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SECTION 5

Error and Alarm Processing

This section provides information on troubleshooting and error processing.

5-1

Error and Alarm Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1-1

Identifying Errors with the LED Indicators . . . . . . . . . . . . . . . . . . .

5-1-2

Error Processing Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1-3

Alarms Detected by the Temperature Control Unit . . . . . . . . . . . . .

5-1-4

Errors Originating in the CPU Unit . . . . . . . . . . . . . . . . . . . . . . . . .

5-1-5

Special I/O Unit Restart Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2-1

Troubleshooting from Symptoms: Measurement Errors . . . . . . . . .

5-2-2

Troubleshooting from Symptoms: Temperature Control Errors. . . .

5-2-3

Troubleshooting from Symptoms: Output Errors . . . . . . . . . . . . . . .

5-2-4

Troubleshooting from Symptoms: HB Alarm Errors . . . . . . . . . . . .

Summary of Contents for Sysmac CJ Series

Page 1: ...OPERATION MANUAL Cat No W396 E1 03 SYSMAC CJ Series CJ1W TC Temperature Control Units...

Page 2: ...CJ1W TC Temperature Control Units Operation Manual Revised December 2005...

Page 3: ...iv...

Page 4: ...n some OMRON products often means word and is abbreviated Wd in documentation in this sense The abbreviation PLC means Programmable Controller PC is used however in some Program ming Device displays t...

Page 5: ...vi...

Page 6: ...rocedure 18 2 3 Part Names and Functions 21 2 4 Wiring 25 2 5 Data Exchange with the CPU Unit 29 2 6 Data Ranges 49 SECTION 3 Settings Required for Temperature Control 51 3 1 Setting the Input Type 52...

Page 7: ...sation 68 4 2 Recovering from Sensor Not Connected Errors 69 4 3 Application without a Cycle Refresh with the CPU Unit 69 SECTION 5 Error and Alarm Processing 71 5 1 Error and Alarm Processing 72 5 2...

Page 8: ...s PLCs using a Program ming Console SYSMAC CS CJ series CS1G H CPU H CS1G H CPU EV1 CS1D CPU H CS1D CPU S CJ1M CPU CS1W SCB21 V1 41 V1 SCU21 V1 CJ1G H CPU H CJ1G CPU CJ1W SCU21 SCU41 Communications Co...

Page 9: ...configuration Section 2 describes the functions and specifications of the Temperature Control Unit including techni cal specifications Unit parts wiring and data allocations Section 3 explains the va...

Page 10: ...S 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...

Page 11: ...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...

Page 12: ...onfirm 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 PERFORMANC...

Page 13: ...xiv...

Page 14: ...the safe and reliable application of the Temperature Control Unit You must read this section and understand the information contained before attempting to set up or operate a Temperature Control Unit...

Page 15: ...for reference during operation WARNING It is extremely important that a PLC and all PLC Units be used for the speci fied purpose and under the specified conditions especially in applications that can...

Page 16: ...may result in injury Caution Tighten the screws on the terminal block of the AC Power Supply Unit to the torque specified in the operation manual The loose screws may result in burning or malfunction...

Page 17: ...Application Precautions WARNING Always heed these precautions Failure to abide by the following precautions could lead to serious or possibly fatal injury Always connect to a ground of 100 or less whe...

Page 18: ...reful in places where the power supply is unstable An incorrect power supply may result in malfunction Install external breakers and take other safety measures against short cir cuiting in external wi...

Page 19: ...ver them in antistatic mate rial to protect them from static electricity and maintain the proper storage temperature When transporting Units pack them in the packing boxes designed for them Do not sub...

Page 20: ...en checked for conformity to EMC standards see the following note Whether the products conform to the standards in the system used by the customer however must be checked by the customer EMC related p...

Page 21: ...nforms to the Common Emission Standards EN61000 6 4 of the EMC Directives However noise generated by relay out put switching may not satisfy these Standards In such a case a surge sup pressor must be...

Page 22: ...he diode connected in parallel with the load changes energy accumulated by the coil into a current which then flows into the coil so that the current will be converted into Joule heat by the resistanc...

Page 23: ......

Page 24: ...s of the Temperature Control Unit and its basic system configuration 1 1 Introduction and Features 2 1 1 1 Introduction 2 1 1 2 Features 3 1 2 System Configuration 6 1 2 1 Basic System Configuration 6...

