Unipulse F159 User manual

F159
07 Nov. 2008
Rev. 1.02
OPERATION MANUAL
PLUG-IN WEIGHT MODULE
for the OMRON SYSMAC CJ1 SERIES PLC

Introduction
Introduction
Backplane Free －Function Block －Program Standardization
The high speed F159 weighing controller is designed to provide efficient
production control functions in a wide variety of process weighing applications.
The F159 directly plugs into the state-of-the-art Omron CJ1 series PLC.
This direct connectivity shortens the system development time when
implementing a process weighing system by simplifying the setup of the
operation, reducing wiring and interfacing cables, drastically reducing the cost of
systems' configuration and programming time for the systems integrator and
designers.
The slim F159 combines with the CJ1 to provide an excellent solution for
process weighing systems. This combination aids in the downsizing of the
controlling installation site. Since the F159 possesses weighing information at a
rate of 500 times per second, this high data processing speed allows for
additional internal measurements, of smaller fluctuations of the weight, at a
higher resolution, which increases the productivity of the weighing system.
The applications for the F159 weigh module includes: Hopper scales, Packing
scales, Bag filling systems, Rotary filling systems and many other weight based
control systems. The F159 can excite up to four (4) 350 ohm load cells while still
providing up to 1/40,000 division resolution.
The F159 stores all the weighing system set up values and the complete feeding /
discharge / weighing control sequence internal to itself, significantly reducing
the burden imposed on the CJ1. This synergy between the PLC and weighing
instrumentation improves system speed and reduces system configuration times.
Functions already programmed into the F159 include: Auto free fall
compensation; Fast-Slow-Dribble filling, Final, High/Low, Tare, and Zero
Tracking functions. Powerful analog filters and selectable moving average
digital filters are used to eliminate the mechanical vibration to achieve the higher
weighing accuracy.
Low development costs, quick system interfacing, high speed and accuracy, and
reduced PLC overhead, all combine to make the F159 weight controller a best
buy choice for your most demanding weight based process control applications.

Safety Precautions
Safety Precautions
Be sure to read for safety.
In order to have an F159 Weight Module used safely, notes I would like you to surely follow
divide into and , and are indicated by the following documents.
Notes indicated here are the serious contents related to safety. Please use F159 after
understanding the contents well.
WARNING
CAUTION
WARNING
Misuse may cause the risk of death or serious
injury to persons.
CAUTION
Misuse may cause the risk of injury to persons
or damage to property.

Safety Precautions
WARNING
●Use F159 with correct supply voltage.
●Do not carry out the direct file of the commercial power supply to a signal input terminal.
●Carefully check wiring, etc. before applying power.
●Do not disassemble the main body for modifications or repair.
●Be sure to ground the protective ground terminal.
●When smoke, a nasty smell, or strange sound, please shut off a power supply
immediately and extract a power supply cable.
●Do not install in the following environments.
- Places containing corrosive gas or flammable gas.
- Where the product may be splashed with water, oil or chemicals.

Safety Precautions
CAUTION
●Be sure to disconnect the power cable when performing the following.
- Wiring/connection of cables to terminal blocks.
●Take an interval of more than 5 seconds when repeating ON/OFF.
●Use shielded cables for the connection of strain gauge type sensor or External output.
●Take adequate shielding measures when using at the following locations.
- Near a power line.
- Where a strong electric field or magnetic field is formed.
- Where static electricity, relay noise or the like is generated.
●Do not install in the following environments.
- Where the temperature and/or humidity exceeds the range in the specifications.
- Places with large quantities of salt or iron powder.
- Where the main body is directly affected by vibration or shock.
●Do not use it, broken down.

CONTENTS
CONTENTS
1．APPEARANCE DESCRIPTION ...............................................1
1-1．Front Panel ............................................................................................ 1
1-2．Status LED ............................................................................................. 2
1-3．Unit Number Select Switch .................................................................. 3
1-4．DIP Switch ............................................................................................. 4
2．CONNECTION ........................................................................5
2-1．F159 Block Terminal ............................................................................. 5
2-2．Load Cell Connection ........................................................................... 5
2-2-1 6-wire Connection .............................................................................. 6
2-2-2 4-wire Connection .............................................................................. 6
2-2-3 Connecting Load cells in Parallel ..................................................... 8
2-3．Output Connection ............................................................................. 12
2-3-1 Equivalent Circuit ............................................................................ 12
2-4．Connections to Terminal Block ......................................................... 13
3．DATA EXCHANGE WITH CPU ............................................14
3-1．High Performance I/O Unit Restart Flag ........................................... 15
3-2．Relay Area ........................................................................................... 16
3-2-1 Allocation of Weight and Status Data ............................................ 16
3-2-2 OUT (CPU unit →F159) ................................................................... 16
3-2-3 IN (F159 →CPU unit) ....................................................................... 19
3-2-4 Register Allocations for Weighing Control ................................... 28
3-2-5 Register Allocations for Initial Settings ......................................... 29

