OMRON NX102 model hardware usage instructions

OMRON NX102 model hardware usage instructions

Product Overview and Model Specifications

1 Product positioning

The NX102 belongs to the Sysmac platform medium-sized PLC, which integrates sequential control and multi axis motion control. The CPU body comes with one EtherCAT master station and dual EtherNet/IP. The rack mounted NX102 can be freely equipped with NX digital/analog/special function modules. The program adopts IEC standards (ladder diagram/ST/FB, etc.) and is fully configured, simulated, and debugged by Sysmac Studio.

2 Hardware specifications (multiple sub models: 9000/1000/1100/1200, with differences in maximum number of controlled axes)

Power supply: DC 20.4~28.8V DC, maximum power consumption of the whole machine is 5.8W;

Storage: 5MB for programs, 1.5MB for holding variables, and 32MB for non holding variables;

Axis resources: Top configuration with 15 axes (12 real axes), supporting linear/circular interpolation and electronic cam;

Interface: PORT1/PORT2 dual EtherNet/IP, PORT3 single EtherCAT (100M), SD card slot, battery compartment;

The body size is 72 × 100 × 90mm, installed on DIN35 guide rails, and the maximum number of NX modules that can be mounted on a single rack is 32.

3 supporting software and hardware

Upper level: Sysmac Studio configuration software; Peripherals: SD card (program/backup/log), CJ1W-BAT01 backup lithium battery (to maintain system clock); Expansion components: NX power module, various I/O modules, terminal accessories.

System architecture design

1. Local CPU rack structure

CPU+various NX modules+end cover plate NX-END02, module back plug NX-BUS internal bus, bus is divided into two power supplies: unit power supply (internal circuit of the module), I/O power supply (external sensor/load). The two power supplies are designed separately and can be expanded with additional power supply expansion units.

2-Bus Network Architecture

EtherCAT (PORT3): Real time devices such as servo, remote NX slave terminal, encoder module, vision, etc., supporting line/tree/ring network redundancy (firmware V1.40 or above);

EtherNet/IP (dual port): HMI, upper PC, other PLCs, database, OPC UA devices, dual network can be divided into internal/external network isolation networking;

Expansion: NX communication module can be installed to expand fieldbus such as RS485 and DeviceNet.

3 upper connections

PC is directly connected to PORT1 through Ethernet cable, automatically addressing or manually setting IP to achieve Sysmac Studio online download, monitoring and simulation.

Hardware component details

1 CPU body components

Indicator lights: POWER power, RUN running, ERROR fault, BUSY non-volatile storage read-write, SD related indicator lights;

DIP dialing: used for SD automatic program loading, safe mode, and compatibility settings with older software versions;

Detachable spring terminal: 24V/0V power supply+grounding;

SD slot: Program backup and restore, recipe/log storage, with power button for plugging and unplugging SD with power on;

Battery compartment: Optional lithium battery, maintains built-in RTC clock in case of power failure (without battery, relies on the body capacitor for short-term duration of about 10 days @ 40 ℃).

2 optional accessories

SD memory card: engineering backup, automatic program loading upon power on, new version CPU supports memory card lifespan warning;

Power expansion unit: divided into two categories: NX unit power expansion and I/O power expansion, to solve the problem of rack power consumption exceeding the limit;

Terminal accessories: anti error coding pin NX-AUX02, rail isolation gasket;

End plate: PFP-M, CLIPFIX guide rail stopper, fixed at both ends of the rack to prevent movement.

3 NX peripheral module

Modular categories such as digital input/relay output/analog AD/DA, temperature measurement, load measurement, communication, etc. are spliced on the right side of the CPU as needed.

Power System Design (Key Points of the Manual)

The system is divided into two independent DC24V power supplies (for the PLC itself and the internal control circuit of the NX module) and I/O power supplies (for external sensors and actuators), which are selected and wired separately.

Unit 1 power supply design

The maximum output power of the CPU native unit power supply is 10W, and additional unit power modules are installed for segmented power supply when the full load exceeds the limit;

SELV safety power supply is required for selection, and Omron S8VK series is recommended;

Power calculation formula: Total power consumption=(CPU power consumption+all NX power consumption)/Power efficiency (80%), with reserved power on surge margin.

2. I/O power supply design

The I/O power supply can be fed uniformly through the NX-BUS bus or separately supplied externally to each module;

The maximum power supply current for a single bus I/O segment is 10A, and overcurrent must be inserted into an additional I/O power supply unit segment;

Mixing of peripherals with different voltages (12V/24V), isolated and segmented power supply through power supply units to avoid abnormal voltage drop.

