OMRON NJ CPU Unit Sofware User Manual

Machine Automation Controller

NJ-series CPU Unit Software

CPU Unit

Users Manual

W501-E1-09

NJ501-15@@ NJ501-14@@ NJ501-13@@ NJ301-12@@ NJ301-11@@

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.

OMRON, 2011

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

Windows, Windows XP, Windows Vista, Windows 7, and Windows 8 are registered trademarks of Microsoft Corporation in the USA and other countries.

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

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.

Trademarks

1Introduction

NJ-series CPU Unit Software Users Manual (W501)

IntroductionThank you for purchasing an NJ-series CPU Unit.This manual contains information that is necessary to use the NJ-series CPU Unit. Please read thismanual and make sure you understand the functionality and performance of the NJ-series CPU Unitbefore 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.

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

This manual covers the following products. NJ-series CPU Units

NJ501-15 NJ501-14 NJ501-13 NJ301-12 NJ301-11

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 35.

Intended Audience

Applicable Products

Relevant Manuals

2 NJ-series CPU Unit Software Users Manual (W501)

Relevant ManualsThe following table provides the relevant manuals for the NJ-series CPU Units.Read all of the manuals that are relevant to your system configuration and application before you usethe NJ-series CPU Unit.Most operations are performed from the Sysmac Studio Automation Software. Refer to the Sysmac Stu-dio Version 1 Operation Manual (Cat. No. W504) for information on the Sysmac Studio.

*1 Refer to the NJ-series Troubleshooting Manual (Cat. No. W503) for the error management concepts and an overview ofthe error items. Refer to the manuals that are indicated with triangles for details on errors for the corresponding Units.

Purpose of use

ManualBasic information

NJ-series CPU Unit

Ha

rdw

are Users

Ma

nu

al

NJ-series CPU Unit

Software Us

ers

Ma

nu

al

NJ-series Instru

ction

s R

eference M

an

ual

NJ-series CPU Unit

Motio

n Co

ntrol Users

Ma

nu

al

NJ-series Motio

n

Co

ntrol Instru

ction

s R

eference M

an

ual

NJ-series CPU Unit

Built

-in EtherCAT P

ort

Users M

anu

al

NJ-series CPU Unit

Built

-in EtherNet/IP

Po

rt U

sers Man

ual

NJ-series Datab

ase C

on

nectio

n C

PU Unit

Users M

anu

al

NJ-series Trouble-

shooting M

anu

al

Introduction to NJ-series Controllers Setting devices and hardware

Using motion control Using EtherCAT Using EtherNet/IP Using the database connection service

Software settings


Writing the user program

Using motion control Using EtherCAT Using EtherNet/IP Using the database connection service Programming error processing

Testing operation and debugging


Learning about error management and corrections*1

Maintenance

Using motion control Using EtherCAT Using EtherNet/IP

3Manual Structure


Manual Structure

The following page structure is used in this manual.

Page Structure

4-9

4 Installation and Wiring

NJ-series CPU Unit Hardware Users Manual (W500)

stin

U gn

itn

uo

M 3-

4

4

stn

en

op

mo

C rell

ortn

oC

gnit

ce

nn

oC

1-3-

4

4-3 Mounting Units

The Units that make up an NJ-series Controller can be connected simply by pressing the Units togetherand locking the sliders by moving them toward the back of the Units. The End Cover is connected in thesame 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 sliderstoward 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

ConnectorHook Hook holes

Slider

Lock

Release

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

Level 1 headingLevel 2 headingLevel 3 headingLevel 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.

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

The sliders on the tops and bottoms of the Power Supply Unit, CPU Unit, I/O Units, Special I/O Units, and CPU Bus Units must be completely locked (until they click into place) after connecting the adjacent Unit connectors.

Manual Structure


Special information in this manual is classified as follows:

Note References are provided to more detailed or related information.

In this manual, download refers to transferring data from the Sysmac Studio to the physical Controllerand upload refers to transferring data from the physical Controller to the Sysmac Studio.For the Sysmac Studio, synchronization is used to both upload and download data. Here, synchronizemeans to automatically compare the data for the Sysmac Studio on the computer with the data in thephysical Controller and transfer the data in the direction that is specified by the user.

Special Information

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

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

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

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

Precaution on Terminology

5Sections in this Manual


Sections in this Manual

CPU Unit Operation

I/O Ports, Slave Configuration, and Unit Configuration

Controller Setup

Designing Tasks

Programming

Checking Operation and Actual Operation

CPU Unit Functions

1 10

2 11

3 12

4 A

5

6

7

8

9

1 10

2 11

3 12

4 A

5 I

6

7

8

9

Communications Setup

Example of Actual Application Procedures

Troubleshooting

Appendices

I Index

Backup Functions

Introduction to NJ-series Controllers

Sections in this Manual


7NJ-series CPU Unit Software Users Manual (W501)

CONTENTS

CONTENTSIntroduction............................................................................................................... 1

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

Manual Structure ...................................................................................................... 3

Sections in this Manual............................................................................................ 5

Terms and Conditions Agreement ........................................................................ 14

Safety Precautions ................................................................................................. 16

Precautions for Safe Use ....................................................................................... 21

Precautions for Correct Use .................................................................................. 27

Regulations and Standards ................................................................................... 30

Unit Versions........................................................................................................... 32

Related Manuals ..................................................................................................... 35

Terminology ............................................................................................................ 37

Revision History ..................................................................................................... 41

Section 1 Introduction to NJ-series Controllers1-1 The NJ-series Controllers ....................................................................................................... 1-2

1-1-1 Features...................................................................................................................................... 1-21-1-2 Introduction to the System Configurations.................................................................................. 1-4

1-2 Main Specifications ................................................................................................................. 1-71-3 Overall Operating Procedure for the NJ-series Controller .................................................. 1-9

1-3-1 Overall Procedure....................................................................................................................... 1-91-3-2 Procedure Details ..................................................................................................................... 1-10

Section 2 CPU Unit Operation2-1 Overview of CPU Unit Operation............................................................................................ 2-2

