Omron CJ1G-CPU42P, CJ1G-CPU42H, CJ1G-CPU43P, CJ1G-CPU44P, CJ1G-CPU45P Operation Manual
...
Cat. No. W406-E1-09
SYSMAC CS/CJ Series
Loop Control Boards
CS1W-LCB01/LCB05
Process-control CPU Units
CS1D-CPU@@P
(CPU Unit: CS1D-CPU@@H, Loop Controller: LCB05D)
Loop-control CPU Units
CJ1G-CPU42P
(CPU Unit: CJ1G-CPU42H, Loop Controller: LCB01)
CJ1G-CPU43P/44P/45P
(CPU Unit: CJ1G-CPU43H/44H/45H, Loop Controller: LCB03)
OPER ATION M ANUAL
SYSMAC CS/CJ Series
Loop Control Boards
CS1W-LCB01/LCB05
Process-control CPU Units
CS1D-CPU@@P
(CPU Unit: CS1D-CPU@@H, Loop Controller: LCB05D)
Loop-control CPU Units
CJ1G-CPU42P
(CPU Unit: CJ1G-CPU42H, Loop Controller: LCB01)
CJ1G-CPU43P/44P/45P
(CPU Unit: CJ1G-CPU43H/44H/45H, Loop Controller: LCB03)
Operation Manual
Revised January 2013
iv
Notice:
r
f
OMRON products are manufactured for use according to proper procedures by a qualified operator
and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always heed
the information provided with them. Failure to heed precautions can result in injury to people or damage to property.
!DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury . Additionally, there may be severe property damage.
!WARNING Indicates 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.
OMRON Product References
All OMRON products are capitalized in this man ual. The w ord “Unit” is also capitalized when it refers to
an OMRON product, regardless of whether or not it appears in the proper name of the product.
The abbreviation “Ch,” which appears in some displays and on some OMRON produc ts, often means
“word” and is abbreviated “Wd” in documentation in this sense.
The abbreviation “PLC” means Programmable Controller. “PC” is used, however, in some Programming Device displa ys to mean Programmable Controller.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of
information.
OMRON, 2002
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, o
by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission o
OMRON.
No patent liability is assumed with respect to the use of th e information contained herein. Moreo v er, 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. Nevert heless, 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.
Note Indicates information of particular interest for efficient and convenient opera-
tion of the product.
1,2,3... 1. Indicates lists of one sort or another , such as procedures, checklists, etc.
v
About Loop Controllers
Loop Control Types, Functional Elements, and Versions
Loop Controller Types
There are two types of CS/CJ-series Loop Controller: Separate Loop Controllers and Loop Controllers Pre-installed in CPU Units
Loop Controller
type
Separate Separate Loop
Pre-installed in
CPU Unit
Type name Product name Model PLC series and Unit type
Controller
CPU Unit with
Pre-installed
Loop Controller
Loop Control Unit CS1W-LC001 CS-series CPU Bus Unit Loop Controller
Loop Control Board CS1W-LCB01/05 CS-series Inner Board Loop Controller
Process-control
CPU Unit
Loop-control CPU
Unit
Loop Controller Functional Elements
• Separate Loop Controllers consist of only the Loop Contr oller f uncti onal element (i.e., the Loop Controller element).
• CPU Units with Pre-installed Loop Controller consists of a CPU Unit functional element (i.e., the CPU Unit element) and the Loop Controller functional element (i.e., the Loop Controller element).
Versions
The functional elements (i.e., the CPU Unit element and Loop Controller element) have versions.
Model Numbers and Functional Elements
The following table lists the Loop Controller product model numbers, the functional element names for the CPU Unit elements and Loop Controller elements, and the versions of the functional elements.
CS1D-CPU@@P A one-Unit Loop Controller consisting of
an Inner Board pre-installed in a CSseries CS1D-H CPU Unit
CJ1G-CPU@@P A one-Unit Loop Controller consisting of
an Inner Board pre-installed in a CJseries CJ1-H CPU Unit
Product name Product model
number
Loop Control
Unit
Loop Control
Board
Process-control
CPU Unit
Loop-control
CPU Unit
CS1W-LC001 Pre-Ver. 2.0 --- LC001 Ver. 2.5
CS1W-LCB01 Ver. 2.0 to Ver.
CS1W-LCB05 LCB05
CS1D-CPU65P --- CS1D-CPU65H Ver. 1.0 or higher LCB05D Ver. 1.0
CS1D-CPU67P CS1D-CPU67H Ver. 1.0 or higher LCB05D
CJ1G-CPU42P --- CJ1G-CPU42H Ver. 3.0 or higher L C B 01 Ver. 2.0 to
CJ1G-CPU43P CJ1G-CPU43H Ver. 3. 0 or higher LC B03
CJ1G-CPU44P CJ1G-CPU44H Ver. 3. 0 or higher LC B03
CJ1G-CPU45P CJ1G-CPU45H Ver. 3. 0 or higher LC B03
Note Only Separate Loop Controllers have a unit version for the product model.