CONTENTS
4．CALIBRATION ......................................................................37
4-1．What is Calibration? ........................................................................... 37
4-2．Actual Load Calibration Procedure ................................................... 38
4-3．Preparation for Calibration ................................................................ 39
4-3-1 LOCK Release .................................................................................. 39
4-3-2 Setting Initial Data ............................................................................ 40
4-4．Zero Calibration .................................................................................. 44
4-5．Span Calibration ................................................................................. 47
5．DISPLAY SETTINGS ............................................................50
5-1．Digital Filter ......................................................................................... 50
5-2．Analog Filter ........................................................................................ 50
5-3．Digital Filter 2 ...................................................................................... 51
5-4．Motion Detection (MD) ........................................................................ 52
5-5．Zero Tracking (ZT) .............................................................................. 54
5-6．Digital Zero (DZ) .................................................................................. 55
5-7．Digital Zero Clear ................................................................................ 55
5-8．DZ Regulation ..................................................................................... 55
5-9．One-Touch Tare Subtraction ............................................................. 56
5-10．One-Touch Tare Subtraction Reset ................................................ 56
5-11．Digital Tare Subtraction ................................................................... 57
5-12．Restriction on Tare Subtraction ...................................................... 57
5-13．Sign Reversal during Discharge Control ........................................ 58

CONTENTS
6．WEIGHING MODE SETTING AND OPERATION ................59
6-1．Feed Weighing and Discharge Weighing ......................................... 60
6-1-1 Feed Weighing ................................................................................. 60
6-1-2 Discharge Weighing ........................................................................ 63
6-1-3 Weighing Mode ................................................................................ 66
6-2．Simple Comparison Control and Sequence Control ....................... 67
6-2-1 Simple Comparison Control ........................................................... 67
6-2-2 Sequence Control ............................................................................ 69
6-2-3 Mode Selection ................................................................................. 74
6-3．FF CPS. Regulation Value / Free Fall Compensation /
Avg. Count of FF CPS. / FF CPS. Coefficient ................................... 75
6-4．Final / Set Point 2 / Set Point 1 / FF CPS. / Over / Under ................. 78
6-5．Near Zero / Upper Limit / Lower Limit ............................................... 79
6-6．U/L Limit Comparison / U/L Limit Comparison Mode/
Near zero Comparison / Over/Under Comparison /
Over/Under Comparison Mode ......................................................... 80
6-7．Complete Signal Output Mode / Complete Output Time /
Compare Time / Comparison Inhibit Time ....................................... 82
6-8．Judging Times / AZ Times / At Start NZ Confirmation /
At Start WV Confirmation /Auto Jog (ON/OFF) / Auto Jog Timer .. 83
6-9．Net Weight Over / Gross Weight Over .............................................. 87
7．LADDER DIAGRAM .............................................................88
8．SETTING VALUES LIST .......................................................95
9．ERROR CODE ......................................................................97
9-1．Error Code and Error Assistance Code ............................................ 97
9-2．Error Description ................................................................................ 98
9-2-1 Calibration Error .............................................................................. 98
9-2-2 Weight Error ................................................................................... 102
9-2-3 Sequence Error .............................................................................. 104
10．BLOCK DIAGRAM ............................................................106

CONTENTS
11．DIMENSIONS ....................................................................107
12．INSTALLATION ................................................................108
12-1．Connection with CJ1 Unit .............................................................. 108
12-2．DIN Rail Installation ........................................................................ 110
13．SPECIFICATIONS ............................................................112
13-1．Analog Section ................................................................................ 112
13-2．Display ............................................................................................. 113
13-3．Setting .............................................................................................. 113
13-4．General Specifications ................................................................... 114
14．STATEMENT OF CONFORMATION TO EC DIRECTIVES 115

1.APPEARANCE DESCRIPTION
1
1. APPEARANCE DESCRIPTION
1-1. Front Panel
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OUT2
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-SIG
+SIG
SHILD
Status LED
Terminal block
Unit number select switch
DIP switch.
The switch is located
beneath the terminal
block.
CAUTION
Terminal block can be detached by
pulling down the lever. Normally, the
lever should be in upper position.
Always turn off the CJ1’s voltage
source before trying to attach/detach
the terminal block.
B1A1
MACH
No.
10
1
10
0
R
F159
UN
ERC
ERH
WERR
OUT1
OUT2