2-1-1 Introduction to CPU Unit ............................................................................................................. 2-22-1-2 Overview of Operation According to CPU Unit Status................................................................ 2-3

2-2 Software ................................................................................................................................... 2-42-2-1 Software Configuration ............................................................................................................... 2-42-2-2 Operation of Software................................................................................................................. 2-5

2-3 Accessing I/O......................................................................................................................... 2-102-3-1 Types of Variables..................................................................................................................... 2-102-3-2 Accessing I/O with Variables .................................................................................................... 2-13

2-4 Sequence Control and Motion Control ................................................................................ 2-182-4-1 Overview of Control .................................................................................................................. 2-182-4-2 Sequence Control System........................................................................................................ 2-202-4-3 Motion Control System ............................................................................................................. 2-21


CONTENTS

2-4-4 Synchronizing Sequence Control and Motion Control .............................................................. 2-222-5 Overview of CPU Unit Data ................................................................................................... 2-232-6 Operation for CPU Unit Status ............................................................................................. 2-25

2-6-1 CPU Unit Status........................................................................................................................ 2-252-6-2 Operation for CPU Unit Status .................................................................................................. 2-272-6-3 Operating Modes....................................................................................................................... 2-28

Section 3 I/O Ports, Slave Configuration, and Unit Configuration3-1 Procedure to Create the Slave and Unit Configurations...................................................... 3-23-2 Creating and Comparing the Slave and Unit Configurations .............................................. 3-5

3-2-1 Creating the EtherCAT Slave Configuration ................................................................................ 3-53-2-2 Creating the Unit Configuration................................................................................................... 3-63-2-3 Verifying the Unit Configuration................................................................................................... 3-6

3-3 I/O Ports and Device Variables ............................................................................................... 3-83-3-1 I/O Ports ...................................................................................................................................... 3-83-3-2 I/O Port Names ........................................................................................................................... 3-93-3-3 Device Variables ....................................................................................................................... 3-10

3-4 Allocating Variables to Units ................................................................................................ 3-133-4-1 Procedure to Assign Variables to Units..................................................................................... 3-133-4-2 Using Variables Assigned to Units ............................................................................................ 3-14

3-5 Creating the Axes and Assigning Them to the Servo Drives/Encoder Input Slaves....... 3-163-5-1 Introduction ............................................................................................................................... 3-163-5-2 Axis Variables and Axes Group Variables ................................................................................. 3-173-5-3 Creating and Using Axes and Axis Variables............................................................................ 3-18

Section 4 Controller Setup4-1 Overview of the Controller Setup........................................................................................... 4-24-2 Initial Settings for the PLC Function Module ........................................................................ 4-4

4-2-1 Introduction ................................................................................................................................. 4-44-2-2 Controller Setup .......................................................................................................................... 4-44-2-3 Task Settings............................................................................................................................... 4-64-2-4 Unit Configuration and Unit Setup............................................................................................. 4-11

4-3 Initial Settings for Special Units........................................................................................... 4-134-4 Initial Settings for the Motion Control Function Module.................................................... 4-15

4-4-1 Introduction ............................................................................................................................... 4-154-4-2 Setting Methods ........................................................................................................................ 4-16

4-5 Initial Settings for the EtherCAT Master Function Module ................................................ 4-174-6 Initial Settings for the EtherNet/IP Function Module.......................................................... 4-18

Section 5 Designing Tasks5-1 Overview of Task Designing Procedure ................................................................................ 5-25-2 Task System............................................................................................................................. 5-4

5-2-1 Overview of Tasks ....................................................................................................................... 5-45-2-2 Specifications of Tasks................................................................................................................ 5-65-2-3 Basic Operation of Tasks ............................................................................................................ 5-75-2-4 Event Task Execution Conditions .............................................................................................. 5-135-2-5 Event Task Execution Timing .................................................................................................... 5-185-2-6 Operation When Execution Condition Is Met Again before Execution

of the Event Task Is Completed ................................................................................................ 5-225-2-7 Tag Data Link Service and System Services ............................................................................ 5-23


CONTENTS

5-2-8 Processing Performed in and Execution Timing of the Tag Data Link Service ......................... 5-265-2-9 Processing Performed in and Execution Timing of the System Services ................................. 5-295-2-10 Assigning I/O Refreshing to Tasks............................................................................................ 5-315-2-11 Assigning Tasks to Programs ................................................................................................... 5-325-2-12 Parameters for Primary Periodic Task and Periodic Tasks ....................................................... 5-335-2-13 Ensuring Concurrency of Variable Values between Tasks........................................................ 5-355-2-14 Variable Access from Outside the Controller ............................................................................ 5-395-2-15 Instructions Related to Tasks.................................................................................................... 5-425-2-16 System-defined Variables Related to Tasks ............................................................................. 5-435-2-17 Errors Related to Tasks ............................................................................................................ 5-455-2-18 Monitoring Task Execution Status and Task Execution Times.................................................. 5-47

5-3 Task Design Methods and I/O Response Times ................................................................. 5-515-3-1 Checking the Task Execution Time........................................................................................... 5-515-3-2 Checking the System Service Monitoring Settings................................................................... 5-535-3-3 Examples of Task Design ......................................................................................................... 5-535-3-4 System Input and Output Response Times.............................................................................. 5-54

Section 6 Programming6-1 Overview of Programming Procedures ................................................................................. 6-36-2 POUs (Program Organization Units)...................................................................................... 6-5

6-2-1 What Are POUs? ........................................................................................................................ 6-56-2-2 Overview of the Three Types of POUs ....................................................................................... 6-66-2-3 Differences between Programs, Functions, and Function Blocks............................................... 6-76-2-4 Details on Programs ................................................................................................................... 6-76-2-5 Details on Function Blocks ......................................................................................................... 6-86-2-6 Details on Functions ................................................................................................................. 6-176-2-7 Operation That Applies to Both Functions and Function Blocks............................................... 6-226-2-8 POU Restrictions ...................................................................................................................... 6-24

