G3ZA Multi-channel Power Controller User Manual
Contents
1. s Oo eg eg 25 1101 NO 222 How To Use the Terminals 5a secre ER e RENS LA GA Ee AA SECTION 3 Usmo iheGoZo ista ADS 232 JCompo Way F Frames trucada raras 5 UN Sam I APA arbo eta dett arcad rata o eed b d oc eo dC 354 Nunable Area WEG d osse hs Cer oe SE S Rep AO e CR Rt apu Sere 25 WVatiablewAted Reatb oue 2 oua oo AT ae Th adotta d ate rd ew 3 07 4 1 Controller AttnDUule RU 9 6 Controller Status RE 3 0 Beho Dack Testa a xa aida SECTION 4 LUNCUUT Luca b 4 1 Changing the Manipulated Variable 4 2 Offsetting Control Output ON Timing 4 3 Turning OFF the Control Output 4 4 Detecting Heater Burnout 4 channel Models Only 4 5 Detecting Heater Overcurrent 4 channel Models Only 4 6 Detecting SSR Short Circuits 4 channel Models Only 4 7 Seine Operation tor ENOS Y ni ace Sa A ae 4 8 Detecting Communications Timeouts SECTION 5 Troubleshooting raise 5 II BEIODSnsbeevu dni esee qus Da as moor ans d RIS be ae Au e 2 Handling Problems yn ad hewn Nae b role oed AAA ace D TE E ADDEN ce ubi ia Ase ee NAS WE Revision E S OEY sisi ON 13 14 15 17 172. 41001 Command length too long The command is too long 1002 Command length too short The command is too short t N co o o per O 2 Y 41100 The operation code or related information is not correct 2203 An error occurred in nonvolatile memory 0000 Processing was completed normally Example The following command starts operation for channel 1 Command STX 0100030050100 E TX BCC Hesponse STX 01000030050000 ETX BCC 3 7 Controller Attribute Read This command reads the model number of the Controller and the communica tions buffer size Command MRC SRC 2 2 Response MRC SRC Response code Model number Buffer size ls 2 2 4 10 4 20 Controller Status Read Section 3 8 1 Model Number Number Code 4 4 channels 8 8 channels HW With current transformer input M q 2 Load power supply 100 to 240 V QO RS 485 2 Buffer Size The buffer size is 217 bytes D9H 3 Response Code Response code Errormame Cause 1001 Command length too long The command is too long 2203 Operation error An error occurred in nonvola tile memory 0000 Normal end Processing was completed normally Example The following command reads the model number and buffer size The response shows the Controller has four channels supports a current transformer and has a load power supply of 400 to 480 V Command STX 010
3. 30 V 50 mA JA 1 s Control power supply Load power supply Control power supply Load power supply 100 to 240 VAC 100 to 240 VAC 100 to 240 VAC 400 to 480 VAC 50 60 Hz 50 60 Hz 50 60 Hz 50 60 Hz G3ZA LIL1203 FLK UTU G3ZA LIL1403 FLK UTU Wiring Diagrams Use one of the following M3 solderless terminals for wiring axe TO 5 8 mm max TO s m 5 8 mm max y Use wires that are rated to withstand 70 C minimum o C O p Ls Q Q How To Use the Terminals Controller Power Supply Terminals gt UN CN ON Nad ARES Load Power Supply Input Terminals CY 3 SCC 3 AP FS Nf Ne of CN d md 7 C 7 EA A 19 20 21 22 2 24 13 14 3e 16 1 18 READY o l SD RD os B o sm o occ sve o OMROI 5 G3ZA ERROR o 4 T 9 n 4 6 Communications Terminals DOTA ee 000 0 10 Section 2 2 In the wiring diagrams the area within the lines indicating terminals numbers is inside the G3ZA and the area outside the lines are outside the G3ZA e Connect terminals 1 and 2 as follows 3 e The input power is 100 to 240 VAC To detect the zero cross point of the load supply connect the load power supply to terminals 4 and 6 as follows 4 0 9 3 The voltage of the load power supply that can be connected depends on the model of the Controller 100 to 240 VAC or 400 to 480 VAC T
4. data length setting Data length Text data This ASOI2OH io 7EH ASCII 20H to 7EH or A1H to FEH 2 Response Codes Response code Erormame Cause 1001 Command length too long The command is too long 2203 Operation error An error occurred in nonvola tile memory 0000 Normal end Processing was completed normally Example Command STX 010000801123 ET X BCC Response STX 01000008010000123 ETX BCC 22 SECTION 4 Functions This section describes the functions of the G3ZA so that these functions can be used effectively according to the application 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 Changing the Manipulated Variable Offsetting Control Output ON Timing Turning OFF the Control Output Detecting Heater Burnout 4 channel Models Only usara Detecting Heater Overcurrent 4 channel Models Only Detecting SSR Short Circuits 4 channel Models Only Setting Operation for Errors Detecting Communications Timeouts 24 25 25 26 28 28 30 30 23 Changing the Manipulated Variable Section 4 1 4 1 Changing the Manipulated Variable The Variable Area Write command is used to change the manipulated vari able The manipulated variable is 0 0 by default when the power supplied is turned ON This value can be changed to another value by using the Manipu lated Variable Save operation c
5. Dielectric strength 1 000 VAC for 1 min Vibration resistance 98 m s 50 Hz Weight Approx 11 5 g Approx 50 g Accessories None Connection terminals 2 Plugs 2 Note The maximum continuous current of the G3ZA is 50 A Dimensions Unit mm E54 CT1 75 15 25 10 5 Two 3 8 dia DC o 36 Appendix E54 CT3 30 E 2 36 dia gt 40 Two M3 holes depth 4 Startup Operation It takes about 1 second for the load power supply to stabilize after the power supply to the G3ZA is turned ON Outputs will not turn ON during this period A stabilization period of 1 second is also executed after clearing a zero cross error Power ON v 1s 4 Outputs stopped Error cleared Example 2 Zero cross error Stabilization Normal operation 4 Outputs stopped Error cleared Stabilization Normal operation Zero cross error Stabilization Normal operation 5 Outputs stopped Outputs stopped Example 3 o 37 o lt Appendix Connecting More Than 16 Controllers If more than 16 G3ZA Controllers are connected set SW2 to between 8 and B for the 17th Controller on The LN between the settings of SW1 and SW2 is shown in the following table 01 02 03 04 05 07 10 11 12 13
6. and then pull down on the End Plate Tighten the screw on the End Plate to secure it READY 8 ff b 4 S a 000000 E E Note Always mount one End Plate on each side of the G3ZA o C O p Ls c Q Q Installation Mounting the G3ZA with Screws Mounting Hole Dimensions Unit mm Two 4 2 dia or M4 holes 84 10 8 Section 2 1 How To Use the Terminals Section 2 2 2 2 How To Use the Terminals Trigger output 4 Trigger output m 12V 21 mA 12 V 21 mA Trigger Trigger TE 12 V CECMOR M NO CH5 CH6 COM CH7 CH8 COM CH1 COM Trigger output T tout Trigger output _ Trigger output 12 21 mA 7 TT 127 21 mA 12V 21 mA Trigger Trigger output 12 V Trigger Trigger J G3ZA 8AL 103 FLK UTU G3ZA 4H 103 FLK UTU V O Y O pur im Q Lum Q TO AD AD Ad AR 05 OC Qe up QZ ND AZ Ei H Z u x AD AD OUS CI m 1 YA ET MD AZ ND NU N ID E 19 20 2 22 23 13 14 15 16 17 READY f SD RD OCC G2ZA ERROR Uo DOBOBO NIZA N 1 ND UZ ML AN Y N Hi El TN ON Z MIN IO r 1 f DEI y QU ND UN Alarm output 30 V 50mA 7 DASADAID0 RS 485 Alarm output
7. 18 19 20 21 22 23 24 25 25 26 28 28 30 30 3l 32 33 35 43 45 xi About this Manual This manual describes the installation and operation of the G3ZA Multi channel Power Controller and includes the sections described below Please read this manual carefully and be sure you understand the information provided before attempting to install or operate the G3ZA Be sure to read the precautions provided at the beginning of this manual The Preface provides precautions for using the G3ZA and information on using this manual Section 1 introduces the G3ZA and its features Section 2 describes preparations for using the G3ZA including installation and wiring Section 3 describes application information including settings communications and controlling oper ation Section 4 describes the functions of the G3ZA so that these functions can be used effectively accord ing to the application Section 5 provides information on problems that may occur during operation and corrective measures The Appendix provides G3ZA specifications tables of settings and other information N WARNING Failure to read and understand the information provided in this manual may result in per sonal 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 give
8. LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS WHETHER SUCH CLAIM IS BASED IN CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY Further in no event shall liability of Omron Companies exceed the individual price of the Product on which liability is asserted Indemnities Buyer shall indemnify and hold harmless Omron Companies and their employees from and against all liabilities losses claims costs and expenses including attorney s fees and expenses related to any claim inves tigation litigation or proceeding whether or not Omron is a party which arises or is alleged to arise from Buyer s acts or omissions under these Terms or in any way with respect to the Products Without limiting the foregoing Buyer at its own expense shall indemnify and hold harmless Omron and defend or set tle any action brought against such Companies to the extent based on a claim that any Product made to Buyer specifications infringed intellectual property rights of another party Property Confidentiality Any intellectual property in the Products is the exclu sive property of Omron Companies and Buyer shall not attempt to duplicate it in any way without the written permission of Omron Notwithstanding any charges to Buyer for engineering or tooling all engineering and tooling shall remain the exclusive property of Omron All information and materials supplied by Omron to Buyer relating to the Produc
