOOL
R
Loop 1 and
Loop 2 Save
Completed
Flag
The value becomes 1 when
writing data to non-volatile
memory is completed after
setting "*_Ch#_SaveCmd"
(Save Settings Bit) of loop 1
and loop 2 from 0 to 1. The
Save Completed Flag initializes to 0 when
"*_Ch#_SaveCmd" (Save
Settings Bit) of loop 1 and
loop 2 is set from 1 to 0. (It is
0 immediately after the controller is reset.)
WORD
R
Loop 1, 2 Decimal Point and
Loop 1, 2 Setting Error Number
Specify the decimal point
position of the PV/SP for loop
1 and loop 2. The number of
loop 1 and loop 2 settings in
which a setting error exists is
stored in hexadecimal.
z Explanation of Decimal Point and Setting Error Numbers
Bit
15
14
13
*_DecPointSetErrSta
12
11
10
09
08
Decimal Point
Loop 1 (0/1)
Loop 2 (0/1)
07
06
05
04
03
02
01
00
Setting Error Numbers
Loop 1 (0 to F)
Loop 2 (0 to F)
z Setting Error Numbers
Setting error number
Setting name
Priority
1
Alarm Mode 1
2
Alarm Mode 2
2
3
Alarm 1 Hysteresis
3
4
Alarm 2 Hysteresis
4
5
Set Point
5
6
Alarm 1 SV
6
7
Alarm 2 SV
7
8
Input Compensation Value
8
9
Control Period
9
A
Control Sensitivity
10
B
Proportional Band
11
C
Integral Time
12
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
1
2-29
2
2-5-4 Operation Data
*_DecPointSetErrSta
R
Name
2-5 Data Exchange with the CPU Unit
Device variable for CJ-series Unit
2 Specifications and Functions
Setting error number
Setting name
Priority
D
Derivative Time
13
E
Heater Burnout Current
14
F
No allocation
15
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 Studio. 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 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
2-5 Data Exchange with the CPU Unit
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
type
R/W
Name
Function
Loop 1
Loop 2
*_Ch1_AL1HystrsC
fg
*_Ch2_AL1HystrsC
fg
UINT
RW
Loop 1 and Loop 2
Alarm 1 Hysteresis
Set the Alarm 1 hysteresis.
*_Ch1_AL2HystrsC
fg
*_Ch2_AL2HystrsC
fg
UINT
RW
Loop 1 and Loop 2
Alarm 1 Hysteresis
Set the Alarm 2 hysteresis.
WORD RW
Loop 1, 2 Alarm 1
Mode and Alarm 2
Mode
Alarm 1 Mode and
Alarm 2 Mode of Loop
1 and Loop 2
*_AlmMd
2
2-5-5 Initialization Data
16#0: No alarm
16#1: Upper and lowerlimit alarm
16#2: Upper-limit alarm
16#3: Lower-limit alarm
16#4: Upper and lowerlimit range alarm
16#5: Upper and lowerlimit 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.
z Explanation of Alarm Modes
Bits
15
14
13
12
*_AlmMd
11
10
09
08
07
06
05
04
Loop 1
Alarm 1 Mode
23
22
21
20
03
02
01
00
Loop 2
Alarm 2 Mode
23
22
21
20
Alarm 1 Mode
23
22
21
20
Alarm 2 Mode
23
22
21
20
Note Setting Alarm 1 or Alarm 2 Mode to "16#FF" will disable the corresponding loop. Control operations will stop
and ERC indicator will 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
2 Specifications and Functions
2-5-6
Operating Parameters
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
Loop 1
Loop 2
Data
type
R/W
Name
Function
*_Ch1_MV
*_Ch2_MV
INT
R
Loop 1 and
When ON/OFF control is
Loop 2 Manipu- used, this value will be 100%
for ON and 0% for OFF.
lated Variable
Monitor
*_Ch1_AL1LvlCfg
*_Ch2_AL1LvlCfg
INT
RW
Loop 1 and
Loop 2 Alarm 1
SV
Set the alarm 1 detection
level.
*_Ch1_AL1LvlSta
*_Ch2_AL1LvlSta
INT
R
Loop 1 and
Loop 2 Alarm 1
SV for Monitor
The Temperature Control
Unit returns the set values
that are actually used for
temperature control.
Use these values to monitor
operation.
*_Ch1_AL2LvlCfg
*_Ch2_AL2LvlCfg
INT
RW
Loop 1 and
Loop 2 Alarm 2
SV
Set the alarm 2 detection
level.
*_Ch1_AL2LvlSta
*_Ch2_AL2LvlSta
INT
R
Loop 1 and
Loop 2 Alarm 2
SV for Monitor
The Temperature Control
Unit returns the set values
that are actually used for
temperature control.
Use these values to monitor
operation.
*_Ch1_AIInOfsCfg
2-32
*_Ch2_AIInOfsCfg
INT
RW
Loop 1 and
Loop 2 Input
Compensation
Value
Set the input compensation
value.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
Loop 1
*_Ch1_AIInOfsSta
Loop 2
*_Ch2_AIInOfsSta
Data
type
INT
R/W
R
Name
Function
Loop 1 and
Loop 2 Input
Compensation
Value for Monitor
The Temperature Control
Unit returns the set values
that are actually used for
temperature control.
Use these values to monitor
operation.
*_Ch2_CtlPrdCfg
UINT
RW
Loop 1 and
Loop 2 Control
Period
Set the control period.
*_Ch1_CtlPrdSta
*_Ch2_CtlPrdSta
UINT
R
Loop 1 and
Loop 2 Control
Period for Monitor
The Temperature Control
Unit returns the set values
that are actually used for
temperature control.
Use these values to monitor
operation.
*_Ch1_CtlHystrsCfg
*_Ch2_CtlHystrsCfg UINT
RW
Loop 1 and
Loop 2 Control
Sensitivity
This setting is valid in
ON/OFF control only.
*_Ch1_CtlHystrsSta
*_Ch2_CtlHystrsSta
R
Loop 1 and
Loop 2 Control
Sensitivity for
Monitor
The Temperature Control
Unit returns the set values
that are actually used for
temperature control.
UINT
Use these values to monitor
operation.
*_Ch1_ProportionalBan *_Ch2_Proportional
dCfg
BandCfg
UINT
RW
Loop 1 and
Loop 2 Proportional Band
The values written here are
not written to RAM while
"*_Ch#_PIDCalcFlg" (PID
Constants Calculated Flag)
is set to 1.
These settings are valid in
PID control only.
*_Ch1_ProportionalBan *_Ch2_Proportional
dSta
BandSta
UINT
R
Loop 1 and
Loop 2 Proportional Band for
Monitor
The Temperature Control
Unit returns the set values
that are actually used for
temperature control.
Use these values to monitor
operation.
*_Ch1_IntgTmCfg
*_Ch2_IntgTmCfg
UINT
RW
Loop 1 and
Loop 2 Integral
Time
The values written here are
not written to RAM while
"*_Ch#_PIDCalcFlg" (PID
Constants Calculated Flag)
is set to 1.
These settings are valid in
PID control only.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2-33
2
2-5-6 Operating Parameters
*_Ch1_CtlPrdCfg
2-5 Data Exchange with the CPU Unit
Device variable for CJ-series Unit
2 Specifications and Functions
Device variable for CJ-series Unit
Loop 1
*_Ch1_IntgTmSta
Loop 2
*_Ch2_IntgTmSta
Data
type
UINT
R/W
R
Name
Loop 1 and
Loop 2 Integral
Time for Monitor
Function
The Temperature Control
Unit returns the set values
that are actually used for
temperature control.
Use these values to monitor
operation.
*_Ch1_DerivativeTmCf
g
*_Ch2_DerivativeT
mCfg
UINT
RW
Loop 1 and
Loop 2 Derivative Time
The values written here are
not written to RAM while
"*_Ch#_PIDCalcFlg" (PID
Constants Calculated Flag)
is set to 1.
These settings are valid in
PID control only.
*_Ch1_DerivativeTmSt
a
*_Ch2_DerivativeT
mSta
UINT
R
Loop 1 and
Loop 2 Derivative Time for
Monitor
The Temperature Control
Unit returns the set values
that are actually used for
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
2-6-1
Range of Set Values and Monitor
Values
Set Values
Device variable for
CJ-series Unit
*_Ch1_SetPointCfg
Setting
*_AlmMd
Default
value
Depends on the Input Type
setting.
°C
or
Refer to 2-1-3 Input Specifica- °F
tions for details.
0
or
0.0
Heater
Burnout
Current*1
0 to 500
(0.0 to 50.0)
A
0.0
Loop 1, 2
Alarm 1
Mode and
Alarm 2
Mode
0 to 9999
---
0
°C
or
°F
0.0
Non-volatile
memory save
2
N/A
2-6-1 Set Values
*_Ch2_HBLvlCfg
Unit
Set point
*_Ch2_SetPointCfg
*_Ch1_HBLvlCfg
Data range
N/A
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
*_Ch1_AL1HystrsCfg
*_Ch2_AL1HystrsCfg
*_Ch1_AL2HystrsCfg
*_Ch2_AL2HystrsCfg
Loop 1 and
Loop 2
Alarm 1 and
Alarm 2
Hysteresis
0 to 9999
(0.0 to 999.9)
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2-6 Range of Set Values and Monitor Values
2-6
2-35
2 Specifications and Functions
Device variable for
CJ-series Unit
*_Ch1_AL1LvlCfg
Setting
Data range
Default
value
Alarm 1 SV
-999 to 9999
(-999 to 9999)
°C
or
°F
0
or
0.0
Alarm 2 SV
-999 to 9999
(-999 to 9999)
°C
or
°F
0
or
0.0
Input Compensation
Value
-999 to 9999
(-999 to 9999)
°C
or
°F
0.0
Control
Period
1 to 99
(1 to 99)
s
20
Control
Sensitivity
0 to 9999
(0.0 to 999.9)
°C
or
°F
0.8
*_Ch2_CtlHystrsCfg
*_Ch1_
ProportionalBandCfg
Proportional Band
0 to 9999
(0.0 to 999.9)
°C
or
°F
8.0
Integral
Time
0 to 9999
(0 to 9999)
s
233
*_Ch2_IntgTmCfg
*_Ch1_DerivativeTmC
fg
Derivative
Time
0 to 9999
s
40
*_Ch2_AL1LvlCfg
*_Ch1_AL2LvlCfg
*_Ch2_AL2LvlCfg
*_Ch1_AIInOfsCfg
*_Ch2_AIInOfsCfg
*_Ch1_CtlPrdCfg
*_Ch2_CtlPrdCfg
*_Ch1_CtlHystrsCfg
*_Ch2_
ProportionalBandCfg
*_Ch1_IntgTmCfg
*_Ch2_DerivativeTmC
fg
2-36
Unit
(0 to 9999)
Non-volatile
memory save
• The Temperature Control
Unit's settings
are written to
RAM. When the
Save Settings Bit
of the device
variables for CJseries Unit (for
operation) is
turned to 1, the
set values are
written to nonvolatile memory.*2
• If DIP switch pin
8 is ON, the settings are automatically
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.
