Omron CX-PROCESS TOOL V5.2, WS02-LCTC1-EV5 V5.2 User Manual
Cat. No. W372-E1-13
SYSMAC CS/CJ Series
WS02-LCTC1-EV5
CX-Process Tool Ver. 5.2
OPERATION MANUAL
WS02-LCTC1-EV5 CX-Process Tool Ver. 5.2
Operation Manual
Revised December 2009
iv
Notice:
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 manual. The word “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 products, 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 displays 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.
Note Indicates information of particular interest for efficient and convenient operation
of the product.
1, 2, 3... 1. Indicates lists of one sort or another, such as procedures, checklists, etc.
Copyrights and Trademarks
Windows is a registered trademark of the Microsoft Corporation.
Other system and product names that appear in this manual are the trademarks or registered trademarks of the respective company.
OMRON, 2000
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.
v
About Loop Controllers
oop
p
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
Pre-installed in
CPU Unit
Type name Product name Model PLC series and Unit type
Loop
Controller
CPU Unit with
Pre-installed
Loop
Controller
Loop Control Unit CS1W-LC001 CS-series CPU Bus Unit Loop
Loop Control
Board
Loop Control
Board with
Gradient
Temperature
Controller
Process-control
CPU Unit
Loop-control CPU
Unit
Loop-control CPU
Unit with Gradient
Temperature
Controller
Loop Controller Functional Elements
• Separate Loop Controllers consist of only the Loop Controller functional 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).
Controller
CS1W-LCB01/05 CS-series Inner Board Loop Controller
CS1W-LCB05-GTC CS-series Inner Board Loop Controller
CS1D-CPUP
CJ1G-CPUP
CJ1G-CPUP-GTC
A one-Unit Loop Controller consisting
of an Inner Board pre-installed in a
CS-series CS1D-H CPU Unit
An Inner Board Loop Controller
integrated into a CS-series CJ1-H CPU
Unit
An Inner Board Loop Controller
integrated into a CJ-series CJ1-H CPU
Unit
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.
vi
Product Product model
t
p
l CPU
p
name number of the
Loop Control
Unit
Loop Control
Board
Loop Control
Board with
Gradient
Temperature
Controller
Processcontro
Unit
Loop-control
CPU Unit
Loop-control
CPU Unit with
Gradient
Temperature
Controller
CS1W-LC001 Pre-Ver. 2.0 --- LC001 Ver. 2.5
CS1W-LCB01
CS1W-LCB05
CS1W-LCB05GTC
CS1D-CPU65P
CS1D-CPU67P CS1D-CPU67H Ver. 1.0 or later LCB05D Ver. 1.0
CJ1G-CPU42P
CJ1G-CPU43P CJ1G-CPU43H Ver. 3.0 or later LCB03 Ver. 2.0 or later
CJ1G-CPU44P CJ1G-CPU44H Ver. 3.0 or later LCB03 Ver. 2.0 or later
CJ1G-CPU45P CJ1G-CPU45H Ver. 3.0 or later LCB03 Ver. 2.0 or later
CJ1G-CPU45PGTC
Unit version
produc
model
(See note.)
Ver. 2.0 or
later
Ver. 3.0 or
later
---
---
Ver. 3.0 or
later
Configuration
CPU unit element Loop Controller element
CPU Unit
model with
same
functionality
---
--- LCB05-GTC Ver. 3.0 or later
CS1D-CPU65H Ver. 1.0 or later LCB05D Ver. 1.0
CJ1G-CPU42H Ver. 3.0 or later LCB01 Ver. 2.0 or later
CJ1G-CPU45H Ver. 3.0 or later LCB05-GTC Ver. 3.0 or later
Functional
element unit
version
Functional
element
name
LCB01 Ver. 2.0 or later
LCB05 Ver. 2.0 or later
Functional
element
Note Only Separate Loop Controllers have a unit version for the product model. CPU
Units with Pre-installed Loop Controllers do not have a unit version for the product model.
Notation in this Manual
This manual uses the following notation.