9. Loose screws may occasionally cause fire resulting in minor or moderate injury or damage to the equipment Terminal screws 0 40 to 0 56 N m 1X Precautions for Safe Use 1 Do not use the product in the following locations e Locations subject to direct radiant heat from heating equipment e Locations where the product may come into contact with water or oil e Locations subject to direct sunlight e Locations where dust or corrosive gases in particular sulfuric or ammonia gas are present e Locations subject to extreme temperature changes e Locations where icing or condensation may occur e Locations subject to excessive shocks or vibration 2 Use this product within the rated load and power supply 3 Ensure that the rated voltage is achieved no longer than 2 s after turning the power ON 4 Use store within the rated temperature and humidity ranges Provide forced cooling if required 5 Minimum mounting distance of G3ZA is 10 mm When mounting the G3ZA near the SSRs mount the G3ZA so as to not interfere with the heat dissipation of the SSR 6 Use the specified size of insulated type crimp terminals M3 width 5 8 mm max for wiring and attach insulative sleeves To connect bare wires use AWG22 cross section 0 326 mm to AWG14 cross section 2 081 mm to wire the power supply terminals and AWG22 cross section 0 326 mm to AWG16 cross section 1 039 mm for other terminals 7 Be sure to confirm t
10. 14 ez ee 57 a mr ss B Note 1 Up to 31 Controllers can be connected 2 Do not set SW2 to between 4 and 7 or C and F 3 It s easiest to set the communications unit number first and then the baud rate Setting example The following settings would be used to set a Controller to communications unit number 7 and a baud rate of 38 4 kbit s SW1 7 and SW2 2 Parameter Tables Parameter Tables Status 31 to 13 Not used Start stop i Operating Not used Not used Alarm output applies to all channels Control output Not used Not used Communications error applies to all channels Zero cross error applies to all channels Not used Heater overcurrent SSR short circuit Heater burnout NO H oO Output Error Example Condition Alarm output and zero cross error bit are ON H 00000210 Stopped with no errors H 00001000 38 Appendix type CO See tion oe 1 1 See note 1 CH1 control variable H 00000000 to H 000003E8 0 0 to 100 0 CH2 control variable H 00000000 to H 000003E8 0 0 to 100 0 CH3 control variable H 00000000 to H 000003E8 0 0 to 100 0 CHA control variable H 00000000 to H 000003E8 0 0 to 100 0 CH5 control variable H 00000000 to H 000003E8 0 0 to 100 0 CH6 control variable H 00000000 to H 000003E8 0 0 to 100 0 CH7 control variab
11. Response STX 01000001020000 ET X BCC Example The following command changes the manipulated variable for channel 1 to 50 set value 4 digits Command STX J01000010281000000000101F4 ETX BCC Response STX 01000001020000 ETX BCC lt N c o o per O 2 9 3 5 Variable Area Read This command reads set values Command Variable Bit MRC SRC type Read start address position No of elements E GE ANN 2 2 2 4 2 4 Note bit position is not used Set it to 00 Response MRC SRC Response code Set values 75 CAE AE l 2 2 4 No of elements x 8 or 4 B Variable Type and Read Start Address Refer to the Parameter Tables on page 38 in the Appendix B Number of Elements Specify the number of elements for which the set value is to be read Up to 8 elements can be specified 18 Operation Command Section 3 6 E Response Code Response code Emornam 1 Cause 1001 Command length too long The command is too long 1002 Command length too short The command is too short 1101 Area type error The specified variable type does not exist 110B Response length too long The number of elements is larger than the maximum number allowed 1100 Parameter error The bit position specification is not 00 2203 Operation error An error occurred in nonvola tile memory 0000 Normal end Processing was completed normally Example The following command rea
12. Section 2 1 2 1 Installation Dimensions Unit mm o o c 9 Av im av o T T pj o a 1 s o 7x5 35 st O ES NL 24 Fo 2 E x mom O 00 x o O o E N 6 Z d o i E m 5 A LO E 22 x E O 111 max 110 typical 35 0 3 S Mounting to DIN Track DIN Track Products When installing a DIN Track inside a control panel secure the DIN Track with screws in at least three locations e DIN Track PFP 50N 50 cm or PFP 100N 100 cm e End Plates PFP M Installation Section 2 1 Mounting the G3ZA Mount the G3ZA as shown in the diagram First pull down the DIN Track mounting hook 1 and hook the top of the G3ZA on the DIN Track 2 Then press the G3ZA onto the DIN Track far enough so that it can be locked in place 3 and push the DIN Track mounting hook up to lock the G3ZA in place 4 eu i 8 6 A E 1 4 o Removing the G3ZA Use a flat blade screvvdriver to pull dovvn the D N Track mounting hook 1 and Q then pull out on the bottom of the G3ZA 2 ra EZ a 2 1 Mounting End Plates Be sure to mount an End Plate on each side of the G3ZA so that it does not slide on the DIN Track To mount an End Plate hook the bottom of the End Plate on the bottom of the DIN Track 1 place the top of the End Plate on the DIN Track 2
13. command changes set values Command Write start MRC SRC Variable type address Bit position No of elements Set values or og ee a ee a 2 2 2 4 2 4 No of elements x 8 or 4 Note bit position is not used Set it to 00 Response MRC SRC Response code dl IA 2 2 4 E Variable Type and Write Start Address Refer to the Parameter Tables on page 38 in the Appendix 1 FINS Short for Factory Interface Network Service The FINS protocol is used for message communications between controllers on OMRON FA networks 17 Variable Area Read Section 3 5 B Number of Elements Specify the number of elements for which the set value is to be changed Up to 8 elements can be specified E Response Code Response code 1002 Command length too short The command is too short 1101 Area type error The specified variable type does not exist 1003 Number of elements Number The specified number of ele of data do not agree ments does not agree with the actual number of data ele ments 1100 Parameter error The bit position specification is not OO A set value is outside of the setting range 2203 Operation error An error occurred in nonvola tile memory 0000 Normal end Processing was completed normally Example The following command changes the manipulated variable for channel 1 to 50 set value 8 digits Command STX 010000102C10000000001000001 F4 ETX BCC
14. current 5 0 5A 2 2 A The above calculation produces 2 5 A The minimum setting unit is 1 A so 2 5 is truncated and 2 A is used Example 2 Using three 1 kW heaters 200 VAC SSR 1000 0 Normal current gt b 200 x3215A 210A 1000 Current for 1 heater 200 x2 10A Heater 10 200 VAC Set value 125A 12A Normal current Burnout current 15 10 5A gt 3A The calculation produces 12 5 A This is truncated to 12 A as explained above 27 Detecting Heater Overcurrent 4 channel Models Only Section 4 5 4 5 Detecting Heater Overcurrent 4 channel Models Only A heater overcurrent is detected by determining if the heater current is above the heater overcurrent detection value when a control output is ON Heater Overcurrent Detection Timing Heater overcurrent detection value Heater ON current ERROR indicator flashing Alarm output Setting range Channels 1 to 4 O to 50 See note 1 Um oo Heater overcurrent detection value Hysteresis 1 to 10 See note 2 Note 1 Heater overcurrents will not be detected if the detection value is set to 50 Detection status will be forced ON if the detection value is set to 0 Use these to check operation during installation 2 Hysteresis is used to prevent chattering at the detection point The same hysteresis setting is used for all heater burnout detection heater overcur rent detection and SSR short cir