Page 25: ...e Units Temperature Ranges I O type Output type NPN outputs PNP outputs Four control loops Thermocouple CJ1W TC001 CJ1W TC002 Platinum resistance thermometer CJ1W TC101 CJ1W TC102 Two control loops wi...

Page 26: ...peration 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 Ter...

Page 27: ...trol 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 PID Control with Two Degrees of Freedom Auto...

Page 28: ...that is offset from the sensor s measurement point use this function to control the temperature at a value near the desired point Heater Burnout Detection Single phase Operation Only When a Two loop T...

Page 29: ...N outputs and a CJ1W TC103 Temperature Control Unit 2 control loops with heater burnout detection platinum resistance thermometer inputs and NPN outputs Note 1 An OMRON E54 CT1 or E54 CT3 Current Tran...

Page 30: ...llation 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 Con trol Unit 1 2 3 1 Align the Units...

Page 31: ...does not carry any high voltage lines or power lines Leave the protective label in place during wiring to prevent stray wire strands from falling into the Unit during wiring After wiring is completed...

Page 32: ...it used in a set with the cold junction compensator 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...

Page 33: ...larger 1 digit max 0 5 or 2 C whichever is larger 1 digit max Platinum resis tance ther mometer input 0 3 or 0 8 C whichever is larger 1 digit max 0 5 or 1 C whichever is larger 1 digit max Storage d...

Page 34: ...Procedure 19 2 3 Part Names and Functions 21 2 3 1 Part Names 21 2 3 2 Indicators 21 2 3 3 Unit Number Switches 22 2 3 4 DIP Switch Setting Functions 23 2 3 5 Setting the Input Type 24 2 4 Wiring 25...

Page 35: ...nit and Temperature Control Unit Alarm value Input compensation value Control period Sensitivity Proportional band Integral time Derivative time Output monitor Insulation resis tance 20 M min at 500 V...

Page 36: ...DIP switch Auto Manual switch for operational out put None Autotuning AT of PID constant Supported Controlled from the CPU Unit through bits allocated in the Special I O Unit area Indication accuracy...

Page 37: ...with 18 points M3 screws Effect on the CPU Unit s cycle time 0 4 ms Item Specification CJ1W TC 0 Output type Always 0 Input type 0 Thermocouple input 1 Platinum resistance thermometer input 1 NPN outp...

Page 38: ...ontrol Forward reverse switching Controller Temperature Control Unit Loop 1 Temperature input Control output Loop 2 Loop 3 Loop 4 Same as 1 Same as 1 Same as 1 Input 1 Control output 1 Input 2 Control...

Page 39: ...00 C 0 0 to 750 0 F 0000 to 0FA0 0 0 to 400 0 0000 to 4000 0 0 to 400 0 0000 to 1D4C 0 0 to 750 0 0000 to 7500 0 0 to 750 0 4 T 200 0 to 400 0 C 300 0 to 700 0 F F830 to FFFF to 0FA0 200 0 to 0 1 to 4...

Page 40: ...9 9 and the upper limit value is 999 9 4 When the input type setting switch has been changed the SV and input compensation values will change as follows If the SV exceeds the setting range it will be...

Page 41: ...h on the front panel of the Tem perature Control Unit Set the function switches on the front panel of the Tem perature Control Unit Forward reverse operation Control method ON OFF control or PID contr...

Page 42: ...r Switches If the unit number is set to 1 CIO 2010 to CIO 2029 and D20100 to D20199 will be allocated to the Unit as a Special I O Unit 2 Set the input type referring to 2 3 5 Setting the Input Type S...

Page 43: ...Program In this example the process value PV output to the words allocated in the CIO Area to the Temperature Control Unit as a Special I O Unit are stored in memory for four loops The words n 3 n 4...

Page 44: ...14 Sensor Error Flag for Loop 4 0 0 9 9 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 0 0 9 9 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 0 0 9 9 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 Connector DIN Track Mounting Pin Sliding Latch T...

Page 45: ...or more Special I O Units are assigned the same unit number a UNIT No DPL ERR error in the Programming Console will be generated A40113 will turn ON and the PLC will not operate ERH CPU Unit Error Red...

Page 46: ...some temperature ranges cannot be displayed in BCD so it will be necessary to use the binary format in those cases Pin Function ON OFF Factory setting 1 Operation when CPU Unit is in PROGRAM mode Cont...

Page 47: ...gs Pin 8 If pin 8 is ON the settings in the Temperature Control Unit s EEPROM will be transferred to the corresponding words in the CPU Unit s DM Area when the Temperature Control Unit is turned ON or...