Unit version of
the product
model
(See note.)
3.6
CPU unit element Loop Controller element
CPU Unit
model with
same function-
ality
--- LCB01 V er. 2.0 to
Configuration
Functional ele-
ment unit version
Functional
element
name
Functional
element
Ver. 3.6
Ver. 3.6
CPU Units with Pre-installed Loop Controllers do not have a unit version for
the product model.
vi
Notation in this Manual
This manual uses the following notation.
• “Loop Controller” is used as a generic term to refer to the L oop Controllers i n
general.
•“LCB@@” is used to refer to specific Loop Controller functional elements.
For example, the Loop Controller function element in a CS1W-LCB05 Loop
Control Board is the LCB05, so “LCB05” is used to ref er to th e Loop Controller functional element. The Loop Controller function element in a CJ1GCPU44P Loop-control CPU Unit is the LCB03, so “LCB03” is used to refer to
the Loop Controller functional elem ent.
• Model numbers are used to refer to specific Loop Controller models.
In the CX-Process Tool Operation Manual for version 3.2 or lower, functional
element names (LCB@@) are given as “Loop Control Board.” In the CX-Pro-
cess Tool Operation Manual for version 4.0 or higher, simply “LCB@@” is
used.
vii
Unit Version Notation on Products
Loop Control Boards A “unit version” has been introduced to manage CPU Units, Special I/O Units,
and Inner Boards in the CS/CJ Series according to differences in functionality
accompanying upgrades. This system applies to Units manufactured since
October 1, 2003. The unit version code is provided on the nameplate of the
product for which unit versions are being managed, as shown below for the
Loop Control Board.
Loop Control Board
Product nameplate
Unit version
Example for unit version 1.5
The CX-Process Tool can be used to co nfirm the un it versions of Loop Control Boards in the Monitor
Run Status Window. After connecting the CX-Process Tool online, select Operation – Monitor Run
Status from the Execute Menu. Confirm the unit version in ITEM099 (MPU/FROM version display)
under from the System Common Block (Block Model 000) in the Monitor Run Status Window.
ITEM Data name Data
099 MPU/FROM version indication V1.50
Version V1.50 and onwards must be indicated.
viii
Functional Element Name and Ver sion Code for Process-control CPU Units and Loopcontrol CPU Units
The functional element name and functional element version code for Process-control CPU Units and Loop-control CPU Units are provided on the
nameplate as shown in the following diagrams.
Process-control CPU Units
Note CPU Unit elements for which no version code is provided are pre-Ver. 2.0
CPU Units.
Nameplate on
left side of Unit
LOOP CONTROL BOARD
Lot No. 031025 Ver.1.5
OMRON Corporation
Loop-control CPU Units
Product model and functional
element name
Recommended location for
attaching version label
Process-control CPU Unit
Product nameplate
Lot No. 031001 0000
OMRON Corporation
Functional element name for
Loop Controller element
CS1D-LCB05D
MADE IN JAPAN
Functional element version code for
Loop Controller element
Loop-control CPU Unit
Functional element name for
CPU Unit element
CS1D-CPU67P
PROCESS CPU UNIT
Functional element
version code for the
CPU Unit element
Product nameplate
Lot No.
CPU Ver.1.0 LCB Ver.1.0
MADE IN JAPAN
Functional element
version code for Loop
Controller element
Unit model number
Functional element
version code for
CPU unit element
Functional element
version code for
Loop Controller
element
Confirming CPU Unit Element Versions with Support Software
CX-Programmer version 4.0 can be used to confirm the unit version using
either of the following two methods.
• Using the PLC Information
• Using the Unit Manufacturing Information (This method can also be used for
Special I/O Units and CPU Bus Units.)
Note CX-Programmer version 3.3 or lower cannot be used to confirm unit versions.
ix
PLC Information
1,2,3... 1. If you know the de vice type and CPU type , select them in the Change PL C
dialog box, go online, and select PLC – Edit – Information from the
menus. If y ou do not know t he de vice type and CPU type , b ut ar e connected directly to the CPU Unit on a serial line, select PLC – Auto Online to
go online, and then select PLC – Edit – Information from the menus.
