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CONTENTS
Section 1 Features and System Configuration
12 CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
Section 2 Nomenclature and Installation
Section 3
Configuration Software
Section 4
Data Exchange with the CPU Unit
Slave Data Exchange Active Flags (*_SlvDatXchg, *_SlvDatXchgL, *_SlvDatXchgH) ........... 4-22
Slave New Diagnostics Flags (*_SlvNewDiagL, *_SlvNewDiagH, *_SlvNewDiag) ................. 4-24
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Section 5
Operation
Section 6
Message Communications
Section 7
Troubleshooting and Maintenance
14 CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
Appendices
A-1 Differences in Available Functions Depending on the CPU Unit (NJ/CJ series) to be
Index
CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509) 15
Read and Understand this Manual
Please read and understand this manual before using the product. Please consult your OMRON representative if you have any questions or comments.
Warranty and Limitations of Liability
WARRANTY
OMRON's exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-
INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE
PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS
DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR
INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES,
LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS,
WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT
LIABILITY.
In no event shall the responsibility of OMRON for 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.
14 CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
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.
CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509) 15
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.
16 CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
Safety Precautions
Definition of Precautionary Information
The following notation is used in this manual to provide precautions required to ensure safe usage of an
NJ-series Controller. 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.
CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509) 17
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.
18 CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
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.
• 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 even if the outputs turn OFF.
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.
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20
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 PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
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.
CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509) 21
Precautions for Safe Use
22
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, Special I/O Unit, and CPU Bus Units must be completely locked (until they click into place) after connecting the adjacent Unit connectors.
Installation
• Always connect to a ground of 100
or less when installing the Units. A ground of 100 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 dust proof 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 FG (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 PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
• 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 Hard-
ware User’s Manual (Cat. No. W500) for surge current specifications.
• If the full dielectric strength voltage is applied or turned OFF using the switch on the tester, the 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. You do not have to disconnect the LG and GR terminals to perform these tests.
• 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.
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
• Connecting cables or wiring the system
• Connecting or disconnecting the connectors
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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 PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
• 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 given in the status flags 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. Restarting these Units is required to read and enable the new routing tables. 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). This is performed to read and enable the 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. Communications with the EtherCAT slaves are cut off for up to 45 seconds. During that period, the slave outputs behave according to the slave settings.
Before you transfer the user program, confirm that the system will not be adversely affected.
• 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.
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• 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.
• 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.
CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
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.
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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 NJ-
series 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.
28 CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
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.
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.
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 PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509) 29
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.
30 CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
Regulations and Standards
Conformance to EC Directives
Applicable Directives
• EMC Directives
• Low Voltage Directive
Concepts
EMC Directive
OMRON devices that comply with EC Directives also conform to the related EMC standards so that they can be more easily built into other devices or the overall machine. The actual products have been checked for conformity to EMC standards.*
Whether the products conform to the standards in the system used by the customer, however, must be checked by the customer. EMC-related performance of the OMRON devices that comply with EC
Directives will vary depending on the configuration, wiring, and other conditions of the equipment or control panel on which the OMRON devices are installed. The customer must, therefore, perform the final check to confirm that devices and the overall machine conform to EMC standards.
* Applicable EMC (Electromagnetic Compatibility) standards are as follows:
EMS (Electromagnetic Susceptibility): EN 61131-2 and EN 61000-6-2
EMI (Electromagnetic Interference): EN 61131-2 and EN 61000-6-4 (Radiated emission: 10-m regulations)
Low Voltage Directive
Always ensure that devices operating at voltages of 50 to 1,000 VAC and 75 to 1,500 VDC meet the required safety standards. The applicable directive is EN 61131-2.
Conformance to EC Directives
The NJ-series Controllers comply with EC Directives. To ensure that the machine or device in which the NJ-series Controller is used complies with EC Directives, the Controller must be installed as 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 PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509) 31
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 a registered trademark of Beckhoff Automation GmbH for their patented technology.
• 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.
32 CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
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 Unit version
NJ501 - 1500 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
Unit model
Unit version
Lot number and serial number
MAC address
Description
Gives the model of the Unit.
Gives the unit version of the Unit.
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)
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.
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 PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509) 33
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.1.0” is displayed next to the unit model.
The following items are displayed.
CPU Unit
Unit model
Unit version
Lot number
CJ-series Units
Unit model
Unit version
Lot number
Rack number, slot number, and unit number
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 Produc-
tion Information.
The Production Information Dialog Box is displayed.
34
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.
CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
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
NJ-series CPU Unit Software User’s Manual
CJ-series PROFIBUS
Master Units Operation
Manual for NJ-series
CPU Unit (This document)
CJ-series PROFIBUS
Slave Unit Operation
Manual for NJ-series
CPU Unit
SmartSlice GRT1-series
Communication Unit
Operation Manual
SmartSlice GRT1 Series
Slice I/O Units
W455
CS/CJ Series PROFI-
BUS Master Unit Operation Manual
Cat. No.
W500
W501
Sysmac Studio Version 1
Operation Manual
W504
W509
W510
W04E
W409
Model numbers Application
NJ501-
□□□□
Learning the basic specifications of the NJ-series
CPU Units, including introductory information, designing, installation, and maintenance. Mainly hardware information is provided.
NJ501-
□□□□
Learning how to program
SYSMAC-
SE2
□□□ and set up an NJ-series
CPU Unit. Mainly software information is provided.
Description
An introduction to the entire NJ-series system is provided along with the following information on a Controller built with an NJ501 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).
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).
Describes the operating procedures of the Sysmac Studio.
CJ1W-PRM21
CJ1W-PRT21
Learning about the operating procedures and functions of the Sysmac Studio.
Learning about the functions and operating procedures when the CJ-series
PROFIBUS Master Unit is used in an NJ-series system configuration.
Learning about the functions and operating procedures when the CJ-series
PROFIBUS Slave Unit is used in an NJ-series system configuration.
Learning about the GRT1series SmartSlice PROFI-
NET Communication Unit.
The functions and operating procedures when the CJ-series PROFIBUS Master Unit is used in an NJ-series system configuration are described as well as the operation of CX-ConfiguratorFDT.
The functions and operating procedures when the CJ-series PROFIBUS Slave Unit is used in an NJ-series system configuration are described as well as the operation of CX-ConfiguratorFDT.
GRT1-PRT
GRT1-series Digital I/O Units, Analog I/O Units,
Counter and Positioning Units, System Units
Learning about the various
SmartSlice I/O Units that work with the GRT1-PRTseries Communication
Unit.
CS1/CJ1W-PRM21 Learning about the
CS1/CJ1W-PRM21 PRO-
FIBUS Master Units.
Describes the GRT1-PRT PROFIBUS Communications Unit for OMRON’s SmartSlice I/O
Units. It also describes how to install and operation the Unit.
Describes the models, specifications, functions, operating procedures, and applications of
GRT1-series Slice I/O Units.
Describes the operation and configuration details of the CS1W-PRM21 and CJ1W PRM21
PROFIBUS DP and PROFIBUS DP-V1 Master
Units when used in CS/CJ series systems.
CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509) 35
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.
W509-E2-01
Revision code
Revision code
01
Date
September 2011 Original production
Revised content
36 CJ-series PROFIBUS Master Unit Operation Manual for NJ-series CPU Unit (W509)
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