OMRON NX102 User Manual

Machine Automation Controller

NX-series

NX102 CPU Unit

Hardware User’s Manual

NX102-

CPU Unit

W593-E1-07

NOTE

• All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in
any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior
written permission of OMRON.

• No patent liability is assumed with respect to the use of the information contained herein.
Moreover, because OMRON is constantly striving to improve its high-quality products, the information contained
in this manual is subject to change without notice.

• Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsi­bility for errors or omissions.
Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

Trademarks

• Sysmac and SYSMAC are trademarks or registered trademarks of OMRON Corporation in Japan and other
countries for OMRON factory automation products.

• Microsoft, Windows, Excel, and Visual Basic are either registered trademarks or trademarks of Microsoft Corpora­tion in the United States and other countries.

• EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.

• ODVA, CIP, CompoNet, DeviceNet, and EtherNet/IP are trademarks of ODVA.

• The SD and SDHC logos are trademarks of SD-3C, LLC.

Other company names and product names in this document are the trademarks or registered trademarks of their
respective companies.

Copyrights

• Microsoft product screen shots reprinted with permission from Microsoft Corporation.

• This product incorporates certain third party software. The license and copyright information associated with this
software is available at http://www.fa.omron.co.jp/nj_info_e/.

Introduction

Thank you for purchasing an NX-series CPU Unit.

This manual contains information that is necessary to use the NX-series CPU Unit. Please read this

manual and make sure you understand the functionality and performance of the NX-series CPU Unit

before you attempt to use it in a control system.

Keep this manual in a safe place where it will be available for reference during operation.

Intended Audience

This manual is intended for the following personnel, who must also have knowledge of electrical sys-

tems (an electrical engineer or the equivalent).

• Personnel in charge of introducing FA systems.

• Personnel in charge of designing FA systems.

• Personnel in charge of installing and maintaining FA systems.

• Personnel in charge of managing FA systems and facilities.

For programming, this manual is intended for personnel who understand the programming language

specifications in international standard IEC 61131-3 or Japanese standard JIS B 3503.

Introduction

Applicable Products

This manual covers the following products.

• NX-series CPU Units

NX102-££££

Part of the specifications and restrictions for the CPU Units are given in other manuals. Refer to Rele-

vant Manuals on page 2 and Related Manuals on page 41.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

1

Relevant Manuals

Relevant Manuals

The following table provides the relevant manuals for the NX-series CPU Units. Read all of the man-

uals that are relevant to your system configuration and application before you use the NX-series CPU

Unit.

Most operations are performed from the Sysmac Studio Automation Software. Refer to the Sysmac

Studio Version 1 Operation Manual (Cat. No. W504) for information on the Sysmac Studio.

Basic informa-

tion

NX-series NX102 CPU Unit

Hardware User’s Manual

NJ/NX-series CPU Unit

Software User’

NJ/NX-series

Instructions Reference Manual

Motion Control User

Manual

NJ/NX-series CPU Unit

NJ/NX-series

Motion Control Instructions Reference Manual

NJ/NX-series CPU Unit

Built-in EtherCA

NJ/NX-series CPU Unit

Built-in EtherNet/IP Port User’

NJ/NX-series CPU Unit

OPC UA User’

NX-series CPU Unit

FINS Function User’

NJ/NX-series Database Connection CPU Units

User's Manual

NJ/NX-series

T
roubleshooting Manual

Purpose of use

Introduction to NX102 CPU Units

Setting devices and hardware

Using motion control

Using EtherCAT

Using EtherNet/IP

Software settings

Using motion control

Using EtherCAT

Using EtherNet/IP

Using OPC UA

Using FINS

Using the database connection service

Writing the user program

Using motion control

Using EtherCAT

Using EtherNet/IP

Using OPC UA

Using FINS

Using the database connection service

Programming error processing

l

l

s Manual

l

l l

’

s Manual

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l

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T Port User

s Manual

s Manual

’s Manual

s Manual

l

l

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l

l

l

l

l

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l

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NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Basic informa-

tion

NX-series NX102 CPU Unit

Hardware User’s Manual

NJ/NX-series CPU Unit

Software User’

NJ/NX-series

Instructions Reference Manual

Motion Control User

Relevant Manuals

Manual

NJ/NX-series CPU Unit

NJ/NX-series

Motion Control Instructions Reference Manual

NJ/NX-series CPU Unit

Built-in EtherCA

NJ/NX-series CPU Unit

Built-in EtherNet/IP Port User’

NJ/NX-series CPU Unit

OPC UA User’

NX-series CPU Unit

FINS Function User’

NJ/NX-series Database Connection CPU Units

User's Manual

NJ/NX-series

T
roubleshooting Manual

s Manual

Purpose of use

Testing operation and debugging

Using motion control

Using EtherCAT

Using EtherNet/IP

Using OPC UA

Using FINS

Using the database connection service

Learning about error management and cor-

rections

Maintenance

*1. Refer to the NJ/NX-series Troubleshooting Manual (Cat. No. W503) for the error management concepts and the error

*1

Using motion control

Using EtherCAT

Using EtherNet/IP

items. However
products with the manuals that are indicated with triangles (r).