• “Loop Controller” is used as a generic term to refer to the Loop Controllers in
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 refer to the Loop Controller functional element. The Loop Controller function element in a CJ1G-CPU44P
Loop-control CPU Unit is the LCB03, so “LCB03” is used to refer to the Loop
Controller functional element.
• Model numbers are used to refer to specific Loop Controller models.
In the CX-Process Tool Operation Manual for version 3.2 or earlier, functional
element names (LCB) are given as “Loop Control Board.” In the CX-Process
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 confirm the unit 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.
Functional Element Name and Version Code for Process-control CPU Units and
Loop-control CPU Units
The functional element name and functional element version code for Processcontrol CPU Units and Loop-control CPU Units are provided on the nameplate
as shown in the following diagrams.
viii
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 CPU Units
Product model and functional
element name
Process-control CPU Unit
Functional element name for
Loop Controller element
Functional element version code for
Loop Controller element
Loop-control CPU Unit
Product nameplate
Product nameplate
Functional element name for
CPU Unit element
Functional element
version code for the
CPU Unit element
Unit model number
Functional element
version code for
Loop Controller element
Functional element
version code for
CPU unit element
Recommended location for
attaching version label
Lot No.
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.
PLC Information
1, 2, 3... 1. If you know the device type and CPU type, select them in the Change PLC
dialog box, go online, and select PLC – Edit – Information from the menus.
If you do not know the device type and CPU type, but are 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
version code for
Loop Controller
element
ix
Functional element name
for CPU Unit element
Functional element version
code for CPU Unit element
Use the above display to confirm the unit version of the CPU Unit that is connected online.
Unit Manufacturing Information
1, 2, 3... 1. In the I/O Table Window, right-click and select Unit Manufacturing In-
formation – CPU Unit.
2. The following Unit Manufacturing Information Dialog Box will be displayed.
x
Functional element version
/
code for CPU Unit element
Use the above display to confirm the unit version of the CPU Unit connected
online.
Functional Element Versions and Programming Devices
The Programming Device that supports the functional element version code
must be used to enable all the functions in the corresponding functional element.
Note Upgrading versions is not necessary if only the basic functions of the CPU Unit
element are required.
CPU Unit Element
Loop Controller Programming Device
Functional
element name
CS1G/H-CPUH
CS1D-CPUH
CJ1G-CPUH
Functional
element version
Pre-Ver. 2.0
Ver. 2.0 Ver. 4.0 or higher
Ver. 3.0 Ver. 5.0 or higher
Ver. 1.1 Ver. 4.0 or higher
Ver. 3.0 Ver. 5.0 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
LCB05
LCB05-GTC Ver. 3.0 Ver. 5.1 or higher
LCB03
LCB03-GTC Ver. 3.0 Ver. 5.1 or higher
LCB05D Ver. 1.0 Ver. 3.1 or higher
Functional
element version
Ver. 1.0 Ver. 3.0 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. 5.23 or higher
Ver. 1.0 Ver. 3.0 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. 5.23 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. 5.23 or higher
CX-Process Tool CX-Programmer
(See note.)
---
xii
TABLE OF CONTENTS
PRECAUTIONS xxiii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Intended Audience xxiv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions xxiv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Safety Precautions xxiv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Application Precautions xxvi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 CX-Process Tool 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Relationship with CX-Process Monitor 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3 CX-Process Tool Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4 Version Improvements 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5 Function Blocks/ITEMs Incompatible with Earlier Versions 25. . . . . . . . . . . . . . . . . . . . . .
1-6 Connecting to the PLC 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7 Basic Operating Procedures 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8 Operations 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2
Preparations to Create Function Blocks 49. . . . . . . . . . . . .
2-1 Installing and Uninstalling the Software 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 Overview of User Interface 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3
Creating Function Blocks 97. . . . . . . . . . . . . . . . . . . . . . . . .