6-3 Variables................................................................................................................................. 6-276-3-1 Variables ................................................................................................................................... 6-276-3-2 Types of Variables..................................................................................................................... 6-276-3-3 Types of User-defined Variables in Respect to POUs .............................................................. 6-286-3-4 Attributes of Variables............................................................................................................... 6-296-3-5 Data Types................................................................................................................................ 6-306-3-6 Derivative Data Types............................................................................................................... 6-396-3-7 Array Specifications and Range Specifications for Data Types ................................................ 6-496-3-8 Variable Attributes..................................................................................................................... 6-546-3-9 Changes to Variables for Status Changes................................................................................ 6-626-3-10 Function Block Instances.......................................................................................................... 6-646-3-11 Monitoring Variable Values ....................................................................................................... 6-646-3-12 Restrictions on Variable Names and Other Program-related Names ....................................... 6-65

6-4 Constants (Literals)............................................................................................................... 6-676-4-1 Constants.................................................................................................................................. 6-676-4-2 Types of Constants ................................................................................................................... 6-67

6-5 Programming Languages ..................................................................................................... 6-726-5-1 Programming Languages ......................................................................................................... 6-726-5-2 Ladder Diagram Language ....................................................................................................... 6-726-5-3 Structured Text Language......................................................................................................... 6-78

6-6 Instructions .......................................................................................................................... 6-1126-6-1 Instructions ............................................................................................................................. 6-1126-6-2 Basic Understanding of Instructions ....................................................................................... 6-1126-6-3 Instruction Errors .................................................................................................................... 6-115

6-7 Namespaces......................................................................................................................... 6-1206-7-1 Namespaces........................................................................................................................... 6-1206-7-2 Namespace Specifications ..................................................................................................... 6-1216-7-3 Procedure for Using Namespaces.......................................................................................... 6-124

6-8 Libraries ............................................................................................................................... 6-1256-8-1 Introduction to Libraries .......................................................................................................... 6-125


CONTENTS

6-8-2 Specifications of Libraries ....................................................................................................... 6-1256-8-3 Library Object Specifications .................................................................................................. 6-1266-8-4 Procedure to Use Libraries ..................................................................................................... 6-127

6-9 Programming Precautions.................................................................................................. 6-1296-9-1 Array Specifications for Input Variables, Output Variables, In-Out Variables........................... 6-1296-9-2 Structure Variables for Input Variables, Output Variables, In-Out Variables............................ 6-1296-9-3 Master Control......................................................................................................................... 6-130

Section 7 Checking Operation and Actual Operation7-1 Overview of Steps in Checking Operation and Actual Operation....................................... 7-27-2 Offline Debugging.................................................................................................................... 7-3

7-2-1 Features of Simulation ................................................................................................................ 7-37-2-2 Simulation Execution................................................................................................................... 7-37-2-3 Setting Up Simulations................................................................................................................ 7-6

7-3 Checking Operation on the Actual System and Actual Operation...................................... 7-87-3-1 Procedures.................................................................................................................................. 7-87-3-2 Downloading the Project ............................................................................................................. 7-87-3-3 Checking I/O Wiring .................................................................................................................... 7-97-3-4 MC Test Run ............................................................................................................................... 7-97-3-5 Checking the Operation of the User Program ............................................................................. 7-97-3-6 Starting Actual Operation.......................................................................................................... 7-10

Section 8 CPU Unit Functions8-1 Data Management, Clock, and Operating Functions............................................................ 8-3

8-1-1 Clearing All Memory.................................................................................................................... 8-38-1-2 Clock ........................................................................................................................................... 8-38-1-3 RUN Output................................................................................................................................. 8-6

8-2 Management Functions for CJ-series Units.......................................................................... 8-78-2-1 Basic I/O Units ............................................................................................................................ 8-78-2-2 Special Units ............................................................................................................................... 8-8

8-3 SD Memory Card Operations................................................................................................ 8-108-3-1 SD Memory Card Operations.................................................................................................... 8-108-3-2 Specifications of Supported SD Memory Cards, Folders, and Files ......................................... 8-118-3-3 SD Memory Card Operation Instructions .................................................................................. 8-128-3-4 FTP Client Communications Instructions.................................................................................. 8-138-3-5 FTP Server................................................................................................................................ 8-138-3-6 File Operations from the Sysmac Studio................................................................................... 8-138-3-7 SD Memory Card Life Expiration Detection .............................................................................. 8-138-3-8 List of System-defined Variables Related to SD Memory Cards............................................... 8-148-3-9 SD Memory Card Self-diagnostic Functions ............................................................................. 8-158-3-10 Exclusive Control of File Access in SD Memory Cards............................................................. 8-17

8-4 Security .................................................................................................................................. 8-188-4-1 Authentication of User Program Execution IDs ......................................................................... 8-198-4-2 User Program Transfer with No Restoration Information........................................................... 8-228-4-3 Overall Project File Protection................................................................................................... 8-228-4-4 Data Protection ......................................................................................................................... 8-238-4-5 Operation Authority Verification................................................................................................. 8-258-4-6 CPU Unit Write Protection ........................................................................................................ 8-268-4-7 CPU Unit Names and Serial IDs ............................................................................................... 8-28

8-5 Debugging .............................................................................................................................. 8-308-5-1 Forced Refreshing..................................................................................................................... 8-308-5-2 Changing Present Values.......................................................................................................... 8-348-5-3 Online Editing............................................................................................................................ 8-358-5-4 Data Tracing .............................................................................................................................. 8-378-5-5 Differential Monitoring ............................................................................................................... 8-42


CONTENTS

8-6 Event Logs ............................................................................................................................. 8-488-6-1 Introduction............................................................................................................................... 8-488-6-2 Detailed Information on Event Logs.......................................................................................... 8-498-6-3 Controller Events (Controller Errors and Information) .............................................................. 8-548-6-4 User-defined Events (User-defined Errors and Information) .................................................... 8-55

8-7 Changing Event Levels ......................................................................................................... 8-628-7-1 Applications of Changing Event Levels..................................................................................... 8-628-7-2 Events for Which the Event Level Can Be Changed................................................................. 8-628-7-3 Procedure to Change an Event Level ....................................................................................... 8-62

Section 9 Backup Functions9-1 The Backup Functions ............................................................................................................ 9-3