, refer to the manuals that are indicated with triangles (r) for details on errors corresponding to the

l

l

’

s Manual

l

l

T Port User

’s Manual

l

l

s Manual

s Manual

s Manual

l

l

l

l

r r r l

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NX-series NX102 CPU Unit Hardware User’s Manual (W593)

3

4-9

4 Installation and Wir

ing

NJ-series CPU Unit Hardware User’s Manual (W500)

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3-

4

4-3 Mounting Units

The Units that make up an NJ-series Controller can be connected simply by pressing the Units together
and locking the sliders by moving them toward the back of the Units. The End Cover is connected in the
same way to the Unit on the far right side of the Controller.

1 Join the Units so that the connectors fit exactly.

2 The yellow sliders at the top and bottom of each Unit lock the Units together. Move the sliders

toward the back of the Units as shown below until they click into place.

Precautions for Correct UsePrecautions for Correct Use

4-3-1 Connecting Controller Components

Connector

Hook

Hook holes

Slider

Lock

Release

Move the sliders toward the back
until they lock into place.

Level 1 heading
Level 2 heading
Level 3 heading

Level 2 heading

A step in a procedure

Manual name

Special information

Level 3 heading

Page tab

Gives the current
headings.

Indicates a procedure.

Icons indicate
precautions, additional
information, or reference
information.

Gives the number
of the main section.

The sliders on the tops and bottoms of the Power Supply Unit, CPU Unit, I/O Units, Special I/O
Units, and CP

U Bus Units must be completely locked (until they click into place) after connecting

the adjacent Unit connectors.

Manual Structure

Manual Structure

Page Structure

The following page structure is used in this manual.

Note This illustration is provided only as a sample. It may not literally appear in this manual.

4

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Special Information

Special information in this manual is classified as follows:

Precautions for Safe Use

Precautions on what to do and what not to do to ensure safe usage of the product.

Precautions for Correct Use

Precautions on what to do and what not to do to ensure proper operation and performance.

Additional Information

Additional information to read as required.
This information is provided to increase understanding or make operation easier.

Manual Structure

Version Information

Information on differences in specifications and functionality for CPU Units with different unit
versions and for different versions of the Sysmac Studio is given.

Precaution on Terminology

In this manual, "download" refers to transferring data from the Sysmac Studio to the physical Control-

ler and

For the Sysmac Studio, "synchronization" is used to both "upload" and "download" data. Here,

"synchronize" means to automatically compare the data for the Sysmac Studio on the computer with

the data in the physical Controller and transfer the data in the direction that is specified by the user.

"upload

" refers to transferring data from the physical Controller to the Sysmac Studio.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

5

Manual Structure

6

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Sections in this Manual

1

2

3

4

5

1

2

3

4

5

A

Introduction to NX-series Controllers

System Configuration

Configuration Units

Designing the Power Supply System

Installation and W

iring

A

6

7

Appendices

6

7

Troubleshooting

Inspection and Maintenance

I

I

Index

Sections in this Manual

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

7

CONTENTS

CONTENTS

Introduction .............................................................................................................. 1

Intended Audience...........................................................................................................................................1

Applicable Products

Relevant Manuals..................................................................................................... 2

Manual Structure...................................................................................................... 4

Page Structure.................................................................................................................................................4

Special Information .......................................................................................................................................... 5

Precaution on Terminology ..............................................................................................................................5

Sections in this Manual ........................................................................................... 7

Terms and Conditions Agreement........................................................................ 12

Warranty, Limitations of Liability ....................................................................................................................12

Application Considerations ............................................................................................................................13

Disclaimers ....................................................................................................................................................13

.........................................................................................................................................1

Safety Precautions................................................................................................. 15

Definition of Precautionary Information.......................................................................................................... 15

Symbols ......................................................................................................................................................... 15

WARNING......................................................................................................................................................16

Cautions......................................................................................................................................................... 18

Precautions for Safe Use ...................................................................................... 20

Precautions for Correct Use ................................................................................. 31

Regulations and Standards .................................................................................. 35

Conformance to EU Directives ......................................................................................................................35

Conformance to UL and CSA Standards.......................................................................................................36

Conformance to KC Certification ...................................................................................................................36

Conformance to Shipbuilding Standards .......................................................................................................36

Software Licenses and Copyrights ................................................................................................................37

Versions.................................................................................................................. 38

Checking Versions.........................................................................................................................................38

Unit Versions of CPU Units and Sysmac Studio Versions.............................................................................40

Related Manuals..................................................................................................... 41

Terminology............................................................................................................ 44

Revision History..................................................................................................... 49

Section 1 Introduction to NX-series Controllers

1-1 The NX-series Controller.......................................................................................................1-2

1-1-1 Features

1-1-2 Introduction to the System Configurations ..................................................................................1-6