15. heaters of less than 10 A and a difference of 3 A or more for heaters of 10 A or more Heaters of less than 10 A Normal current burnout current gt 2 A Detection will not be stable if the difference is less than 2 A Heaters of 10 A or more Normal current burnout current gt 3 A Detection will not be stable if the difference is less than 3 A If the conditions for stable detection cannot be met increase the number of turns of the heater wire through the current transformer The monitor value for the heater ON current is proportional to the number of turns Detecting Heater Burnout 4 channel Models Only Section 4 4 Example pelle e Heater burnout detection status can be confirmed by reading the status for individual channels Calculating the Detection Current for Heater Burnout Use the following formula to calculate the detection current Normal current Burnout current Set value 2 When two or more heaters are connected through the current transformer set the detection current to detect burnouts on the heater vvith the smallest cur rent f the heater currents are all the same set the detection current for one wire Application Example Example 1 Using one 1 kW heater 200 VAC SSR 1000 Normal current b 200 5 A 10A 4 Burnout current 0 A Heater 200 VAC 540 Set value 0 25bA 2A Normal current Burnout
16. risk of loss shall pass from Omron to Buyer provided that Omron shall retain a security inter est in the Products until the full purchase price is paid d Delivery and shipping dates are estimates only and e Omron will package Products as it deems proper for protection against nor mal handling and extra charges apply to special conditions Claims Any claim by Buyer against Omron for shortage or damage to the Products occurring before delivery to the carrier must be presented in writing to Omron within 30 days of receipt of shipment and include the original trans portation bill signed by the carrier noting that the carrier received the Products from Omron in the condition claimed Warranties a Exclusive Warranty Omron s exclusive warranty is that the Products will be free from defects in materials and workmanship for a period of twelve months from the date of sale by Omron or such other period expressed in writing by Omron Omron disclaims all other warranties express or implied b Limitations OMRON MAKES NO WARRANTY OR REPRESENTATION EXPRESS OR IMPLIED ABOUT NON INFRINGEMENT MERCHANTABIL 14 ITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCTS BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE Omron further disclaims all warranties and responsibility of any type for claims or expenses based on infringement by the Prod
17. software reset with an Operation Command If operation still does not recover the G3ZA needs to be repaired e Check to see if the communications line is bro ken e Check to see if a communications error has occurred e Check the host to see if it is functioning cor rectly e Check the information provided in 4 8 Detecting Communications Timeouts on page 30 e Check to see if the load power supply s voltage and frequency are within specifications The specified ranges are as follows Controllers with 100 to 240 V Load Voltage 75 to 264 VAC Controllers with 400 to 480 V Load Voltage 340 to 528 VAC Frequency all models 47 to 63 Hz Noise may be a factor Check the load power supply line for noise and check the general area around the G3ZA for noise The heater has burned out Repair the heater or the heater line e Check the information provided in 4 4 Detecting Heater Burnout 4 channel Models Only on page 26 e An overcurrent has occurred to the heater Return the current to the correct range Check the information provided in Wiring Dia grams on page 9 and in 4 5 Detecting Heater Overcurrent 4 channel Models Only on page 28 e The SSR has short circuited Replace the SSH e Check the information provided in Wiring Dia grams on page 9 and in 4 6 Detecting SSR Short Circuits 4 channel Models Only on page 28 Handling Problems Section 5 2 5 2 Handling Problems Handling Problems P
18. the right to stop shipments or require satisfactory security or payment in advance If Buyer fails to make payment or otherwise comply with these Terms or any related agreement Omron may without liabil ity and in addition to other remedies cancel any unshipped portion of Prod ucts sold hereunder and stop any Products in transit until Buyer pays all amounts including amounts payable hereunder whether or not then due which are owing to it by Buyer Buyer shall in any event remain liable for all unpaid accounts Cancellation Etc Orders are not subject to rescheduling or cancellation unless Buyer indemnifies Omron against all related costs or expenses Force Majeure Omron shall not be liable for any delay or failure in delivery resulting from causes beyond its control including earthquakes fires floods strikes or other labor disputes shortage of labor or materials accidents to machinery acts of sabotage riots delay in or lack of transportation or the requirements of any government authority Shipping Delivery Unless otherwise expressly agreed in writing by Omron a Shipments shall be by a carrier selected by Omron Omron will not drop ship except in break down situations b Such carrier shall act as the agent of Buyer and delivery to such carrier shall constitute delivery to Buyer c All sales and shipments of Products shall be FOB shipping point unless oth erwise stated in writing by Omron at which point title and
19. turn Unless the OCC indicator is lit or the control variable is set to ON 0 0 then there is a problem in the wiring Check the wiring of the control outputs f the ERROR indicator is lit or flashing refer to the correc tions given in the Error Table on page 32 Returning settings to Initialize the settings with an Operation Command All of the default values settings can be returned to their default values Refer to the Parameter Tables on page 38 in the Appendix for default val ues 33 O c o Ka Y 2 2 5 o E Handling Problems Section 5 2 O 2 o O L Y o 2 O p H 34 Appendix Specifications Specifications Ratings Control power supply voltage 100 to 240 VAC 50 60 Hz Control power supply voltage range 85 to 264 VAC Power consumption Approx 5 9 W Load power supply voltage 100 to 240 VAC 400 to 480 VAC Load power supply voltage range 1 Controllers for 100 to 240 VAC 75 to 264 VAC Controllers for 400 to 480 VAC 340 to 528 VAC Manipulated variable inputs 0 0 to 100 0 via RS 485 communications Current transformer inputs Single phase AC 0 to 50 A Trigger outputs One for each channel 12 VDC 15 max load current 21 mA with built in short circuit protection circuit Alarm output NPN open collector one output Max load voltage 30 VDC max load current 50 mA max residual voltage 1 5 V max leakage current 1 0 mA Indication
20. warranty lt 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 document has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions Vii Safety Precautions M Definition of Precautionary Information The following notation is used in this manual to provide precautions required to ensure safe usage of the product The safety precautions that are provided are extremely important to safety Always read and heed the information provided in all safety precautions The following notation is used Indicates a potentially hazardous situation which if not avoided will result in minor or moderate injury or may A WARNING result in serious injury or death Additionally there may be significant property damage Indicates a potentially hazardous situation which if not PANE NUTONE avoided may result in minor or moderate injury or in property damage E Symbols General Caution Indicates non specific general cautions warnings and dangers Caution Electrical Shock Caution AN Indicates possibility of electric shock under specific conditions General Prohibition Prohibition Indicates non specific general prohibitions General Ca
21. 0 to H 00000FAO 0 0 to 400 0 0008 CH1 slope 0009 CH2 slope H 00000000 to H 00000FAO 0 0 to 400 0 100 0 100 0 39 c o lt o lt Level Variable Address type Opera C1 See 1 000A tion 40 note 1 Parameter Setting monitor range Appendix Default Unit CH3 slope H 00000000 to 0 0 to 400 0 100 0 CH4 slope H 00000000 to 0 0 to 400 0 100 0 CH5 slope 100 0 CH6 slope H 00000000 to H 00000FAO0 0 0 to 400 0 100 0 CH7 slope H 00000000 to H 00000FAO 0 0 to 400 0 H 00000000 to 0 0 to 400 0 CH8 slope CH1 offset H 00000000 to H 00000FAO0 0 0 to 400 0 H FFFFFO60 to H 00000FAO0 400 0 to 400 0 CH2 offset H FFFFFO60 to H 00000FAO0 400 0 to 400 0 CH3 offset H FFFFFO60 to H 00000FAO0 400 0 to 400 0 CHA offset H FFFFFO60 to H 00000FAO0 400 0 to 400 0 CH5 offset CH6 offset H FFFFFO60 to H 00000FAO0 400 0 to 400 0 CH7 offset H FFFFFO60 to H 00000FAO0 400 0 to 400 0 CH8 offset CH1 source channel e e er Sr H FFFFFO60 to H 00000FAO0 400 0 to 400 0 H FFFFFO60 to H 00000FAO0 400 0 to 400 0 H 00000001 to H 00000008 1 to 8 CH2 source channel H 000