• The Temperature Control
Unit's settings
are written to
RAM. When the
Save Settings Bit
of the device
variables for CJseries Unit (for
operation) is
turned to 1, the
set values are
written to nonvolatile memory.
• If DIP switch pin
8 is ON, the settings are automatically
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.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
2 Specifications and Functions
*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 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.)
2-6-2
2-6 Range of Set Values and Monitor Values
*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
Monitor Values
2
*_Ch1_PV
Setting
Process Value
*_Ch2_PV
Data range
Depends on the Input Type setting.
Refer to 2-1-3 Input Specifications for details.
*_Ch1_HtrCurVal
*_Ch2_MV
°C
or
°F
---
Heater Current *1
0 to 550
(0.0 to 55.0)
A
---
Manipulated Variable
Monitor *2
0 to 1000
(0.0 to 100.0)
%
---
*_Ch2_HtrCurVal
*_Ch1_MV
Default
value
Unit
*1 If the 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
2-6-2 Monitor Values
Device variable for
CJ-series Unit
2 Specifications and Functions
2-38
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Settings Required for
Temperature Control
3
This section explains the various settings required for temperature control.
3-1 Setting the Input Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 Selecting the Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3 Setting the Pin 3 of the DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-4 Selecting the Control Operation (Forward/Reverse) . . . . . . . . . . . . . . . . . . 3-6
3-5 Selecting PID Control or ON/OFF Control . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-6 Setting the Control Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-7 Setting the Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-8 Using ON/OFF Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-9 Setting the PID Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-10 Using the Alarm Output Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-11 Using the Heater Burnout Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-12 Starting and Stopping Temperature Control . . . . . . . . . . . . . . . . . . . . . . . 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 thermometer 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.
Setting 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.
Input Type Settings
z Thermocouple Input Types
Sensor
Thermocouple
Type
Input type
setting
Temperature ranges
Centigrade
Fahrenheit
0
−200 to 1,300°C
−300 to 2,300°F
1
0.0 to 500.0°C
0.0 to 900.0°F
2
−100 to 850°C
−100 to 1,500°F
3
0.0 to 400.0°C
0.0 to 750.0°F
T
4
−200.0 to 400.0°C
−300.0 to 700.0°F
L
5
−100 to 850°C
−100 to 1,500°F
6
0.0 to 400.0 °C
0.0 to 750.0°F
7
0 to 1,700°C
0 to 3,000 °F
S
8
0 to 1,700°C
0 to 3,000 °F
B
9
100 to 1,800°C
300 to 3,200 °F
K
J
R
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
z Platinum Resistance Thermometer Input Types
Sensor
Input type
setting
Temperature ranges
Centigrade
Fahrenheit
0
−200.0 to 650.0°C
−300.0 to
1,200.0°F
JPt100 1
−200.0 to 650.0°C
−300.0 to
1,200.0°F
----
Do not set 2 through 9.
Pt100
2 to 9
3-1 Setting the Input Type
Platinum
resistance
thermometer
Type
The factory setting is 0.
3
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
3-3
3 Settings Required for Temperature 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
O
N
1 2 3 4 5 6 7 8
Temperature unit
Setting
°C
OFF
°F
ON
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 controller 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
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.)
O
N
1 2 3 4 5 6 7 8
Pin 3
Data storage/display
format
Do not set.
Setting
16-bit binary
ON
OFF
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.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
3-5
3
3 Settings Required for Temperature Control
3-4
Selecting the Control Operation
(Forward/Reverse)
Forward (Cooling)/Reverse (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
temperature
SV
High
temperature
SV
Low
temperature
High
temperature
Reverse operation
Forward 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 "forward 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)
z 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.
O
N
1 2 3 4 5 6 7 8
Pins 4 and 5
Control Operation Setting
Reverse
OFF
Forward
ON
The factory setting is OFF.
3-6
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
3 Settings Required for Temperature Control
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 control method settings for the different control loops.
If the control method setting is changed during operation, the new setting will not become effective until
the power is turned OFF and ON again.
3-5 Selecting PID Control or ON/OFF Control
3-5
O
N
1 2 3 4 5 6 7 8
3
Pin 6
Setting
Control method
PID control
OFF
ON/OFF control
ON
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 controller is reset, including when the power is turned ON.
Setting the Control Method (Pin 6)
z 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.
z 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 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.
• Each control loop has a separate control period setting.
• Setting the Loop 1 Control Period to 2 s
Set *_Ch1_CtlPrdCfg to 2.
Variable name
3-8
Type
Name
Function
*_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-series Unit Loop 1 and 2 Set point
(*_Ch1_SetPointCfg, *_Ch2_SetPointCfg). (See the following table.)
Type
Name
Function
*_Ch1_SetPointCfg
INT
Loop 1 Set point
Set the set point of loop 1.
*_Ch2_SetPointCfg
INT
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 *_Ch1_SetPointCfg to 200.
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
3-7 Setting the Set Points
Variable name
3
3 Settings Required for Temperature Control
3-8
Using ON/OFF Control
With ON/OFF control, you set a set point in advance. During reverse operation, the Temperature Controller 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 variable increases as the PV increases; with reverse operation, the manipulated variable decreases as the PV increases.
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.
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
PV
OFF
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.
• 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.)
• Set device variable for CJ-series Unit Loop 1 Set point (*_Ch1_SetPointCfg) to 200.
See 3-7 Setting the Set Points for details.
• Set device variable for CJ-series Unit Loop 1 Control Sensitivity (*_Ch1_CtlHystrsCfg) to 20.
Variable name
3-10
Type
Name
Function
*_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
control.
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
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 determines 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.
z Starting Autotuning
• 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.
• 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 Controller's PID constants to be refreshed with
the new Setting PID constants.
Read PID Constant
Variable name
*_Ch1_ProportionalBandSta
Type
Name
Function
UINT
Loop 1 Proportional Band for Monitor
---
*_Ch2_ProportionalBandSta
UINT
Loop 2 Proportional Band for Monitor
---
*_Ch1_IntgTmSta
UINT
Loop 1 Integral Time for Monitor
---
*_Ch2_IntgTmSta
UINT
Loop 2 Integral Time for Monitor
---
*_Ch1_DerivativeTmSta
UINT
Loop 1 Derivative Time for Monitor
---
*_Ch2_DerivativeTmSta
UINT
Loop 2 Derivative Time for Monitor
---
Setting PID Constant
Variable name
Type
Name
Function
*_Ch1_ProportionalBandCfg
UINT
Loop 1 Proportional Band
---
*_Ch2_ProportionalBandCfg
UINT
Loop 2 Proportional Band
---
*_Ch1_IntgTmCfg
UINT
Loop 1 Integral Time
---
*_Ch2_IntgTmCfg
UINT
Loop 2 Integral Time
---
*_Ch1_DerivativeTmCfg
UINT
Loop 1 Derivative Time
---
*_Ch2_DerivativeTmCfg
UINT
Loop 2 Derivative Time
---
z Stopping Autotuning
• 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.
• 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.
• If 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
3-9 Setting the PID Constants
Setting PID Constants with Autotuning
3
3 Settings Required for Temperature Control
Setting PID Constants Manually
Set "Proportional Band (P)", "Integral Time (I)" and "Derivative Time (D)" of the Setting PID Constants
for the use of manually set PID constants.
Additional Information
• 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), integral time (I), and derivative time (D).
• The Unit will operate with basic proportional operation if the integral time (I) and derivative
time (D) are set to 0. If the factory settings are used, the proportional band will produce a
manipulated variable of 0.0% at the set point.
Example PID Control Application
z 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_StartATCmd) from 0 to 1.
Next, perform PID constants calculation.
2
3
3-12
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_PIDCalcFlg) 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.
After the PID constants have been transferred to the output area by the user program, turn the
Loop 1 change PID Constants Bit (*_Ch1_ChgPIDCmd) from 0 to 1.
The Temperature Control Unit will read the Setting PID Constants.
The PID Constants Calculated Flag (*_Ch1_PIDCalcFlg) will be turned from 1 to 0 automatically
when you turn the Change PID Constants Bit (*_Ch1_ChgPIDCmd) from 0 to 1.
Refer to A-4 Sample Programming for an example user program that performs the steps outlined above.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
3 Settings Required for Temperature Control
z Timing Chart
Start AT Bit
1
0
Set to 1 by the system
after calculations are
completed.
1
PID Constants
Calculated Flag
(System-controlled.) 0
Change PID
Constants Bit
(User-controlled.)
Automatic
calculations
completed.
3-9 Setting the PID Constants
AT in progress
The PID constants haven't
been refreshed from the
CPU Unit if this bit is ON.
When this bit goes
ON, the PID Constants Calculated
Flag is unlatched
and goes OFF.
1
0
3
Reflects Setting PID Constant
Reflects Setting PID Constant Contains the PID
(transferred PID constants calcuconstants calculated by lated automatically by AT). (This
(this starts operation).
autotuning.
starts operation.)
Setting PID
Constant
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-
Setting PID
Constant
PID constants (user settings) PID constants automatically calculated by autotuning
Output area data read to the Nothing is read to the
CJ1W-TC@@@ Unit's RAM by Unit's RAM during this
I/O refreshing.
interval.
Output area data read to the
CJ1W-TC@@@ Unit's RAM by
I/O refreshing.
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.)
• Changing P (The Proportional Band)
Increasing P
Decreasing P
SP
SP
It takes 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.
• Changing I (The Integral Time)
Increasing I
SP
Decreasing I
SP
It takes longer to reach the SP,
but hunting, overshooting and
undershooting are reduced.
Overshooting and undershooting occur. Hunting occurs.
The PV rises quickly.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
3-13
3 Settings Required for Temperature Control
• Changing D (The Derivative Time)
Increasing D
Decreasing D
3-14
SP
SP
Overshooting, undershooting,
and the set time are reduced,
but hunting will occur from
small changes in the system
itself.
Overshooting and undershooting are increased. It takes time
to return to the SP.
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
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
(*_AlmMd) of the device variable for CJ-series Unit. Set the Alarm Mode for each loop.