1-2 Specifications.........................................................................................................................1-9

1-3 Overall Operating Procedure for the CPU Unit ................................................................. 1-15

8

......................................................................................................................................1-3

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

1-3-1 Overall Procedure .....................................................................................................................1-15

1-3-2 Procedure Details

......................................................................................................................1-16

Section 2 System Configuration

2-1 Basic System Configuration.................................................................................................2-2

2-1-1 EtherCA

2-1-2 NX Unit Configuration .................................................................................................................2-4

T Network Configuration ................................................................................................2-3

2-2 Connecting to the Sysmac Studio........................................................................................2-6

2-3 Network Configuration .......................................................................................................... 2-7

Section 3 Configuration Units

3-1 CPU Units ...............................................................................................................................3-2

3-1-1 Models and Specifications

3-1-2 Part Names and Functions..........................................................................................................3-4

3-1-3 Operation Status Indicators.........................................................................................................3-6

3-1-4 Terminal Blocks ......................................................................................................................... 3-11

3-1-5 Battery .......................................................................................................................................3-12

3-1-6 ID Information Indication ...........................................................................................................3-13

3-2 SD Memory Cards................................................................................................................3-15

3-2-1 Models and Specifications ........................................................................................................3-15

3-2-2 Purpose .....................................................................................................................................3-15

3-3 Power Supply-related Units ................................................................................................ 3-16

3-4 NX Units................................................................................................................................3-17

3-5 Sysmac Studio ..................................................................................................................... 3-18

3-5-1 Model Numbers .........................................................................................................................3-18

3-5-2 Connection ................................................................................................................................3-18

..........................................................................................................3-2

CONTENTS

Section 4 Designing the Power Supply System

4-1 Power Supply System ...........................................................................................................4-2

4-1-1 NX Unit Power Supply and I/O Power Supply.............................................................................4-2

4-1-2 NX-series Power Supply-related Units ........................................................................................4-3

4-2 Designing the NX Unit Power Supply System...................................................................4-10

4-2-1 Procedure for Designing the NX Unit Power Supply System ....................................................4-10

4-2-2 Calculation Example for the NX Unit Power Supply..................................................................4-11

4-3 Designing the I/O Power Supply System...........................................................................4-13

4-3-1 I/O Power Supply Method .........................................................................................................4-13

4-3-2 Designing the I/O Power Supply from the NX Bus ....................................................................4-14

4-3-3 Designing the I/O Power Supply from External Sources...........................................................4-19

4-3-4 Restrictions on Inrush Current for ON/OFF Operation ..............................................................4-20

4-4 Selecting External Power Supplies and Protective Devices............................................4-21

4-4-1 Selecting the Unit Power Supply ...............................................................................................4-21

4-4-2 Selecting the I/O Power Supplies..............................................................................................4-23

4-4-3 Selecting Protective Devices.....................................................................................................4-24

Section 5 Installation and Wiring

5-1 Processing at Power ON and Power OFF............................................................................5-2

5-1-1 Power ON Operation

5-1-2 Power OFF Operation .................................................................................................................5-4

5-1-3 Resetting the Controller from the Sysmac Studio .......................................................................5-6

...................................................................................................................5-2

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

9

CONTENTS

5-2 Fail-safe Circuits....................................................................................................................5-7

5-3 Mounting and Removing Units

5-4 Wiring....................................................................................................................................5-41

5-5 Control Panel Installation....................................................................................................5-65

.............................................................................................5-9

5-3-1 Installation in a Control Panel ...................................................................................................5-10

5-3-2 Preparations for Installation ......................................................................................................5-14

5-3-3 Installing the CPU Unit ..............................................................................................................5-16

5-3-4 Attaching Markers .....................................................................................................................5-19

5-3-5 Installing and Connecting NX Units...........................................................................................5-20

5-3-6 Mounting the End Cover ...........................................................................................................5-24

5-3-7 Mounting the End Plates ...........................................................................................................5-25

5-3-8 Installing and Removing the SD Memory Card .........................................................................5-27

5-3-9 Battery Installation.....................................................................................................................5-32

5-3-10 Removing CPU Unit ..................................................................................................................5-35

5-3-11 Removing NX Units...................................................................................................................5-36

5-3-12 Assembled Appearance and Dimensions .................................................................................5-37

5-4-1 Wiring the Unit Power Supply ...................................................................................................5-42

5-4-2 Wiring the Additional NX Unit Power Supply Unit .....................................................................5-42

5-4-3 Wiring the Additional I/O Power Supply Unit .............................................................................5-42

5-4-4 Wiring the Protective Devices ...................................................................................................5-43

5-4-5 Grounding .................................................................................................................................5-44

5-4-6 Wiring the Built-in EtherCAT Port..............................................................................................5-49

5-4-7 Wiring the Built-in EtherNet/IP Port ...........................................................................................5-49

5-4-8 Wiring to the CPU Unit Terminal Block......................................................................................5-49

5-5-1 Temperature ..............................................................................................................................5-65