22. 00001 to H 00000008 1 to 8 CH3 source channel H 00000001 to H 00000008 1 to 8 CH4 source channel H 00000001 to H 00000008 1 to 8 CH5 source channel CH6 source channel H 00000001 to H 00000008 1 to 8 CH7 source channel H 00000001 to H 00000008 1 to 8 CH8 source channel CH1 heater burnout detection value e ee Sr ee Sr H 00000001 to H 00000008 1 to 8 H 00000001 to H 00000008 1 to 8 H 00000000 to H 00000032 0 to 50 CH2 heater burnout detection value H 00000000 to H 00000032 0 to 50 CH3 heater burnout detection value H 00000000 to H 00000032 0 to 50 CH4 heater burnout detection value H 00000000 to H 00000032 0 to 50 O O O O O O OT BA O N CH1 SSR short cir H 00000000 to H 00000032 0 to 50 50 cuit detection value CH2 SSR short cir H 00000000 to H 00000032 0 to 50 50 cuit detection value CH3 SSR short cir H 00000000 to H 00000032 0 to 50 50 cuit detection value CH4 SSR short cir H 00000000 to H 00000032 0 to 50 50 cuit detection value CH1 heater overcur H 00000000 to H 00000032 0 to 50 50 rent detection value CH2 heater overcur H 00000000 to H 00000032 0 to 50 50 rent detection value CH3 heater overcur H 00000000 to H 00000032 0 to 50 50 rent detection value CHA heater overcur H 00000000 to H 00000032 0 to 50 50 rent detectio
23. 000503 ETX BCC Response STX 01000005030000G3ZA 4H40300D9 ETX BCC 3 8 Controller Status Read This command reads the operating status of the Controller Command MRC SRC we tor 2 2 Response Operating Related MRC SRC Response code status information ee 1 1 Operating Status Operating status Mann 0 The control output is ON for one or more channels 01 The Controller is stopped or a zero cross error has occurred during operation 2 Related Information An OR of status bits O to 7 for all channels Refer to the Status in the Parameter Tables in the Appendix Note To read the status of individual channels use the Variable Area Read com mand for the desired channel Refer to 3 5 Variable Area Head for details 21 t N o o E m O Y Echo back Test Section 3 9 3 Response Code Response code Errormame 1 Cause 1001 Command length too long The command is too long 2203 Operation error An error occurred in nonvola tile memory 0000 Normal end Processing was completed normally Example Command STX 010000601 ETX BCC Response STX 010000060100000100 ETX BCC 3 9 Echo back Test This command performs an echo back test Command 77 4 0 to 200 N 5 Response o 177 code Test Data E li a DL 0 to 200 E 1 Test Data Set the test data within the following ranges according to the communications
24. 2 The trigger outputs for channels 1 to 4 are output on terminals 13 to 18 CH1 CH3 R R SS CH2 58 4 SSR SSR 12 VDC _ 12VDC 21 mA 12VDC 21mA 21mA 21mA Output voltage 12 VDC 15 PNP Maximum load current 21 mA Short circuit protection circuit provided Controllers without a Current Transformer Input Circuit G3ZA 8A 103 FLK UTU The trigger outputs for channels 5 to 8 are output on terminals 19 to 24 CH5 CH7 SSR cHe SSH CH8 SSR SSR 12 VDC 12 VDC _21 mA 12vDc 21 MA_ 21 mA 21 mA Controllers with Built in Current Transformer Circuits G3ZA 4H 103 FLK UTU e Connect terminals 19 to 24 to the current transformers no polarity to detect heater burnouts heater overcurrents and SSR short circuits There are four current transformer inputs that can be used Use the E54 CT1 or the E54 CT3 from OMRON as the current transform er Heater Alarm TT Host PLC Power Controller Load power supply power supply for zero cross detection SECTION 3 Using the G3ZA This section describes application information including settings communications and controlling operation
25. 50 Detection status will be forced ON if the detection value is set to 0 Use these to check operation during installation 2 Hysteresis is used to prevent chattering at the detection point The same hysteresis setting is used for all heater burnout detection heater overcur rent detection and SSR short circuit detection functions Operating Conditions e The actual current flowing in the heater may not be the same as the heater s rated current Check the heater current under actually conditions using the Heater OFF Current parameters for channels 1 to 4 e SSR short circuit detection status can be confirmed by reading the status for individual channels Calculating the Detection Current for SSR Short circuits Set the detection current to the value calculated with the following formula or higher Set value gt Normal leakage current x 2 29 Setting Operation for Errors Section 4 7 4 7 Setting Operation for Errors The operation to be used when the following errors occur can be set e Zero cross error See note 2 e Heater burnout detection e Heater overcurrent detection e SSR short circuit detection Operation at error Clearing the error Continue with error 1 Continues The error is cleared when normal status is clear recovered i e the status ERROR indica tor and alarm output are turned OFF Continue without Continues The error is not cleared even if normal sta error clear tus is recovered Restore normal st
26. ING 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 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 exhaustive list of all possible uses of the products nor is it intended to imply that the uses listed may be suitable for the products e Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses not described in this manual e 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 e Systems machines and equ
27. NS mini command text Refer to 3 9 Echo back Test on page 22 for echo back tests Subaddress error One or more of the subaddresses is missing Frame length error 1 The received frame exceeds the required num ber of bytes Normal end Command was executed normally without error Data Type Notation In this manual hexadecimal and ASCII characters are expressed as shown in the following table Hexadecimal An H is added to the end of the hexadecimal number Example 02H ASCII characters ASCII characters are given in quotation marks Example 00 t N o o E ex mm O 2 Y 16 FINS mini Text Section 3 3 3 3 FINS mini Text The structure of FINS command and response text is shown below Command Text Node N SID FINS mini BC STX badan command text ETX SPP Response Text xm No End code FINS mini ETX Subaddress response text BCC List of FINS mini Service Commands 01 02 Variable Area Write Changes set values 01 01 Variable Area Read Reads set values 30 05 Operation Command Executes commands such as start stop manipulated variable save and software reset lt N o o E m O Y 05 03 Controller Attribute Read Reads the model number of the Controller 06 15017 Controller Status Read Reads the operating status 08 1 017 Echo back Test Performs an echo back test 3 4 Variable Area Write This
28. Nel A Nou NANI CO ae NC Aw AA Converter K3SC RS 232C RS 485 Interface Converter K32 23209 Adapter K3SC 10 RS 232C RS 485 E Converter RS 232C D sub 9 pin straight Terminator 100 to 125 O 1 2 W G3ZA Terminator No 0 No 1 No 31 100 to 125 Q 1 2 W 7 Dade Y O pur im Q o Q e Alarms are output on terminals 9 and 11 OR The alarm output specifications are as follows Maximum load voltage 30 VDC Maximum load current 50 mA Maximum residual voltage 1 5 V Maximum leakage current 1 mA e Alarms are output on pins A and B of the connector e The alarm output specifications are as follows A Maximum load voltage 30 VDC ai d l Maximum load current 50 mA B Maximum residual voltage 1 5 V Maximum leakage current 1 mA e The C Grid SL connector for Molex Incorporated can be used for the con nector Model number 51030 6030 C Grid SL Housing Model number 52109 0660 C Grid SL Housing Press fit Type e The G3ZA A300C Cable from OMRON also can be used 11 How To Use the Terminals Trigger Output Terminals CYC CYC SAC YC 5 7777777 uu Na co cal IS o C O p Ls Q Q Current Transformer Input Terminals x a CX SACO X WX Ne Nul ku Nu Neu ccu Wiring Example G3ZA 4H 103 FLK UTU 12 Section 2
29. Overview G3ZA Multi channel Power Controller Preparations Using the G3ZA O ul o o La 0 2 Q gt 2 E Appendix Cat No Z200 E1 01 G3ZA Multi channel Power Controller User s Manual Produced April 2004 Preface OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual This manual describes the functions performance and application methods needed for optimum use of the G3ZA Please observe the following items when using the G3ZA e This product is designed for use by qualified personnel with a knowledge of electrical systems e Read this manual carefully and make sure you understand it well to ensure that you are using the G3ZA correctly e Keep this manual in a safe location so that it is available for reference when required OMRON 2004 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 con stantly 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 o
30. atus and then use an Operation Command Start operation again Stops for the The error is not cleared even if normal sta channel with an 1tus is recovered and operation will error See note remained stopped Restore normal status and then use an Operation Command Start operation Note 1 Operation will stop for all channels if a zero cross error occurs 2 Zero cross error A zero cross error will occur when there is an error in the load power supply voltage frequency or waveform Refer to SEC TION 5 Troubleshooting for details 4 8 Detecting Communications Timeouts Operation can be stopped if the time when normal communications cannot be performed exceeds the communications timeout time G3ZA Stopped I Communications timeout time Set value Settingrange 80 range Default Communications O to 60 min 0 disabled timeout time Note 1 Communications timeouts will not be detected if the time is set to O 2 The setting is not valid and communications timeout detection will not start until the G3ZA is reset or until the power supply is cycled Operation will stop when a communications timeout is detected and the com munications error bit in status the ERROR indicator and the alarm output will turn ON Use an Operation Command to clear the error 30 SECTION 5 Troubleshooting This section provides information on problems that may occur during operation and corrective measures for t