3-1 Creating Function Block 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 Using the CX-Process Monitor 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 Using the CX-Process Monitor Plus 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4 Using SCADA Software 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5 User Link Tables 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6 Creating User-defined Blocks 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7 Creating Step Ladder Program Instructions 180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8 Creating Sequence Tables 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9 Displaying and Setting in Engineering Units 207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10 Displaying Loop Controller Memory Maps 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11 Printing 216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12 Setting Options 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4
Online Operation 235. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 Overview of Online Functions 236. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 Initial Settings for Online Connections 238. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3 Downloading, Uploading and Comparing Data 251. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4 Run/Stop Command 264. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5 Monitor Run Status 266. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6 Operation Check 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7 Tuning 294. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8 Backup and Recovery 306. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9 Transferring Tag and Comment Data 309. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10 Clear All 313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11 Controlling the CPU Unit 314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12 Password Protection 315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5
Troubleshooting 317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Troubleshooting 318. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 Error Codes 319. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xiii
TABLE OF CONTENTS
Appendices
A Table of LC Type Changes 323. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B ITEM Notation in Block Diagrams 325. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C Setting Segment Programs 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D Sequence Table Design Sheet 337. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision History 339. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xiv
About this Manual:
This manual describes the installation and operation of the WS02-LCTC1-EV5 CX-Process Tool software
package and includes the sections described below. The CX-Process Tool is used to create and test function blocks for the CS1W-LC001 Loop Control Unit, the CS1W-LCB01, CS1W-LCB05, and
CS1W-LCB05-GTC Loop Control Boards, the CS1D-CPUP Process-control CPU Units, and the
CJ1G-CPUP and CJ1G-CPUP-GTC Loop-control CPU Units.
In this manual, the WS02-LCTC1-EV5 CX-Process Tool software package is generally referred to as simply the “CX-Process Tool.”
Please read this manual carefully and be sure you understand the information provided before attempting
to install and operate the CX-Process Tool. Please read the following manuals carefully and be sure you
understand the information provided before setting up or using an application for a Loop Control Unit/
Board.
xv
Product Manual name Cat. No. Contents
WS02-LCTC1-EV5
CX-Process Tool
CXONE-ALC-EV
4/ALD-EV4
CX-One FA
Integrated Tool
Package
WS02-LCTC1-E
CX-Process Monitor
WS02-LCMC1-E
CX-Process Monitor
Plus
CS1W-LC001
Loop Control Unit
CS1W-LCB01/05
Loop Control Boards,
CS1D-CPUP
Process-control CPU
Units, and
CJ1G-CPUP
Loop-control CPU
Units
CS1W-LC001
Loop Control Unit
CS1W-LCB01/05
Loop Control Boards,
CS1D-CPUP
Process-control CPU
Units, and
CJ1G-CPUP
Loop-control CPU
Units
CS1W-LCB05-GTC
Loop Control Board
with Gradient
Temperature
Controller
CJ1G-CPU45P-GTC
Loop-control CPU
Unit with Gradient
Temperature
Controller
CX-Process Tool
Operation Manual
CXONE-ALC-EV
4/ALD-EV4
CX-One FA
Integrated Tool
Package Setup
Manual
CX-Process Monitor
Operation Manual
CX-Process Monitor
Plus Operation
Manual
Loop Control Unit
Operation Manual
Loop Control Board
Operation Manual
Loop Control Unit
Function Block
Reference Manual
Loop Control Board
Function Block
Reference Manual
Loop Control Board
with Gradient
Temperature
Controller
User’s Manual
W372
(this manual)
W463 Provides an overview of the
W373 Installation and operation
W428 Installation and operation
W374 Installation and operation
W406 Installation and operation
W375 Detailed information on function
W407 Detailed information on function
W460 Provides information required
Installation and operation
procedures for the CX-Process
Tool.
CX-One and describes the
installation procedures for
CX-One software.
Refer to this manual when
installing the CX-Integrator from
the CX-One.
procedures for the CX-Process
Monitor.
procedures for the CX-Process
Monitor Plus.
procedures for the Loop Control
Unit (except for function blocks).
procedures for the Loop Control
Boards (except for function
blocks).
blocks for Loop Control Units.
blocks for Loop Control Boards
when using the gradient
temperature control functions. For
information not related to the
gradient temperature control
functions, please refer to the
Loop Control Board Operation
Manual (Cat. No. W406).
xvi
For details on procedures for installing the CX-Process Tool from the CX-One FA Integrated Tool Package, refer to the CX-One Setup Manual provided with CX-One.