9-1-1 Applications of Backup Functions............................................................................................... 9-39-1-2 Examples of Operating Procedures for the Backup Functions ................................................... 9-39-1-3 Data That Is Backed Up.............................................................................................................. 9-69-1-4 Types of Backup Functions......................................................................................................... 9-79-1-5 Relation Between the Different Types of Backup Functions and Data Groups........................... 9-99-1-6 Applicable Range of the Backup Functions .............................................................................. 9-10

9-2 SD Memory Card Backups.................................................................................................... 9-129-2-1 Backup (Controller to SD Memory Card) .................................................................................. 9-139-2-2 Restore (SD Memory Card to Controller) ................................................................................. 9-189-2-3 Verify (between Controller and SD Memory Card) ................................................................... 9-20

9-3 Disabling Backups to SD Memory Cards ............................................................................ 9-259-4 Automatic Transfers from SD Memory Cards ..................................................................... 9-269-5 Sysmac Studio Controller Backups..................................................................................... 9-28

9-5-1 Backup (Controller to Computer) .............................................................................................. 9-299-5-2 Restore (Computer to Controller) ............................................................................................. 9-309-5-3 Verify (between Controller and Computer) ............................................................................... 9-31

9-6 Importing and Exporting Sysmac Studio Backup File Data .............................................. 9-329-7 Sysmac Studio Variable and Memory Backup Functions.................................................. 9-33

9-7-1 Applicable Data for Sysmac Studio Variable and Memory Backup Functions .......................... 9-339-7-2 Using Sysmac Studio Variable and Memory Backup Functions ............................................... 9-339-7-3 Compatibility between CPU Unit Models .................................................................................. 9-34

9-8 Backup Functions When EtherCAT Slaves Are Connected............................................... 9-369-8-1 Backed Up EtherCAT Slave Data ............................................................................................. 9-369-8-2 Backup Support Depending on the Controller Status............................................................... 9-369-8-3 Conditions for Restoring EtherCAT Slave Data ........................................................................ 9-379-8-4 EtherCAT Slaves for Which You Can Back Up Data ................................................................. 9-38

9-9 Backup Functions When EtherCAT Slave Terminals Are Connected............................... 9-409-9-1 Backing Up Data in an EtherCAT Slave Terminal ..................................................................... 9-409-9-2 Backup Support Depending on the EtherCAT Slave Terminal Status....................................... 9-419-9-3 Conditions for Restoring EtherCAT Slave Terminal Data.......................................................... 9-41

9-10 Backup Functions When CJ-series Units Are Connected ................................................. 9-429-10-1 Backed Up CJ-series Unit Data ................................................................................................ 9-429-10-2 Backup Support Depending on the Controller Status............................................................... 9-429-10-3 Conditions for Restoring CJ-series Unit Data ........................................................................... 9-42

9-11 Backup-related Files ............................................................................................................. 9-449-11-1 Types of Backup-related Files................................................................................................... 9-449-11-2 Specifications of a Backup File................................................................................................. 9-459-11-3 Specifications of a Restore Command File............................................................................... 9-459-11-4 Specifications of an Automatic Transfer Command File ........................................................... 9-479-11-5 Specifications of a Controller Verification Results File.............................................................. 9-499-11-6 Specifications of an EtherCAT Verification Results File............................................................ 9-499-11-7 Specifications of an EtherCAT Slave Terminal Verification Results File ................................... 9-519-11-8 Specifications of CJ-series Unit Verification Results File.......................................................... 9-52


CONTENTS

9-12 Compatibility between Backup-related Files ...................................................................... 9-549-12-1 Compatibility between Backup Functions ................................................................................. 9-549-12-2 Compatibility between CPU Unit Models .................................................................................. 9-559-12-3 Compatibility between Unit Versions of CPU Units ................................................................... 9-56

9-13 Functions That Cannot Be Executed during Backup Functions....................................... 9-57

Section 10 Communications Setup10-1 Communications System Overview..................................................................................... 10-2

10-1-1 Introduction ............................................................................................................................... 10-3

10-2 Connection with Sysmac Studio.......................................................................................... 10-410-2-1 Configurations That Allow Online Connections......................................................................... 10-410-2-2 Configurations That Do Not Allow Online Connections............................................................. 10-5

10-3 Connection with Other Controllers or Slaves ..................................................................... 10-710-3-1 Connection Configurations between Controllers....................................................................... 10-710-3-2 Connection Configuration between Controllers and Slaves .................................................... 10-10

10-4 Connection with HMIs or Serial Communications Devices ............................................. 10-1110-4-1 Connections to HMIs............................................................................................................... 10-1110-4-2 Connections to Devices with Serial Communications ............................................................. 10-12

Section 11 Example of Actual Application Procedures11-1 Example Application ............................................................................................................. 11-2

11-1-1 System Configuration................................................................................................................ 11-211-1-2 Operation .................................................................................................................................. 11-2

11-2 Overview of the Example Procedure ................................................................................... 11-311-2-1 Wiring and Settings................................................................................................................... 11-311-2-2 Software Design........................................................................................................................ 11-311-2-3 Software Settings from the Sysmac Studio............................................................................... 11-411-2-4 Programming with the Sysmac Studio ...................................................................................... 11-711-2-5 Simulation with the Sysmac Studio ........................................................................................... 11-811-2-6 Checking Operation and Starting Operation on the Actual System .......................................... 11-9

Section 12 Troubleshooting12-1 Operation after an Error ........................................................................................................ 12-2

12-1-1 Overview of NJ-series Status.................................................................................................... 12-212-1-2 Fatal Errors in the CPU Unit...................................................................................................... 12-312-1-3 Non-fatal error in CPU Unit ....................................................................................................... 12-4

12-2 Troubleshooting................................................................................................................... 12-1212-2-1 Checking to See If the CPU Unit Is Operating ........................................................................ 12-1212-2-2 Troubleshooting Flowchart for Non-fatal Errors....................................................................... 12-1312-2-3 Error Table............................................................................................................................... 12-1312-2-4 Error Descriptions ................................................................................................................... 12-2212-2-5 Troubleshooting Errors That Are Not in the CPU Unit ............................................................. 12-55