5-5-2 Humidity ....................................................................................................................................5-67

5-5-3 Vibration and Shock ..................................................................................................................5-67

5-5-4 Atmosphere ...............................................................................................................................5-67

5-5-5 Electrical Environment ..............................................................................................................5-68

5-5-6 Grounding .................................................................................................................................5-72

Section 6 Troubleshooting

6-1 Overview of Troubleshooting ...............................................................................................6-2

Section 7 Inspection and Maintenance

7-1 Cleaning and Maintenance....................................................................................................7-2

7-1-1 Cleaning

7-1-2 Periodic Inspections ....................................................................................................................7-3

7-1-3 Unit Replacement Precautions....................................................................................................7-4

......................................................................................................................................7-2

7-2 Replacing the Battery............................................................................................................7-6

Appendices

A-1 Specifications........................................................................................................................ A-2

A-2 Dimensions............................................................................................................................ A-3

A-2-1 NX-series NX102 CPU Unit ....................................................................................................... A-3

A-2-2 End Cover .................................................................................................................................. A-4

A-2-3 SD Memory Card ....................................................................................................................... A-4

A-3 List of Terminal Block Models ............................................................................................. A-5

A-3-1 Model Notation ........................................................................................................................... A-5

A-3-2 List of Terminal Block Models..................................................................................................... A-5

A-4 Version Information .............................................................................................................. A-7

A-4-1 Relationship between Unit Versions of CPU Units and Sysmac Studio Versions...................... A-7

A-4-2 Functions That Were Added or Changed for Each Unit Version................................................ A-8

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NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Index

CONTENTS

A-5 Support Functions of the CPU Units and Restrictions on the NX Units........................ A-10

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

11

Terms and Conditions Agreement

Terms and Conditions Agreement

Warranty, Limitations of Liability

Warranties

Exclusive Warranty

l

Omron’s exclusive warranty is that the Products will be free from defects in materials and work-

manship for a period of twelve months from the date of sale by Omron (or such other period ex-

pressed in writing by Omron). Omron disclaims all other warranties, express or implied.

Limitations

l

OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT

NON-INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF

THE PRODUCTS. BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE

PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE.

Omron further disclaims all warranties and responsibility of any type for claims or expenses based

on infringement by the Products or otherwise of any intellectual property right.

Buyer Remedy

l

Omron’s sole obligation hereunder shall be, at Omron’s election, to (i) replace (in the form originally

shipped with Buyer responsible for labor charges for removal or replacement thereof) the non-com-

plying Product, (ii) repair the non-complying Product, or (iii) repay or credit Buyer an amount equal

to the purchase price of the non-complying Product; provided that in no event shall Omron be re-

sponsible for warranty, repair, indemnity or any other claims or expenses 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. Return

of any Products by Buyer must be approved in writing by Omron before shipment. Omron Compa-

nies shall not be liable for the suitability or unsuitability or the results from the use of Products in

combination with any electrical or electronic components, circuits, system assemblies or any other

materials or substances or environments. Any advice, recommendations or information given orally

or in writing, are not to be construed as an amendment or addition to the above warranty.

12

See http://www.omron.com/global/ or contact your Omron representative for published information.

Limitation on Liability; Etc

OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CON-

SEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED IN CONTRACT,

WARRANTY

Further, in no event shall liability of Omron Companies exceed the individual price of the Product on

which liability is asserted.

, NEGLIGENCE OR STRICT LIABILITY.

Application Considerations

Suitability of Use

Omron Companies shall not be responsible for conformity with any standards, codes or regulations

which apply to the combination of the Product in the Buyer’

er’s request, Omron will provide applicable third party certification documents identifying ratings and

limitations of use which apply to the Product. This information by itself is not sufficient for a complete

determination of the suitability of the Product in combination with the end product, machine, system, or

other application or use. Buyer shall be solely responsible for determining appropriateness of the par-

ticular Product with respect to Buyer’s application, product or system. Buyer shall take application re-

sponsibility in all cases.

Terms and Conditions Agreement

s application or use of the Product. At Buy-

NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR

PROPERTY OR IN LARGE QUANTITIES WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE

HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT(S) IS

PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIP-

MENT OR SYSTEM.

Programmable Products

Omron Companies shall not be responsible for the user’s programming of a programmable Product, or

any consequence thereof.

Disclaimers

Performance Data

Data presented in Omron Company websites, catalogs and other materials is provided as a guide for

the user in determining suitability and does not constitute a warranty. It may represent the result of

Omron’

formance is subject to the Omron’s Warranty and Limitations of Liability.

s test conditions, and the user must correlate it to actual application requirements. Actual per-

Change in Specifications

Product specifications and accessories may be changed at any time based on improvements and oth-

er reasons. It is our practice to change part numbers when published ratings or features are changed,

or when significant construction changes are made. However, some specifications of the Product may

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

13

Terms and Conditions Agreement

be changed without any notice. When in doubt, special part numbers may be assigned to fix or estab-

lish key specifications for your application. Please consult with your Omron’s representative at any

time to confirm actual specifications of purchased Product.