If 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.
z 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
0
No alarm
1
Upper and lower-limit alarm
Output OFF
X X
ON
OFF
2
4
5
6
7
8
9
Lower-limit alarm
X
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
ON
OFF
SP
ON
OFF
ON
OFF
Always OFF
Always OFF
SP
X
X
SP
ON
OFF
X
ON
OFF
SP
X
SP
X
0
ON
OFF
0
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
SP
X
ON
OFF
X
ON
OFF
SP
SP
X X
ON
OFF
SP
X
SP
ON
OFF
ON
OFF
X
X
XX
ON
OFF
Always ON
SP
Upper-limit alarm
ON
OFF
3
Alarm SV (X) is negative
ON
OFF
0
X
0
3-15
3-10 Using the Alarm Output Function
This section explains the alarm modes, standby sequence, and alarm values.
3
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
alarm
Lower-limit
alarm
Alarm hysteresis
ON
ON
OFF
OFF
Alarm hysteresis
Alarm SV
Alarm SV
Set device variables for CJ-series Unit "Alarm 1 Hysteresis" (*_Ch1_AL1HystrsCfg,
*_Ch2_AL1HystrsCfg) and "Alarm 2 Hysteresis" (*_Ch1_AL2HystrsCfg, *_Ch2_AL2HystrsCfg) independently for each alarm. The standard setting is 0.2.
If the alarm hysteresis settings are 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 these
settings.
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_AL1LvlCfg, *_Ch2_AL1LvlCfg)
and "Alarm 2 SV" (*_Ch1_AL2LvlCfg, *_Ch2_AL2LvlCfg).
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 following situations:
• 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
• When the alarm SV, input calculated values, or set point is changed
• 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
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
3
Example Alarm Settings
z Alarm Mode and Alarm Hysteresis
The alarm mode and alarm hysteresis for loops 1 and 2 are set as shown in the following table.
Loop
Loop 1
Loop 2
1
2
3
Alarm
3-10 Using the Alarm Output Function
The following timing chart shows the operation of alarms with a standby sequence. In this example, the alarm mode is Upper and Lower-limit Alarm with Standby Sequence.
Alarm mode
Hysteresis
Alarm 1
3: Lower-limit alarm
2.0°C
Alarm 2
2: Upper-limit alarm
0.5°C
Alarm 1
1: Upper and lower-limit alarm
1.0°C
Alarm 2
8: Absolute-value lower-limit alarm
2.0°C
Set "Loop 1, 2 Alarm 1 Mode and Alarm 2 Mode" (*_AlmMd) to "16#3218".
Set hysteresis values in "Alarm Hysteresis" (*_Ch1_AL1HystrsCfg, *_Ch2_AL1HystrsCfg,
*_Ch1_AL2HystrsCfg and *_Ch2_AL2HystrsCfg).
To enable the new settings, reset the controller or restart the Unit.
z Setting Alarm 1 SV of Loop 2 to 20 °C
Set "Loop 2 Alarm 1 SV" (*_Ch2_AL1LvlCfg) to 20.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
3-17
3 Settings Required for Temperature Control
Summary of Alarm Output Function Settings
Variable name
*_AlmMd
Type
WORD
Name
Function
Loop 1, 2 Alarm 1 Mode and Alarm 2
Mode
Set the Alarm 1 Mode and
Alarm 2 Mode of loop 1
and loop 2.
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 upperlimit alarm
9: Absolute-value lowerlimit alarm
3-18
*_Ch1_AL1HystrsCfg
UINT
Loop 1 Alarm 1 Hysteresis
*_Ch1_AL2HystrsCfg
UINT
Loop 1 Alarm 2 Hysteresis
*_Ch2_AL1HystrsCfg
UINT
Loop 2 Alarm 1 Hysteresis
*_Ch2_AL2HystrsCfg
UINT
Loop 2 Alarm 2 Hysteresis
*_Ch1_AL1LvlCfg
INT
Loop 1 Alarm 1 SV
*_Ch1_AL2LvlCfg
INT
Loop 1 Alarm 2 SV
*_Ch2_AL1LvlCfg
INT
Loop 2 Alarm 1 SV
*_Ch2_AL2LvlCfg
INT
Loop 2 Alarm 2 SV
Set the loop 1 alarm hysteresis.
Set the loop 2 alarm hysteresis.
Set the loop 1 detection
level.
Set the loop 2 detection
level.
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
3-11 Using the Heater Burnout Alarm
Heater Burnout Detection
• Follow this procedure to detect heater burnout (an open heating wire).
To the CT terminals
CT
Heater wire
1
2
3
4
3
Pass the heater wire through the hole in the Current Transformer (CT). Refer to Current Transformer (CT) Ratings in 2-1 Specifications and A-1 Dimensions for details on the specifications,
model numbers, and dimensions.
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.
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.
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.
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 Temperature Control 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 current 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
3 Settings Required for Temperature Control
• The heater burnout detection function cannot be used if the heater is being controlled with the position 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 K2CU-F@@A-@GS (with gate input terminals). Refer to the catalog for more details.
Determining the Heater Burnout Current
• Use the following equation to calculate the average of the normal current and the current with a
heater burnout:
SV =
Current in normal operation + current after heater burnout
2
• If 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 consume the same current, set the heater burnout current to the current induced when one of the heaters is burned out.
• 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.)
• 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.
• The total heater current during normal operation must not exceed 50.0 A.
Example Applications
Control output
Heater
Example 1:
A single 1-kW 200-VAC heater is
controlled through OUT1.
1 kW
200 VAC
CT
Normal current =
1,000
200
= 5 A (< 10 A)
Current when control output is OFF = 0 A
SV =
5+0
= 2.5 A
2
Normal current - control-OFF current = 5 - 0 = 5 A
(Operation will be stable with difference ≥ 1.0 A.)
Control output
Heaters
1 kW × 3
CT
200 VAC
Example 2:
Three 1-kW 200-VAC heaters are
controlled through OUT2.
1,000 × 3
= 15 A (≥ 10 A)
200
1,000 × 2
= 10 A
Current with 1 burnout =
200
15 + 10
SV =
= 12.5 A
2
Normal current =
Normal current - control-OFF current = 15 - 10 = 5 A
(Operation will be stable with difference ≥ 2.5 A.)
3-20
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
3 Settings Required for Temperature Control
To start temperature control for a loop that has been stopped, turn device variables for CJ-series Unit
"Stop Bit" (*_Ch1_StopCtlCmd and *_Ch2_StopCtlCmd) to OFF.
To stop temperature control for the loop, turn ON the Stop Bit.
• The factory setting of the bits is OFF (running).
z Starting Loop 1 and Stopping Loop 2
• To start control in loop 1 and stop control in loop 2, turn OFF "Loop 1 Stop Bit"
(*_Ch1_StopCtlCmd) and turn ON "Loop 2 Stop Bit" (*_Ch2_StopCtlCmd).
3-12 Starting and Stopping Temperature Control
3-12 Starting and Stopping Temperature
Control
3
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
This section explains how to use the input compensation value.
4
4-1 Shifting the Input Value (Input Compensation) . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 Recovering from Sensor Not Connected Errors . . . . . . . . . . . . . . . . . . . . . 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)
• 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
Upper
limit
After
compensation
Before
compensation
Input
compensation
value
Input
0
100% FS
• The factory setting of the input compensation value is 0.0 for all loops.
z Example Application
1
2
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 workpiece (C).)
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)
with the temperature indicated by thermometer (B). The input compensation value is correct if
the two readings are approximately equal.
(D) Temperature sensor
Furnace
100
(C) Workpiece temp.
(B)
Thermometer
Figure 1. Input Compensation
Configuration
(A) Temperature
Control Unit
Unit's temperature
reading (A)
Temperature after
compensation (e.g., 120°C)
Temperature before
compensation (e.g., 110°C)
After compensation
Input compensation value (e.g., 10°C)
Before compensation
Lower limit input
compensation value
(e.g., 10°C)
SP region
(e.g., 120°C)
Thermometer reading (B)
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
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 disabled. The status will be as follows.
• The ERC indicator will not light to indicate sensor errors for the loop. (Refer to 5-1 Error and Alarm
Processing.)
• Control will not be performed for the loop.
• Alarms will not be given for the loop.
• 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 Unit "Loop 1, 2 Alarm 1 Mode and Alarm 2 Mode"
(*_AlmMd) to 16#F (i.e.,16#FF).
DM Area address
*_AlmMd
4
Bits
15
14
13
12
11
10
09
Loop 1
Alarm mode 1
08
07
06
05
04
03
02
01
00
Loop 2
Alarm mode 2
4-2 Recovering from Sensor Not Connected Errors
Recovering from Sensor Not
Connected Errors
Alarm mode 1
Alarm mode 2
Example) To disable loop 2, set "Loop 1, 2 Alarm 1 Mode and Alarm 2 Mode" (*_AlmMd) to 16#FF. (In
this case, Alarm Mode 1 and Alarm Mode 2 of loop 1 are set to 0.)
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
This section provides information on troubleshooting and error processing.
5-1 Error and Alarm Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-3 Event Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-3-1
5-3-2
5-3-3
Overview of the Event Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Error Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Error Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5-1
5
5 Error and Alarm Processing
5-1
Error and Alarm Processing
Identifying Errors with the Indicators
The ERC Indicator or ERH Indicator will light if an alarm or error occurs in the Temperature Control
Unit.
(Front of Temperature Control Unit)
RUN
ERC
ERH
Indicator
Name
Color
Status
Meaning
RUN
RUN Indicator
Green
Lit
The Temperature Control Unit is operating normally.
Not lit
The Temperature Control Unit is stopped.
ERC
Temperature Control
Unit Error
Red
Lit
An error occurred in the Temperature Control Unit itself.
Not lit
There is no error in the Temperature Control Unit.
ERH
CPU Unit Error
Red
Lit
An error occurred in the CPU Unit.
Not lit
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
Error Processing Flowchart
Use the following flowchart to identify the error when an error has occurred in the Temperature Control
Unit.
Error occurred.
Yes
Is the ERC Indicator lit?
Yes
An alarm occurred while the Unit
was operating.
Is the RUN Indicator lit?
5-1 Error and Alarm Processing
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
Yes
Is the ERH Indicator lit?
Is the RUN Indicator lit?
Refer to Errors Originating in the
CPU Unit.
No
5
No
Confirm that the Unit's unit number
setting is correct.
Refer to Errors Originating in the
CPU Unit.
Refer to 5-2 Troubleshooting.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5-3
5 Error and Alarm Processing
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.
