Omron CJ, SYSMAC CJ, CJ1W-TC Operation Manual
OPERATION MANUAL
Cat. No. W396-E1-03
SYSMAC CJ Series
CJ1W-TC@@@
Temperature Control Units
CJ1W-TC@@@
Temperature Control Units
Operation Manual
Revised December 2005
iv
v
Notice:
OMRON products are manufactured for use according to proper procedures by a qualified operator
and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always heed
the information provided with them. Failure to heed precautions can result in injury to people or damage to property.
!DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. Additionally, there may be severe property damage.
!WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury. Additionally, there may be severe property damage.
!Caution Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury, or property damage.
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it refers to
an OMRON product, regardless of whether or not it appears in the proper name of the product.
The abbreviation “Ch,” which appears in some displays and on 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 Programming Device displays to mean Programmable Controller.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of
information.
Note Indicates information of particular interest for efficient and convenient opera-
tion of the product.
1,2,3... 1. Indicates lists of one sort or another, such as procedures, checklists, etc.
OMRON, 2001
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, o
r
by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission o
f
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.
vi
vii
TABLE OF CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii
6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
SECTION 1
Features and System Configuration . . . . . . . . . . . . . . . . . . . 1
1-1 Introduction and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-3 Comparison to C200H Temperature Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 2
Specifications and Functions . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-2 Application Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
3-2 Selecting the Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3-3 Setting the Data Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3-4 Selecting the Control Operation (Forward/Reverse). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3-5 Selecting PID Control or ON/OFF Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3-6 Setting the Control Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3-7 Setting the Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3-8 Using ON/OFF Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
3-9 Setting the PID Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
3-10 Using the Alarm Output Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3-11 Using the Heater Burnout Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3-12 Starting and Stopping Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3-13 Precautions for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
viii
TABLE OF CONTENTS
SECTION 4
Optional Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4-1 Shifting the Input Value (Input Compensation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Appendices
A Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
B Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
ix
About this Manual:
This manual describes the installation and operation of the CJ1W-TC@@@ Temperature Control Units
and includes the sections described on the following page.
Please read this manual and all related manuals listed in the following table carefully and be sure you
understand the information provided before attempting to install or operate the MC Unit. Be sure to
read the precautions provided in the following section.
Name Cat. No. Contents
SYSMAC CJ Series
CJ1W-TC@@@
Temperature Control Units
Operation Manual
W396 Describes the application methods for the CJ-
series Temperature Control Units.
(This manual)
SYSMAC CJ Series
CJ1G/H-CPU@@H, CJ1M-CPU@@, CJ1G-CPU@@
Programmable Controllers
Operation Manual
W393 Provides an outlines of and describes the
design, installation, maintenance, and other
basic operations for the CJ-series PLCs.
SYSMAC CS/CJ Series
CJ1G/H-CPU@@H, CJ1M-CPU@@,
CS1G/H-CPU@@-EV1, CJ1G-CPU@@
Programmable Controllers
Programming Manual
W394 This manual describes programming and other
methods to use the functions of the CS/CJseries PLCs.
SYSMAC CS/CJ-series
CQM1H-PRO01-E, C200H-PRO27-E,
CQM1-PRO01-E
Programming Consoles
Operation Manual
W341 Provides information on how to program and
operate CS/CJ-series PLCs using a Programming 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 Commands
Reference Manual
W342 Describes the C-series (Host Link) and FINS
communications commands used with CS/CJseries PLCs.
SYSMAC CX-Programmer Ver.5.0
WS02-CXPC1-E-V5
Operation Manual
W437 Provide information on how to use the CX-Pro-
grammer, a programming device that supports
the CS/CJ-series PLCs, and the CX-Net contained within CX-Programmer.
SYSMAC CS/CJ-series
CS1W-SCB21-V1/41-V1, CS1W-SCU21-V1,
CJ1W-SCU21/41
Serial Communications Boards and Serial
Communications Units
Operation Manual
W336 Describes the use of Serial Communications
Unit and Boards to perform serial communications with external devices, including the usage
of standard system protocols for OMRON products.