31. ault settings are shaded in the above table Other Communications Settings Communications are used to set the data length number of stop bits parity and send standby time To change the settings use communications with the default communications settings Refer to 3 4 Variable Area Write on page 17 for the procedure for changing these settings Note settings will be enabled only when the power is turned ON again or the G3ZA is reset 14 Compo VVay F Frame Structure Section 3 2 Send Standby Time 3 2 CompoWay F Frame Structure Command Frames Response Frames The send standby time is used to adjust the time required for the host to switch from sending to receiving status For the G3ZA this adjusts the time between creating a response after receiving a transmission and switching to send status Host Send status Send 7 Receive Receive Send G3ZA Send status Response created 9 Send standby time If switching time will not cause problems the send standby time can be short ened to reduce the communications time with the host The propriety OMRON communications protocol called CompoWay F is used as the communications protocol Commands from the host and responses from the G3ZA are sent in data packets called frames The structures of the command and response frames are shown below SID FINS mini BCC STX Node No Subaddress command text ETX 11 17 E 1 1 2 2 1 1 BCC calculation ran
32. cuit detection functions Operating Conditions e The actual current flowing in the heater may not be the same as the heater s rated current Check the heater current under actually conditions using the Heater ON Current parameter for the relevant channel e Detection will be unstable if there is only a small difference between the normal current and overcurrent current To achieve stable detection set the parameters so that there will be a difference of at least 2 A for heaters of less than 10 A and a difference of 3 A or more for heaters of 10 A or more Heater overcurrent detection status can be confirmed by reading the sta tus for individual channels Calculating the Detection Current for Heater Overcurrent Set the detection current according to the needs of the application 4 6 Detecting SSR Short Circuits 4 channel Models Only An SSR short circuit is detected by determining if the heater current is above the SSR short circuit detection value when a control output is OFF 28 Detecting SSR Short Circuits 4 channel Models Only Section 4 6 SSR Short circuit Detection Timing SSR short circuit detection value Heater OFF current ERROR indicator Alarm output Setting range Defaut Channels 1 to 4 O to 50 See note 1 50 disabled SSR short circuit detection value Hysteresis 1 to 10 1 See note 2 Note 1 SSR short circuits will not be detected if the detection value is set to
33. ds the control variable for channel 1 set value 8 digits Command STX 010000101C00001000001 ETX BCC Response STX 0100000101000000000000 ETX BCC Example The following command reads the control variable for channel 1 set value 4 digits Command STX 010000101800001000001 ETX BCC Response STX 010000010100000000 ETX BCC 3 6 Operation Command This command is used to start and stop operation save the manipulated vari able execute a software reset or initialize settings lt N o o E m O 2 Y Command Operation Related MRC SRC code information 2 2 2 2 Response 19 Controller Attribute Read Section 3 7 1 Operation Code and Related Information code 01 Start stop Upper digit Channel specification Refer to 4 3 Turning OFF the Control Output 0 Channel 1 on page 25 1 Channel 2 2 Channel 3 3 Channel 4 4 Channel 5 5 Channel 6 6 Channel 7 7 Channel 8 F All channels Lower digit Start stop O Start 1 Stop M variable Refer to 4 1 Changing the Manipulated Vari tne able on page 24 Software reset Performs the same processing as when the G3ZA is turned ON OB Initialize settings 00 Refer to 5 2 Handling Problems Note There is no response for a software reset Responses are returned for all other operation codes 2 Response Codes Response code Erormame 1 Case
34. es the right to increase or decrease prices on any unshipped portions of outstanding orders Payments for Products are due net 30 days unless otherwise stated in the invoice Discounts Cash discounts if any will apply only on the net amount of invoices sent to Buyer after deducting transportation charges taxes and duties and will be allowed only if i the invoice is paid according to Omron s payment terms and ii Buyer has no past due amounts Interest Omron at its option may charge Buyer 1 1 2 interest per month or the maximum legal rate whichever is less on any balance not paid within the stated terms Orders Omron will accept no order less than 200 net billing Governmental Approvals Buyer shall be responsible for and shall bear all costs involved in obtaining any government approvals required for the impor tation or sale of the Products Taxes All taxes duties and other governmental charges other than general real property and income taxes including any interest or penalties thereon imposed directly or indirectly on Omron or required to be collected directly or indirectly by Omron for the manufacture production sale delivery importa tion consumption or use of the Products sold hereunder including customs duties and sales excise use turnover and license taxes shall be charged to and remitted by Buyer to Omron Financial If the financial position of Buyer at any time becomes unsatisfactory to Omron Omron reserves
35. f 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 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 materials 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 NON INFRINGEMENT 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 event shall the responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANT Y REPAIR OR OTHER CLAIMS REGARD
36. ge t N o o E m O Y FINS mini ETX STX Node No Subaddress End code response text BCC Code that indicates the beginning of the communications frame Always set 02H STX Node No This number specifies the destination This is the same as the communications unit number set on SW1 and SW2 Subaddress and SID These are not used by the G3ZA Set them to all zeros FINS mini The text of the command Refer to 3 6 Operation Command command text on page 19 for details ETX Code that indicates the end of the communications frame Always set 03H This stores the result of the BCC calculation from the Node No to EXT FINS mini STX Node No SubaddressSID commandtext ETX BCC 02H soH 30H 30H 30H 30H 30H 35H 30H 30H BCC 30H 30HO 30H 30H 30H O 30H 35H 30H 30HO 03H 36H E indicates an exclusive OR 15 Compo VVay F Frame Structure Section 3 2 End Codes CompoWav F Communications End code Description OF FINS command Could not execute the specified FINS command error 10 Parity error Sum of bits that are 1 in received data does not agree with the set communications parity value 1 Flaming eror Stop bitis 0 12 Overrun error The next data was received when the received data buffer was full 13 Calculated BCC differs from received BCC 14 Format error Characters other than O to 9 or A to F in FI
37. he G3ZA detects the zero cross point of the load power supply e To communicate with a host system connect the communications line to terminals 7 and 8 as follows 7 8 8 9 RS 485 e The connection type can be 1 1 or 1 N For 1 N connections up to 32 Units can be connected including the host The maximum cable length is 500 m total Cable Diagram Reference e Use shielded twisted pair cables AWG28 to AWG16 AWG28 Cross sectional area of core 0 081 mm min lt 2 P e A terminator must be connected to both ends of the communications path including the PLC Use a resistance of 100 to 125 Q 1 2 W in the termi nators e Use an RS 232C RS 485 converter to connect to a personal computer or other host with an RS 232C connection How To Use the Terminals Section 2 2 Alarm Output Terminals for the G3ZA 1 1203 FLK UTU DADO NR M M NANA IF NL C MC NCC 1000 NA NA NA NA NA KY 19 20 21 22 23 24 13 14 15 16 17 18 READY INE A r SD RD Pee B o sm o occ sve o omron a G3ZA S u ERROR pS S 7 8 9 11 1 2 4 6 K r DN a Id oed a e uw EII V B Alarm Output Terminals for the G3ZA 1 403 FLK UTU Rae ee Nu Nou NL Neo NL NU Ou SS SEES A A A x 19 20 2 22 23 24 13 14 15 16 17 18 READY Pal SD RD y B sw O OCC sve o omron G3ZA it o ERROR 2 7 8 9 11 1 2 4 6