Bits
Name of device variable for
CJ-series Unit
*_Ch1_StaWd
Type
WORD
R/W
R
Name
Loop 1 Status
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: Loop 1 Stop Flag
Bit 09: Loop 1 Setting Error Flag
Bit 10: Loop 1 PID Constants Calculated
Flag
Bit 11: Loop 1 Standby Flag
Bit 12: Loop 1 Cold Junction Sensor Error
Bit 13: Loop 1 CT Overflow Flag
Bit 14: Loop 1 Sensor Error Flag
Bit 15: Loop 1 Save Completed Flag
00
*_Ch1_AL2Flg
BOOL
R
Loop 1 AL2
Flag
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.
01
*_Ch1_AL1Flg
BOOL
R
Loop 1 AL1
Flag
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.
02
*_Ch1_HBFlg
BOOL
R
Loop 1 HB Flag The value becomes 1 when the heater current detection value falls below the Heater
Burnout Current.
03
*_Ch1_ATFlg
BOOL
R
Loop 1 AT Flag
The value becomes 1 during Autotuning
(AT) of loop 1.
The value becomes 0 when Autotuning (AT)
stops or finishes.
04
*_Ch1_CtlOutFlg
BOOL
R
Loop 1 Control
Output Flag
The value becomes 1 during output of loop 1
Control Output.
08
*_Ch1_StopFlg
BOOL
R
Loop 1 Stop
Flag
The value becomes 0 when temperature
control of loop 1 executes and 1 when control stops.
09
*_Ch1_SetErr
BOOL
R
Loop 1 Setting
Error Flag
The value becomes 1 when there is an error
in the set value set as a device variable for
CJ-series Unit.
5-4
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5 Error and Alarm Processing
Bits
Name of device variable for
CJ-series Unit
10
*_Ch1_PIDCalcFlg
Type
BOOL
R/W
R
Name
Loop 1 PID
Constants Calculated Flag
Function
The value becomes 1 when PID constants
calculated by the Temperature Control Unit
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.
*_Ch1_StbyFlg
BOOL
R
Loop 1 Standby
Flag
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.
12
*_Ch1_CJErr
BOOL
R
Loop 1 Cold
Junction Sensor Error
The value becomes 1 when:
• Cold junction sensor error occurs.
13
*_Ch1_CTOvfFlg
BOOL
R
Loop 1 CT
Overflow Flag
The value becomes 1 when the heater current of the CT (current detector) exceeds
55.0 A.
14
*_Ch1_SensErr
BOOL
R
Loop 1 Sensor
Error Flag
The value becomes 1 when:
15
*_Ch1_SaveFlg
BOOL
R
Loop 1 Save
Completed
Flag
• Sensor is not connected to loop 1.
• Sensor of loop 1 disconnects.
• Input temperature exceeds the measurement temperature range.
The value becomes 1 when you select save
loop 1 (change from 0 to 1) and data is written to the non-volatile memory.
This flag initializes to 0 when Loop 1 Save
changes from 1 to 0 (however, the value is 0
immediately after a controller reset).
*_Ch2_StaWd
WORD
R
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
5-1 Error and Alarm Processing
11
5
5 Error and Alarm Processing
Bits
Name of device variable for
CJ-series Unit
00
*_Ch2_AL2Flg
Type
BOOL
R/W
R
Name
Loop 2 AL2
Flag
Function
The value becomes 1 when the temperature
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
R
Loop 2 AL1
Flag
The value becomes 1 when the temperature
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
R
Loop 2 HB Flag The value becomes 1 when the heater current detection value falls below the Heater
Burnout Current.
03
*_Ch2_ATFlg
BOOL
R
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
R
Loop 2 Control
Output Flag
The value becomes 1 during output of loop 2
Control Output.
08
*_Ch2_StopFlg
BOOL
R
Loop 2 Stop
Flag
The value becomes 0 when temperature
control of loop 2 executes and 1 when control stops.
09
*_Ch2_SetErr
BOOL
R
Loop 2 Setting
Error Flag
The value becomes 1 when there is an error
in the setting value set as a device variable
for CJ-series Unit
10
*_Ch2_PIDCalcFlg
BOOL
R
Loop 2 PID
Constants Calculated Flag
The value becomes 1 when PID constants
calculated by the Temperature Control Unit
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
*_Ch2_StbyFlg
BOOL
R
Loop 2 Standby
Flag
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.
12
*_Ch2_CJErr
BOOL
R
Loop 2 Cold
Junction
Sensor Error
The value becomes 1 when:
• Cold junction sensor error occurs.
13
*_Ch2_CTOvfFlg
BOOL
R
Loop 2 CT
Overflow Flag
The value becomes 1 when the heater current of the CT (current detector) exceeds
55.0 A.
14
*_Ch2_SensErr
BOOL
R
Loop 2 Sensor
Error Flag
The value becomes 1 when:
Loop 2 Save
Completed
Flag
The value becomes 1 when you select save
loop2 (change from 0 to 1) and data is written to the non-volatile memory.
15
*_Ch2_SaveFlg
BOOL
R
• Sensor is not connected to loop 2.
• Sensor of loop 2 disconnects.
• Input temperature exceeds the measurement temperature range.
This flag initializes to 0 when Loop 2 Save
changes from 1 to 0 (however, the value is 0
immediately after a controller reset).
5-6
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5 Error and Alarm Processing
ERC Indicator Lit and RUN Indicator Lit
RUN
ERC
Lit
ERH
Not lit
These alarms indicate that an incorrect operation was performed while the Unit was operating normally.
These alarms are cleared automatically when the cause of the alarm is corrected.
*_Ch1_SensErr
*_Ch2_SensErr
*_Ch1_CTOvfFlg
*_Ch2_CTOvfFlg
*_Ch1_SetErr
*_Ch2_SetErr
*_Ch1_HBFlg
*_Ch2_HBFlg
Error
Sensor Error
CT Overflow
Setting Error
Heater Burnout Alarm
Cause
An input error has occurred.
The heater current is above
55.0 A.
There is an error in a setting.
A heater circuit has burned
out.
Control
status
• Control operation continues (Output OFF).
Control operation continues.
The incorrect set value will
be ignored and operation will
continue with the set values
retained in the Temperature
Control Unit.
Control operation continues.
The heater current value will
be correct when the current
is within range.
Check the "Setting Error
Number" in
*_DecPointSetErrSta. Correct the indicated setting.
Check the heater and repair
the heater where the burnout
occurred.
• Alarm operates as if the
temperature is out of
range.
Processing
Check for incorrect input wiring, disconnection, short-circuit, and incorrect input type
setting.
5
Setting Error Numbers
Setting error
number
Setting name
Priority
0
No incorrect settings
-
1
Alarm mode 1
1
2
Alarm mode 2
2
3
Alarm 1 hysteresis
3
4
Alarm 2 hysteresis
4
5
Set point
5
6
Alarm 1 SV
6
7
Alarm 2 SV
7
8
Input compensation value
8
9
Control period
9
A
Control sensitivity
10
B
Proportional band
11
C
Integral time
12
D
Derivative time
13
E
Heater burnout current
14
F
Not allocated
15
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)
5-1 Error and Alarm Processing
If pin 1 of the Temperature Control Unit's DIP Switch is OFF (stop operation when CPU Unit is in PROGRAM mode), the RUN Indicator will be OFF when the CPU Unit is in PROGRAM mode.
5-7
5 Error and Alarm Processing
ERC Indicator Lit and RUN Indicator Not Lit
RUN
ERC
Lit
ERH
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
Hardware Check
Error
Cause
Control status
An error occurred in the
Control operation
Unit's peripheral hardware. will stop.
Processing
• Restart the Unit or reset the controller (including by turning ON the power).
• If 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
Sensor Error
An error occurred in the
cold junction sensor.
Control operation
will stop.
Check the connections at the cold junction sensor on the terminal block and restart the Unit or
reset the controller, including by turning ON the
power.
DM Setting Error
(Initialization Data)
There is an error in the Initialization Data settings.
Control operation
will stop.
Check the location of the error, correct the initialization data (alarm mode or alarm hysteresis),
and then restart the Unit, or reset the controller
including by turning ON the power.
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.
z ERH Indicator Lit and RUN Indicator Lit
RUN
ERC
Lit
ERH
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 NJ-series CPU Unit Hardware User's Manual (Cat. No. W500).
Error
CPU Unit Monitor
Error
5-8
Cause
Control status
A response was not
returned from the CPU
Unit within the fixed interval.
Control operation
will continue.
Processing
Check the I/O refreshing interval.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5 Error and Alarm Processing
ERH Indicator Lit and RUN Indicator Not Lit
RUN
ERC
Lit
ERH
Not lit
Error
Cause
Control status
Duplicate Unit Number
The Temperature Control Unit's unit number
is duplicated on another Special I/O Unit or is
not within the allowed range (00 to 94).
Control operation
will stop.
Processing
Correct the unit number settings. Turn the Controller
power supply OFF and ON.
(The Temperature Control Unit occupies two
unit numbers for one unit.)
I/O Setting Check
Error
The Special I/O Units registered in the Unit
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
Check that the sliders connect all of the Units securely
and the End Cover is locked.
Turn the Controller power
supply OFF and ON.
5
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.
Initialization Data will be updated after restart.
• Reset the Controller from Sysmac Studio.
• Reset the Controller by turning the Controller power supply OFF and ON.
• Restart using the ResetUnit instruction of the program.
• Restart using a system-defined variable.
Variable name
Type
_CJB_SIO**Restart
BOOL
Unit number 00 to 94 in **
Precautions for Correct Use
• If the error persists after the restart, replace this Unit.
• During restart, output is 0 V as the data immediately before restart is maintained for input.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5-1 Error and Alarm Processing
If there is an error in the 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.
5-9
5 Error and Alarm Processing
5-2
Troubleshooting
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.
5-10
Check the Temperature Controller Unit's operating status with the
Indicators.
Follow the procedures described in 5-1 Error and Alarm Processing
to isolate and correct any problems indicated by the LED Indicators.
Check the switch settings and wiring.
• Power Supply
1. Is the power supply ON?
2. Is the voltage at the terminals within the allowed range?
• Switches
Are the switch settings correct for the system you are using?
• 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 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
Troubleshooting from Symptoms: Measurement Errors
z Incorrect Measurement or No Measurement
Step
Possible Cause
Connection The temperature sensor is connected to the
wrong terminals or polarity is reversed.
Remedy
Wire temperature sensor correctly.
Replace the temperature sensor with one that is compatible with the Temperature Control Unit.