SYSMAC WS02-PSTC1-E
CX-Protocol
Operation Manual
W344 Describes the use of the CX-Protocol to create
protocol macros as communications sequences
to communicate with external devices.
!WARNING Failure to read and understand the information provided in this manual may result in per-
sonal injury or death, damage to the product, or product failure. Please read each section
in its entirety and be sure you understand the information provided in the section and
related sections before attempting any of the procedures or operations given.
x
About this Manual, Continued
Precautions provides general precautions for using the Temperature Control Unit, Programmable
Controller, and related devices.
Section 1 describes the features of the Temperature Control Unit and its basic system 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 various settings required for temperature control.
Section 4 explains how to use the input compensation value.
Section 5 provides information on troubleshooting and error processing.
The Appendices provide Unit dimensions and sample programming.
xi
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 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.
xii
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.
xiii
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.
xiv
xv
PRECAUTIONS
This section provides general precautions for using the Temperature Control Unit, Programmable Controller, and related
devices.
The information contained in this section is important for 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 and PC system.
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii
6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
xvi
Intended Audience 1
1 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 installing FA systems.
• Personnel in charge of designing FA systems.
• Personnel in charge of managing FA systems and facilities.
2 General Precautions
The user must operate the product according to the performance specifications described in the operation manuals.
Before using the product under conditions which are not described in the
manual or applying the product to nuclear control systems, railroad systems,
aviation systems, vehicles, combustion systems, medical equipment, amusement machines, safety equipment, and other systems, machines, and equipment that may have a serious influence on lives and property if used
improperly, consult your OMRON representative.
Make sure that the ratings and performance characteristics of the product are
sufficient for the systems, machines, and equipment, and be sure to provide
the systems, machines, and equipment with double safety mechanisms.
This manual provides information for installing and operating OMRON Temperature Control Units. Be sure to read this manual before operation and keep
this manual close at hand 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 directly or indirectly affect human life. You must consult with your OMRON
representative before applying a PLC system to the above mentioned applications.
3 Safety Precautions
!WARNING Do not attempt to take any Unit apart while the power is being supplied. Doing
so may result in electric shock.
!WARNING Do not touch any of the terminals or terminal blocks while the power is being
supplied. Doing so may result in electric shock.
!WARNING Provide safety measures in external circuits (i.e., not in the Programmable
Controller), including the following items, to ensure safety in the system if an
abnormality occurs due to malfunction of the PLC or another external factor
affecting the PLC operation. Not doing so may result in serious accidents.
• Emergency stop circuits, interlock circuits, limit circuits, and similar safety
measures must be provided in external control circuits.
• The PLC will turn OFF all outputs when its self-diagnosis function detects
any error or when a severe failure alarm (FALS) instruction is executed.
As a countermeasure for such errors, external safety measures must be
provided to ensure safety in the system.
• The PLC outputs may remain ON or OFF due to deposition or burning of
the output relays or destruction of the output transistors. As a counter-
xvii
Operating Environment Precautions 4
measure for such problems, external safety measures must be provided
to ensure safety in the system.
• When the 24-V DC output (service power supply to the PLC) is overloaded or short-circuited, the voltage may drop and result in the outputs
being turned OFF. As a countermeasure for such problems, external
safety measures must be provided to ensure safety in the system.
!Caution Confirm safety before transferring data files stored in the file memory (Mem-
ory Card or EM file memory) to the I/O area (CIO) of the CPU Unit using a
Programming Device. Otherwise, the devices connected to the output unit
may malfunction regardless of the operation mode of the CPU Unit.
!Caution Execute online edit only after confirming that no adverse effects will be
caused by extending the cycle time. Otherwise, the input signals may not be
readable.
!Caution Do not touch the Power Supply Unit while power is being supplied or immedi-
ately after power is turned OFF. Doing so may result in electric shock.
!Caution Confirm safety at the destination node before transferring a program to
another node or changing contents of the I/O memory area. Doing either of
these without confirming safety 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.