38. he correct terminal and polarity when wiring the terminal block and connectors E Do not connect any conductors to unused terminals E In order to prevent inductive noise wire the lines connected to the product separately from power lines carrying high voltages or currents Do not wire in parallel with or in the same cable as power lines Other measures for reducing noise include running lines along separate ducts and using shield lines 10 Attach a surge suppressor or noise filter to peripheral devices that generate noise in particular motors transformers solenoids magnetic coils or other equipment that have an inductance component Do not install the product near devices generating strong high frequency fields or surges When using a noise filter check the voltage and current and install it as close to the product as possible 11 For a safety disconnection of the power line in the application the equipment shall be provided with disconnecting devices suitable for isolation e g circuit breakers IEC60947 2 power switches IEC60947 3 power plugs etc 12 The G3ZA is for single phase loads only Connect only single phase zero cross SSRs Do not connect three phase SSRs magnetic relays or SSRs that do not have zero cross function TABLE OF CONTENTS SECTION 1 2200102475 0075075777 Ri SECTION 2 Preparations e e o o o
39. hem Sl A A s eae s b sama 32 032 JHandline Problems suspenda e ted 33 O o O Y o 2 o Som 31 O 2 o L Y o 2 o p H Errors 5 1 Error Table Errors Section 5 1 ERROR Operation Correction indicator Flashing 32 No response or an error response Communica tions error bit is ON Zero cross error bit is ON Heater burnout bit is ON Heater overcur rent bit is ON SSR short cir cuit bit is ON According to the operation at error setting According to the operation at error setting According to the operation at error setting According to the operation at error setting There is an error in internal memory or in non volatile memory A communica tions timeout has occurred A zero cross error has been detected A heater burn out has been detected A heater over current has been detected An SSR short circuit has been detected Cycle the power supply If operation does not recover use the following procedure noting that all settings will be returned to their default values e Error Response Received Initialize the settings and perform a software reset with an Operation Command e Error Response Not Received Set the host data length stop bits and parity to the default values for the G3ZA if a Converter is being used set it to the same values and then initialize the settings and perform a
40. ipment 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 product or any consequence thereof vi 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 special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your OMRON representative 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 Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a
41. ircuit calculating the detection current 29 detection 30 detection value 29 SSRs 2 starting operation 19 startup operation 37 stop bits 14 stopping operation 19 switches SVV1 3 SW2 3 T Z trigger output terminals 12 troubleshooting 31 handling problems 33 wiring example 12 Zero cross errors 30 Index Revision History A manual revision code appears as a suffix to the catalog number on the front cover of the manual Cat No Z200 E1 01 Revision code The following table outlines the changes made to the manual during each revision Page numbers refer to the previous version Revision code Date Revised content April 2004 Original production 45 46 Revision History Terms and Conditions of Sale OMRON 5 7 10 11 12 13 Offer Acceptance These terms and conditions these Terms are deemed part of all quotes agreements purchase orders acknowledgments price lists catalogs manuals brochures and other documents whether electronic or in writing relating to the sale of products or services collectively the Products by Omron Electronics LLC and its subsidiary companies Omron Omron objects to any terms or conditions proposed in Buyer s purchase order or other documents which are inconsistent with or in addition to these Terms Prices Payment Terms All prices stated are current subject to change with out notice by Omron Omron reserv
42. l to perform this Offset Control is enabled by default Disabled No Offset In the following diagram the ON timing overlaps between the channels mA YA A N N VN A AAA VM V VV FEE EV ez N YN N N N N A A AA M MUVUUUVUUV EV Maly V FF YF YE FV c PA AAA AA AAA VW VVVVVV UV VY Enabled Offset In the following diagram overlapping of the ON timing has been reduced PEDIA IA II YI NV A RNANANNXNANA ER VN UY DCN YAN AL AC ACA AAA TU VU UYU UY Note Overlapping will vary with the control variables and changes to the control variables 4 3 Turning OFF the Control Output Use the start stop operation command to turn OFF control outputs The start stop command can be used for all channels or for individual channels Note The start stop status is written to nonvolatile memory If the power is turned OFF when a control output is stopped it will still be stopped when power is turned back ON Use the Start Stop operation command to enable operation again 25 Detecting Heater Burnout 4 channel Models Only Section 4 4 4 4 Detecting Heater Burnout 4 channel Models Only Heater Burnout Detection Timing Note Operating Conditions 26 A heater burnout is detected by determining if the heater current is below the heater burnout detection value when a control output is ON Heater ON current y Hvsterisis 2 AS aa 1 1 1 Heater burnout detection val
43. le H 00000000 to H 000003E8 0 0 to 100 0 CH8 control variable CH1 status MR AS AS ASAS 01 ef wef es A A H 00000000 to H 000003E8 0 0 to 100 0 CH2 status CHS status CH4 status CH5 status CH6 status CH7 status CH8 status CH1 heater ON cur rent H 00000000 to H 00000037 0 to 55 CH2 heater ON cur rent H 00000000 to H 00000037 0 to 55 CH3 heater ON cur rent H 00000000 to H 00000037 0 to 55 CH4 heater ON cur rent CH1 heater OFF cur rent H 00000000 to H 00000037 0 to 55 H 00000000 to H 00000037 0 to 55 CH2 heater OFF cur rent H 00000000 to H 00000037 0 to 55 CH3 heater OFF cur rent H 00000000 to H 00000037 0 to 55 CH4 heater OFF cur rent CH1 manipulated vari able H 00000000 to H 00000037 0 to 55 H 00000000 to H 000003E8 0 0 to 100 0 CH2 manipulated vari able H 00000000 to H 000003E8 0 0 to 100 0 CH3 manipulated vari able H 00000000 to H 000003E8 0 0 to 100 0 CH4 manipulated vari able H 00000000 to H 000003E8 0 0 to 100 0 CH5 manipulated vari able H 00000000 to H 000003E8 0 0 to 100 0 CH6 manipulated vari able H 00000000 to H 000003E8 0 0 to 100 0 CH7 manipulated vari able H 00000000 to H 000003E8 0 0 to 100 0 CH8 manipulated vari able H 00000000 to H 000003E8 0 0 to 100 0 H 0000000
44. ment regulations iv Systems machines and equipment that could present a risk to life or prop erty Please know and observe all prohibitions of use applicable to this Prod uct NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY OR IN LARGE QUANTITIES WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS AND THAT THE OMRON S PRODUCT IS PROP ERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM Programmable Products Omron Companies shall not be responsible for the user s programming of a programmable Product or any consequence thereof Performance Data Data presented in Omron Company websites catalogs and other materials is provided as a guide for the user in determining suitabil ity and does not constitute a warranty It may represent the result of Omron s test conditions and the user must correlate it to actual application require ments Actual performance is subject to the Omron s Warranty and Limitations of Liability Change in Specifications Product specifications and accessories may be changed at any time based on improvements and other reasons It is our prac tice to change part numbers when published ratings or features are changed or when significant construction changes are made However some specifica tions of the Product may be changed without any notice When in doubt spe cial part numbers may be assigned to fix o
45. n xiii XIV SECTION 1 Overview Oo Z gt O This section introduces the G3ZA and its features OU 2 HH Z o gt O Features Section 1 1 1 1 Features The G3ZA is a Multi channel Power Controller with externally connected SSRs It can receive manipulated variables from a PLC or other host via RS 485 communications and control heater power with high precision via the SSRs Overview Optimum Cycle Control e Optimum cycle control is performed by driving SSRs according to load power detection and trigger signals Zero cross SSRs are used Noise is suppressed while ensure high speed response by turning out puts ON and OFF each half cycle to achieve high precision temperature control 1 5th ON 20 Manipulated variable 20 Offset Control e The timing of turning ON the control outputs for G3ZA channels be offset Manipulated Value e The manipulated variable can be calculated for one channel and the cal Calculations culated value can be output for another channel Error Detection 4 channel The current flowing through the heater can be monitored to detect heater Controllers Only burnouts heater overcurrents and SSR short circuits Number of Outputs e Between one and four outputs can be connected to 4 channel Controllers Connected and between one and eight outputs can be connected to 8 channel Con trollers Alarm Output e An open collector output terminal can be used to inform the h