The temperature sensor wires are broken, shortcircuited, or damaged.
Replace the temperature sensor with a good one.
No temperature sensor is connected.
Connect a temperature sensor.
The compensating conductor being used is not
compatible with the thermocouple.
• Directly connect a thermocouple with long lead wires.
• Use a compensating conductor that is compatible
with the thermocouple.
Some equipment is connected between the thermocouple and Temperature Control Unit that
uses metal different than the metal in the compensating conductor or thermocouple.
The equipment used for connections must be made
specifically for use with thermocouples.
The terminal screws are loose so there is poor
contact between the wires and terminals.
Tighten the terminal screws.
5
The thermocouple's lead wires or the compensat- • Use thicker compensating conductors.
ing conductors are too long, so the resistance in
• Change the wiring location to reduce the length of
the wires is affecting operation.
the wiring.
Installation
The conductors between the temperature sensor
and the Temperature Control Unit's terminals
have three different conductive resistances.
Use conductors with the same resistance for the A, B,
and B' terminals.
Noise from electric equipment around the Temperature Control Unit is affecting operation.
• Move the Temperature Control Unit away from the
equipment that is generating the noise.
• Install surge protectors or noise filters on the equipment that is generating the noise.
The temperature sensor's leads run close to
power lines, so noise is being induced from the
power lines.
• Separate the temperature sensor's leads from the
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
the point being controlled, so the response to
temperature changes is delayed.
Install the temperature sensor in a protective tube
closer to the point being controlled.
The ambient temperature where the Temperature
Control Unit is installed exceeds the Unit's ratings.
Install the Temperature Control Unit in a location with
an ambient temperature between 0 and 55°C.
Wireless equipment is being used near the Temperature Control Unit.
Shield the Temperature Control Unit.
The temperature around the Temperature Control
Unit is not uniform because of heat-generating
equipment near the Unit.
Move the Temperature Control Unit to a location where
it won't be affected by heat-generating equipment.
There is a draft (breeze) on the Temperature
Control Unit's terminal block.
Eliminate or block the draft.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5-2 Troubleshooting
The temperature sensor connected to the Temperature Control Unit is not compatible with the
Unit.
5-11
5 Error and Alarm Processing
Step
Possible Cause
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
because of the Input Compensation Value setting.
Set the Input Compensation Value to 0.0.
The data storage/display format setting is incorrect.
• Check the "data storage/display format" of pin 3 of
the DIP switch and correct the user program.
• Always set pin 3 of the DIP switch to ON when connected with the NJ series.
The user program of the Host System is not correct.
Usage
Remedy
There is a thermocouple input and the input termi- Connect a thermocouple.
nals are shorted.
The temperature sensor was replaced or switch
settings were changed while the power was ON.
Turn the power OFF and then ON again.
Additional Information
Here is a simple method to check the temperature sensor inputs:
With a resistance-thermometer Unit, connect a 100-Ω 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 Control Unit is operating normally if the measured temperature is the temperature in the vicinity of
the terminal block.
Troubleshooting from Symptoms: Temperature Control Errors
z Temperature Does Not Rise
Step
Connection
Possible Cause
Remedy
The measured temperature is incorrect.
Refer to Troubleshooting from Symptoms: Measurement
Errors for troubleshooting directions.
There is no load connected to the control output terminals.
Connect a load.
The load's polarity is reversed or the load is wired to the
wrong terminals.
Wire the load correctly.
The terminal screws are loose so there is poor contact
between the wires and terminals.
Tighten the terminal screws.
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 heater's heat output is insufficient.
• Replace the heater with one that has a higher output.
• When using two or more heaters, check whether one is
burned out. Replace if necessary.
Settings
An overheating protection device is operating.
Increase the overheating protection device's temperature setting so it is higher than the Temperature Controller Unit's set
point.
The forward operation/reverse operation setting is
incorrect
Correct the setting.
The PID constant settings are not correct.
• Perform autotuning.
• Make the correct PID constant settings manually.
5-12
Temperature control has not been started.
Start temperature control.
A cooling fan is operating.
Turn OFF the cooling fan.
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
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
heater is being controlled by another loop's control output.
Wire the load correctly.
The contacts are fused in the relay operated by the control output.
Replace the relay with a good one.
There is a short circuit in the relay operated by the control output.
Replace the relay with a good one.
Current is flowing to the heater because of leakage current through the relay operated by the control output.
Connect a bleeder resistor to prevent operation due to the
leakage current.
The forward operation/reverse operation setting is
incorrect.
Correct the setting.
The PID constant settings are not correct.
• Perform autotuning.
5-2 Troubleshooting
Settings
Remedy
• When autotuning is completed, refresh the PID constants
properly so that the Unit operates with the calculated PID
constants.
• Make the correct PID constant settings manually.
Usage
There is excessive overshooting.
Refer to Excessive Overshooting or Undershooting for troubleshooting directions.
5
Excessive Overshooting or Undershooting
Step
Possible Cause
Connection The measured temperature is incorrect.
Settings
Remedy
Refer to Troubleshooting from Symptoms: Measurement Errors for troubleshooting directions.
A general-purpose temperature sensor is being
used in a system with a very fast heating
response.
Change to a sheathed sensor.
The proportional band is narrow because PID
constant P is too small.
• Increase the P constant to a level that produces an
acceptable response delay.
• Perform autotuning.
The integral time is short because PID constant I
is too small.
• Increase the I constant to a level that produces an
acceptable response delay.
• Perform autotuning.
The derivative time is short because PID constant
D is too small.
• Increase the D constant to a level that produces
acceptable stability.
• Perform autotuning.
ON/OFF control is being used.
Use P (proportional) control or PID control.
A long control period has been set in a system
with a very fast heating response.
Reduce the control period.
Autotuning was performed, but the Temperature
Control Unit's PID constants were not refreshed
with the calculated PID constants.
Refresh the Temperature Control Unit's PID constants
with the calculated PID constants. Refer to 3-9 Setting
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
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 problems.
Step
Usage
Possible Cause
Remedy
The heater's output is too large for the controlled
system.
Use a heater that is suitable for the controlled system.
Something disturbs the system periodically and
changes it's heating requirement.
Arrange the controlled system to minimize external disturbances.
Autotuning is in progress.
The hunting will stop when autotuning is completed.
Troubleshooting from Symptoms: Output Errors
z No Control Output or No Alarm Output
Step
Possible Cause
Connection The measured temperature is incorrect.
Settings
5-14
Remedy
Refer to Troubleshooting from Symptoms: Measurement Errors for troubleshooting directions.
The load's polarity is reversed or the load is wired
to the wrong terminals.
Wire the load correctly.
The connected load exceeds the output ratings.
• Use a load within the output's ratings.
• Repair the load if it is malfunctioning.
A load power supply is not connected to the transistor output.
Provide a power supply that is suitable for the output
ratings and load.
The polarity is reversed to the transistor output's
load power supply.
Wire the power supply correctly.
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
mode 2 are set to FF.)
Set an alarm mode. Refer to 3-10 Using the Alarm Output 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
been set incorrectly.
Set the correct alarm mode.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5 Error and Alarm Processing
Troubleshooting from Symptoms: HB Alarm Errors
z Heater Burnout Not Detected
Step
Possible Cause
Connection A Current Transformer (CT) is not connected.
Settings
Remedy
Connect a CT.
The CT is connected to the wrong channel.
Input the CT correctly.
The heater is being operating with another output,
i.e., one from an Output Unit.
Change the wiring to control output that corresponds to
the CT input.
The connected CT is not an OMRON E54-CT1 or
E54-CT3.
CTs other than the OMRON E54-CT1 and E54-CT3
cannot be used. Connect an E54-CT1 or E54-CT3.
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.
The heater's power supply was turned ON after
temperature control was started.
Start temperature control after the heater's power supply has been turned ON.
The heater burnout current is set to 0.0 or 50.0 A. Set the appropriate heater burnout current between 0.1
and 49.9 A
Usage
The heater burnout current is based on the
heater's rated current.
Take an actual measurement of the heater's current to
determine the appropriate heater burnout current.
The heater burnout current from the actual measurement is not appropriate.
Consider the voltage range of the heater's power supply and current measurement error. Set the heater
burnout current again.
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 actual 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
5-2 Troubleshooting
Temperature control has not been started.
5
5 Error and Alarm Processing
5-3
5-3-1
Event Logs
Overview of the Event Logs
You use the same methods to manage all of the events that occur on the NJ-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.
Sysmac Studio
CJ-series
Units
NJ-series CPU Unit
Event source
PLC Function
Module
Motion Control EtherCAT Master
Function Module Function Module
EtherNet/IP
Function Module
Errors in
Special Units
User program
Or
Create User-defined
Error instruction:
SetAlarm
Event logs
Create User-defined
Information
instruction: SetInfo
NS-series PT
Backup battery
Check current Controller
events and the event log
EtherCAT
slave
of past events.
To use an NS-series PT to check events, connect the PT to the built-in EtherNet/IP port on the CPU
Unit.
5-16
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
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
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.
Event name
Meaning
Assumed cause
0468 0000 hex
Cold Junction
Sensor Error
An error occurred in
the cold junction
sensor.
• Faulty connection to the cold
junction sensor.
Level
Maj
Prt
Info
Reference
Min
Obs
U
S
page 19
• The cold junction sensor failed.
3494 0000 hex
Setting Error
There is an illegal
setting.
• The set value is incorrect.
U
S
page 19
6484 0000 hex
Sensor Error
An error occurred in
the sensor input.
• Error in input from the Sensor.
U
S
page 20
6485 0000 hex
CT Overflow
An overflow
occurred in the CT
input.
• The heater current exceeded
55.0 A.
U
S
page 20
6486 0000 hex
Heater Burnout Alarm
A heater burnout
occurred.
• The power supply to the heater
is not ON.
U
S
page 21
• The heater is burned out or
deteriorated.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5-17
5
5-3-2 Error Table
Event code
5-3 Event Logs
S
5 Error and Alarm Processing
5-3-3
Error Descriptions
This section describes the information that is given for individual errors.
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.
Meaning
Gives a short description of the error.
Event code
Gives the code of the error.
Source
Gives the source of the error.
Source details
Gives details on
the source of the
error.
Detection
timing
Tells when the
error is detected.
Error attributes
Level
Tells the level of
influence on control.*1
Recovery
Gives the recovery method.*2
Log category
Tells which log
the error is saved
in.*3
Effects
User program
Tells what will happen to execution of
the user program.*4
Operation
Provides special information on the operation that results
from the error (event).