!Caution To provide for safe operation even in the event that the 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.
!Caution At least approximately 4 seconds are required for control or heater burnout
outputs to be made from the Temperature Control Unit after power is turned
ON to the PLC. When using the Temperature Control Unit in an external
sequence circuit, allow for this time delay in the system design.
!Caution Do not turn OFF the power supply while data is being written to the EEPROM
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 EEPROM may be destroyed.
4 Operating Environment Precautions
!Caution Do not operate the control system in the following locations:
• Locations subject to direct sunlight.
• Locations subject to temperatures or humidity outside the range specified
in the specifications.
xviii
Application Precautions 5
• 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.
!Caution Take appropriate and sufficient countermeasures when installing systems in
the following locations:
• 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 supplies.
!Caution The operating environment of the PLC System can have a large effect on the
longevity and reliability of the system. Improper operating environments can
lead to malfunction, failure, and other unforeseeable problems with the PLC
System. Be sure that the operating environment is within the specified conditions at installation and remains within the specified conditions during the life
of the system.
5 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
Ω or less when installing the Units. Not
connecting to a ground of 100
Ω or less may result in electric shock.
• Always turn OFF the power supply to the PLC before attempting any of
the following. Not turning OFF the power supply may result in malfunction
or electric shock.
• Mounting or dismounting Power Supply Units, I/O Units, CPU Units, or
any other Units.
• Assembling the Units.
• Setting DIP switches or rotary switches.
• Connecting cables or wiring the system.
• Connecting or disconnecting the connectors.
!Caution Failure to abide by the following precautions could lead to faulty operation of
the PLC or the system, or could damage the PLC or PLC Units. Always heed
these precautions.
• Do not attempt to take any Units apart, to repair any Units, or to modify
any Units in any way.
• Do not drop the Temperature Control Unit or subject it to abnormal shock
or vibration.
• Always turn ON power to the PLC before turning ON power to the I/O circuits. If the PLC power supply is turned ON after the I/O power supply,
correct operation may not be possible for a period of time.
xix
Application Precautions 5
• Fail-safe measures must be taken by the customer to ensure safety in the
event that outputs from Output Units remain ON as a result of internal circuit failures, which can occur in relays, transistors, and other elements.
• Fail-safe measures must be taken by the customer to ensure safety in the
event of incorrect, missing, or abnormal signals caused by broken signal
lines, momentary power interruptions, or other causes.
• Interlock circuits, limit circuits, and similar safety measures in external circuits (i.e., not in the Programmable Controller) must be provided by the
customer.
• Do not turn OFF the power supply to the PLC when data is being transferred.
• If the I/O Hold Bit is turned ON, the outputs from the PLC will not be
turned OFF and will maintain their previous status when the PLC is
switched from RUN or MONITOR mode to PROGRAM mode. Make sure
that the external loads will not produce dangerous conditions when this
occurs. (When operation stops for a fatal error, including those produced
with the FALS(007) instruction, all outputs from Output Unit will be turned
OFF and only the internal output status will be maintained.)
• Always use the power supply voltages specified in the operation manuals.
An incorrect voltage may result in malfunction or burning.
• Take appropriate measures to ensure that the specified power with the
rated voltage and frequency is supplied. Be particularly careful 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-circuiting in external wiring. Insufficient safety measures against short-circuiting may result in burning.
• Separate the Temperature Control Unit from devices that generate short
harmonics.
• Always be sure that the power supply voltage and loads are within specifications and ratings.
• Disconnect the LG terminal on the Power Supply Unit from the GR terminal when performing withstand voltage tests or insulation resistance tests.
Not disconnecting the functional ground terminal may result in burning.
• Install the Units properly as specified in the operation manuals. Improper
installation of the Units may result in malfunction.
• Be sure that all the terminal screws, and cable connector screws are tightened to the torque specified in the relevant manuals. Incorrect tightening
torque may result in malfunction.
• Leave the label attached to the Unit when wiring. Removing the label may
result in malfunction if foreign matter enters the Unit.