Errors and Omissions

Information presented by Omron Companies has been checked and is believed to be accurate; how-

ever, no responsibility is assumed for clerical, typographical or proofreading errors or omissions.

14

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Safety Precautions

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.

WARNING

Ca

ution

Definition of Precautionary Information

The following notation is used in this manual to provide precautions required to ensure safe usage of

the NX-series CPU Unit.

The safety precautions that are provided are extremely important for safety. Always read and heed the

information provided in all safety precautions.

The following notation is used.

Safety Precautions

Symbols

The circle and slash symbol indicates operations that you must not do.
The specific operation is shown in the circle and explained in text.
This example indicates prohibiting disassembly

The triangle symbol indicates precautions (including warnings).
The specific operation is shown in the triangle and explained in text.
This example indicates a precaution for electric shock.

The triangle symbol indicates precautions (including warnings).
The specific operation is shown in the triangle and explained in text.
This example indicates a general precaution.

The filled circle symbol indicates operations that you must do.
The specific operation is shown in the
This example shows a general precaution for something that you must do.

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 high temperatures.

circle and explained in text.

.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

15

WARNING

Safety Precautions

WARNING

During Power Supply

Do not touch any of the terminals or terminal blocks while the power is being supplied.
Doing so may result in electric shock.

Do not attempt to take any Unit apart.
In particular, high-voltage parts are present in the Power Supply Unit while power is
supplied or immediately after power is turned OFF
result in electric shock. There are sharp parts inside the Unit that may cause injury.

. Touching any of these parts may

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, slaves, or Units 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 digital outputs on the CPU Rack in the following cases.

• While the CPU Unit is on standby until RUN mode is entered after the power is
turned ON
If an error occurs in the power supply

•

• If a system initialization error occurs

Digital outputs on the CPU Rack will produce outputs according to the settings in the
following cases.

• If a CPU Unit error or CPU Unit reset occurs

• If a major fault level Controller error occurs

External safety measures must be provided to ensure safe operation of the system in
such cases.

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 settings in the slaves and Units.

If external power supplies for Units, slaves or other devices are overloaded or short­circuited, 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.

16

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Safety Precautions

Unintended outputs may occur when an error occurs in variable memory. 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.

The NX-series Controller continues normal operation for a certain period of time when
a momentary power interruption occurs. This means that the NX-series Controller may
receive incorrect signals from external devices that are also affected by the power in­terruption.
Accordingly, take suitable actions, such as external fail-safe measures and interlock
conditions, to monitor the power supply voltage of the external device as required.

You must take fail-safe measures to ensure safety in the event of incorrect, missing, or
abnormal signals caused by broken signal lines, momentary power interruptions, or
other causes.
Not doing so may result in serious accidents due to incorrect operation.

Voltage and Current Inputs

Make sure that the voltages and currents that are input to the slaves and Units 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, or device variables from the Sysmac Studio.
The devices or machines may perform unexpected operation regardless of the operat­ing mode of the CPU Unit.

Actual Operation

Check the user program, data, and parameter settings for proper execution before you
use them for actual operation.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

17

Caution

Internal

power supply

circuit

(No-isola-

tion)

CPU Unit

Cable

External device
(e.g. computer)

External power supply (Unit power supply)

Non-isolated type Communication Interface Unit, etc.

Unit power

supply

terminals

Non-isolated DC

power supply

Safety Precautions

Cautions

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.

When you connect a computer or other peripheral device to a Controller that has a
non-isolated DC power supply, either ground the 0-V side of the external power supply
for the Unit power supply or do not ground it at all.
If the peripheral devices are grounded incorrectly, the external power supply for the
Unit power supply may be short-circuited. Never ground the 24-V side of the power
supply, as shown in the following figure.

.

Online Editing

18

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.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Safety Precautions

EtherCAT Communications

If the cable redundancy function is enabled, always write a program to confirm that the
network is in the cable redundancy status. If the program is not written, you cannot
check that the network is not in the cable redundancy status due to a disconnection on
the ring topology.
Use the _EC_RingBreaking system-defined variable to confirm that the network is in
the cable redundancy status.

Version Information

The cable redundancy function can be used with project unit version 1.40 or later.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

19

Precautions for Safe Use

Precautions for Safe Use

Transporting and Disassembly

• 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 mal-

function or burning.

• When transporting any Unit, use the special packing box for it. Also, do not subject the Unit to ex-

cessive vibration or shock during transportation.

Mounting

• Always turn OFF the power supply before mounting the Units. If the power supply is not OFF, the

Unit may result in malfunction or may be damaged.

• Do not apply labels or tape to the Unit. When the Unit is installed or removed, adhesive or scraps

may adhere to the pins in the NX bus connector, which may result in malfunctions.

• Do not touch the pins in the NX bus connector on the Unit. Dirt may adhere to the pins in the NX bus

connector, which may result in malfunctions.