3. Selection of air switches/fuses

Select circuit breakers based on impulse current and steady-state current, distinguish between unit circuit and I/O circuit melting curves, and standardize installation positions.

4. Explanation of Power on Surge

The peak value of instantaneous impulse current during cold start of the whole machine is large, and a margin is reserved for power supply selection to prevent power on and power off.

Installation specifications (DIN rail installation)

1. Requirements for Cabinet Environment

The ambient temperature is 0-55 ℃, the humidity is 5-95% RH, and there is no condensation. Keep away from dust, corrosive gases, and high-power frequency converters;

The installation position should be 1-1.6m above the ground, with a distance of ≥ 200mm from high-voltage components, and ventilation space should be reserved above and below the control cabinet.

2 DIN rail installation steps

The guide rail is made of PFP (Ohmic Aluminum Rail)/NS (Steel DIN35) and locked with standard torque;

The CPU is first inserted into the guide rail, and then the NX modules are spliced one by one. When the buckles are in place, a locking sound is heard;

The NX-END02 end cover is installed at the far right end of the rack, and fixed end plates are installed on both sides of the machine to prevent displacement;

Inverted or side mounted PLCs are prohibited and must be installed upright to ensure heat dissipation.

3 SD/battery disassembly and assembly

SD: First turn on the SD power switch, wait for all SD-PWR/SD-BUSY lights to turn off before unplugging the card; Power off is strictly prohibited during reading and writing;

Battery: Power on for 5 minutes and then power off for replacement. Anti static, factory does not come with a battery, default low voltage error is turned off.

Wiring specifications

1. Power wiring

A1/B1 is connected to DC24V, A3/B3 is connected to 0V, and the spare terminals can be connected in parallel and series to the power supply of the next device. The single terminal has a current limit of 4A;

Grounding terminal ≤ 100 Ω grounding, ground wire ≥ 2.0mm ², steel guide rail can omit single point grounding of the body.

2 Terminal Wiring Rules

Wire gauge: 0.08-1.5mm single core/multi strand wire, recommended cold pressed terminal;

A straight screwdriver should be used to press the wire at an angle of 10-15 degrees, and it is forbidden to forcefully poke or damage the terminal buckle;

High power cables are fixed by tying wires within 30mm of the terminal.

3 Communication wiring

EtherCAT/EtherNet/IP uses Category 5e or higher shielded Ethernet cables, with a single point grounding on the shielding layer;

EtherCAT ring network models support automatic switching of line redundancy and disconnection.

4 Key points of safety wiring

Connect the control circuit power supply to the PLC power supply first, and then to the equipment load power supply; Power off reverse operation to avoid output misoperation at the moment of power on.

Power on/off timing and safety design

1. Power on process

After power on, the CPU performs a self check for about 20 seconds. During the self check phase, all DO outputs of the rack are forcibly turned off, and the EtherCAT slave station defines the output status according to its own parameters. After completing the self check, it enters RUN/ROG mode.

2 Power failure detection

If the voltage drops below 20.4V and lasts for 2-8ms, it will be judged as power failure. The system will immediately stop the program, cut off the digital output of the main body, terminate SD reading and writing, and record the power failure fault log.

5 Fault safety design (emphasis)

Emergency stop and equipment interlock must be implemented through external hard wiring, and cannot rely solely on PLC programs;

Output contact adhesion/transistor breakdown risk, external contactor hardware interlock;

When communication is disconnected or modules fail, the output of the slave station is determined by its own parameters, and the system requires an external safety circuit to provide backup.

Troubleshooting and Maintenance

Quick determination of fault indicator light

RUN off: shutdown/fatal malfunction; ERROR is constantly on, indicating a major fault, and flashing is slightly abnormal; BUSY flashing: built-in flash storage;

Network port L/A: The link usually lights up or flashes to indicate data transmission and reception, while the NET-ERR light indicates communication abnormalities.

2 Daily inspections

Regularly check the wiring tightness, temperature and humidity inside the cabinet, and dust;

Lithium battery: 5-year lifespan, regularly check for low voltage alarms;

Regular backup program for SD card, pay attention to the card lifespan alarm variable.

3. Equipment replacement

Replacing the same model of CPU with an SD card allows for one click recovery of programs and parameters without the need for reconfiguration.