• Remove the label after the completion of wiring to ensure proper heat dissipation. Leaving the label attached may result in malfunction.
• Use crimp terminals for wiring. Do not connect bare stranded wires
directly to terminals. Connection of bare stranded wires may result in
burning.
• Wire all connections correctly as specified in this manual.
• Check the polarity before wiring terminals.
• Double-check all wiring and switch settings before turning ON the power
supply. Incorrect wiring may result in burning.
xx
Application Precautions 5
• Mount Units only after checking terminal blocks and connectors completely.
• Be sure that the terminal blocks, Memory Units, expansion cables, and
other items with locking devices are properly locked into place. Improper
locking may result in malfunction.
• Check the user program for proper execution before actually running it on
the Unit. Not checking the program may result in an unexpected operation.
• Confirm that no adverse effect will occur in the system before attempting
any of the following. Not doing so may result in an unexpected operation.
• Changing the operating mode of the PLC (including the Startup Mode)
• Force-setting/force-resetting any bit in memory.
• Changing the present value of any word or any set value in memory.
• Do not pull on the cables or bend the cables beyond their natural limit.
Doing either of these may break the cables.
• Do not place objects on top of the cables or other wiring lines. Doing so
may break the cables.
• When replacing parts, be sure to confirm that the rating of a new part is
correct. Not doing so may result in malfunction or burning.
• Before touching a Unit, be sure to first touch a grounded metallic object in
order to discharge any static build-up. Not doing so may result in malfunction or damage.
• When transporting or storing circuit boards, cover them in antistatic material 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 subject to excessive shock or vibration, or drop them, during
transport.
• Store the Unit between -20 and 75
°C and 10% to 90% humidity (with no
icing or condensation).
• Do not drop the Unit or allow it to fall during installation.
• Always use the specified wiring material when connecting the Unit.
Terminal block on the Temperature Control Unit: AWG22 to AWG18 (0.32
to 8.2 mm
2
).
• When not using temperature input terminals, connect between 100 and
200
Ω between terminals A and B, as well as B and B’ for platinum resis-
tance thermometer and short the input terminals for thermocouples. Do
not connect anything to terminals that are not being used.
• 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.
• Be sure that the rated voltage is reached within 2 seconds of turning ON
the power supply.
• 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.
xxi
Conformance to EC Directives 6
• 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.
• Do not use the Unit in locations where it will be subject to direct radiant
head from a heater.
• Always use round crimp terminals on the AC power terminals of the
Power Supply Unit. Never connect twisted wires to the terminals.
• Do not install the Unit in locations subject to excessive noise. Noise can
cause malfunctions.
• Wire signal lines in separate ducts from high-voltage or power supply
lines.
• Abide by all applicable laws, ordinances, and regulations when disposing
of the Unit.
• Confirm that ratings are correct before replacing any part.
6 Conformance to EC Directives
6-1 Applicable Directives
•EMC Directives
• Low Voltage Directive
6-2 Concepts
EMC Directives
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 (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 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.
Note Applicable EMC (Electromagnetic Compatibility) standards for the CS-series
and CJ-series PLCs are as follows:
EMS (Electromagnetic Susceptibility): EN61000-6-2
EMI (Electromagnetic Interference): EN61000-6-4
(Radiated emission: 10-m regulations)
Low Voltage Directive
Always ensure that devices operating at voltages of 50 to 1,000 V AC and 75
to 1,500 V DC meet the required safety standards for the PLC (EN61131-2).
6-3 Conformance to EC Directives
The CS/CJ-series PLCs comply with EC Directives. To ensure that the
machine or device in which the CS/CJ-series PLC is used complies with EC
Directives, the PLC must be installed as follows:
1,2,3... 1. The CS/CJ-series PLC must be installed within a control panel.
xxii
Conformance to EC Directives 6
2. You must use reinforced insulation or double insulation for the DC power
supplies used for the communications power supply and I/O power supplies.
3. CS/CJ-series PLCs complying with EC Directives also conform to the
Common Emission Standard (EN61000-6-4). 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.