2. In either case, the following PLC Information Dialog Box will be displayed.
Functional element name
for CPU Unit element
Functional element version
code for CPU Unit element
Unit Manufacturing Information
1,2,3... 1. In the I/O Table Window, right-click and select Unit Manufacturing Infor-
Use the above display to confirm the unit version of the CPU Unit that is
connected online.
mation – CPU Unit.
2. The following Unit Manuf acturing Information Dialog Box will be displa yed.
x
Functional element version
code for CPU Unit element
Use the above displa y to conf irm the unit version of the CPU Unit connected online.
Functional Element Versions and Programming Devices
The Programming Device that suppor ts the functional element version code
must be used to enable all the functions in the corresponding functional element.
Note Upgrading versions is not necessar y if only the basic functions of the CPU
Unit element are required.
CPU Unit Element
Loop Controller Programming Device
Functional
element name
CS1G/H-CPU@@H Pre-Ver. 2.0 --- ---
CS1D-CPU@@H Ver. 1.1 Ver. 4.0 or higher
CJ1G-CPU@@H Ver. 3.0 Ver. 5.0 or higher
Functional
element version
Ver. 2.0 Ver. 4.0 or higher
Ver. 3.0 Ver. 5.0 or higher
Ver. 4.0 Ver. 7.0 or higher
Ver. 4.0 Ver. 7.0 or higher
CX-Process Tool CX-Programmer
(See note.)
xi
Loop Controller Element
Loop Controller Programming Device
Functional
element name
LCB01 Ver. 1.0 Not specific ---
LCB05 Ver. 1.0 Not specific
LCB05D Ver. 1.0 Ver. 3.2 or higher
LCB03 Ver. 2.0 Ver. 4.0 or higher
Functional
element version
Ver. 1.5 Ver. 3.2 or higher
Ver. 2.0 Ver. 4.0 or higher
Ver. 3.0 Ver. 5.0 or higher
Ver. 3.5 Ver. 5.2 or higher
Ver. 3.6 Ver. 5.2 or higher
Ver. 1.5 Ver. 3.2 or higher
Ver. 2.0 Ver. 4.0 or higher
Ver. 3.0 Ver. 5.0 or higher
Ver. 3.5 Ver. 5.2 or higher
Ver. 3.6 Ver. 5.2 or higher
Ver. 3.0 Ver. 5.0 or higher
Ver. 3.5 Ver. 5.2 or higher
Ver. 3.6 Ver. 5.2 or higher
CX-Process Tool CX-Programmer
(See note.)
(See note.)
(See note.)
(See note.)
Note When using function component version 3.6 for LCB01, LCB03, or
LCB05, use the CX-One Auto Update function to update the CX-Process Tool Software to version 5.23 or higher.
xii
TABLE OF CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiii
1 Intended Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv
2 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv
3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv
4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxviii
5 Application Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxix
6 EC Directives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxi
7 Other Applicable Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxi
SECTION 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 Configuration of Instrumentation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1-3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1-4 How to Use Function Blocks for Specific Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1-5 Basic Procedure for Using the Loop Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SECTION 2
Components, Installation, and Wiring . . . . . . . . . . . . . . . . . 71
2-1 Names and Functions of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2-3 Connecting to CX-Process Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
SECTION 3
Mechanism of the Loop Controller. . . . . . . . . . . . . . . . . . . . 81
3-1 Configuration of Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3-2 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3-3 Exchanging Data with the CPU Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3-4 Exchanging Data Using SCADA an d Other Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3-5 Duplex Operation of Loop Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3-6 Fail-safe Countermeasure Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
SECTION 4
Simple Example of Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4-1 Simple Example of Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
SECTION 5
Examples of Function Block Combinations . . . . . . . . . . . . . 183
5-1 Basic Examples of PID Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 84
5-2 Examples of Applied Control Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
xiii
TABLE OF CONTENTS
SECTION 6
How to Use FINS Commands . . . . . . . . . . . . . . . . . . . . . . . . 203
6-1 How to Use FINS Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6-2 FINS Commands for Loop Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6-3 Description of FINS Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
SECTION 7
Errors and Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . 221
7-1 Errors and Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
7-2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Appendices
A How to Use the Step Ladder Program Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
B How to Use the Sequence Table Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
xiv
About this Manual:
This manual describes the installation and operation of the CS-series CS1W-LCB01 and CS1WLCB05 Loop Control Boards, CS1D-CPU@@P Process-control CPU Units, and CJ1G-CPU@@P Loopcontrol CPU Units, and includes the sections described below.
The CS-series CS1W-LCB01 and CS1W-LCB05 Loop Control Boards, CS1D-CPU@@P Process-control CPU Units, and CJ1G-CPU@@P Loop-control CPU Units help you build an instrumentation system
comprising multiple loops. A Loop Control Board is installed as an Inner Board in the CPU Unit of a
CS-series PLC (Programmable Controller).