Page 48: ...Input 2 Input 2 Cold junction comp Cold junction comp Input 1 Input 1 N C N C CT input 1 CT input 1 Output 1 HB output 1 24 V COM B1 B2 B3 B4 B5 B6 B7 B8 B9 CT input 2 CT input 2 Output 2 HB output 2...

Page 49: ...its The following diagrams show the internal output circuits Output Circuits NPN Outputs CJ1W TC 01 and CJ1W TC 03 NPN Outputs CJ1W TC 02 and CJ1W TC 04 24 V COM Output Indicator Internal circuits COM...

Page 50: ...mbers 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 E54...

Page 51: ...tightened to a torque of 0 5 N m 5 Use wire that is AWG 22 to AWG 18 6 Observe the following precautions when wiring to minimize noise and op timize the Temperature Control Unit s operation Use twiste...

Page 52: ...to operate the Temperature Control Unit is exchanged with the CPU Unit as Operation Data during the CPU Unit s I O refresh period Operation Data includes the Process Values Set Points Stop Bits Start...

Page 53: ...t operate 2 Each Temperature Control Unit is allocated the words for two unit numbers Do not use assign the unit number after one assigned to a Temperature Control Unit to any other Unit For example i...

Page 54: ...ed enabling operation with the data stored in the EEPROM Note 1 The PID constants resulting from autotuning are automatically written to RAM at the end of autotuning 2 The EEPROM has a life of 100 000...

Page 55: ...RR error in the Programming Console will be generat ed A40113 will turn ON and the PLC will not operate EPROM RAM CPU Unit I O refresh Power ON or restart I O refresh At power ON or restart if pin 8 o...

Page 56: ...on stants Calcu lated Setting Error Stop 0 0 0 Control Output AT 0 AL1 AL2 n 9 Loop 2 Status Save Com pleted Sensor Error 0 Fatal Control Error Stand by PID Con stants Calcu lated Setting Error Stop 0...

Page 57: ...ing Error Number Loop 2 Setting Error Number n 8 Loop 1 Status Save Com pleted Sensor Error CT Over flow Fatal Control Error Stand by PID Con stants Calcu lated Setting Error Stop 0 0 0 Control Output...

Page 58: ...ants stored as Operating PID Constants will be retransferred to the Temperature Control Unit 12 Loop 2 Change PID Constants Bit 08 to 11 Leave set to all zeros 7 Leave set to 0 6 Loop 1 Stop Bit Turn...

Page 59: ...A temperature exceeding the specified temperature range has been input 13 Leave set to 0 12 Fatal Control Error Flag The Fatal Control Error Flag turns ON for the following Cold junction compensator e...

Page 60: ...Calculated Flag turns ON when the PID constants calculated for autotuning have been updated When this flag is ON the PID constants in the Operating Parameters Output Area have not been output to the T...

Page 61: ...it 08 to 11 Leave set to all zeros 7 Leave set to 0 6 Loop 3 Stop Bit Turn OFF the Stop Bit to perform temperature control for loop 3 and turn it ON to stop temperature control for loop 3 The Stop Bit...

Page 62: ...to sensor is broken A temperature exceeding the specified temperature range has been input 13 Leave set to 0 12 Fatal Control Error Flag The Fatal Control Error Flag turns ON for the following Cold j...

Page 63: ...lculated Flag turns ON when the PID constants calculated for autotuning have been updated When this flag is ON the PID constants in the Operating Parameters Output Area have not been output to the Tem...

Page 64: ...ture Control Unit 12 Loop 2 Change PID Constants Bit 08 to 11 Leave set to all zeros 7 Leave set to 0 6 Loop 1 Stop Bit Turn OFF the Stop Bit to perform temperature control for loop 1 and turn it ON t...

Page 65: ...ken A temperature exceeding the specified temperature range has been input 13 CT Overflow Flag The CT Overflow Flag turns ON if the heater current detected by the CT Current Transformer exceeds 55 0 A...

Page 66: ...power is turned ON or the Unit is restarted 10 PID Con stants Calcu lated Flag The PID Constants Calculated Flag turns ON when the PID con stants calculated for autotuning have been updated When this...

Page 67: ...its binary If the value is set to 0 0 heater burnouts will not be detected If the value is set to 50 0 the heater burnout output will always be ON This can be used to test wiring n 11 00 to 15 Loop 2...