46. n value 002C Offset control H 00000000 Disabled H 00000001 Enabled Enabled 5 Appendix Opera C3 See 0000 Data length H 00000000 7 i tion 1 See note 2 H 00000001 8 Stop bits See note 2 H 00000000 1 i H 00000001 2 Parity See note 2 H 00000000 None H 00000001 Even H 00000002 Send standby time H 00000000 to H 00000063 0 to 99 See note 2 Communications time H 00000000 Disabled out time See note 2 400000001 to H 0000003C 1 to 60 Operation at error H 00000000 Continue with error clear H 00000001 Continue with no error clear H 00000002 Stop See note 3 0007 H 00000001 to H 0000000A 1 to 10 Note 1 If C in the variable type is changed to 8 4 digit data can be set or monitored 2 These settings are valid until the G3ZA is reset or the power is turned ON again 3 Only the channel with the error will stop ASCII Character Table Upper byte Lower byte 00 m pe se o 2 o lt 41 Appendix xipuadd y 42 A B alarm output 2 terminals on 200 V Controllers 11 terminals on 400 V Controllers 11 baud rate 14 C communications specifications 14 communications terminals 10 communications timeout time 30 communications timeouts 30 communications unit number 14 CompoWay F 15 end codes 16 control channels maximum number 2 control outputs turning OFF 25 control power s
47. ommand Example The following procedure can be used to change the manipulated variable to 20 0 whenever the power supply is turned ON 1 23 1 Execute the Variable Area Write command to set the manipulated variable to 20 0 for all channels 2 Execute the Manipulated Variable Save operation command 3 The manipulated variables will be set to 20 0 the next time power is turned ON Using Manipulated Manipulated variable calculations can be used to set the control variable for Variable Calculations one change based on the manipulated variable for another channel The fol lowing calculation method and set values can be used Control variable Manipulated variable of source channel x Slope 100 0 Offset aaa Ong Channels 1 to 8 Source channel Channel 1 to 8 Set the channel to use as the source for calculation Channels 1 to 8 Slope 0 0 to 400 0 Channels 1 to 8 Offset 400 0 to 400 0 Note 1 The control variable will be clamped at 0 or 100 if it exceeds the range of 0 to 100 2 The control variable can be read using the Variable Area Read command Example Channel 3 2 3 4 Ote iso 00 50 i00 Control variable 96 20 0 ch1 ch2 ch3 ch4 24 Offsetting Control Output ON Timing Section 4 2 4 2 Offsetting Control Output ON Timing The ON timing of control outputs for all of the channels can be adjusted to reduce overlapping with each other Set the Offset Contro
48. os Communications Sete Ss sese di ae er dr RE deu de ee 14 3 2 CompoWay F BPtame 5tpuctufe ciar a R HA a needs 15 NS 17 3 4 Vanable Arca ar RC Saw BSBA Per AR RAO HES 17 250 Reads ita 18 9 6 Operation Command midi dia been 19 3 7 Controller Attribute Read 20 30 Controller Status Read acuda ESSERE SS a d a 21 5 0 Beho Dack TES aes van ssa SX RE E EU inicias Ades 22 lt N c g o 1e p O 2 Y 13 Communications Settings Section 3 1 3 1 Communications Settings G3ZA settings and operation are performed using RS 485 communications Communications Stop bits aras O contro me 0 Communications settings are made as shown in the following table Seting Settingrange Defaut Setting method Communications unit 1 0 to 31 1 SW1 number Baud rate 9 6 19 2 38 4 or 9 6 kbit s SW2 57 6 kbit s Setting the Communications Unit Number and Baud Rate The communications unit number and baud rate are set first These settings are made with SW1 and SW on the front of the G3ZA t N co o o per O 9 SV 0 1 2 3 4 5 6 7 8 9 A B C D E F Unit number 100 101102 103104 105 06 07 os 09 10 11 12 13 14 15 s lolrl ols Baud rate kou BBN 19 2 38 4 576 Note 1 Refer to Connecting More Than 16 Controllers on page 38 in the Appen dix when connecting more than 16 Controllers 2 The def
49. ost of errors without using communications Installation e RS 485 communications can be used to set and operate the G3ZA reducing the amount of wiring required between the G3ZA and host e Up to 31 Controllers can be connected to one communications line With 4 channel Controllers up to 124 channels can be controlled and with 8 channel Controllers up to 248 channels can be controlled The following four models are available No of channels Error detection Load power supply 4 channels Supported 100 to 240 V 400 to 480 V 8 channels Not supported 100 to 240 V 400 to 480 V Features Section 1 1 Connections e Z gt O Load power suppl Load e g heater Note Connect a power supply with the same phase as the SSRs to the load power supply input terminals on the G3ZA Component Names and Functions N N 1 LI MAI DON ATA T N JAN Operation Indicators Operation indicator Switches SW1 and SW2 SW1 and SW2 are used to set the communications unit number and baud rate Refer to 3 1 Communications Settings on page 14 for details Features Section 1 1 o gt O SECTION 2 Preparations This section describes preparations for using the G3ZA including installation and wiring 2 6 2 2 How To Use the Terminals Y per 5 pun Q o Bu Q Installation
50. r establish key specifications for your application Please consult with your Omron s representative at any time to confirm actual specifications of purchased Product Errors and Omissions Information presented by Omron Companies has been checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions OMRON OMRON ELECTRONICS LLC 1 Commerce Drive Schaumburg IL 60173 847 843 7900 For US technical support or other inquiries 800 556 6766 OMRON CANADA INC 885 Milner Avenue Toronto Ontario MIB 5V8 416 286 6465 OMRON ON LINE Global http www omron com USA http www omron com oei Canada http www omron ca UNITED STATES To locate a Regional Sales Office local Distributor or to obtain product information call 847 843 7900 CANADA REGIONAL SALES OFFICES Ontario Toronto 416 286 6465 Kitchener 519 896 1144 Kingston 613 376 3968 Quebec Montreal 514 636 6676 British Columbia Vancouver 604 522 8855 Alberta Edmonton 403 440 0818 Calgary 403 257 3095 Sao Paulo 55 11 5564 6488 Cono Sur 54 114 787 1129 Florida 954 227 2121 Ciudad Juarez 656 623 7083 Mexico D F 555 534 1195 Monterrey N L 818 377 4281 Z200 E1 01 6 06 2006 OMRON ELECTRONICS LLC Specifications subject to change without notice Printed in the U S A
51. reliminary Checks Is the power supply If the power supply is turned ON the READY indicator will be turned ON lit Was wiring per Check all of the wiring formed correctly Were settings per Check the switches to see if they are set correctly formed correctly Read out the settings to see if they have been set correctly Read out all settings to see if any of them are incorrect Handling Problems Communications e If the SD RD indicator does not light when communications cannot be per are attempted there is a problem with the communications formed line Check the wiring of the communications line lf a communications converter is being used check the set tings of the converter to see if they are correct e Check the settings of SW1 and SW to see if they agree with the settings of the host Check the data length number of stop bits and parity to see if they are the same as the host If any of the settings are incorrect or if any are unknown use the following method for communications 1 Set SW to 7 If more than 16 communications unit num bers are used set SW2 to F 2 Set the baud rate data length number of stop bits and par ity of the host to the default values for the G3ZA If a converter is being used set the converter to the same values 3 This should enable communications Change all settings to the correct values e Check the communications line to see if it is correct Outputs do not