The CS1W-LCB01 and CS1W-LCB05 Loop Control Boards must be installed in CS1-H CPU Units.
They cannot be used in CS1 CPU Units.
Please read this manual and the other manuals related to the CS1W-LCB01 and CS1W-LCB05 Loop
Control Boards, CS1D-CPU@@P Process-control CPU Units, and CJ1G-CPU@@P Loop-control CPU
Units carefully and be sure you understand the information provided before attempting to install and
operate the products. The manuals used with the CS1W-LCB01 and CS1W-LCB05 Loop Control
Boards, CS1D-CPU@@P Process-control CPU Units, and CJ1G-CPU@@P Loop-control CPU Units
are listed in the follo wing t able. The suffixes have bee n omit ted f ro m the cat alog numbers. Be sure you
are using the most recent version for your area.
Name Contents Cat. No.
SYSMAC CS/CJ Series
CS1W-LCB01, CS1W-LCB05, CS1DCPU@@P, and
CJ1G-CPU@@P
Operation Manuals
SYSMAC CS/CJ Series
CS1W-LCB01, CS1W-LCB05,CS1DCPU@@P, and CJ1G-CPU@@P
Function Block Reference Manual
SYSMAC CX-One FA Integrated Tool
Package
CXONE-AL@@C-V4/AL@@D-V4
CXONE-LT@@C-V4
Setup Manual
SYSMAC CS/CJ Series
CX-Process Tool
Operation Manual
Faceplate Auto-Builde r for NS
Operation Manual
(suffixes omitted)
Describes the basic running of the Loop Control
Boards (excluding detailed descriptions of the
function blocks).
Provides detailed information on the function
blocks.
Provides an overview of the CX-One FA Integrated
Tool and installation procedures.
Describes operation of the CX-Process Tool. W372
Describes operation of the software that generates
NS-series PT projects from a SCADA CSV file output by the CX-Process Tool.
W406
W407
W463
W418
When using CS1D Process-control CPU Units, refer to the following manuals for information on the
CS1D CPU Unit elements.
Name Contents Cat. No.
(suffixes omitted)
SYSMAC CS Series
CS1D-CPU
CS1D-PA/PD
CS1D Duplex System
Operation Manual
@@H, CS1D-DPL01
@@@
Describes the setup and operation of CS1D
Duplex systems.
W405
xv
About this Manual, Continued
When using CJ Series Loop-c ontrol CPU Units, refer to the following manuals for infor mation on the
CJ1-H CPU Unit elements.
Name Contents Cat. No.
(suffixes omitted)
SYSMAC CJ Series
Programmable Controllers Operation Manual
CJ1G/H-CPU@@H, CJ1G-CPU@@P,
CJ1MCPU
SYSMAC CS/CJ Series
Programmable Controllers
Programming Manual
CS1G/H-CPU
CS1DCPU@@H, CS1D-CPU@@S,
CJ1G/H-CPU
CJ1M-CPU
SYSMAC CS/CJ/NSJ Series
CJ2H-CPU6
CJ2M-CPU
CS1G/H-CPU
CS1D-CPU@@S, CJ1H-CPU@@H-R,
CJ1G/H-CPU
CJ1M-CPU
NSJ@-@@@@(B)-G5D,
NSJ
Programmable Controllers Instructions Refer-
ence Manual
@@,CJ1G-CPU@@
@@-EV1, CS1G/H-CPU@@H,
@@H, CJ1G-CPU@@P,
@@, CJ1G-CPU@@
@-EIP, CJ2H-CPU6@,
@@, CS1G/H-CPU@@H,
@@-EV1, CS1D-CPU@@H,
@@H, CJ1G-CPU@@P,
@@, CJ1G-CPU@@,
@-@@@@(B)-M3D
Provides an outlines of and describes the
design, installation, maintenance, and other
basic operations for the CJ-series PLCs.
This manual describes programming and
other methods to use the functions of the
CS/CJ-series PLCs.
Provides detailed descriptions of the instructions. When programming, use this manual
together with the manuals for your CPU
Unit.
W393
W394
W474
Section 1 outlines the features and application of the Loop Controllers and provides Loop Controller
specifications.
Section 2 describes the names and functions of parts, and provides other information required to
install and operate Loop Controllers.
Section 3 provides info rmation on the cont rol mech anism, basic operation, exchanging data with other
Units and software, and fail-safe countermeasures for Loop Controllers.
Section 4 describes a simple example of how to use Loop Controllers.
Section 5 describes basic examples of combining function blocks.
Section 6 provides information on how to use FINS commands.