AppendicesA-1 Specifications ..........................................................................................................................A-3

A-1-1 General Specifications ................................................................................................................A-3A-1-2 Performance Specifications.........................................................................................................A-4A-1-3 Function Specifications ...............................................................................................................A-6

A-2 Calculating Guidelines for the Real Processing Times of Tasks ......................................A-13A-2-1 Calculating the Average Real Processing Times of Tasks ........................................................A-13


CONTENTS

A-2-2 Example of Calculating the Average Real Processing Time of a Task and Setting the Task Period.......................................................................................A-22

A-3 System-defined Variables .....................................................................................................A-26A-3-1 System-defined Variables for the Overall NJ-series Controller (No Category) .........................A-26A-3-2 PLC Function Module, Category Name: _PLC.........................................................................A-33A-3-3 PLC Function Module, Category Name: _CJB .........................................................................A-34A-3-4 Motion Control Function Module, Category Name: _MC..........................................................A-36A-3-5 EtherCAT Master Function Module, Category Name: _EC.......................................................A-37A-3-6 EtherNet/IP Function Module, Category Name: _EIP ..............................................................A-41A-3-7 Meanings of Error Status Bits ...................................................................................................A-47

A-4 Specifications for Individual System-defined Variables ....................................................A-49A-4-1 System-defined Variables for the Overall NJ-series Controller (No Category) .........................A-49A-4-2 PLC Function Module, Category Name: _PLC.........................................................................A-60A-4-3 PLC Function Module, Category Name: _CJB .........................................................................A-61A-4-4 Motion Control Function Module, Category Name: _MC..........................................................A-65A-4-5 EtherCAT Master Function Module, Category Name: _EC.......................................................A-66A-4-6 EtherNet/IP Function Module, Category Name: _EIP ..............................................................A-73

A-5 Attributes of CPU Unit Data ..................................................................................................A-81A-6 Contents of Memory Used for CJ-series Units ...................................................................A-85

A-6-1 CIO Area...................................................................................................................................A-85A-6-2 Internal I/O Area .......................................................................................................................A-87A-6-3 Holding Area.............................................................................................................................A-88A-6-4 DM Area....................................................................................................................................A-88A-6-5 EM Area....................................................................................................................................A-89

A-7 Variable Memory Allocation Methods..................................................................................A-90A-7-1 Variable Memory Allocation Rules............................................................................................A-90A-7-2 Important Case Examples ........................................................................................................A-98

A-8 Registering a Symbol Table on the CX-Designer .............................................................A-102A-9 Enable/Disable EtherCAT Slaves and Axes.......................................................................A-105

A-9-1 Project Settings When Using EtherCAT Slaves and Axes ...................................................... A-105A-9-2 Using Instructions to Enable/Disable EtherCAT Slaves and Axes .......................................... A-105A-9-3 System-defined Variables That Indicate EtherCAT Slave or Axis Status................................ A-106A-9-4 Enabling/Disabling Execution of Program............................................................................... A-107A-9-5 Checking Enabled/Disabled Program ..................................................................................... A-107A-9-6 Settings with the Sysmac Studio ............................................................................................ A-107A-9-7 Examples of Applications of Enabling/Disabling EtherCAT Slaves and Axes ......................... A-108

A-10 Size Restrictions for the User Program.............................................................................A-111A-10-1 User Program Object Restrictions .......................................................................................... A-111A-10-2 Counting User Program Objects............................................................................................. A-114

A-11 Replacing CPU Units with Unit Version 1.02 or Earlier ....................................................A-116A-11-1 Uploading the Data from the CPU Unit................................................................................... A-116A-11-2 Connecting the New CPU Unit ............................................................................................... A-119A-11-3 Downloading the Data to the CPU Unit .................................................................................. A-120

A-12 Version Information .............................................................................................................A-124A-12-1 Relationship between Unit Versions of CPU Units and Sysmac Studio Versions................... A-124A-12-2 Functions That Were Added or Changed for Each Unit Version............................................. A-126A-12-3 Performance Improvements for Unit Version Upgrades.......................................................... A-128

Index

Terms and Conditions Agreement



Exclusive WarrantyOmrons exclusive warranty is that the Products will be free from defects in materials and workman-ship for a period of twelve months from the date of sale by Omron (or such other period expressed in writing by Omron). Omron disclaims all other warranties, express or implied.

LimitationsOMRON 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 RemedyOmrons sole obligation hereunder shall be, at Omrons 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 responsible for warranty, repair, indemnity or any other claims or expenses regarding the Products unless Omrons 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 Companies shall not be liable for the suitability or unsuitability or the results from the use of Products in combi-nation with any electrical or electronic components, circuits, system assemblies or any other materi-als 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.

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

OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CON-SEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE OR STRICT LIABILITY.

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

Warranty, Limitations of Liability

Warranties

Limitation on Liability; Etc

15



Omron Companies shall not be responsible for conformity with any standards, codes or regulations which apply to the combination of the Product in the Buyers application or use of the Product. At Buyers 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 com-plete determination of the suitability of the Product in combination with the end product, machine, sys-tem, or other application or use. Buyer shall be solely responsible for determining appropriateness of the particular Product with respect to Buyers application, product or system. Buyer shall take applica-tion responsibility in all cases.

NEVER USE THE PRODUCT 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 PRODUCT(S) IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.

Omron Companies shall not be responsible for the users programming of a programmable Product, or any consequence thereof.

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 Omrons test conditions, and the user must correlate it to actual application requirements. Actual perfor-mance is subject to the Omrons Warranty and Limitations of Liability.

Product specifications and accessories may be changed at any time based on improvements and other 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 be changed without any notice. When in doubt, special part numbers may be assigned to fix or establish key specifications for your application. Please consult with your Omrons representative at any time to confirm actual specifications of purchased Product.

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.

Application Considerations

Suitability of Use

Programmable Products

Disclaimers

Performance Data

Change in Specifications

Errors and Omissions

Safety Precautions


Safety Precautions

The following notation is used in this manual to provide precautions required to ensure safe usage of anNJ-series Controller. The safety precautions that are provided are extremely important to safety. Alwaysread and heed the information provided in all safety precautions.The following notation is used.