20

• Do not write on the CPU Unit with ink within the restricted region that is shown in the following fig-

ure. Also do not get this area dirty. When the Unit is installed or removed, ink or dirt may adhere to

the pins in the NX bus connector

Refer to the user’s manual for the connected NX Unit for information on the restricted region for the

NX Unit.

, which may result in malfunctions in the Unit.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Restricted region

(shaded portion)

Precautions for Safe Use

• The End Cover has a metal portion and is heavier than it looks. Be careful not to drop it when han-

dling.

Installation

• Always connect to a ground of 100 Ω or less when installing the Units.

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 the methods that are specified in this manual for wiring the terminal blocks.

• Use crimp terminals for wiring the M3 screw terminal blocks. Do not connect bare stranded wires

directly to the M3 screw terminal blocks.

• Use the correct wiring parts and tools when you wire the system. Otherwise, cables may be discon-

nected to cause short-circuit or wire breakage.

• 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 ca-

bles.

• Mount terminal blocks, connectors, and other parts only after checking the mounting location care-

fully.

• Be sure that the terminal blocks and communications cables with tightening screws or locking devi-

ces are properly tightened to or locked into place.

• If the external power supply to an Output Unit or slave has polarity, connect it with the correct polari-

ty. If the polarity is reversed, current may flow in the reverse direction and damage the connected

devices regardless of the operation of the Controller.

• Do not press a flat-blade screwdriver straight into the release hole on a screwless clamping terminal

block. Doing so may break the terminal block.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

21

Precautions for Safe Use

• When you insert a flat-blade screwdriver into a release hole on a screwless clamping terminal block,

press it down with a force of 30N or less. Applying excessive force may damage the terminal block.

• Do not incline or twist the flat-blade screwdriver while it is in a release hole on a screwless clamping

terminal block. Doing so may break the terminal block.

Power Supply Design

• Select an external power supply with sufficient capacity by considering the power supply capacity or

inrush current when the power is turned ON that is specified in this manual.

Otherwise, the external power supply may not be turned ON or malfunction due to unstable power

supply voltage.

• Use all Units within the I/O power supply ranges that are given in the specifications.

•

Do not apply voltages that exceed the rated value to any Input Unit.

• Do not apply voltages or connect loads to the Output Units or slaves in excess of their 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 this manual for surge current specifications.

• If the full dielectric strength voltage is applied or turned OFF using the switch on the tester, the gen-

erated impulse voltage may damage the Power Supply Unit. Use the adjustment on the tester to

gradually increase and decrease the voltage.

• Install external breakers and take other safety measures against short-circuiting and overcurrents in

external wiring.

Turning ON the Power Supply

22

• It takes approximately 20 seconds to enter RUN mode after the power supply is turned ON. During

that time, digital outputs on the CPU Rack will be OFF. The slave outputs behave according to the

setting values.

Use the system-defined variables and the NX Unit device variables in the user program to confirm

that I/O data communications are established before attempting control operations. External com-

munications are also not performed during startup.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Precautions for Safe Use

• 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 be-

cause the output terminals on Output Units may momentarily turn ON when power supply is turned

ON to the Controller

• If you transfer data from a backup file on an SD Memory Card to the Controller when the power sup-

ply is turned ON, properly select the data groups to transfer. If the data for an unintended data group

is transferred to the Controller, it may cause the equipment to operate unpredictably.

• You cannot obtain normal input data from NX Units while the Units are restarting. Use the system-

defined variables or device variables for the NX Units on the CPU Unit in the user program to check

the validity of the I/O data before you attempt control operations.

.

Actual Operation

• If you change the fail-soft operation setting, the output status when the error occurs may also

change. Confirm safety before you change the setting.

• If you use fail-soft operation, write programming to determine whether Unit I/O data is valid. Without

such programming, the user program cannot distinguish between Units for which I/O refreshing is

continued and Units for which I/O refreshing is stopped.

Turning OFF the Power Supply

• Never turn OFF the power supply to the Controller when the BUSY indicator is flashing. While the

BUSY indicator is lit, the user program and settings in the CPU Unit are being backed up in the built-

in non-volatile memory. This data will not be backed up correctly if the power supply is turned OFF.

Also, a major fault level 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 and SD PWR indicator to turn OFF before you remove the SD Mem-

ory Card.

• If the Unit power supply is turned OFF before the I/O power supply for the control system is turned

OFF, the output terminals of Output Units may malfunction and the control system may perform in-

correct output temporarily. To avoid this problem, configure the external circuit to make sure that the

Unit power supply is turned OFF only after the power supply for the control system is turned OFF.

• 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.

a) Mounting or removing the Units

b) Assembling the Units

c) Setting DIP switches or rotary switches

d) Connecting cables or wiring the system

e) Connecting or disconnecting the terminal blocks or connectors

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

23

Precautions for Safe Use

The power supply circuit in the CPU Unit may continue to supply power to the Controller for a few

seconds after the power supply turns OFF. The POWER indicator is lit during this time. Confirm that

the POWER indicator is not lit before you perform any of the above actions.