Section 7 provides information on errors that may occur while running of Loop Controllers and guide-
lines for troubl eshooting these errors.
Appendix A describes how to use the Step Ladder Program block on the LCB@@s and Appendix B
describes how to use the Sequence Table block on the LCB@@s.
xvi
WARNING
Failure to read and understand the information provided in this manual may result in
personal injury or death, damage to the product, or product failure. Plea se read each
section in its entirety and be sure you understand the information provided in the
section and related sections before attempting any of the procedures or operations
given.
xvii
xviii
Read and Understand this Manual
Please read and understand this manual before using the product. Please consult your OMRON
representative if you have any questions or comments.
Warranty and Limitations of Liability
WARRANTY
OMRON's exclusive warranty is that the products are free from defects in mat erials and workmanship for a
period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NONINFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE
PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS
DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR
INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES,
LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS,
WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT
LIABILITY.
In no eve nt shall the responsibil ity of OMR ON fo r any act e xcee d the individual price of the product on which
liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS
REGARDING THE PRODUCTS UNLESS OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS
WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO
CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.
xix
Application Considerations
SUITABILITY FOR USE
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the
combination of products in the customer's application or use of the products.
At the customer's request, OMRON will provide applicable third party certification documents identifying
ratings and limitations of use that apply to the products. This information by itself is not sufficient for a
complete determination of the suitability of the products in combination with the end product, machine,
system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not
intended to be an e xhaustive list of all possible uses of the products, nor is it inte nded to imply that the uses
listed may be suitable for the products:
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or
uses not described in this manual.
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical
equipment, amusement machines, vehicles, safety equipment, and installations subject to separate
industry or government regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS 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 PRODUCTS ARE PROPERLY RATED AND
INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user's programming of a programmable pr oduct, or any
consequence thereof.
xx
Disclaimers
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other
reasons.
It is our practice to change model numbers when published ratings or features are changed, or when
significant construction changes are made. However, some specifications of the products may be changed
without any notice. When in doubt, sp ecial model numbers may be assigned to fix or establish key
specifications for your application on your request. Please consult with your OMRON represe ntative at any
time to confirm actual specifications of purchased products.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when
tolerances are shown.
PERFORMANCE DATA
Perf ormance data given in this manual is provided as a guide for the user in determining suitability and does
not constitute a warranty. It may represent the result of OMRON's test conditions, and the users must
correlate it to actual application requirements. Actual performance is subject to the OMRON Warranty and
Limitations of Liability.
ERRORS AND OMISSIONS
The information in this manual has been ca refully checked and is believed to be accurate; however, no
responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.
xxi
xxii
PRECAUTIONS
This section provides general precautions for using the Programmable Controller (PLC) and related devices.
The information contained in this section is important for the safe and reliable application of the Programmable
Controller. You must read this section and understand the information contained before attempting to set up or
operate a PLC system.
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv
3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv
4 Oper a ting Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxviii
5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxix
6 EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxi
7 Other Applicable Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxi
xxiii
Intended Audience 1
1 Intended Audience
This manual is intended for the following personnel, who must also have
knowledge of electrical systems (an elec trical engineer or the equivalent) and
knowledge about instrumentation systems.
• Personnel in charge of installing FA systems
• Personnel in charge of designing FA system s
• Personnel in charge of managing FA systems and facilities
2 General Precautions
The user must operate the product according to the performance specifications described in the operation manuals.
Before using the product under conditions which are not described in this
manual or applying the product to nuclear control systems, railroad systems,
aviation systems, vehicles, combustion systems, medical equipment, amusement machines, safe ty equipment, petrochemical plants, and other systems,
machines, and equipment that may have a serious influence on lives and
property if used improperly, consult your OMRON representative.
Make sure that the ratings and performance characteristics of the product are
sufficient for the systems, machines, and equipment, and be sure to provide
the system, machines and equipment with double safety mechanism.
This manual provides information for running CS1W-LCB01 and CS1WLCB05 Loop Control Boards, CS1D-CPU@@P Process-control CPU Unit, and
CJ1G-CPU@@P Loop-control CPU Unit. Be sure to read this manual before
attempting to use these products and related software (CX-Process Tool) and
keep this manual close at hand for reference during running.
!WARNING It is extremely important that a PLC and all PLC Units be used for the speci-
fied purpose and under the specified conditions, especially in a pplications that
directly or indirectly affect human life. You must consult with your OMRON
representative before applying a PLC System to the above-mentioned applications.
xxiv
Safety Precautions 3
3 Safety Precautions
!WARNING Do not attempt to take any Unit or Board apar t while power is being supplied.
Doing so may result in electric shock.
!WARNING Do not touch live terminals. Electric shock will result.