System-defined
variables
Variable
Cause and correction
Assumed cause
Attached
information
This is the attached information that is displayed by the Sysmac Studio or an NS-series PT.
Precautions/
Remarks
Provides precautions, restrictions, and supplemental information. If the user can set the event level, the event levels
that can be set, the recovery method, operational information, and other information are also provided.
Data type
Name
Lists the variable names, data types, and meanings for system-defined variables that provide direct error notification,
that are directly affected by the error, or that contain settings that cause the error.
Correction
Prevention
Lists the possible causes, corrections, and preventive measures for the error.
*1 One of the following:
Major fault: Major fault level
Partial fault: Partial fault level
Minor fault: Minor fault level
Observation
Information
*2 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.
*3 One of the following:
System: System event log
Access: Access event log
*4 One of the following:
Continues: Execution of the user program 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
Error Descriptions
Event name
Cold Junction Sensor Error
Event code
04680000 hex
An error occurred in the cold junction sensor.
Source
PLC Function Module
Source details
CJ-series Unit
Detection
timing
Continuously
Error attributes
Level
Observation
Recovery
---
Log category
System
Effects
User program
Continues.
Operation
Control operations of the Unit will stop.
System-defined
variables
Variable
Data type
Name
None
---
---
Cause and
correction
Assumed cause
Correction
Prevention
Faulty connection to the cold junction
sensor.
Check the connections to the cold
junction sensor (i.e., terminal block),
reconnect it if the connection is faulty,
and then cycle the power supply or
restart the Unit.
Securely connect the cold junction
sensor (i.e., terminal block).
The cold junction sensor failed.
If the cause is not a faulty connection,
replace the Temperature Control Unit.
None
5-3 Event Logs
Meaning
Attached
information
Attached information 1: Loop number where error was detected
Precautions/
Remarks
You can change the event level to the minor fault level. If you change the level to the minor fault level, the Recovery column above will be changed to “Error reset.”
Setting Error
Meaning
There is an illegal setting.
Event code
34940000 hex
Source
PLC Function Module
Source details
CJ-series Unit
Detection
timing
Continuously for
operating data
and operation
adjustment data,
or at power ON or
Controller reset
for initial setting
data
Error attributes
Level
Effects
User program
Observation
Recovery
---
Log category
System
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.
System-defined
variables
Variable
Data type
Name
None
---
---
Cause and
correction
Assumed cause
Correction
Prevention
The set value is incorrect.
Check the content of the setting error
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.
Check and correct the settings.
Attached
information
Attached information 1: Loop number where error was detected
Precautions/
Remarks
You can change the event level to the minor fault level. If you change the level to the minor fault level, the Recovery column above will be changed to “Error reset.”
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5-19
5-3-3 Error Descriptions
Event name
5
5 Error and Alarm Processing
Event name
Sensor Error
Event code
6484 0000 hex
Meaning
An error occurred in the sensor input.
Source
PLC Function Module
Source details
CJ-series Unit
Detection
timing
Continuously
Error attributes
Level
Observation
Recovery
---
Log category
System
Effects
User program
Continues.
Operation
Control operations will continue. Control outputs for the
loop of the Unit will stop. The present temperature
reaches the measurement upper limit, and so the alarm
operation will be performed due to the high temperature.
System-defined
variables
Variable
Data type
Name
None
---
---
Cause and
correction
Assumed cause
Correction
Prevention
Error in input from the Sensor.
Check the input for incorrect wiring,
disconnection, or short circuits, and
correct any problems. Or, correct the
input type setting if the input type setting is incorrect.
Check for incorrect wiring, broken
wires, and short circuits.
Attached
information
Attached information 1: Loop number where error was detected
Precautions/
Remarks
You can change the event level to the minor fault level. If you change the level to the minor fault level, the Recovery column above will be changed to “Error reset.”
Event name
CT Overflow
Meaning
An overflow occurred in the CT input.
Source
PLC Function Module
Error attributes
Level
Effects
User program
System-defined
variables
Variable
Data type
Name
None
---
---
Cause and
correction
Assumed cause
Correction
Prevention
The heater current exceeded 55.0 A.
Set the CT input so that it does not
exceed 55.0 A.
Set the CT input so that it does not
exceed 55.0 A.
Attached
information
Attached information 1: Loop number where error was detected
Precautions/
Remarks
You can change the event level to the minor fault level. If you change the level to the minor fault level, the Recovery column above will be changed to “Error reset.”
5-20
Event code
6485 0000 hex
Source details
CJ-series Unit
Detection
timing
Continuously
Observation
Recovery
---
Log category
System
Continues.
Operation
Not affected.
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5 Error and Alarm Processing
Event name
Heater Burnout Alarm
Event code
64860000 hex
Meaning
A heater burnout occurred.
Source
PLC Function Module
Source details
CJ-series Unit
Detection
timing
Continuously
Error attributes
Level
Observation
Recovery
---
Log category
System
Effects
User program
Continues.
Operation
Not affected.
System-defined
variables
Variable
Data type
Name
None
---
---
Cause and
correction
Assumed cause
Correction
Prevention
The power supply to the heater is not
ON.
Turn ON the power supply to the
heater.
When you use the Temperature Controller Unit, turn ON the power supply
to the connected heater.
The heater is burned out or deteriorated.
If the above causes does not apply,
replace the heater.
None
Attached information 1: Loop number where error was detected
Precautions/
Remarks
You can change the event level to the minor fault level. If you change the level to the minor fault level, the Recovery column above will be changed to “Error reset.”
5-3 Event Logs
Attached
information
5
5-3-3 Error Descriptions
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
5-21
5 Error and Alarm Processing
5-22
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
pp
Appendices
A-1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A-2 Functional Differences due to CPU Units (NJ/CJ-series) to be
Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
A-4 Sample Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
A-1
App
A-3 Correspondence Table of Device Variables for CJ-series Unit and
Memory Used for CJ-series Unit Addresses . . . . . . . . . . . . . . . . . . . . . . . . A-4
Appendices
A-1
Dimensions
All dimensions are in mm.
CJ1W-TC@@@
89
65
27
31
7 8
4
0 1
5 6
9
2 3
7 8
4
0 1
5 6
9
90
2 3
7 8
4
0 1
5 6
9
27
2 3
Current Transformer (Sold Separately)
E54-CT3
E54-CT1
21
15
2.36 dia.
30
9
2.8
7.5
12 dia.
40×40
5.8 dia.
25
10.5
3
Two 3.5 dia. holes
15
40
Two M3
holes,
Depth 4
10
30
30
A-2
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Appendices
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 connected, compared when an NJ-series CPU Unit is connected.
Name
Model
Use with NJ-series
Use with CJ-series
CJ1W-TC003/004
CJ1W-TC001/002/003/004
CJ1W-TC103/104
CJ1W-TC101/102/103/104
Unit type
SYSMAC CJ-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)
PID or ON/OFF
PID: 2 degrees of freedom with Autotuning (AT)
Control output
CJ1W-TC@03:
Open collector (NPN) output (pulse)
External 24-VDC power supply
CJ1W-TC@04:
Open collector (PNP) output (pulse)
External 24-VDC power supply
Setting accuracy
Instruction
accuracy
CJ1W-TC@01/@03:
Open collector (NPN) output (pulse)
External 24-VDC power supply
CJ1W-TC@02/@04:
Open collector (PNP) output (pulse)
External 24-VDC power supply
Thermocouple
input
±0.3% or ±1 °C (whichever is larger) ±1 digit or less
Resistance thermometer input
±0.3% or ±0.8 °C (whichever is larger) ±1 digit or less
Data storage/display format of data
exchanged with CPU Unit
16-bit binary only (variable)
Use with pin 3 of the DIP switch set to
ON.
RUN/STOP control
Supported
Operation during CPU Unit PROGRAM mode
Continue or stop operating (selectable)
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
BCD or 16-bit binary (selectable)
Set with pin 3 of the DIP switch.
OFF: BCD, ON: Binary
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)
App
Control Mode
A-2 Functional Differences due to CPU Units (NJ/CJ-series) to be Connected
A-2
A-3
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 CJ-series CPU Unit and memory used for CJ-series Unit of the NJseries CPU Unit are shown below.
Start address of special I/O Unit area: n = 2000 words + Unit number × 10 (Unit number: 0 to 94)
Start address of special I/O Unit DM area: m = D20000 + Unit number × 100 (Unit number: 0 to 94)
Set the CIO and DM area words allocated to the Unit by using the unit number switches on the front
panel of the Unit.
0
Unit 0
CIO 2000 to CIO 2019
D20000 to D20099
1
Unit 1
CIO 2010 to CIO 2029
D20100 to D20199
2
Unit 2
CIO 2020 to CIO 2039
D20200 to D20299
3
Unit 3
CIO 2030 to CIO 2049
D20300 to D20399
4
Unit 4
CIO 2040 to CIO 2059
D20400 to D20499
5
Unit 5
CIO 2050 to CIO 2069
D20500 to D20599
6
Unit 6
CIO 2060 to CIO 2079
D20600 to D20699
7
Unit 7
CIO 2070 to CIO 2089
D20700 to D20799
8
Unit 8
CIO 2080 to CIO 2099
D20800 to D20899
9
Unit 9
CIO 2090 to CIO 2109
D20900 to D20999
D20000+n×100 to
D20000+n×100+99
···
CIO 2000+n×10 to
CIO 2000+n×10+19
···
Unit n
···
n
···
···
Data Memory (DM) Area allocated DM number
···
Special I/O Unit area allocated
CIO number
···
Unit No.
···
Switch No.
94
Unit 94
CIO 2940 to CIO 2959
D29400 to D29499
There are two unit numbers per Temperature Control Unit. Hence, the unit numbers 0 to 94 are available. Please note that this is different from other Special I/O Units.
A-4
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Appendices
• If 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.
• After correcting the unit number setting, turn the Controller power supply OFF and ON.
A-3 Correspondence Table of Device Variables for CJ-series Unit and Memory Used for CJseries Unit Addresses
Additional Information
App
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
A-5
Appendices
z Operation Data
I/O
Output
(CPU Unit to
this Unit)
A-6
CJ-series I/O
memory address
Word
No.
n+0
Bit No.