Cat. No. Model Manual name Contents
W463
CXONE-ALC-EV
4/ALD-EV4
CX-One Setup
Manual
Installation and overview of
CX-One FA Integrated Tool
Package.
Section 1 introduces the operations of the CX-Process Tool and connections to the PLC.
Section 2 describes installing the CX-Process Tool and provides an overview of the user interface.
Section 3 describes how to create and manipulate function blocks.
Section 4 describes online operations for uploading, downloading, and testing function block data.
Section 5 describes errors that can occur while using the CX-Process Tool.
!
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. Please 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
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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 materials and workmanship for
БББББББББББББББББББББББББББББББ
a period of one year (or other period if specified) from date of sale by OMRON.
БББББББББББББББББББББББББББББББ
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING
БББББББББББББББББББББББББББББББ
NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE
БББББББББББББББББББББББББББББББ
PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS
БББББББББББББББББББББББББББББББ
DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR
INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
БББББББББББББББББББББББББББББББ
БББББББББББББББББББББББББББББББ
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
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PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR
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STRICT LIABILITY.
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In no event shall the responsibility of OMRON for any act exceed the individual price of the product on
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which liability is asserted.
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IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS
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REGARDING THE PRODUCTS UNLESS OMRON’S ANALYSIS CONFIRMS THAT THE PRODUCTS
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WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO
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CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.
xix
Application Considerations
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SUITABILITY FOR USE
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to
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the combination of products in the customer’s application or use of the products.
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At the customer’s request, OMRON will provide applicable third party certification documents identifying
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ratings and limitations of use that apply to the products. This information by itself is not sufficient for a
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complete determination of the suitability of the products in combination with the end product, machine,
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system, or other application or use.
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The following are some examples of applications for which particular attention must be given. This is not
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intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the
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uses listed may be suitable for the products:
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• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions
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or uses not described in this manual.
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• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical
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equipment, amusement machines, vehicles, safety equipment, and installations subject to separate
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industry or government regulations.
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• Systems, machines, and equipment that could present a risk to life or property.
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Please know and observe all prohibitions of use applicable to the products.
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NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR
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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
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INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
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PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user’s programming of a programmable product, or any
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consequence thereof.
xx
Disclaimers
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CHANGE IN SPECIFICATIONS
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Product specifications and accessories may be changed at any time based on improvements and other
reasons.
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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
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changed without any notice. When in doubt, special model numbers may be assigned to fix or establish
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key specifications for your application on your request. Please consult with your OMRON representative
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at any time to confirm actual specifications of purchased products.
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DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when
tolerances are shown.
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PERFORMANCE DATA
Performance data given in this manual is provided as a guide for the user in determining suitability and
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does not constitute a warranty. It may represent the result of OMRON’s test conditions, and the users
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must correlate it to actual application requirements. Actual performance is subject to the OMRON
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Warranty and Limitations of Liability.
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The information in this manual has been carefully checked and is believed to be accurate; however, no
responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.
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ERRORS AND OMISSIONS
xxi
xxii
PRECAUTIONS
This section provides general precautions for using the CX-Process Tool, CS/CJ-series Programmable Controllers (PLCs),
and related devices.
The information contained in this section is important for the safe and reliable application of Programmable Controllers. 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 xxiv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Application Precautions xxvi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xxiii
1 Intended Audience
This manual is intended for the following personnel, who must also have knowledge of electrical systems (an electrical engineer or the equivalent) and instrumentation systems (a process engineer or the equivalent).
• Personnel in charge of installing FA systems.
• Personnel in charge of designing FA systems.
• 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 the manual
or applying the product to nuclear control systems, railroad systems, aviation
systems, vehicles, combustion systems, medical equipment, amusement machines, safety 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
systems, machines, and equipment with double safety mechanisms.
This manual provides information for programming and operating the Loop Controller. Be sure to read this manual before attempting to use the Loop Controller
and keep this manual close at hand for reference during operation.
