Experiment preparation, Omron programming, external DC power, heater enable, heating, observation, normal shutdown and abnormal stop for one or both channels.
This procedure applies to the two-channel controller documented in electrical issue R1.2. Each channel uses an Omron E5CC-T, Schneider CONTROL selector, Finder 13.61 RI enable relay, Finder 62.31 DC contactor relay, Weidmüller interface, Crydom DC SSR, EAO momentary ENABLE switch and an amber ACTIVE indicator.
r-r = rst and r-r = run must be changed on the Omron itself.rtsm = stop / mv-r = 0.0% output-off state.0 of 23 checklist items checked in this browser session (not an approved inspection record).
No electrical power applied to the heater circuit
Have a test ID, authorised specimen/fixture, maximum temperature, heating rate, duration, cooling arrangement and sample-specific risk controls. Confirm that the outstanding Murata PV1/PV2 input-wiring protection issue has been formally closed and the equipment released for this test.
Check enclosure, ventilation, access restrictions, guards, hot-zone exclusion, monitoring, independent cut-off and emergency arrangements. Identify the DC supply's accessible OFF/isolation control.
Check mains cable, door/earth strap, 24 V controls, banana leads and connectors for damage, looseness, scorching and correct current ratings.
Secure the heater in its approved fixture, maintain specified contact, insulation, ventilation and separation from combustibles; place additional independent over-temperature sensing if required.
With power isolated, connect to the matching green JTC input. Confirm it measures the intended heated location, is securely mounted and is correctly polarised.
Confirm external PSU OUTPUT OFF and isolated. Connect positive/negative from PSU to the matching upper PSU IN pair. Connect heater to the lower HEATER OUT pair on the same channel. Check red/black polarity and conductor/connector current rating.
External heater DC output remains OFF
External DC PSU OUTPUT OFF; Omron CONTROL selectors OFF; no channel enabled. Decide which channel will be used; use one channel first unless simultaneous operation is specifically approved.
Apply mains through the installed inlet switch using the site's approved energising procedure. The shared 24 V supply should start.
Turn the channel's maintained CONTROL selector ON and observe the Omron boot to its temperature screen.
Compare PV with independently known ambient/process temperature; check sensor type and units match the fitted Type K. Move no leads while powered.
From normal screen use MODE briefly to reach r-r and confirm rst. Continue MODE to prg and select the approved programme slot; return/read back prg and pgsg. Review target, ramp, soak, repetition, end and limits against the test plan.
Before enabling DC, confirm the approved configuration rtsm = stop, p-on = rst, mv-r = 0.0%; with r-r = rst, check the SSR demand output is actually inactive on this installed system.
Set and record the authorised DC voltage ceiling and current limit using the PSU manufacturer's instructions. External supply must support the required current and have appropriate independent protective/isolation devices.
One deliberate action per subsystem; no automatic link between EAO and Omron RUN
With controls checked and heater ENABLE still OFF, turn on external supply/output using the approved supply operating method.
Press and release the momentary EAO ENABLE button once; do not hold it. Confirm the enable state using the button's ring LED and Finder 13.61 indication.
At the Omron operation level, press MODE briefly until r-r. Set rst → run using the appropriate UP/DOWN key, then press MODE to confirm. Use the controller's exact displayed codes; do not use an unverified keyboard shortcut.
Check PV vs SP, actual independent process temperature where provided, heat response, noise, odour, current/voltage readings on the EXTERNAL supply and the amber ACTIVE LED.
Remain within the approved supervision arrangement; log PV/SP, programme/segment/time, external PSU settings/current, independent temperature and anomalies at the agreed intervals.
Normal shutdown versus urgent stop
On completion, confirm the intended Omron end behaviour and actual heating demand; do not infer heater-off from a timer alone.
Use MODE to r-r and set rst. Confirm the commanded heating output ceases under the verified RESET configuration.
Press the momentary EAO button once to turn its ring OFF; verify Finder enables drop and no heater output remains.
Switch external PSU OUTPUT OFF, then isolate it using the approved disconnect; verify output has been de-energised by a suitable method. Keep the heater connections undisturbed until safe.
Continue safe temperature monitoring until heater, fixture and specimen reach the authorised handling temperature; then switch controller mains/CONTROL OFF as appropriate. Record final PV, run ID, profile, voltage/current, trips, deviations and observations.
| Indication | Normal meaning | What it cannot prove |
|---|---|---|
| Omron PV / SP | Measured temperature / commanded setpoint. Monitor both throughout. | Accurate sensor mounting, correct sample temperature, or independent high-temperature protection. |
r-r = rst | Programme RESET. Required starting condition. | True heater isolation; reset output behaviour depends on rtsm and mv-r configuration. |
r-r = run | Programme running and elapsed time advancing. | Actual heater current or controlled heating rate. |
prg / pgsg | Selected programme / programme-segment monitor. | The entered programme is necessarily safe for the specimen. |
| EAO ENABLE ring | Finder 13.61 channel-enable output energised when installed as R1. | Heater actually drawing current. |
| Amber ACTIVE lamp | On the R1 circuit: ENABLE ON and Omron SSR demand. It can pulse with time-proportional control. | Actual heater current. The ACTIVE LED is powered from Finder 13.61 terminal 14 and returned through the Weidmüller interface; check each channel as part of pre-use inspection. |
| Murata DC VOLTS | Input voltage of the external heater PSU, visible roughly from 6 V onwards. | Power at the heater, current through the heater or absence of residual DC when blank. |
| Finder 13.61 LED | Its status indication follows the selected relay function; validate OFF/ON indication during commissioning. | Contact welded/open state or complete electrical isolation. |
s.err, e111, e333 | Sensor/input, memory or A/D fault codes; not normal test displays. | Safe output state without physically isolating DC. |
The separate programme RUN/RESET and heater ENABLE functions are intentional on the present controllers. Disabling the heater while RUN remains active will not pause the Omron programme. For an interrupted test, isolate the external DC source and treat the run as aborted; command RESET before a new test.
Emergency response must match the site test-cell/emergency procedures and specimen-specific assessment. The safe upstream DC disconnect, fire response and evacuation routes must be identified before the test.
Use the approved external DC emergency isolation or upstream disconnect immediately if safe to do so. Do not rely solely on Omron RESET or the EAO enable button. Warn others, keep clear and follow local emergency response.
Isolate external heater power. Do not bypass the thermocouple; verify cable, connector, sensor type and controller condition before restarting.
Raise the alarm, evacuate/exclude personnel and follow the facility's approved sample-specific emergency plan; do not attempt close intervention or assume power removal halts a reaction.
Treat the run as aborted. Isolate DC output; check the Omron remains in RESET, Finder ENABLE OFF and demand inactive before beginning an entirely new test.
Stop, isolate both external sources as applicable, and trace cable/indicator wiring against R1. Do not interpret an LED alone as proof of current or electrical isolation.