NJ-series device variable for
CJ-series Unit
Variable name
Name
Data type
00-15
*_Ch1_SetPointCfg
Loop 1 Set point
INT
n+1
00-15
*_Ch2_SetPointCfg
Loop 2 Set point
INT
n+2
00
*_Ch2_StartATCmd
Loop 2 Start AT Bit
BOOL
01
*_Ch2_StopATCmd
Loop 2 Stop AT Bit
BOOL
02
*_Ch1_StartATCmd
Loop 1 Start AT Bit
BOOL
03
*_Ch1_StopATCmd
Loop 1 Stop AT Bit
BOOL
04
*_Ch2_StopCtlCmd
Loop 2 Stop Bit
BOOL
06
*_Ch1_StopCtlCmd
Loop 1 Stop Bit
BOOL
12
*_Ch2_ChgPIDCmd
Loop 2 change PID Constants Bit
BOOL
13
*_Ch1_ChgPIDCmd
Loop 1 change PID Constants Bit
BOOL
14
*_Ch2_SaveCmd
Loop 2 Save Settings Bit
BOOL
15
*_Ch1_SaveCmd
Loop 1 Save Settings Bit
BOOL
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Appendices
Input
(This Unit to
CPU Unit)
Word
No.
n+3
Bit No.
00-15
NJ-series device variable for
CJ-series Unit
Variable name
*_Ch1_PV
Name
Data type
Loop 1 Process Value
INT
n+4
00-15
*_Ch2_PV
Loop 2 Process Value
INT
n+5
00-15
*_Ch1_SetPointSta
Loop 1 Set point for Monitor
INT
n+6
00-15
*_Ch2_SetPointSta
Loop 2 Set point for Monitor
INT
n+7
00-15
*_DecPointSetErrSta
Loop 1, 2 Decimal Point
and Loop 1, 2 Setting
Error Number
WORD
n+8
*_Ch1_StaWd
Loop 1 Status
WORD
*_Ch1_AL2Flg
Loop 1 AL2 Flag
BOOL
01
*_Ch1_AL1Flg
Loop 1 AL1 Flag
BOOL
02
*_Ch1_HBFlg
Loop 1 HB Flag
BOOL
03
*_Ch1_ATFlg
Loop 1 AT Flag
BOOL
04
*_Ch1_CtlOutFlg
Loop 1 Control Output
Flag
BOOL
08
*_Ch1_StopFlg
Loop 1 Stop Flag
BOOL
09
*_Ch1_SetErr
Loop 1 Setting Error Flag
BOOL
10
*_Ch1_PIDCalcFlg
Loop 1 PID Constants
Calculated Flag
BOOL
11
*_Ch1_StbyFlg
Loop 1 Standby Flag
BOOL
12
*_Ch1_CJErr
Loop 1 Cold Junction
Sensor Error
BOOL
13
*_Ch1_CTOvfFlg
Loop 1 CT Overflow Flag
BOOL
14
*_Ch1_SensErr
Loop 1 Sensor Error Flag
BOOL
15
*_Ch1_SaveFlg
Loop 1 Save Completed
Flag
BOOL
00-15
*_Ch2_StaWd
Loop 2 Status
WORD
00
*_Ch2_AL2Flg
Loop 2 AL2 Flag
BOOL
01
*_Ch2_AL1Flg
Loop 2 AL1 Flag
BOOL
02
*_Ch2_HBFlg
Loop 2 HB Flag
BOOL
03
*_Ch2_ATFlg
Loop 2 AT Flag
BOOL
04
*_Ch2_CtlOutFlg
Loop 2 Control Output
Flag
BOOL
08
*_Ch2_StopFlg
Loop 2 Stop Bit
BOOL
09
*_Ch2_SetErr
Loop 2 Setting Error Flag
BOOL
10
*_Ch2_PIDCalcFlg
Loop 2 PID Constants
Calculated Flag
BOOL
11
*_Ch2_StbyFlg
Loop 2 Standby Flag
BOOL
12
*_Ch2_CJErr
Loop 2 Cold Junction
Sensor Error
BOOL
13
*_Ch2_CTOvfFlg
Loop 2 CT Overflow Flag
BOOL
14
*_Ch2_SensErr
Loop 2 Sensor Error Flag
BOOL
15
*_Ch2_SaveFlg
Loop 2 Save Completed
Flag
BOOL
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
App
n+9
00-15
00
A-3 Correspondence Table of Device Variables for CJ-series Unit and Memory Used for CJseries Unit Addresses
I/O
CJ-series I/O
memory address
A-7
Appendices
I/O
Output
(CPU Unit to
this Unit)
Input
(This Unit to
CPU Unit)
CJ-series I/O
memory address
Word
No.
Bit No.
NJ-series device variable for
CJ-series Unit
Variable name
Name
Data type
n+10
00-15
*_Ch1_HBLvlCfg
Loop 1 Heater Burnout
Current
UINT
n+11
00-15
*_Ch2_HBLvlCfg
Loop 2 Heater Burnout
Current
UINT
n+13
00-15
*_Ch1_HtrCurVal
Loop 1 Heater Current
UINT
n+14
00-15
*_Ch2_HtrCurVal
Loop 2 Heater Current
UINT
n+15
00-15
*_Ch1_HBLvlSta
Loop 1 Heater Burnout
Current for Monitor
UINT
n+16
00-15
*_Ch2_HBLvlSta
Loop 2 Heater Burnout
Current for Monitor
UINT
z Initialization Data
CJ-series I/O memory
address
DM No.
NJ-series device variable for CJ-series Unit
Bit No.
Variable name
Name
Data type
D(m+0)
00-15
*_AlmMd
Loop 1, 2 Alarm 1 Mode and Alarm 2
Mode
WORD
D(m+2)
00-15
*_Ch1_AL1HystrsCfg
Loop 1 Alarm 1 Hysteresis
UINT
D(m+3)
00-15
*_Ch1_AL2HystrsCfg
Loop 1 Alarm 2 Hysteresis
UINT
D(m+4)
00-15
*_Ch2_AL1HystrsCfg
Loop 2 Alarm 1 Hysteresis
UINT
D(m+5)
00-15
*_Ch2_AL2HystrsCfg
Loop 2 Alarm 2 Hysteresis
UINT
z Operating Parameter
I/O
CJ-series I/O
memory address
DM No.
Output
(CPU Unit to
this Unit)
A-8
Bit No.
NJ-series device variable for
CJ-series Unit
Variable name
Name
Data type
D(m+10)
00-15
*_Ch1_AL1LvlCfg
Loop 1 Alarm 1 SV
INT
D(m+11)
00-15
*_Ch1_AL2LvlCfg
Loop 1 Alarm 2 SV
INT
D(m+12)
00-15
*_Ch1_AIInOfsCfg
Loop 1 Input Compensation Value
INT
D(m+13)
00-15
*_Ch1_CtlPrdCfg
Loop 1 Control Period
UINT
D(m+14)
00-15
*_Ch1_CtlHystrsCfg
Loop 1 Control Sensitivity
UINT
D(m+15)
00-15
*_Ch1_ProportionalBand
Cfg
Loop 1 Proportional Band
UINT
D(m+16)
00-15
*_Ch1_IntgTmCfg
Loop 1 Integral Time
UINT
D(m+17)
00-15
*_Ch1_DerivativeTmCfg
Loop 1 Derivative Time
UINT
D(m+20)
00-15
*_Ch2_AL1LvlCfg
Loop 2 Alarm 1 SV
INT
D(m+21)
00-15
*_Ch2_AL2LvlCfg
Loop 2 Alarm 2 SV
INT
D(m+22)
00-15
*_Ch2_AIInOfsCfg
Loop 2 Input Compensation Value
INT
D(m+23)
00-15
*_Ch2_CtlPrdCfg
Loop 2 Control Period
UINT
D(m+24)
00-15
*_Ch2_CtlHystrsCfg
Loop 2 Control Sensitivity
UINT
D(m+25)
00-15
*_Ch2_ProportionalBand
Cfg
Loop 2 Proportional Band
UINT
D(m+26)
00-15
*_Ch2_IntgTmCfg
Loop 2 Integral Time
UINT
D(m+27)
00-15
*_Ch2_DerivativeTmCfg
Loop 2 Derivative Time
UINT
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Appendices
CJ-series I/O
memory address
DM No.
Input
(This Unit to
CPU Unit)
Bit No.
NJ-series device variable for
CJ-series Unit
Variable name
Name
Data type
00-15
*_Ch1_AL1LvlSta
Loop 1 Alarm 1 SV for
Monitor
INT
D(m+31)
00-15
*_Ch1_AL2LvlSta
Loop 1 Alarm 2 SV for
Monitor
INT
D(m+32)
00-15
*_Ch1_AIInOfsSta
Loop 1 Input Compensation Value for Monitor
INT
D(m+33)
00-15
*_Ch1_CtlPrdSta
Loop 1 Control Period for
Monitor
UINT
D(m+34)
00-15
*_Ch1_CtlHystrsSta
Loop 1 Control Sensitivity
for Monitor
UINT
D(m+35)
00-15
*_Ch1_ProportionalBandS Loop 1 Proportional Band
ta
for Monitor
UINT
D(m+36)
00-15
*_Ch1_IntgTmSta
Loop 1 Integral Time for
Monitor
UINT
D(m+37)
00-15
*_Ch1_DerivativeTmSta
Loop1 Derivative Time for
Monitor
UINT
D(m+38)
00-15
*_Ch1_MV
Loop 1 Manipulated Variable Monitor
INT
D(m+40)
00-15
*_Ch2_AL1LvlSta
Loop 2 Alarm 1 SV for
Monitor
INT
D(m+41)
00-15
*_Ch2_AL2LvlSta
Loop 2 Alarm 2 SV for
Monitor
INT
D(m+42)
00-15
*_Ch2_AIInOfsSta
Loop 2 Input Compensation Value for Monitor
INT
D(m+43)
00-15
*_Ch2_CtlPrdSta
Loop 2 Control Period for
Monitor
UINT
D(m+44)
00-15
*_Ch2_CtlHystrsSta
Loop 2 Control Sensitivity
for Monitor
UINT
D(m+45)
00-15
*_Ch2_ProportionalBandS Loop 2 Proportional Band
ta
for Monitor
UINT
D(m+46)
00-15
*_Ch2_IntgTmSta
Loop 2 Integral Time for
Monitor
UINT
D(m+47)
00-15
*_Ch2_DerivativeTmSta
Loop 2 Derivative Time for
Monitor
UINT
D(m+48)
00-15
*_Ch2_MV
Loop 2 Manipulated Variable Monitor
INT
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
App
D(m+30)
A-3 Correspondence Table of Device Variables for CJ-series Unit and Memory Used for CJseries Unit Addresses
I/O
A-9
Appendices
A-4
Sample Programming
Process Value (PV) Import
z 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.
z Defined-variable
User-defined variable
Data
type
Name
Factory
setting
Allocated address (AT)
Comments
Temperature1
BOOL
False
---
Loop 1 PV Data Storage
Destination
Temperature2
BOOL
False
---
Loop 2 PV Data Storage
Destination
Device variable for CJ-series Unit
Data
type
Name
Factory
setting
Allocated address (AT)
Comments
J01_Ch1_PV
INT
0
IOBus://rack#0/slot#0/Ch1_
PV
Loop 1 Process Value
J01_Ch2_PV
INT
0
IOBus://rack#0/slot#0/Ch2_
PV
Loop 2 Process Value
J01_Ch1_SensErr
BOOL
---
IOBus://rack#0/slot#0/Ch1_
StaWd/Ch1_SensErr
Loop 1 Sensor Error Flag
J01_Ch2_SensErr
BOOL
---
IOBus://rack#0/slot#0/Ch2_
StaWd/Ch2_SensErr
Loop 2 Sensor Error Flag
z Programming Example
J01_Ch1_SensErr
(Loop 1 Sensor Error Flag)
MOVE
J01_Ch1_ PV
EN
In
ENO
Out
Temperature1
ENO
Out
Temperature2
J01_Ch2_SensErr
(Loop 2 Sensor Error Flag)
MOVE
J01_Ch2_ PV
A-10
EN
In
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Appendices
AT Execution and PID Constants Calculation
z Outline
The program from AT execution of loop 1 to PID constants calculation is shown below.