6-4 Relay Output Noise Reduction Methods
The CS/CJ-series PLCs conforms to the Common Emission Standards
(EN61000-6-4) of the EMC Directives. However, noise generated by relay output switching may not satisfy these Standards. In such a case, a surge suppressor must be connected to the load side or other appropriate
countermeasures must be provided external to the PLC.
Countermeasures taken to satisfy the standards vary depending on the
devices on the load side, wiring, configuration of machines, etc. Following are
examples of countermeasures for reducing the generated noise.
Countermeasures
(Refer to EN61000-6-4 for more details.)
Countermeasures are not required if the frequency of load switching for the
whole system with the PLC included is less than 5 times per minute.
Countermeasures are required if the frequency of load switching for the whole
system with the PLC included is 5 times or more per minute.
xxiii
Conformance to EC Directives 6
Countermeasure Examples
When switching an inductive load, connect an surge protector, diodes, etc., in
parallel with the load or contact as shown below.
When switching a load with a high inrush current such as an incandescent
lamp, suppress the inrush current as shown below.
Circuit Current Characteristic Required element
AC DC
Yes Yes If the load is a relay or solenoid, there is
a time lag between the moment the circuit is opened and the moment the load
is reset.
If the supply voltage is 24 or 48 V, insert
the surge protector in parallel with the
load. If the supply voltage is 100 to
200 V, insert the surge protector
between the contacts.
The capacitance of the capacitor must
be 1 to 0.5 µF per contact current of
1 A and resistance of the resistor must
be 0.5 to 1 Ω per contact voltage of 1 V.
These values, however, vary with the
load and the characteristics of the
relay. Decide these values from experiments, and take into consideration that
the capacitance suppresses spark discharge when the contacts are separated and the resistance limits the
current that flows into the load when
the circuit is closed again.
The dielectric strength of the capacitor
must be 200 to 300 V. If the circuit is an
AC circuit, use a capacitor with no
polarity.
No Yes The 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
resistance of the inductive load.
This time lag, between the moment the
circuit is opened and the moment the
load is reset, caused by this method is
longer than that caused by the CR
method.
The reversed dielectric strength value
of the diode must be at least 10 times
as large as the circuit voltage value.
The forward current of the diode must
be the same as or larger than the load
current.
The reversed dielectric strength value
of the diode may be two to three times
larger than the supply voltage if the
surge protector is applied to electronic
circuits with low circuit voltages.
Yes Yes The varistor method prevents the impo-
sition of high voltage between the contacts by using the constant voltage
characteristic of the varistor. There is
time lag between the moment the circuit is opened and the moment the load
is reset.
If the supply voltage is 24 or 48 V, insert
the varistor in parallel with the load. If
the supply voltage is 100 to 200 V,
insert the varistor between the contacts.
---
CR method
Inductive
load
Power
supply
C
R
Diode method
Powe r
supply
Inductive
load
Varistor method
Power
supply
Inductive
load
OUT
COM
R
OUT
COM
R
Countermeasure 1
Providing a dark current of
approx. one-third of the rated
value through an incandescent
Countermeasure 2
Providing a limiting resistor
lamp
1
SECTION 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-1-1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-1-2 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-2-1 Basic System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-2-2 Mounting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-3 Comparison to C200H Temperature Control Units . . . . . . . . . . . . . . . . . . . . 10
2
Introduction and Features Section 1-1
1-1 Introduction and Features
1-1-1 Introduction
The CJ1W-TC@@@ Temperature Control Units are Special I/O Units that
receive inputs directly from thermocouple or platinum resistance thermometers, perform PID control with two degrees of freedom, and output results
through open collector outputs.
There are two main types of Unit: One provides four control loops and the
other provides two control loops with a heater burnout detection function.
Each of these has one model that is compatible with thermocouples (R, S, K,
J, T, B, or L) and another model that is compatible with platinum resistance
thermometers (JPt100 or Pt100). Both NPN outputs and PNP outputs are
available.