Definition of Precautionary Information

WARNINGIndicates 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.

Precautions for Safe UseIndicates precautions on what to do and what not to do to ensure safe usage of the product.

Precautions for Correct UseIndicates precautions on what to do and what not to do to ensure proper operation and performance.

17

Safety Precautions


Symbols

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

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

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

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

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.

Safety Precautions


Warnings

WARNINGDuring Power Supply

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

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

Fail-safe Measures

Provide safety measures in external circuits to ensure safety in the system if an abnormality occurs due to malfunction of the CPU Unit, 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 countermea-sure for such problems, external safety measures must be provided to ensure safe operation of the system.

The CPU Unit will turn OFF all outputs from Basic Output Units in the follow-ing cases. The slaves will operate according to the settings in the slaves. If an error occurs in the power supply If the power supply connection becomes faulty If a CPU watchdog timer error or CPU reset occurs If a major fault level Controller error occurs While the CPU Unit is on standby until RUN mode is entered after the

power is turned ONExternal safety measures must be provided to ensure safe operation of the system in such cases.

If external power supplies for slaves or other devices are overloaded or short-circuited, the voltage will drop, outputs will turn OFF, and the system may be unable to read inputs. Provide external safety measures in controls with mon-itoring of external power supply voltage as required so that the system oper-ates safely in such a case.

19

Safety Precautions


Unintended outputs may occur when an error occurs in variable memory or in memory used for CJ-series Units. As a countermeasure for such prob-lems, external safety measures must be provided to ensure safe operation of the system.

Provide measures in the communications system and user program to ensure safety in the overall system even if errors or malfunctions occur in data link communications or remote I/O communications.

If there is interference in remote I/O communications or if a major fault level error occurs, output status will depend on the products that are used.Confirm the operation that will occur when there is interference in communi-cations or a major fault level error, and implement safety measures.Correctly set all of the settings in the slaves and Units.

The NJ-series Controller continues normal operation for a certain period of time when a momentary power interruption occurs. This means that the NJ-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 acci-dents 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, device variables, or values in memory used for CJ-series Units from the Sysmac Studio. The devices or machines may perform unexpected operation regardless of the operating mode of the CPU Unit.

Actual Operation

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

Safety Precautions


Version Information

This error message is displayed by and the above option setting is available on Sysmac Studioversion 1.02.

Cautions

CautionApplication

Do not touch any Unit when power is being supplied or immediately after the power supply is turned OFF. Doing so may result in burn injury.

Wiring

Be sure that all terminal screws and cable connector screws are tightened to the torque specified in the relevant manuals. The loose screws may result in fire or malfunction.

Online Editing

Execute online editing only after confirming that no adverse effects will be caused by deviations in the timing of I/O. If you perform online editing, the task execution time may exceed the task period, I/O may not be refreshed with external devices, input signals may not be read, and output timing may change.

Precaution on Error Message That Says an Instruction May CauseUnintended Operation

Instructions may results in unexpected operation and affect the system if you clear the selection of the Detect an error when an in-out variable is passed to specific instruction argument Check Box in the Program Check Area. Always confirm that the conditions for use that are given in the NJ-series Instructions Reference Manual (Cat. No. W502) are met before you clear the selection of this check box.

21

Precautions for Safe Use



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 malfunc-

tion or burning.

The sliders on the tops and bottoms of the Power Supply Unit, CPU Unit, I/O Units, and other Unitsmust be completely locked (until they click into place) after connecting the adjacent Unit connectors.

Always connect to a ground of 100 or less when installing the Units. A ground of 100 or less mustbe installed when shorting the GR and LG terminals on the Power Supply Unit.

Follow the instructions in this manual to correctly perform wiring.Double-check all wiring and switch settings before turning ON the power supply.

Use crimp terminals for wiring.Do not connect bare stranded wires directly to terminals.

Do not pull on the cables or bend the cables beyond their natural limit.Do not place heavy objects on top of the cables or other wiring lines. Doing so may break the cables.

Mount terminal blocks and connectors only after checking the mounting location carefully.Be sure that the terminal blocks, expansion cables, and other items with locking devices are properlylocked into place.

Always remove any dustproof labels that are on the top of the Units when they are shipped beforeyou turn ON the power supply. If the labels are not removed, heat will accumulate and malfunctionsmay occur.

Before you connect a computer to the CPU Unit, disconnect the power supply plug of the computerfrom the AC outlet. Also, if the computer has an FG terminal, make the connections so that the FGterminal has the same electrical potential as the GR terminal on the Power Supply Unit. A differencein electrical potential between the computer and Controller may cause failure or malfunction.

If the external power supply to an Output Unit or slave has polarity, connect it with the correct polarity.If the polarity is reversed, current may flow in the reverse direction and damage the connecteddevices regardless of the operation of the Controller.

Do not exceed the rated supply capacity of the Power Supply Units in the NJ-series Controller. Therated supply capacities are given in the NJ-series CPU Unit Hardware Users Manual (Cat. No.W500).If the capacity is exceeded, operation may stop, malfunctions may occur, or data may not be backedup normally for power interruptions.Use NJ-series Power Supply Units for both the NJ-series CPU Rack and Expansion Racks.Operation is not possible if a CJ-series Power Supply Unit is used with an NJ-series CPU Unit or anNJ-series Power Supply Unit is used with a CJ-series CPU Unit.

Disassembly and Dropping

Mounting

Installation

Wiring

Power Supply Design



Do not apply voltages or connect loads to the Output Units or slaves in excess of the maximum rat-ings.

Surge current occurs when the power supply is turned ON. When selecting fuses or breakers forexternal circuits, consider the above precaution and allow sufficient margin in shut-off performance.Refer to the relevant manuals for surge current specifications. Refer to the NJ-series CPU Unit Hard-ware Users Manual (Cat. No. W500) for surge current specifications.

If the full dielectric strength voltage is applied or turned OFF using the switch on the tester, the gener-ated impulse voltage may damage the Power Supply Unit. Use the adjustment on the tester to gradu-ally increase and decrease the voltage.