3Safety Precautions
WARNING It is extremely important that a PLC and all PLC Units/Boards be used for the
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specified purpose and under the specified conditions, especially in applications
that can directly or indirectly affect human life. You must consult with your
OMRON representative before applying a PLC System to the above-mentioned
applications.
3 Safety Precautions
WARNING Check the following items before starting to run the LCB:
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• Do not allow the bank of the EM Area with the number specified for allocation to
the HMI (human-machine interface) data to be used by the CPU Unit or other
Units for any other purpose. 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. If areas overlap, the system may operate in an unexpected
fashion, which may result in injury.
• Do not allow the area to which user link table data is written to be used by the
CPU Unit or other Units for any other purpose. If areas overlap, the system
may operate in an unexpected fashion, which may result in injury.
• Analog Input/Output Units used in combination with the LCB 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 (i.e., the one whose unit number is set on the
Field Terminal block).
• The defaults of the System Common block on the LCB must be set correct-
ly.
xxiv
WARNING Check the following items before starting Loop Controller operation:
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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 overlap, 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 memory 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 I/O Units used in combination with the Loop Controller must be mounted
correctly.
The unit number set on the front panel of the Analog I/O Unit must be the same
as the unit number set on the Field Terminal Function Block. If the unit numbers
are not the same, I/O (read/write) will be performed on the data for another Special I/O Unit (i.e., the one whose unit number is set in the Field Terminal Function
Block).
The initial settings of the System Common Block in the Loop Controller must be
set correctly. In particular, make sure that words in the Data Memory used for the
Node Terminals in the CPU Unit controlling the Loop Controller are not used for
other applications on the PLC.
When writing data to the I/O memory in the CPU Unit with function blocks (e.g.,
using Send All Blocks, Expanded DO/AO Terminal to CPU Unit, or DO/AO Terminal to CPU Unit), be sure that the words written to in I/O memory are not being
used for any other purpose. If I/O memory words are allocated to more than one
purpose, the PLC system may act unexpectedly and cause injury.
3Safety Precautions
WARNING Always stop the operation of the LCB before converting any of the EM Area
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to file memory. If any part of the EM Area that is being used by the LCB for
the HMI is converted to file memory during Board operation, the system may
operate in an unexpected fashion, which may result in injury.
WARNING Do not perform processing in such a way that the Loop Controller and CPU Unit
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write to identical I/O memory words allocated to a contact output or analog
output of an external Unit. If the same words are written to, the externally
connected loads may act unexpectedly and cause injury.
WARNING When the calibration function is executed, the MV (manipulated variable) will
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change due to changes in the PVs (present values) input to the control block.
Therefore, set pseudo-input values to confirm safety when the MW changes
before executing the calibration function. Devices may perform unexpected
operations, resulting in serious accidents.
Caution Before transferring function block data (initial setting data or operation data) to
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the Loop Controller, confirm that the destination for the data is correct and also
confirm the overall safety of the system (including the Loop Controller). Not doing so may result in unexpected operation.
Caution Before performing Validate Action, be sure to perform Compare on currently
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opened function files and the Loop Controller’s function block data. If there are
inconsistencies in the registered function blocks (block address vs. block model), it will not be possible to perform Validate Action correctly.
xxv
Before forcing changes of analog signals or contact signals using Validate Action, confirm the safety of the instrumentation system as a whole. Not doing so
may result in unexpected operation.
Caution When downloading a sequence table for the LCB (unit ver. 1.5 or later) that
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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.
Caution Confirm in advance the conditions at any node for which the sequence table is
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being edited over a Controller Link or Ethernet network. Not doing so may result
in unexpected operation.
Caution Confirm the status of connected devices before transferring the setting for the
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MV tight shut function and MV analog output reverse function to the Loop Controller. Devices and equipment may perform unexpected operations if the data
destination is mistaken.
Caution When the calibration function is executed, the MV (manipulated variable) will
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change due to changes in the PVs (present values) input to the control block.
Therefore, set pseudo-input values to confirm safety when the MW changes before executing the calibration function. Devices may perform unexpected operations, resulting in serious accidents.