!WARNING Provide safety measures in external circuits (i.e., not in the Programmable
Controller), including the following items, to ensure safety in the system if an
abnormality occurs due to malfunction of the PLC or another external factor
affecting the PLC operation. Not doing so may result in serious accidents.
• Emergency stop circuits, interlock circuits, limit circuits, and similar safety
measures must be provided in external control circuits.
• When using a CS1D-CPU@@P Process-control CPU Unit, the CS1D
Duplex System will stop operating and all outputs will be turned OFF in
the following cases:
• The self-diagnostic function detected errors at the same time in both
the active side (CPU Unit or Loop Controller) and the standby side
(CPU Unit or Loop Controller).
• A SEVERE F AILURE ALARM (FALS) instruction is executed and generated fata l errors at the same time in both the a ctive CPU Unit and t he
standby CPU Unit.
• The self-diagnostic function detected an error while operating in simplex mode or performing duplex initialization in duplex mode.
• A SEVERE FAILURE ALARM (FALS) instruction was executed and
generated a fatal error while operating in simplex mode or performing
duplex initialization in duplex mode.
Unexpected operation, however, may still occur for errors in the I/O control section, errors in I/O memory, and other errors that cannot be
detected by the self-diagnosis function. As a countermeasure for all such
errors, external safety measures must be provided to ensure safety in the
system.
• When a CS1W-LCB01 or CS1W-LCB05 Loop Control Board is mounted
in a CS1-H CPU Unit, the CPU Unit will stop operating and all outputs will
be turned OFF if the self-diagnostic function detected an error or a
SEVERE FAILURE ALARM (FALS) instruction was executed. As a countermeasure for such errors, external safety measures must be provided to
ensure safety in the system.
• The PLC outputs may remain ON or OFF due to depos ition or burning o f
the output relays or destr uction of the output transistors. As a countermeasure for such problems, external safety measures must be provided
to ensure safety in the system.
• When the 24-V DC output (service power supply to the PLC) is overloaded or short-circuited, the voltage may drop and result in the outputs
being turned OFF. As a countermeasure for such problems, external
safety measures must be provided to ensure safety in the system.
!WARNING Check the following items before starting to run the Loop Controller:
xxv
Safety Precautions 3
• Do not allow the bank of the EM Area wit h the number specified f or a llocation to the HMI (human-machine interface) data to overlap with any other
area used by the CPU Unit or other Units. The block allocated for the HMI
is specified in ITEM 050 (EM Area Bank Allocated for HMI Memory = 0 to
12) of the System Common block (Block Model 000). If areas overlap, the
system may operate in an unexpected manner, which may result in injury.
• Do not allow the area to which user link table data is written to overlap
with any other area used by the CPU Unit or other Units. If areas over lap,
the system may operate in an unexpected manner, which may result in
injury.
• When using a user link table to write bit data to I/O memor y in the CPU
Unit. Never allow ladder programming or communications processes in
the CPU Unit to write to any bits in the words in which bits are written from
a user link table. Depending on the timing, any attempts to write to these
words from ladder programming or communications processes may be
ignored. Example: If tag A in a user link table writes to bit 00 of W000 and
an OUT instruction in the ladder program in the CPU Unit write to bit 01 of
W000, the write from the ladder program may be ignored.
• Analog Input/Output Units used in combination with the Loop Controller
must be mounted correctly, and the unit number set on the front panel of
the Analog Input/Output Unit must match the unit number set on the Field
Terminal block. If the unit numbers do not match, input/output (read/write)
is performed on the data of another Special I/O Unit (whose unit number
is set on the Field Terminal block).
• The defaults of the System Common block on the Loop Controller must
be set correctly.
• Always stop the operation of the Loop Controller before converting any of
the EM Area to file memory. If any part of the EM Area that is being used
by the Loop Controller for the s is converted to file memory during Board
operation, the system may operate in an unexpected manner, which may
result in injury.
!WARNING Do not use battery-fr ee operation for the CS1-H CPU Unit or the CPU Unit
element of a Process-control CPU Unit or Loop-control CPU Unit. If batteryfree operation is used for the CPU Unit or CPU Unit element, the contents of
the EM Area will not be stable when the power supply is turned ON, possibly
causing illegal values in the HMI data in the Loop Controller.