Apply the voltage between the Power Supply Unit's L1 or L2 terminal and the GR terminal when test-ing insulation and dielectric strength.

Do not supply AC power from an inverter or other device with a square-wave output. Internal temper-ature rise may result in smoking or burning. Always input a sinusoidal wave with the frequency that isgiven in the NJ-series CPU Unit Hardware Users Manual (Cat. No. W500).

Install external breakers and take other safety measures against short-circuiting in external wiring.

It takes up to approximately 10 to 20 s to enter RUN mode after the power is turned ON. The outputsduring this time behave according to the slave or Unit specifications. Use the RUN output on thePower Supply Unit, for example, to implement fail-safe circuits so that external devices do not operateincorrectly.

Configure the external circuits so that the power supply to the control system turns ON only after thepower supply to the Controller has turned ON. If the power supply to the Controller is turned ON afterthe control power supply, temporary errors may result in incorrect control system signals because theoutput terminals on Output Units may momentarily turn ON when power supply is turned ON to theController.

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

Never turn OFF the power supply to the Controller until RUN mode is entered after the power isturned ON. If the power supply is turned OFF, a Battery-backup Memory Check Error may occur atnext time you start operation. If a Battery-backup Memory Check Error occurs, the variables retainedare set to their initial values and the Holding, DM and EM Areas in memory used for CJ-series Unitsare cleared to all zeros. If you want to resume the operation, reload the correct data for the variablesretained and CJ-series Unit memory, as required.

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

Do not turn OFF the power supply or remove the SD Memory Card while SD Memory Card access isin progress (i.e., while the SD BUSY indicator flashes). Data may become corrupted, and the Control-ler will not operate correctly if it uses corrupted data. To remove the SD Memory Card from the CPUUnit while the power supply is ON, press the SD Memory Card power supply switch and wait for theSD BUSY indicator to turn OFF before you remove the SD Memory Card.

Do not disconnect the cable or turn OFF the power supply to the Controller when downloading dataor the user program from Support Software.

Always turn OFF the power supply to the Controller before you attempt any of the following. Mounting or removing I/O Units or the CPU Unit Assembling the Units

Turning ON the Power Supply

Turning OFF the Power Supply

23



Setting DIP switches or rotary switches Connecting cables or wiring the system Connecting or disconnecting the connectors

The Power Supply Unit may continue to supply power to the rest of the Controller for a few secondsafter the power supply turns OFF. The PWR indicator is lit during this time. Confirm that the PWRindicator is not lit before you perform any of the above.

Confirm that no adverse effect will occur in the system before you attempt any of the following. Changing the operating mode of the CPU Unit (including changing the setting of the Startup

Mode) Changing the user program or settings Changing set values or present values Forced refreshing

After you change any slave or Unit settings, carefully check the safety of the controlled system beforeyou restart the Unit.

If two different function modules are used together, such as when you use CJ-series Basic Units andEtherCAT slaves, take suitable measures in the user program and external controls to ensure thatsafety is maintained in the controlled system if one of the function modules stops. The relevant out-puts will behave according to the slave or Unit specifications if a partial fault level error occurs in oneof the function modules.

Always confirm safety at the connected equipment before you reset Controller errors with an eventlevel 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 Oper-ational 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 ofpartial fault have occurred for the EtherCAT Master Function Module.

Always confirm safety at the connected equipment before you reset Controller errors for a CJ-seriesSpecial Unit. When a Controller error is reset, the Unit where the Controller error with an event levelof observation or higher will be restarted.Before you reset all errors, confirm that no Controller errors with an event level of observation orhigher have occurred for the CJ-series Special Unit. Observation level events do not appear on theController Error Tab Page, so it is possible that you may restart the CJ-series Special Unit withoutintending to do so.You can check the status of the _CJB_UnitErrSta[0,0] to _CJB_UnitErrSta[3,9] error status variableson a Watch Tab Page to see if an observation level Controller error has occurred.

The user program and initial values for the variables are stored in non-volatile memory in the CPUUnit. The present values of variables with the Retain attribute and the values of the Holding, DM, andEM Areas in the memory used for CJ-series Units are backed up by a Battery. If the Battery is notconnected or the Battery is exhausted, the CPU Unit detects a Battery-backup Memory Check Error.If that error is detected, variables with a Retain attribute are set to their initial values and the Holding,DM, and EM Areas in memory used for CJ-series Units are cleared to all zeros. Perform thoroughverifications and provide sufficient measures to ensure that the devices perform safe operation for theinitial values of the variables with Retain attributes and the resulting operation.

The absolute encoder home offsets are backed up by a Battery. If the CPU Unit detects a low batteryvoltage or the absence of a mounted battery when the power supply to the Controller is turned ON,the absolute encoder home offsets are cleared to zeros and an Encoder Home Offset Read Erroroccurs. Reset the error and perform homing to define home. If you do not define home, unintendedoperation of the controlled system may occur.

Operation

Battery Backup



Forced refreshing ignores the results of user program execution and refreshes I/O with the specifiedvalues. If forced refreshing is used for inputs for which I/O refreshing is not supported, the inputs willfirst take the specified values, but they will then be overwritten by the user program. This operationdiffers from the force-set/reset functionality of the CJ-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 wouldmake the user program more difficult to understand and possibly cause programming mistakes.

When you use data link communications, check the error information that is given in _ErrSta (Control-ler Error Status) to make sure that no error has occurred in the source device. Create a user programthat uses reception data only when there is no error in the source device. If there is an error in thesource 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 linktables have been set, confirm that the controlled system will not be adversely affected before youtransfer the data link tables. The data links start automatically after the data link tables are trans-ferred.

All CPU Bus Units are restarted when routing tables are transferred from Support Software to theCPU Unit. Confirm that the system will not be adversely affected by restarting before you transfer therouting tables.

Tag data links will stop between related nodes while tag data link parameters are transferred duringController operation. Confirm that the system will not be adversely affected before you transfer thetag data link parameters.