4Application Precautions
4 Application Precautions
Observe the following precautions when using CX-Process Tool and Loop Controller.
Caution If the power supply is turned OFF while function block data is being backed up
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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. (For LCB only)
Caution Loop Control Unit data is monitored and operated using CX-Process Monitor or
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CX-Process Monitor Plus based on the monitor tag files created using CX-Process Tool. When creating monitor tag files using CX-Process Tool, CX-Process
Monitor must be installed on the same computer.
Caution Before using function block data in actual operation, confirm operation by moni-
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toring run status (to check the load rate; select Execute/Operation/Monitor
Run Status) and validating actions (select Validate Action/Start) with CX-Pro-
cess Tool. In particular, be sure to confirm that the load rate will be less than 60%.
(For details on the load rate, refer to the Operation Manual for the Loop Controller.)
xxvi
Caution When uploading the Loop Controller’s function block data, observe the following
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precautions.
When performing Upload New for Loop Control Units of version 1.5 or earlier,
data on the Edit Block Diagram Screen (function block information) will be lost,
and the block diagram showing the connections between function blocks will not
be displayed.
When performing Upload Previous, if the data in the source file currently
opened using the CX-Process Tool and the Loop Controller’s function block data
does not match the registered function blocks or the data on the Edit Block Diagram Screen, the data currently opened may change to illegal data.
Caution The Loop Controller can read and write I/O memory in the CPU Unit using the
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Field Terminal Function Blocks or CPU Terminal Blocks independent of the user
program (Step Ladder Program) in the CPU Unit. Do not write to the same I/O
memory words from both the Loop Controller and the CPU Unit.
Caution To hold an analog output or contact output at a specific value (for example, the
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maximum value or minimum value) when the Loop Controller stops running,
create a Step Ladder Program in the CPU Unit so that the corresponding output
bit allocated to Analog Output Unit or Contact Output Unit is set to the desired
value using an NC condition of the Loop Controller Running Flag (bit 00 in allocated CIO word “n”) as an input condition.
4Application Precautions
Caution If a fatal error occurs in the CPU Unit (including fatal errors created by execution
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of a FALS instruction), the Loop Controller will also stop running. To hold analog
outputs to the previous values before the stop occurred, and to set analog outputs to either the minimum value or maximum value, use the output hold function
of the Analog Output Unit or Analog I/O Unit.
Caution Before turning ON the power to the PLC, make sure that the facilities are safe.
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The analog output values and contact outputs from the Loop Controller are updated when the power to the PLC is turned ON regardless of the operating mode
of the CPU Unit (including in the PROGRAM mode). (Internally, the analog output values and contact outputs are sent from the CPU Unit to Basic I/O Units and
Analog Output Units.)
Caution 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 interruptions, or other causes.
Caution Confirm that no adverse effect will occur in the system before attempting any of
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the following:
• Changing the operating mode of the PLC (including the setting of the startup
operating mode).
• Force-setting/force-resetting any bit in memory
• Changing the present value or any set value in memory
Caution Be sure that all mounting screws, terminal screws, and cable connector screws
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are tightened to the torque specified in the user manuals. Incorrect tightening
torque may result in malfunction.
xxvii
Caution In the event of system or power failure, CX-Process function files (extension
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“.ist”) may not be saved. It is recommended that function files are saved regularly.
Caution Do not connect pin 6 (+5 V power supply line) of the RS-232C port on the CPU
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Unit to any external device except the CJ1W-CIF11 RS-422A Adapter or NTAL001 RS-232C/RS-422A Adapter. Doing so may damage the external device
or CPU Unit.
4Application Precautions
xxviii
This section introduces the operations of the CX-Process Tool and connections to the PLC.
1-1 CX-Process Tool 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1-1 Overview 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1-2 Project Workspace 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1-3 Files Created with CX-Process Tool 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1-4 Relationships between Tag Files 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1-5 Operating Conditions of CX-Process Tool 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Relationship with CX-Process Monitor 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2-1 Overview of the CX-Process Monitor and CX-Process Monitor Plus 9. . . . . . . . .