!WARNING Do not perform processing in such a way that the Loop Controller and CPU
Unit perform writing on identical I/O memory addresses allocated to an contact output or analog output to an e xternal Unit. If writing is perf ormed on identical addresses, the externally connected load may act unexpectedly and
cause injury.
xxvi
Safety Precautions 3
!WARNING The Loop Controller will automatically start using a cold star t even if the star-
tup mode is set to a hot star t if the power is turned ON after being OFF for
24 hours or longer. If this happens, the auto/manual setting for the Control
Block will be set to manual mode (MV=0%) and the remote/local setting will
be set to local. To automatically switch to auto mode at th e same time as starting operation after the power is turned ON after being OFF for 24 hours or
longer, the ladder diagrams in the Sequence Table or Step Ladder Program
blocks must be programmed as follows (same as the procedure for switching
to remote operation):
Processing: ITEM 086 (Auto/Manual switch) of the Basic PID block or
Advanced PID block is set to 1 using ITEM019 (Run Start Flag) and ITEM017
(cold start in progress) of the System Common block as the input conditions.
Sequence Table
Signal
000.019 Y
000.017 Y
001.086 Y
000.019 N
STEP
STEP
Run Start flag
Cold start in progress
A/M
Run Start flag
THENNEXT
ELSE
00
Step Ladder Program
000-019 000-017
Run Start
flag
Cold start in
progress
S
A/M
000-019
R
Run Start
flag
PID1 is Auto at power ON.
For details on hot and cold start operations, refer to 3-2-3 Details of Hot Start,
Cold Start and Stop State.
!WARNING When using the CS1D-CPU@@P Process-control CPU Unit, both the CPU
Unit’s cycle time and the Loop Controller’s operation cycle will be temporarily
longer than normal during duplex initialization (i n duple x mode). The extended
cycle time and operation cycle may temporarily worsen the control characteristics, so verify the system’s operation in test runs before actually running the
system.
!Caution When downloading a sequence table for the Loop Control Board (version 1.5
or higher) that has been edited online with the CX-Process Tool version 3.2 or
higher, confirm that the system will operate normally with the edited
sequence. If the sequence is not suitable for operation, unexpected operation
may result.
xxvii
Operating Environment Precautions 4
!Caution Confirm in advance the conditions at an y node for which the sequence table is
being edited over a Controller Link or Ethernet network. Not doing so may
result in unexpected operation.
!Caution Do not use the HMI function to write a value that is ou tside of the data range
shown in the ITEM list in the Function Block Reference Manual (Cat. No.
W407) to the receive area (CPU Unit to Loop Controller) in the EM Area. Writing an out-of-range value can result in unexpected operation by the controlled
machine or equipment.
!Caution When executing calibration functions, the MV (manipulated variable) will be
changed when the PV (process value) is changed in the control block. Therefore, before executing this function, make sure that the equipment will be safe
even if the MV changes by setting pseudo-inputs. Otherwise, unexpected
equipment operation may result, causing a serious accident.
4 Operating Environment Precautions
4-1 CS1D-CPU@@P Process-control CPU Unit Precautions
• Normal operation will be possible only if the CS1D-CPU@@P Processcontrol CPU Unit is used in the combination in which it was shipped. Normal operation may not be po ssible if the CS1D-CPU@@P Process-control
CPU Unit is used in any other combination. Therefore, do not remove the
Loop Controller component from the CPU Unit. Always replace the entire
CS1D Process-control CPU Unit as on e Unit even if only the Loop Controller or CPU Unit has failed.
• The CS1D CPU Unit’s cycle time and the Loop Controller component’s
LCB load rate are different in duplex mode and simplex mode. Verify the
system’s oper ation in bo th modes in trial opera tion before actually running
the system.
• When replacing a CS1D Process-control CPU Unit while powe r is supplied to the PLC, always switch the DPL Unit’s CPU U SE/NO USE switch
to “NO USE.” Removing the CS1D Process-control CPU Unit with the
switch set to “USE” (power supplied) may damage the CPU Duplex Backplane, CS1D CPU Unit, DPL Unit, and Loop Controller component of the
Process-control CPU Unit.
4-2 CS1W-LCB01/CS1W-LCB05 Loop Control Board Precautions
Do not use a CS1W-LCB01 or CS1W-LCB05 Loop Control Board in any CPU
Unit other than the CS1-H.
• If a CS1W-LCB01 or CS1W-LCB05 Loop Control Board is used in a CS1
CPU Unit, a non-fatal INNER Board error will occur and the Loop Control
Board will not operate. (The CPU Unit itself will be able to operate.)
• If a CS1W-LCB01 or CS1W-LCB05 Loop Control Board is used in a
CS1D CPU Unit, a fatal INNER Board error will occur. (In this case, neither the Loop Control Board nor the CPU Unit will operate.)
• Loop Control Boards before version 1.5 cannot be used with CS1DCPU@@S CS1D CPU Units for Single-CPU Systems.