Operation

• Confirm that no adverse effect will occur in the system before you attempt any of the following.

a) Changing the operating mode of the CPU Unit (including changing the setting of the Startup

Mode)

b) Changing the user program or settings

c) Changing set values or present values

d) Forced refreshing

e) Starting the CPU Unit with the battery exhausted

f) Restarting a slave or Unit after you change any settings

g) Transferring a backup file on the SD Memory Card

• After you change any slave or Unit settings, carefully check the safety of the controlled system be-

fore you restart the Unit.

•

If two different function modules are used together, such as when you use EtherNet/IP and Ether-

CAT slaves, 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

behave according to the slave or Unit specifications 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 Con-

troller error with an event level of partial fault or higher (in which outputs are disabled) will go to Op-

erational state and the outputs will be enabled.

Before you reset all errors or restart a slave, confirm that no Controller errors with an event level of

partial fault have occurred for the EtherCAT Master Function Module.

24

Designing Tasks

• If the following variables are specified for a condition expression when the execution condition of

event tasks is the same as the condition expression for a variable, event tasks may not be executed

when conditions are met, or event tasks may be executed when conditions are not met.

a) Structure members whose data size is 16 bits or more, except for system-defined variables for

motion control

b) Array elements whose data size is 16 bits or more

Refer to the NJ/NX-series CPU Unit Software User’

event task execution conditions.

s Manual (Cat. No. W501) for information on

Battery Backup

• If you use the clock data in the user program and turn OFF the power supply for a long time, use a

Battery which is sold separately.

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Precautions for Safe Use

The Battery is not mounted when the product is at factory setting. The clock data is retained by the

built-in capacitor. The capacitor is charged while the power is supplied and discharged while the

power is not supplied. If the power OFF time rate is high, the clock data is initialized and malfunc-

tions may occur in the program for which the clock data is used.

•

If you use the Battery, connect the Sysmac Studio and set the Battery-related error detection to

Use. The Battery-related error detection is set to Do not use at the factory setting because the

Battery is not built in. If the Battery-related error detection is set to Do not use, an error cannot be

detected when the Battery is exhausted and malfunctions may occur in the program for which the

clock data is used.

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. Be careful that

this operation differs from the force-set/reset functionality of the CJ/CP-series PLCs.

•

You cannot upload or download information for forced refreshing with the Sysmac Studio.

After downloading data that contains forced refreshing, change to RUN mode and then use the Sys-

mac Studio to perform the operation for forced refreshing.

Depending on the difference in the forced status, the control system may operate unexpectedly.

• Do not specify the same address for the AT specification for more than one variable.

Doing so would allow the same entity to be accessed with different variable names, which would

make the user program more difficult to understand and possibly cause programming mistakes.

General Communications

• When you use data link communications, check the error information that is given in _ErrSta (Con-

troller Error Status) to make sure that no error has occurred in the source device. Create a user pro-

gram that uses reception data only when there is no error in the source device.

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.

EtherNet/IP Communications

• Make sure to use the communications distance, number of nodes connected, and method of con-

nection for EtherNet/IP within specifications. Do not connect EtherNet/IP communications to Ether-

CAT or other networks. An overload may cause the network to fail or malfunction.

•

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). The settings can only be enabled after the re-

set. 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 communica-

tions load on the network will increase. This will increase collisions and may prevent stable

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

25

Precautions for Safe Use

communications. Do not use repeating hubs on networks where tag data links are used. Use an

Ethernet switch instead.

EtherCAT Communications

• Make sure to use the communications distance, number of nodes connected, and method of con-

nection for EtherCAT within specifications.

Do not connect EtherCA

works. An overload may cause the network to fail or malfunction.

• Malfunctions or unexpected operation may occur for some combinations of EtherCAT revisions of

the master and slaves. If you disable the revision check in the network settings, use the Sysmac

Studio to check the slave revision settings in the master and the actual slave revisions, and then

make sure that functionality is compatible in the slave manuals or other references. You can check

the actual slave revisions from the Sysmac Studio or on slave nameplates.

• After you transfer the user program, the CPU Unit is restarted and communications with the Ether-

CAT slaves are cut off. During that period, the slave outputs behave according to the slave specifi-

cations. The time that communications are cut off depends on the EtherCAT network configuration.

Before you transfer the user program, confirm that the system will not be adversely affected.

• If the Fail-soft Operation Setting is set to Stop, process data communications will stop for all

slaves when an EtherCAT communications error is detected in a slave. At that time, the Servo Drive

will operate according to the Servo Drive specifications. Make sure that the Fail-soft Operation

setting results in safe operation when a device error occurs.

• Even if the Process Data Communication is stopped and subsequently restored automatically, take

the external safety measures or set the Fail-soft Operation Settings to Stop to make the system op-

erate safe.

• 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 es-

tablished before attempting control operations.