1-2-2 Settings Required on the CX-Process Tool 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3 CX-Process Tool Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4 Version Improvements 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-1 Version 1.20 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-2 Version 1.50 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-3 Version 2.00 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-4 Version 2.50 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-5 Version 3.00 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-6 Version 3.1 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-7 Version 3.2 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-8 Version 4.0 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-9 Version 4.1 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-10 Version 5.0 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-11 Version 5.1 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4-12 Version 5.2 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5 Function Blocks/ITEMs Incompatible with Earlier Versions 25. . . . . . . . . . . . . . . . . . . . . . .
1-5-1 Incompatibility with Versions Earlier than Version 1.20 25. . . . . . . . . . . . . . . . . . . .
1-5-2 Incompatibility with Versions Earlier than Version 1.50 25. . . . . . . . . . . . . . . . . . . .
1-5-3 Incompatibility with Versions Earlier than Version 2.00 26. . . . . . . . . . . . . . . . . . . .
1-5-4 Incompatibility with Versions Earlier than Version 2.50 28. . . . . . . . . . . . . . . . . . . .
1-5-5 Incompatibility with Versions Earlier than Version 3.2 29. . . . . . . . . . . . . . . . . . . . .
1-5-6 Incompatibility with Versions Earlier than Version 4.0 30. . . . . . . . . . . . . . . . . . . . .
1-5-7 Incompatibility with Versions Earlier than Version 5.0 30. . . . . . . . . . . . . . . . . . . . .
1-5-8 Incompatibility with Versions Earlier than Version 5.2 30. . . . . . . . . . . . . . . . . . . . .
1-6 Connecting to the PLC 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6-1 Features of FinsGateway and CX-Server 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6-2 Selecting the Communications Driver 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6-3 Using FinsGateway 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6-4 Connecting Cables 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7 Basic Operating Procedures 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8 Operations 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8-1 Creating Function Blocks 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8-2 Online Operations 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1
Introduction
1
1-1 CX-Process Tool
1-1-1 Overview
The CX-Process Tool supports the following functions for Loop Controllers.
In this manual, the WS02-LCTC1-EV5 CX-Process Tool software package is
generally referred to as simply the “CX-Process Tool.”
• Creating function blocks, including the following functions
1-1SectionCX-Process Tool
• Setting the Step Ladder Program Block (block 000), including the following: System common operation cycle, Loop Control Unit number (Loop
Control Unit only), start mode, first address of data memory of node terminal (Loop Control Unit only)
• Registering function blocks (allocating block addresses)
• Connecting function blocks with analog and accumulator signals
• Setting ITEMs in function blocks
• Editing sequence tables (Block 302) and the Step Ladder Program Block
(Block 302) (See note.)
Note Editing sequence tables is supported only by the CS1W-LCB05 Loop
Control Board (00-LCB05) and CS1D-LCB05D Loop Control Board
(00-LCB05D).
• Settings tags for CX-Process Monitor (Loop Control Unit only) or CX-Process Monitor Plus software or setting CSV tags for SCADA software (Tag
Names and Analog Signals) and creating monitor tag files (Loop Control
Unit only, CX-Process Monitor must be already installed), or CSV tag files.
• Downloading function block data to Loop Controllers
• Uploading data from Loop Controllers
• Comparing function block data with data in a Loop Controller or Function Block
File
• Sending Run/Stop Commands to Loop Controller
• Monitoring status (including System Common Block Settings, Load Rate per
Operation Cycle Group, and Execution Errors)
• Monitoring actions of Loop Controllers (including operation checks on function
block diagrams and ladder diagrams)
• Tuning parameters such as PID constants in function blocks (Control Blocks)
• Backing up function block data from the Loop Controller’s RAM to flash
memory and restoring that function block data from flash memory back to RAM
• Initializing function block data in Loop Controllers
Note To create monitor tag files using the CX-Process Tool with the CX-Process Moni-
tor or CX-Process Monitor Plus software, both the CX-Process Tool, and CXProcess Monitor or CX-Process Monitor Plus, must be installed on the same
computer.
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