Page 68: ...re output from the CPU Unit to the Temperature Control Unit DM word Bit 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 D m 0 Loop 1 Loop 2 Alarm 1 mode Alarm 2 mode Alarm 1 mode Alarm 2 mode 23 22 21...

Page 69: ...error in the Programming Console will be generat ed A40113 will turn ON and the PLC will not operate D m 2 00 to 15 Loop 1 Alarm 1 hysteresis Set each alarm s hysteresis in 4 digit BCD or 16 bit binar...

Page 70: ...ion Value D m 62 Input Compensation Value D m 23 Control Period D m 63 Control Period D m 24 Control Sensitivity D m 64 Control Sensitivity D m 25 Proportional Band D m 65 Proportional Band D m 26 Int...

Page 71: ...he description for D m 10 through D m 19 D m 50 to D m 59 Loop 3 Same as the settings for loop 1 These settings are valid in Temperature Control Units with four control loops and are the same as the s...

Page 72: ...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 Absol...

Page 73: ...ettings are written to RAM When the Save Bit is turned ON the settings are written to EEPROM See notes 2 and 3 If DIP switch pin 8 is ON the settings are automatically trans ferred from EEPROM to the...

Page 74: ...Settings 55 3 7 Setting the Set Point 56 3 7 1 Setting the SP 56 3 8 Using ON OFF Control 56 3 8 1 ON OFF Control Operation 56 3 8 2 Required Settings 57 3 9 Setting the PID Constants 57 3 9 1 Settin...

Page 75: ...tting will not become effective until the power is turned ON or the Unit is restarted The diagram above shows the input type set for a K type thermocouple with a temperature range of 0 0 to 500 0 C In...

Page 76: ...3 3 Setting the Data Format A switch on the front of the Unit pin 3 of the DIP switch selects whether the Temperature Control Unit s data is handled as 4 digit BCD or binary i e 4 digit hexadecimal T...

Page 77: ...peration with pins 4 and 5 of the Unit s DIP switch Pin 4 controls the operation of loops 1 and 3 pin 5 controls the opera tion of loops 2 and 4 3 4 2 Setting the Control Operation Pins 4 and 5 Exampl...

Page 78: ...SV This is the operation when the Unit is set for reverse operation This operation will work in the opposite way for forward operation 3 6 Setting the Control Period This setting determines the output...

Page 79: ...ontrol output goes OFF the system temperature will begin to drop and the control output will be turned ON again when the sys tem temperature falls below the set point This ON OFF operation is repeated...

Page 80: ...lculate the opti mal PID constants for the set point during operation This Temperature Con trol Unit uses the limit cycle method which determines the controlled system s characteristics by forcibly ch...

Page 81: ...corre sponding words of the Operating Parameters in the DM words allocated to the Unit Note 1 When you already know the system s control characteristics set the PID constants directly to adjust the co...

Page 82: ...ng PID constants automatically calculated by autotuning Use the PID Constants Calculated Flag as an input condition to trigger the transfer of the calculated PID constants from the input words in DM A...

Page 83: ...rn the power supply OFF and ON again or restart the Unit after changing the alarm mode Alarm Modes In the following diagrams the X indicates the alarm SV The initial value is 0 Increasing D Overshooti...

Page 84: ...a words allocated to the Unit See 3 10 5 Summary of Alarm Output Function Settings for the actual DM addresses of these words About the Standby Sequence The standby sequence disables the alarm output...

Page 85: ...rd m contains the loop 1 alarm mode and loop 2 alarm mode Set D m to 3218 2 DM Area words m 2 through m 5 contain the alarm hysteresis settings for loop 1 and loop 2 Set the appropriate values for the...

Page 86: ...larm 1 mode 0 to 9 0000 08 to 11 Alarm 2 mode 0 to 9 04 to 07 Loop 4 Alarm 1 mode 0 to 9 00 to 03 Alarm 2 mode 0 to 9 D m 2 00 to 15 Loop 1 Alarm 1 hysteresis 0000 to 9999 0000 to 270F C or F 0 0 D m...

Page 87: ...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...

Page 88: ...rence less than 2 5 A The setting 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 ala...

Page 89: ...er the status of external loads because the output bits will not be cleared when the PLC is switched to PROGRAM mode from RUN or MONITOR mode Caution It takes approximately 4 seconds for outputs from...

Page 90: ...gs This section explains how to use the input compensation value 4 1 Shifting the Input Value Input Compensation 68 4 2 Recovering from Sensor Not Connected Errors 69 4 3 Application without a Cycle R...