In this example, the device name "J01" is used when this Unit is registered in Unit Configuration.
z Defined-variable
User-defined variable
Name
ATrun
Data
type
BOOL
Factory
setting
False
Allocated address (AT)
---
Comments
AT Start Signal
Device variable for CJ-series Unit
Name
Data
type
J01_Ch1_ATFlg
BOOL
False
IOBus://rack#0/slot#0/Ch1_
StaWd/Ch1_ATFlg
Loop 1 AT Flag
J01_Ch1_PIDCalcFlg
BOOL
False
IOBus://rack#0/slot#0/Ch1_
StaWd/Ch1_PIDCalcFlg
Loop 1 PID Constants
Calculated Flag
J01_Ch1_SaveFlg
BOOL
False
IOBus://rack#0/slot#0/Ch1_
StaWd/Ch1_SaveFlg
Loop 1 Save Completed
Flag
J01_Ch1_ProportionalBa
ndSta
UINT
0
IOBus://rack#0/slot#0/Ch1_
ProportionalBandSta
Loop 1 Proportional Band
for Monitor
J01_Ch1_ProportionalBa
ndCfg
UINT
0
IOBus://rack#0/slot#0/Ch1_
ProportionalBandCfg
Loop 1 Proportional Band
J01_Ch1_IntgTmSta
UINT
0
IOBus://rack#0/slot#0/Ch1_
IntgTmSta
Loop 1 Integral Time for
Monitor
J01_Ch1_IntgTmCfg
UINT
0
IOBus://rack#0/slot#0/Ch1_
IntgTmCfg
Loop 1 Integral Time
J01_Ch1_DerivativeTmSt
a
UINT
0
IOBus://rack#0/slot#0/Ch1_
DerivativeTmSta
Loop 1 Derivative Time for
Monitor
J01_Ch1_DerivativeTmCf
g
UINT
0
IOBus://rack#0/slot#0/Ch1_
DerivativeTmCfg
Loop 1 Derivative Time
J01_Ch1_StartATCmd
BOOL
False
IOBus://rack#0/slot#0/Ch1_
StartATCmd
Loop 1 Start AT Bit
J01_Ch1_ChgPIDCmd
BOOL
False
IOBus://rack#0/slot#0/Ch1_
ChgPIDCmd
Loop 1 change PID Constants Bit
J01_Ch1_SaveCmd
BOOL
False
IOBus://rack#0/slot#0/Ch1_
SaveCmd
Loop 1 Save Settings Bit
Allocated address (AT)
App
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Comments
A-4 Sample Programming
Factory
setting
A-11
Appendices
z Programming Example
Start AT Bit
ATrun
J01_Ch1_StartATCmd
J01_Ch1_ATFlg
J01_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_ProportionalBandSta
J01_Ch1_IntgTmSta
MOVE
EN
ENO
In
Out
MOVE
EN
ENO
In
Out
J01_Ch1_DerivativeTmSta
J01_Ch1_ProportionalBandCfg
J01_Ch1_IntgTmCfg
MOVE
EN
ENO
In
Out
J01_Ch1_DerivativeTmCfg
J01_Ch1_ChgPIDCmd (*1)
J01_Ch1_SaveCmd (*2)
S
After saving to the non-volatile memory is complete, the save instruction is switched OFF.
J01_Ch1_SaveFlg (*2)
J01_Ch1_SaveCmd (*2)
R
*1 Change of Change PID Constants Bit (J01_Ch1_ChgPIDCmd) from OFF to ON changes the PID Constants
Calculated Flag (J01_Ch1_PIDCalcFlg) 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
I
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Index-1
Index
Index
A
F
(AT) autotuning .....................................................1-5, 3-11
Alarm ............................................................................. 5-2
Alarm hysteresis .......................................................... 3-16
Alarm mode ................................................................. 3-15
Alarm output function .................................................. 3-15
Alarm SVs ................................................................... 3-16
Assumed cause ........................................................... 5-17
AT (autotuning) .....................................................1-5, 3-11
AT execution ................................................................A-11
Autotuning execution ...................................................A-11
C
°C/°F ............................................................................ 2-13
Cold junction sensor error ....................................5-8, 5-19
Connector .................................................................... 2-11
Control method .............................................................. 3-7
Control operation ....................................................1-5, 3-6
Control output ................................................................ 2-2
Control period ................................................................ 3-8
Control sensitivity ........................................................ 3-10
Controller errors .......................................................... 5-16
CPU unit error ............................................................... 5-2
CPU unit monitor error .................................................. 5-8
CPU unit WDT error ...................................................... 5-9
CT (current transformer) .......................................2-4, 3-19
CT overflow ..........................................................5-7, 5-20
Current transformer (CT) ......................................2-4, 3-19
Current transformer (CT) ratings ................................... 2-4
D
Data storage/display format ......................................... 2-14
Decimal point ............................................................... 2-29
Derivative time ......................................................3-7, 3-14
Device variables for CJ-series unit .............................. 2-21
Dielectric strength .......................................................... 2-2
DIP switch setting functions ........................................ 2-13
Disabled loop ................................................................. 4-3
DM setting error (initialization data) ............................... 5-8
Duplicate unit number ................................................... 5-9
E
ERC indicator .......................................................2-11, 5-2
ERH indicator .......................................................2-11, 5-2
Error processing flowchart ............................................ 5-3
Event code .................................................................. 5-17
Event name ................................................................. 5-17
Events ......................................................................... 5-16
Forward ......................................................................... 3-6
H
Hardware check error .................................................... 5-8
HB (heater burnout alarm) ............................................. 2-4
HB alarm errors ........................................................... 5-15
Heater burnout .............................................................. 1-5
Heater burnout (HB) .................................................... 3-19
Heater burnout alarm ....................................2-4, 5-7, 5-21
Heater burnout current ..............................3-19, 3-20, 5-15
Heater burnout detection ............................................. 3-19
Hunting ........................................................................ 5-14
I
I/O bus check error ........................................................ 5-9
I/O map ........................................................................ 2-22
I/O port ........................................................................ 2-22
I/O setting check error ................................................... 5-9
I/O wiring examples ..................................................... 2-18
Indication accuracy ........................................................ 2-3
Initialization data .................................................2-21, 2-30
Input compensation function ......................................... 1-5
Input function block diagram .......................................... 2-5
Input specifications ........................................................ 2-5
Input type settings ......................................................... 3-2
Input type switch ..........................................2-11, 2-15, 3-2
Insulation resistance ...................................................... 2-2
Integral time ..........................................................3-7, 3-13
Internal alarm ................................................................ 1-6
Internal current consumption ......................................... 2-2
L
Limit-cycle method ........................................................ 1-5
M
Measured temperature higher than
control temperature .................................................. 5-13
Memory used for CJ-series unit ....................................A-4
Mounting the unit ........................................................... 1-8
N
Non-volatile memory ............................................1-6, 2-23
O
ON/OFF control .............................................1-4, 3-7, 3-10
Operating parameter ..........................................2-21, 2-32
Index-2
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Index
Operation data ................................................... 2-21, 2-24
Output circuits ............................................................. 2-17
Output errors ............................................................... 5-14
Output indicators ......................................................... 2-11
Overshooting ............................................................... 5-13
Temperature control method ......................................... 2-2
Temperature control unit error ....................................... 5-2
Temperature units ......................................................... 3-4
Thermocouple input setting ranges ............................... 2-5
U
P
PID constant ...................................................... 3-11, 3-13
PID constants bit ......................................................... 3-11
PID constants calculated flag ...................................... 3-11
PID control ............................................................. 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) .............................. 2-13
Pin 2 of the DIP switch (°C/°F) ...................... 2-5, 2-13, 3-4
Pin 3 of the DIP switch ......................................... 2-14, 3-5
Pin 4 of the DIP switch
(control operation for loop 1) ............................. 2-14, 3-6
Pin 5 of the DIP switch
(control operation for loop 2) ............................. 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 .......................................... A-10
Proportional band ................................................ 3-7, 3-13
PV (process value) ........................................................ 1-5
Undershooting ............................................................. 5-13
Unit configuration .......................................................... 2-7
Unit number switches ...........................................2-12, A-4
Unit restart .................................................................. 2-22
W
Warmup time ................................................................. 2-3
R
I
RAM ............................................................................ 2-23
Restart ........................................................................ 2-22
Reverse ......................................................................... 3-6
RUN indicator ....................................................... 2-11, 5-2
S
(SP) set point ......................................................... 1-5, 3-9
Sampling period ............................................................ 2-3
Sensor error ......................................................... 5-7, 5-20
Set point ................................................................. 1-5, 3-9
Setting error ......................................................... 5-7, 5-19
Setting error numbers .......................................... 2-29, 5-7
Simple method to check the temperature
sensor inputs ............................................................ 5-12
Special I/O unit area ..................................................... A-4
Special I/O unit DM area ............................................... A-4
Standby sequence ...................................................... 3-16
Status indicators ......................................................... 2-11
Stop bit ........................................................................ 3-21
Sysmac Studio .............................................................. 2-7
System-defined variable ............................................. 2-21
T
Temperature control errors .......................................... 5-12
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
Index-3
Index
Index-4
CJ-series Temperature Control Units Operation Manual for NJ-series CPU Unit(W491)
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