1.APPEARANCE DESCRIPTION
2
1-2. Status LED
Status LEDs display the current operating status of the unit. The following table
summaries their names and meanings.
LED Name State Description
RUN
（Green）Operation status ON Normal operation
OFF Data exchange with CPU has been aborted
ERC
（Red）
Error detected
by the unit
ON Error occurred in F159
OFF Normal operation
ERH
（Red）CPU error ON Error occurred during data exchange with CPU
OFF Normal operation
WERR
（Red）Weight error ON One or more of the following alarms are in
place: ±LOAD, OFL1, OFL2, OFL3, ZALM
OFF Normal operation
OUT1
（Orange）OUT1 output ON OUT1 =ON
OFF OUT1 = OFF
OUT2
（Orange）OUT2 output ON OUT2 = ON
OFF OUT2 = OFF

1.APPEARANCE DESCRIPTION
3
1-3. Unit Number Select Switch
F159 acts as a high performance weighing processing module for Omron SYS-
MAC CJ1 series PLC. The data exchange between CPU unit and F159 are
carried out by the high performance relay area of I/O and DM area.
Relay and DM number used by F159 can be selected by the unit number
selection switch located on the front panel.
Unit number must be unique: duplicate use of the same number for multiple of
I/O units will cause operation error “Error: Duplicate use of unit No.”
(“Duplicate use of unit No.” in programming console), disabling normal
operation (A40113 turns ON).
Switch
No.
Unit
No.
Channel number allocated
to the I/O unit relay area
DM number allocated
to the I/O unit DM area
0 0 2000 - 2009CH D20000 - 20099
1 1 2010 - 2019CH D20100 - 20199
2 2 2020 - 2029CH D20200 - 20299
3 3 2030 - 2039CH D20300 - 20399
4 4 2040 - 2049CH D20400 - 20499
5 5 2050 - 2059CH D20500 - 20599
6 6 2060 - 2069CH D20600 - 20699
7 7 2070 - 2079CH D20700 - 20799
8 8 2080 - 2089CH D20800 - 20899
9 9 2090 - 2099CH D20900 - 20999
10 10 2100 - 2109CH D21000 - 21099
ｎｎ 2000 ＋n×10 - 2000 ＋n×10 ＋9CH D20000 ＋n×100 - D20000 ＋n×100 ＋99
95 95 2950 - 2959CH D29500 - 29599
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1.APPEARANCE DESCRIPTION
4
1-4. DIP Switch
DIP switch is used to LOCK calibration and restore default settings.
When switch 2 is set to ON position, F159 initializes set value whenever F159 is
powered on.
Switch 3 and 4 are undefined: they should always be set to OFF position. When
they are set to ON position, F159 can’t operate normally.
Switch No. State
ON OFF
1 Calibration LOCK ON Calibration LOCK OFF
2 Default set ON Default set OFF
3 Undefined Undefined
4 Undefined Undefined
NO
1234
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CAUTION
Terminal block can be detached by
pulling down the lever. Normally, the
lever should be in upper position.
Always turn off the CJ1’s voltage
source before trying to attach/detach
the terminal block.
B1A1
MACH
No.
10
1
10
0
R
F159
UN
ERC
ERH
WERR
OUT1
OUT2

2.CONNECTION
5
2. CONNECTION
2-1. F159 Block Terminal
2-2. Load Cell Connection
Connect leads from the load cell to F159 terminal block.
+EXC B1
+S B2
-EXC B3
-S B4
RSV B5
RSV B6
RSV B7
OUT1 B8
OUT1 B9
A1 SHIELD
A2 +SIG
A3 -SIG
A4 RSV
A5 RSV
A6 RSV
A7 RSV
A8 OUT2
A9 OUT2
Load cell signal
F159 6-wire connection 4-wire connection
+EXC +EXC +EXC
+S +S connected to +EXC
-EXC -EXC -EXC
-S -S connected to -EXC
+SIG +SIG +SIG
-SIG -SIG -SIG
SHIELD SHIELD SHIELD

2.CONNECTION
6
2-2-1. 6-wire Connection
F159 input uses an accurate 6-wire load cell connection (remote sense method).
Use shielded 6-core cable for this connection and route it apart from noisy lines
(power and digital devices) and AC power lines.
※Remote sense method can apply correct voltage to the load cell compensating
cable resistance change due to temperature variation along the cable. It is
capable of stabilizing excitation voltage in the vicinity of the load cell.
2-2-2. 4-wire Connection
F159 is also capable of 4-wire connection, in which case additional jumper
connections between B1 and B2, and B3 and B4 are required. Although the
system may function apparently correctly with B2 and B4 open, this
configuration can produce over-voltage excitation, resulting in over heating and
damage of the load cell. Connect these terminals using the supplied short-bars.
＋IN
－OUT
－IN
Load cell ＋EXC
＋S
－S
－EXC
＋SIG
－SIG
FG
＋OUT
Red
Yellow
Orange
Black
Green
White
B1
B2
B4
B3
A2
A3
A1
Color coding used
in UNIPULSE supplied 6-core cable
＋IN
－OUT
－IN
Load cell ＋EXC
＋S
－S
－EXC
＋SIG
－SIG
FG
＋OUT
Red
Black
Green
White
B1
B2
B4
B3
A2
A3
A1
Color coding used
Short these terminals
in UNIPULSE supplied 4-core cable