All related EtherNet/IP nodes are reset when you transfer settings for the built-in EtherNet/IP port(including IP addresses and tag data links settings). Confirm that the system will not be adverselyaffected 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 communi-cations. Do not use repeating hubs on networks where tag data links are used. Use an Ethernetswitch instead.

Make sure that the communications distance, number of nodes connected, and method of connectionfor EtherCAT are within specifications.Do not connect EtherCAT communications to EtherNet/IP, a standard in-house LAN, or other net-works. An overload may cause the network to fail or malfunction.

Malfunctions or unexpected operation may occur for some combinations of EtherCAT revisions of themaster and slaves. If you disable the revision check in the network settings, use the Sysmac Studio tocheck the slave revision settings in the master and the actual slave revisions, and then make surethat functionality is compatible in the slave manuals or other references. You can check the actualslave revisions from the Sysmac Studio or on slave nameplates.

Debugging

General Communications

EtherNet/IP Communications

EtherCAT Communications

25



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 specifica-tions. 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 parameter is set to stop operation, process data communications will stopfor all slaves when an EtherCAT communications error is detected in a slave. At that time, the ServoDrive will operate according to the Servo Drive specifications. For this reason, if Servo Drives areconnected, the Servos for all axes will be turned OFF. Make sure that the Fail-soft Operation parame-ter setting results in safe operation when a device error occurs.

EtherCAT communications are not always established immediately after the power supply is turnedON. Use the system-defined variables in the user program to confirm that communications are estab-lished before attempting control operations.

If noise occurs or an EtherCAT slave is disconnected from the network, any current communicationsframes may be lost. If frames are lost, slave I/O data is not communicated, and unintended operationmay occur. The slave outputs will behave according to the slave specifications. If a noise counter-measure or slave replacement is required, perform the following processing. Program the _EC_InDataInvalid (Input Data Disable) system-defined variable as an interlock con-

dition in the user program. Set the PDO communications timeout detection count setting in the EtherCAT master to at least 2.

Refer to the NJ-series CPU Unit Built-in EtherCAT Port Users Manual (Cat. No. W505) for details. When an EtherCAT slave is disconnected or disabled, communications will stop and control of the

outputs will be lost not only for the disconnected slave, but for all slaves connected after it. Confirmthat the system will not be adversely affected before you disconnect or disable a slave.

NX bus communications 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 pro-gram to confirm that communications are established before attempting control operations.

You cannot use standard Ethernet hubs or repeater hubs with EtherCAT communications. If you useone of these, a major fault level error or other error may occur.

Confirm the axis number carefully before you perform an MC Test Run. The motor is stopped if communications are interrupted between the Sysmac Studio and the CPU

Unit during an MC Test Run. Connect the communications cable between the computer and CPUUnit securely and confirm that the system will not be adversely affected before you perform an MCTest Run.

Always execute the Save Cam Table instruction if you change any of the cam data from the user pro-gram in the CPU Unit or from the Sysmac Studio. If the cam data is not saved, the previous conditionwill be restored when the power is turned ON again, possibly causing unexpected machine operation.

The positive drive prohibit input (POT), negative drive prohibit input (NOT), and home proximity input(DEC) of the Servo Drive are used by the MC Function Module as the positive limit input, negativelimit input, and home proximity input. Make sure that the signal widths for all of these input signals arelonger than the control period of the MC Function Module. If the input signal widths are shorter thanthe control period, the MC Function Module may not be able to detect the input signals, resulting inincorrect operation.

If you make any changes in the Detailed Settings Area of the Axis Basic Settings Display of the Sys-mac Studio, make sure that the devices or machines perform the expected operation before you startactual operation.If the relationship between the functions of the Motion Control Function Module and the EtherCATslave process data that is assigned to the axes is not correct, the devices or machines may performunexpected operation.

Motion Control



You cannot back up, restore, or compare some or all of the settings for certain slaves and Units. Also,you cannot back up, restore, or compare data for disabled slaves or Units. After you restore data, suf-ficiently confirm that operation is correct before you start actual operation.

The absolute encoder home offsets are backed up with a Battery in the CPU Unit as absoluteencoder information. If any of the following conditions is met, clear the absolute encoder home offsetsfrom the list of data items to restore, and then restore the data. Then, define the absolute encoderhome again. If you do not define home, unintended operation of the controlled system may occur. The Servomotor or Servo Drive was changed since the data was backed up. The absolute encoder was set up after the data was backed up. The absolute data for the absolute encoder was lost.

The Battery may leak, rupture, heat, or ignite. Never short-circuit, charge, disassemble, heat, or incin-erate the Battery or subject it to strong shock.

Dispose of any Battery that has been dropped on the floor or otherwise subjected to excessive shock.Batteries that have been subjected to shock may leak if they are used.

UL standards require that only an experienced engineer replace the Battery. Make sure that an expe-rienced engineer is in charge of Battery replacement.

Apply power for at least five minutes before changing the Battery. Install a new Battery within fiveminutes (at 25C) of turning OFF the power supply. If power is not supplied for at least 5 minutes, thesaved data may be lost.

We recommend replacing the Battery with the power turned OFF to prevent the CPU Units sensitiveinternal components from being damaged by static electricity and to prevent malfunctions. The Bat-tery can be replaced without turning OFF the power supply. To do so, always touch a grounded pieceof metal to discharge static electricity from your body before you start the procedure.After you replace the Battery, connect the Sysmac Studio and clear the Low Battery Voltage error.

Make sure that the required data, including the user program, configurations, settings, variables, andmemory used for CJ-series Units, is transferred to a CPU Unit that was replaced and to externallyconnected devices before restarting operation.Be sure to include the tag data link settings, routing tables, and other CPU Bus Unit data, which arestored in the CPU Unit.

The absolute encoder home offsets are backed up with a Battery in the CPU Unit as absoluteencoder information. When you change the combination of the CPU Unit and Servomotor, e.g., whenyou add or replace a Servomotor, define the absolute encoder home again.

Dispose of the product and Batteries according to local ordinances as they apply.

The following information must be displayed for all products that contain primary lithium batteries with aperchlorate content of 6 ppb or higher when shipped to or transported through the State of Cali

Documents

OMRON NJ CPU Unit Sofware User Manual