Autotuning of the PID control is also possible.
Available 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
(with heater burnout detection function)
Thermocouple CJ1W-TC003 CJ1W-TC004
Platinum resistance thermometer CJ1W-TC103 CJ1W-TC104
Item Thermocouple Platinum resistance
thermometer
K(CA) K(CA) J(IC) J(IC) T(CC) L L R S B Pt100 JPt100 ---
Input Type Setting
01234567890 12 to 9
Minimum Units 1°C0.1°C1°C0.1°C0.1°C1°C0.1°C1°C1°C1°C0.1°C0.1°C ---
1300
−200
500.0
0.0
850
−100
0.0
400.0 400.0
−200.0
−100
850
0.0
400.0
0
1700
0
1700
100
1800
−200.0
650.0
−200.0
650.0
K (CA): Chromel-alumel
J (IC): Iron-constantan
T (CC): Copper-constantan
L: Iron-constantan
R: Platinum 13% Rhodium-Platinum
S: Platinum 10% Rhodium-Platinum
B: Platinum 30% Rhodium-Platinum 6% Rhodium
Usable temperature range
(
°
C)
Settings 2 to 9 are not allowed.
1800
1600
1400
1200
1000
800
600
400
200
0
-200
3
Introduction and Features Section 1-1
Word Allocation Data is exchanged between the CPU Unit and the Temperature Control Unit
through the PLC’s memory areas. A part of the CIO Area (the Special I/O Unit
Area) and part of the DM Area are reserved for the Special I/O Units.
The Temperature Control Unit requires 20 words in the CIO Area and 100
words in the DM Area. (The unit number set on the front of the Unit determines which words are actually allocated to the Unit.)
1-1-2 Features
Use ON/OFF Control or
PID Control with 2 or 4
Control Loops
The Temperature Control Unit can perform basic ON/OFF control as well as
PID control of two or four control loops. The PID control function has two
degrees of freedom and an autotuning function that can be used to autotune
the PID value.
Connect Temperature
Sensors Directly
Temperature sensors can be connected directly to the Temperature Control
Unit (two or four inputs). There are two models that support thermocouples
(R, S, K, J, T, B, and L thermocouples) and two models that support platinum
resistance thermometers.
500-ms Sampling Cycle PID control is performed with a sampling cycle of 500 ms, regardless of the
CPU Unit’s cycle time.
Unrestricted CPU Unit
Cycle Time
There are no restrictions on the CPU Unit’s cycle time.
RUN/STOP Control from
CPU Unit
Commands can be sent from the CPU Unit to switch the Temperature Control
Unit’s PID control between RUN and STOP.
Independent Operation in
PROGRAM Mode
A switch on the front of the Unit (pin 1 of the DIP switch) selects whether the
Temperature Control Unit will continue operation or stop when the CPU Unit is
in PROGRAM mode.
Termina l Block
Connections
Both inputs and outputs are connected through a terminal block.
Store and Display Data in
BCD or Hexadecimal
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., 4digit hexadecimal.) This switch setting controls both the display format and the
storage format in the memory areas (CIO and DM Areas) used to exchange
data between the CPU Unit and Temperature Control Unit.
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.
Control Methods • 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 weak-
Example Data storage/display format
Sensor input Binary (4-digit hexadecimal) 4-digit BCD
K: −200 to 1,300°C FF38 to FFFF to 0514
(−200 to −1 to 1,300)
F200 to 1300
(−200 to 1,300)
4
Introduction and Features Section 1-1
ness in this design was that both responses could not be satisfied at the
same time.
1. If the disturbance response were emphasized (i.e., P and I were re-
duced and D was increased), the SV response would oscillate and
overshoot.
2. If the SV response were 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
■ PID Control with Two Degrees of Freedom
■ Autotuning (AT) Function
The Temperature Control Unit is equipped with an autotuning (AT) function
that uses the “limit-cycle method” to calculate the optimum PID constant for
the controlled system. (The SV cannot be written for a loop if the loop is being
autotuned.)