2.CONNECTION
7
CAUTION
・F159 supplies 10V excitation voltage. Use a load cell with rated excitation voltage of 10V
or higher, otherwise abnormal heating and damage to the cell may result.
・If you use F159 using 4-wire connection configuration, never fail to connect between
+EXC and +S, and –EXC and –S. Although the system may function apparently well
without these jumpers, over-voltage excitation can occur any time resulting in anomalous
heating and damage to the load cell.

2.CONNECTION
8
2-2-3. Connecting Load cells in Parallel
Some industrial applications require multiple of load cells connected in parallel
to configure, for example, a hopper scales or track scale. A typical parallel
connection is shown below.
Parallel connection can easily realized using the 4-point multi load cell summing
box (e.g. B41X series provided by UNIPULSE).
R
R
R
R
R
R
+EXC
-SIG
+SIG
-EXC
+EXC
-SIG
-EXC
+SIG
F・G
+S
-S
Seen from F159, the parallel
connection of n load cells is
considered to be a single load cell
with a capacity multiplied by n and
the same sensitivity with the
constituent load cells.
The averaging resistor (R) takes the
value between 300 and 500Ω, with
the same relative ratio and low
temperature coefficients. They are
not required if the load cell is
specifically designed for parallel
connection application.
If you connect multiple of load cells in parallel, use load cells with extra capacity margin.
Biased loading or mechanical shock may result in overload in some of the cells.
R
R
Request
CAUTION
Parallel connection of multiple of
load cells can drastically change
power consumption.
Power supply with sufficient
capacity should be selected. See
next page for proper evaluation of
power requirement.

2.CONNECTION
9
2-2-3-1. Power consumption evaluations for parallel connection
Power consumed by a F159 can vary depending on the number of load cells
connected in parallel. For an each additional 350Ωload cell, power requirement
will increase by approx.0.13 A.
The system must be so designed that it can provide enough power to drive the
whole system including F159 and CJ series units (CPU and I/O units). Select a
power unit with ample capacity.
Depending on the specification of CJ series device used, up to ten units can be
connected to a F159.
(Some CPU units allow expanded installation up to 40 units)
Number of 350Ωload cells
connected in parallel
Power
consumption [A]
10.30
20.43
30.56
40.69
For details on the power requirement of CJ series units, see “OMRON
CJ Series: CJ1/CJ1-H/CJ1M CPU Unit User’s Manual (Setup)”
provided by OMRON.
Request

2.CONNECTION
10
<Connection of single 350Ωload cell>
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Power unit
PA202
CPU unit
CJ1M-CPU11
Input unit
CJ1W-ID211
Output unit
CJ1W-OD211 F159 End coverF159 F159
Single load cell connection
0.58[A] 0.08[A] 0.10[A] 0.30[A] 0.30[A] 0.30[A]Power consumption →
Source capacity
5[V] 2.8[A]
Unit type Unit name Qty Power consumption (A)
CPU unit CJ1M-CPU11 1 0.58A
Input unit CJ1W-ID211 1 0.08A
Output unit CJ1W-OD211 1 0.10A
Weight Module F159 3 0.90A
Consumption（A）Calculation 0.58 ＋0.08 ＋0.10 ＋0.90
Result 1.66A（≦ 2.8A）

2.CONNECTION
11
<Connection of three 350Ωload cells in parallel>
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Power unit
PA205R
CPU unit
CJ1M-CPU11
Input unit
CJ1W-ID211
Output unit
CJ1W-OD211 F159 End coverF159 F159
Three load cells are connected in parallel
0.58[A] 0.08[A] 0.10[A] 0.56[A] 0.56[A] 0.56[A]Power consumption →
Source capacity
5[V] 5[A]
Unit type Unit name Qty Power consumption (A)
CPU unit CJ1M-CPU11 1 0.58A
Input unit CJ1W-ID211 1 0.08A
Output unit CJ1W-OD211 1 0.10A
Weight Module F159 3 1.68A
Consumption（A）Calculation 0.58 ＋0.08 ＋0.10 ＋1.68
Result 2.44A（≦ 5A）