52. s or similar words mean Omron Corporation and any direct or indirect subsidiary or affiliate thereof Certain Precautions on Specifications and Use 1 Suitability of Use Omron Companies shall not be responsible for conformity with any standards codes or regulations which apply to the combination of the Product in the Buyer s application or use of the Product At Buyer s request Omron will provide applicable third party certification documents identifying ratings and limitations of use which apply to the Product This information by itself is not sufficient for a complete determination of the suitability of the Prod uct in combination with the end product machine system or other application or use Buyer shall be solely responsible for determining appropriateness of the particular Product with respect to Buyer s application product or system Buyer shall take application responsibility in all cases but the following is a non exhaustive list of applications for which particular attention must be given i Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses not described in this document ii Use in consumer products or any use in significant quantities iii Energy control systems combustion systems railroad systems aviation systems medical equipment amusement machines vehicles safety equip ment and installations subject to separate industry or govern
53. s Ambient operating temperature Ambient operating humidity 25 to 85 Storage temperature Elevation Accessories Instruction Sheet Performance Current accuracy 3 A Insulation resistance 100 MQ min at 500 VDC between primary and secondary Dielectric strength 2 000 VAC 50 60 Hz for 1 min between primary and secondary Vibration resistance Vibration frequency 10 to 55 to 10 Hz acceleration 50 m s in X Y Z directions Shock resistance 300 m s three times each in six directions along three axes Weight of main body Approx 200 g including terminal cover Degree of protection IP20 Memory backup EEPROM non volatile memory write life 100 000 writes Installation environment Overvoltage category Ill pollution degree 2 according to IEC 60664 1 Approved standards UL508 Listing CSA22 2 No 14 EN50178 EN61000 6 4 EN5501 1 1998 A1 1999 Class A Group 1 EN61000 6 2 2001 35 C o lt Appendix Model Numbers Model Numbers G3ZA 1 23 4 5 6 No of control points 4 4 channels 8 8 channels Control method Ideal cycle control Current transformer input H Yes A None 4 Load power supply voltage 2 100 to 240 VAC 4 400 to 480 VAC O Communications specifications RS 485 CompoWay F International standards Approved by T V Current Transformer Specifications Specification Model number E54 CT1 E54 CT3 Max continuous heater current 120 A See note
54. ts are confidential and proprietary and Buyer shall limit distribution thereof to its trusted employees and strictly prevent disclosure to any third party Export Controls Buyer shall comply with all applicable laws regulations and licenses regarding i export of products or information iii sale of products to forbidden or other proscribed persons and ii disclosure to non citizens of regulated technology or information Miscellaneous a Waiver No failure or delay by Omron in exercising any right and no course of dealing between Buyer and Omron shall operate as a waiver of rights by Omron b Assignment Buyer may not assign its rights hereunder without Omron s written consent c Law These Terms are governed by the law of the jurisdiction of the home office of the Omron company from which Buyer is purchasing the Products without regard to conflict of law princi ples d Amendment These Terms constitute the entire agreement between Buyer and Omron relating to the Products and no provision may be changed or waived unless in writing signed by the parties e Severability If any provi sion hereof is rendered ineffective or invalid such provision shall not invalidate any other provision f Setoff Buyer shall have no right to set off any amounts against the amount owing in respect of this invoice g Definitions As used herein including means including without limitation and Omron Compa nie
55. ucts or oth erwise of any intellectual property right c Buyer Remedy Omron s sole obli gation hereunder shall be at Omron s election to i replace in the form originally shipped with Buyer responsible for labor charges for removal or replacement thereof the non complying Product ii repair the non complying Product or iii repay or credit Buyer an amount equal to the purchase price of the non complying Product provided that in no event shall Omron be responsi ble for warranty repair indemnity or any other claims or expenses regarding the Products unless Omron s analysis confirms that the Products were prop erly handled stored installed and maintained and not subject to contamina tion abuse misuse or inappropriate modification Return of any Products by Buyer must be approved in writing by Omron before shipment Omron Compa nies shall not be liable for the suitability or unsuitability or the results from the use of Products in combination with any electrical or electronic components Circuits system assemblies or any other materials or substances or environ ments Any advice recommendations or information given orally or in writing are not to be construed as an amendment or addition to the above warranty See http oeweb omron com or contact your Omron representative for pub lished information Limitation on Liability Etc OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES
56. ue ON Status heater burnout bit T T OFF ERROR indicator Alarm output Set value Setting range range Default Channels 1 to 4 Heater burnout detec 1 O to 50 See note 1 10 disabled tion value Hysteresis See note 2 wwo ppo 1 Heater burnouts will not be detected if the detection value is set to O Detection status will be forced ON if the detection value is set to 50 Use these to check operation during installation 2 Hysteresis is used to prevent chattering at the detection point The same hysteresis setting is used for all heater burnout detection heater overcur rent detection and SSR short circuit detection functions e Turn ON the power supply to the heater either simultaneously with or before the power supply to the G3ZA False detection will occur if the heater power supply is turned ON after the G3ZA power supply e The actual current flowing in the heater may not be the same as the heater s rated current Check the heater current under actually conditions using the Heater ON Current parameters for channels 1 to 4 e Keep the total normal heater current to 50 A or less If 55 A is exceeded the Heater ON Current parameters for channels 1 to 4 will be 55 e Detection will be unstable if there is only a small difference between the normal current and burnout current To achieve stable detection set the parameters so that there will be a difference of at least 2 A for
57. upply terminals 10 controller attributes reading 20 controller status reading 21 crimp terminals 9 current transformer 36 input terminals 12 D data length 14 detecting heater burnout 26 detecting heater overcurrent 28 detecting SSR short circuits 28 E E54 CT1 36 E54 CT3 37 echo back test 22 error detection 2 ERROR indicator 3 errors setting operation for errors 30 Index table 32 F H FINS mini command and response text 17 heater burnout 26 calculating the detection current 27 detection 30 detection value 26 heater overcurrent calculating the detection current 28 detection 28 30 detection value 27 28 hysteresis 26 28 29 I L ideal cycle control 2 initializing settings 19 installation 2 6 mounting 6 removing 7 using screws 8 load power supply terminals 10 M manipulated variable calculations 2 calculations using 24 changing 24 saving 19 model numbers 36 O OCC indicator 3 offset control 2 25 offset for manipulated variable calculations 24 offsetting ON timing 25 disabled 25 enabled 25 operation command 19 43 44 R READY indicator 3 resetting software reset 19 S SD RD indicator 3 send standby time 14 15 set values reading 18 writing 17 slope for manipulated variable calculations 24 source channel for manipulated variable calculations 24 specifications 35 SSR short c
58. ution Indicates non specific general cautions warnings and dangers Mandatory Caution viii B Precautions N WARNING Do not touch the terminals and the wires while power is being supplied Doing so may possibly result in electric shock Make sure that the terminal cover is installed before using the product N CAUTION Do not allow pieces of metal wire clippings or fine metallic chips or filings from installation to enter the product Doing so may occasionally result in electric shock fire or malfunction Do not use the product in locations of flammable or explosive gases Doing so may occasionally result in minor or moderate explosion causing minor or moderate injury or property damage Do not attempt to disassemble repair or modify the product Doing so may occasionally result in minor or moderate injury due to electric shock Perform correct setting of the product according to the application Failure to do so may occasionally cause unexpected operation resulting in minor or moderate injury or damage to the equipment Ensure safety in the event of product failure by taking safety measures such as installing a separate monitoring system to provide alarms for preventing excessive temperature rise Product failure may occasionally prevent control operation resulting in damage to the connected facilities and equipment Tighten the terminal screws securely using a tightening torque within the following ranges
Download Pdf Manuals
Related Search