1
2
The disturbance response is good, but
the SV response is delayed.
The SV response is good, but the
disturbance response is not.
3
Both the SV response and disturbance
response are good.
SV
AT starts.
AT stops.
Hunting period
Amplitude
5
Introduction and Features Section 1-1
Note The “limit-cycle method” uses ON/OFF operation to cause hunting around the
SV, measures the amplitude and hunting period, and calculates the optimum
PID constants.
Control Operation
(Forward and Reverse)
The Temperature Control Unit’s control can be set to reverse operation or forward operation with pins 4 and 5 of the Unit’s DIP switch. The factory setting is
for reverse operation (heating).
One forward/reverse setting controls the operation of loops 1 and 3, and the
other forward/reverse setting controls the operation of loops 2 and 4.
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.
For example, when heating control is being performed and the present temperature (PV) is lower than the target temperature (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.”
Input Compensation
Function
This function adjusts the PV by adding an input compensation value to the
temperature measured by the sensor.
If you have an application where you want to control and display the temperature at a point that is offset from the sensor’s measurement point, use this
function to control the temperature at a value near the desired point.
Heater Burnout Detection
(Single-phase Operation
Only)
When a Two-loop Temperature Control Unit is being used, a Current Transformer (CT) can be connected to each loop to detect a heater burnout.
Two Internal Alarms for
Each Loop
There are two internal alarms per loop. Alarms can be output to the allocated
areas 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 upperlimit alarm, and absolute-value lower-limit alarm
Store Settings in EEPROM Various Temperature Control Unit settings, such as the alarm SVs and PID
constants, can be stored in the Unit’s EEPROM using a control bit in the CPU
Unit’s allocated memory area.
Also, it is possible to set the Temperature Control Unit so that the settings
stored in EEPROM are automatically written to the appropriate area in the
CPU Unit when the power is turned ON or the Unit is restarted. This automatic
transfer function is controlled by a switch (pin 8 of the DIP switch) on the front
of the Temperature Control Unit.
0%
100%
Low
temperature
SV
High
temperature
Forward operation
0%
100%
Low
temperature
SV
High
temperature
Reverse operation
Manipulated variable
Manipulated variable
6
System Configuration Section 1-2
Once the settings 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 settings can be changed
after startup if necessary.)
To simplify Temperature Control Unit operation, pin 8 on 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 default
values. (Refer to 2-6-1 Settings for the default settings.)
1-2 System Configuration
1-2-1 Basic System Configuration
The following diagram shows a basic system with a CJ1W-TC001 Temperature Control Unit (4 control loops, thermocouple inputs, and NPN 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 Transformer must be used as
the Current Transformer (CT). Do not use any other Current Transformer.
2. 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.
1-2-2 Mounting the Unit
The CJ1W-TC@@@ Temperature Control Units are CJ-series Special I/O
Units, so they can be mounted in a CJ-series CPU Rack or Expansion Rack.
CJ1W-TC001
Four-loop Unit,
Thermocouple,
NPN outputs
CJ1W-TC103
Two-loop Unit, platinum resistance
thermometer, NPN outputs
Power supply
for outputs
(24 VDC)
Heater
Current
Transformer
E54-CT1 or E54-CT3
Temperature Sensor
Thermocouple or platinum
resistance thermometer
Control output
200 VAC
1 kW
7
System Configuration Section 1-2
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.
Note I/O words are allocated to the Special I/O Units based on the unique unit num-
ber set on the front of each Unit.
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.
1,2,3... 1. Align the Units and connect them together so that the connectors join
smoothly and completely.
2. Slide the yellow latches on the top and bottom of the Unit until you hear the
latches click and lock the Units together.
3. Install an End Cover on the rightmost Unit.
Precautions The Unit’s functions may not be completely operational if the latches are not
locked securely.
Power Supply Unit CJ1W-TC@@@
CJ1W-PA205R 10 Units
Hooks
Connector
Openings for hooks
Slide latches back until they lock.
(The latches will click when they lock.)
Release
Lock
Sliding
latch
Loading...