Page 91: ...is just the difference between the work piece s temperature B and the Temperature Control Unit s reading A Figure 2 shows the process values before and after compensation Input Compensation Value Wor...

Page 92: ...ion for a loop while leav ing the alarm function enabled set the alarm modes for the loop and then turn ON the Stop Bit for the same loop 4 3 Application without a Cycle Refresh with the CPU Unit Cycl...

Page 93: ......

Page 94: ...cessing Flowchart 72 5 1 3 Alarms Detected by the Temperature Control Unit 73 5 1 4 Errors Originating in the CPU Unit 75 5 1 5 Special I O Unit Restart Bits 75 5 2 Troubleshooting 76 5 2 1 Troublesho...

Page 95: ...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...

Page 96: ...tandby Standby Standby 10 PID Constants Calculated PID Constants Calculated PID Constants Calculated PID Constants Calculated 09 Setting Error Setting Error Setting Error Setting Error 08 Stop Stop St...

Page 97: ...Control sensitivity 10 B Proportional band 11 C Integral time 12 D Derivative time 13 E Heater burnout current 14 F Not allocated 15 Lit RUN ERC ERH Not lit Error Cause Control status Processing Hardw...

Page 98: ...ted by turning the PLC s power ON again or tog gling OFF ON OFF the corresponding Special I O Unit Restart Bit Lit RUN ERC ERH Not lit Error Cause Control status Processing CPU Unit Monitor Error A re...

Page 99: ...start Bit Check LED Indicators Check switch settings and wiring Check the Temperature Controller Unit s operating status with the LED Indicators Follow the procedures described in 5 1 Error and Alarm...

Page 100: ...ffecting operation Move the Temperature Control Unit away from the equipment that is generating the noise Install surge protectors or noise filters on the equip ment that is generating the noise The t...

Page 101: ...erature 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 tem perature is the tem...

Page 102: ...ct Correct the setting The PID constant settings are not correct Perform autotuning Make the correct PID constant settings manually Temperature control has not been started Start temperature control A...

Page 103: ...onstant 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 accep...

Page 104: ...de Step Possible Cause Remedy Connection A Current Transformer CT is not connected Connect a CT The CT is connected to the wrong channel Input the CT correctly The heater is being operating with anoth...

Page 105: ......

Page 106: ...ld Separately 0 0 9 9 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 0 0 9 9 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 0 0 9 9 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 89 65 31 27 90 27 30 2 36 dia 40 40 15 30 9 2 8 7 1 12 dia 21 15 5...

Page 107: ......

Page 108: ...Unit Settings Unit CJ1W TC001 Temperature Control Unit Unit number 00 Note The unit number switches are on the front of the Unit Refer to 2 3 3 Unit Number Switches for details Example Program The Se...

Page 109: ...CJ1W TC001 Temperature Control Unit Unit number 00 Note The unit number switches are on the front of the Unit Refer to 2 3 3 Unit Number Switches for details Example Program The Setting Error Flag for...

Page 110: ...n 2 and the Loop 1 Change PID Constants Bit is bit 13 of CIO n 2 3 The PID Constants Calculated Flag will go OFF when the Change PID Constants Bit is turned ON 4 If pin 8 of the DIP Switch is set to...

Page 111: ...etails 2 Turn ON pin 3 of the DIP switch to select the binary data format Example Program MOV 021 2003 D00000 MOV 021 0000 D00001 ANDW 034 8000 D00000 D00002 NEG 060 D00000 ERR D00000 MOV 021 F000 D00...

Page 112: ...Analog Output Unit 32 45 46 O operating environment precautions xvii P precautions applications xviii operating environment xvii Programming Console errors Analog Output Unit 32 45 46 S Special I O U...

Page 113: ......

Page 114: ...ogrammable Controller Page ix Model numbers added and entries for CX Programmer changed Page 20 Manual name changed Page 36 Setting for n 7 removed Page 66 Stop Bits changed to bits Page 75 Manual nam...

Page 115: ......

Page 116: ...rlands Tel 31 2356 81 300 Fax 31 2356 81 388 OMRON ELECTRONICS LLC 1 East Commerce Drive Schaumburg IL 60173 U S A Tel 1 847 843 7900 Fax 1 847 843 8568 OMRON ASIA PACIFIC PTE LTD 83 Clemenceau Avenue...

Page 117: ...Authorized Distributor Cat No W396 E1 03 Note Specifications subject to change without notice Printed in Japan This manual is printed on 100 recycled paper...

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