• Do not connect pin 6 (+5 V power supply line) of the RS-232C port on the
CPU Unit to any external device except the CJ1W-CIF11 RS-422A
Adapter or NT-AL001 RS-232C/RS-422A Adapter. Doing so may damage
the external device or Loop Control Board.
xxviii
Application Precautions 5
4-3 Precautions for All Loop Control Boards, Process-control CPU
Units, and Loop-control CPU Units
!Caution Do not operate the control system in the following places:
• Locations subject to direct sunlight
• Locations subject to temperature or humidity outside the range specified
in the specifications
• Locations subject to condensation as the r esult of severe changes in temperature
• Locations subject to corrosive or flammable gases
• Locations subject to dust (especially iron dust) or salts
• Locations subject to exposure to water, oil, or chemicals
• Locations subject to shock or vibration
!Caution Take appropriate and sufficient countermeasures when installing systems in
the following locations:
• Locations subject to static electricity or other forms of noise
• Locations subject to strong electromagnetic fields
• Locations subject possible exposure to radioactivity
• Locations close to power supplies
!Caution The operating environment of the PLC System can have a large effect on the
longevity and reliability of the system. Improper operating environments can
lead to malfunction, failure, and other unforeseeable problems with the PLC
System. Be sure that the operating environment is within the specified conditions at installation and remains within the specified conditions during the life
of the system.
5 Application Precautions
Observe the following precautions when using the PLC.
!WARNING Always heed these precautions. Failure to abide by the following precautions
could lead to serious or possibly fatal injury.
• Always turn OFF the power to the PLC before attempting any of the following. Not turning OFF the power may result in malfunction or electric
shock.
• Mounting or dismounting I/O Units, including Inner Boards
• Assembling the Racks
• Setting DIP switches or unit number setting switches
• Connecting or wiring the cables
• Connecting or disconnecting the connectors
!Caution Failure to abide by the following precautions could lead to faulty operation of
the PLC or the system, or could damage the PLC or PLC Units. Always heed
these precautions.
xxix
Application Precautions 5
• If the power supply is turned OFF while function block data is being
backed up from RAM to flash memory, the backup will not be completed
normally. If the power supply is turned back ON within 24 hours, however,
the super capacitor will have held the RAM data. The backup operation
will restart when power is turned ON and operation will start when the
backup has been completed. If the power supply is turned OFF for more
than 24 hours, however, RAM data will be lost and operation will be
started with the data that was previously saved to flash memory. If this
happens, the Cold Start Auto-execution Flag (A35807) will turn ON to
show that the previous data has been used. Use this bit in programming
to take whatever steps are necessary, such as downloading the most
recent function block data.
• To hold analog outputs o r contact outp uts at spec ific values (for example,
maximum value or minim um v alue ) when the Loop Controller has stop ped
running, create a Step Ladd er Program on the CPU Unit so that each of
the allocated bits on the Analog Output Unit or Contact Output Unit are
set to a specific value taking the N.C. condition of the Loop Controller
Running flag (A35801) as the input condition.
• When a fatal error occurs on the CPU Unit (including execution of the
FALS instruction), the Loop Controller also stops running. To hold the
analog output to the previous value before the stop occurred, and to set
the analog output to either the minimum value or maximum value, use the
output hold function of the Analog Output Unit or Analog Input/Output
Unit.
• Before turning ON the power to the PLC, make sure that the facilities are
safe.
• The analog output values and contact outputs from the Loop Controller
are updated at the same time that the power to the PLC is turned ON
regardless of the operation mode of the CPU Unit (including the PROGRAM mode). (Internally, the analog output values and contact outputs
are sent via the CPU Unit to the Basic I/O Unit and Analog Output Unit.)
• The Loop Controller itself does not have a human-machine interface. So,
an external interface such as SCADA software must be provided.
• Fail-safe measures must be taken by the customer to ensure safety in the
event of incorrect, missing, or abnormal signals caused by broken signal
lines, momentary power interruption s or other causes.
• Before touching the PLC, be sure to first touch a grounded metallic object
in order to discharge any static build-up. Otherwise, it might result in a
malfunction or damage.
• Take appropriate measures to ensure that the specified power with the
rated voltage and frequency is supplied. Be particularly careful in places
where the power supply is unstable. An incorrect power supply may result
in malfunction.
• Do not attempt to disassemble, repair, or modify any Units or Boards.
• Leave the dust-protection label attached to the top Unit when wiring.
Removing the label may result in malfunction.
• Remove the label afte r the co mpletio n of wiring to ensure proper heat dissipation. Leaving the label attached may result in malfunction.
• Check the user program for proper execution before actually running it on
the Unit or Board. Not checking the program may result in an unexpected
operation.
xxx
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