• If noise occurs or an EtherCAT slave is disconnected from the network, any current communications

frames may be lost. If frames are lost, slave I/O data is not communicated, and unintended opera-

tion may occur. The slave outputs will behave according to the slave specifications. Refer to the

manual for the slave. If a noise countermeasure or slave replacement is required, perform the fol-

lowing processing.

a) Program the Input Data Invalid system-defined variable as an interlock condition in the user pro-

gram.

b) Set the PDO communications timeout detection count setting in the EtherCAT master to at

least 2. Refer to the NJ/NX-series CPU Unit Built-in EtherCAT Port User’s Manual (Cat. No.

W505) 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 through to the physi-

cal end node. Confirm that the system will not be adversely affected before you disconnect a slave.

• I/O data communications of NX bus are not always established immediately after the power supply

is turned ON. Use the system-defined variables and the EtherCAT Coupler Unit device variables in

the user program to confirm that I/O data communications are established before attempting control

operations.

• You cannot use standard Ethernet hubs or repeater hubs with EtherCAT communications. If you use

one of these, a major fault level error or other error may occur.

T communications to EtherNet/IP, a standard in-house LAN, or other net-

26

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

Precautions for Safe Use

• If the actual configuration changes, for example, when actual configuration does not contain a disa-

ble slave and subsequently you include it in the actual configuration, set the total cable length for the

case of the worst scenario.

• Confirm that all of the slaves are connected before you set the transmission delay time by the actual

measurement. If the transmission delay time is exceeded from the set values due to the changes of

the unit configuration, such as when the disabled salve is connected to the actual configuration after

the setting, it may cause illegal communications with slaves.

•

When the communications cable that is connected to the slave from other manufacturers on the ring

topology is broken or the power supply to the slave from other manufacturers is interrupted, any cur-

rent communications frames may be lost.

If frames are lost, slave I/O data is not communicated, and unintended operation may occur.

When slaves from other manufacturers are connected on the ring topology, check the followings in

advance.

a) Disconnect and connect communications cables that are connected to the output ports of slaves

from other manufacturers several times, and there is no error except for a Ring Disconnection

Detected.

b) Disconnect and connect communications cables that are connected to the input ports of slaves

from other manufacturers several times, and there is no error except for a Ring Disconnection

Detected.

c) Turn OFF and ON the power supply to the slaves from other manufacturers, and there is no er-

ror except for a Illegal Slave Disconnection Detected.

• If you use the cable redundancy function, confirm that the task execution time is within the task peri-

od while the cable for the end port of the ring is disconnected. When a disconnection occurred on

the ring topology, the transmission delay time is increased and the task execution time may be lon-

ger.

Version Information

The cable redundancy function can be used with project unit version 1.40 or later.

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 T

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 con-

dition 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 in-

put (DEC) of the Servo Drive are used by the MC Function Module as the positive limit input, nega-

tive limit input, and home proximity input. Make sure that the signal widths for all of these input sig-

nals 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.

est Run. Connect the communications cable between the computer and CPU

NX-series NX102 CPU Unit Hardware User’s Manual (W593)

27

FirstOnPosition LastOnPosition

OnCompensation

FirstOnPosition

after compensation

FirstOnPosition LastOnPosition

OffCompensation

LastOnPosition

after compensation

Precautions for Safe Use

• If you make any changes in the Detailed Settings Area of the Axis Basic Settings Display of the

Sysmac Studio, make sure that the devices or machines perform the expected operation before you

start actual operation.

If the relationship between the functions of the Motion Control Function Module and the EtherCAT

slave process data that is assigned to the axes is not correct, the devices or machines may perform

unexpected operation.

•

Always use the axis at a constant velocity for the MC_DigitalCamSwitch (Enable Digital Cam

Switch) instruction.

If you set the Count Mode to Rotary Mode, the following operation will occur if you use OnCompen-

sation or OffCompensation and the axis velocity changes abruptly.

a) If the value of OnCompensation or OffCompensation is equivalent to the time for half a rotation

or more, InOperation will be FALSE.

b) If the value of OnCompensation results in exceeding LastOnPosition, the output timing will be

unstable.

c) If the value of OffCompensation results in exceeding FirstOnPosition, the output timing will be

unstable.

• Use the NX_AryDOutTimeStamp (Write Digital Output Array with Specified Time Stamp) instruction

only after you confirm that InOperation from the MC_DigitalCamSwitch (Enable Digital Cam Switch)

instruction is TRUE.

• If you change the unit conversion settings, perform homing again. If you do not perform homing, un-

intended operation of the controlled system may occur

Backing Up Data

• Backup function allows to save various setting data in the Controller to an SD Memory Card or a

computer.

If you back up data when the operating mode is set to the RUN mode, the concurrency of variables

with a Retain attribute (i.e., structure and array variables of two bytes or more) may be lost.

T

o ensure data concurrency, we recommend that you back up data when the operating mode is set

to PROGRAM mode.

• We recommend that you back up the present values of variables while the retained variables are not

refreshed.

.

28

NX-series NX102 CPU Unit Hardware User’s Manual (W593)