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G3ZA Users Manual

1. Appendix 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 vvill not turn ON during this period A stabilization period of 1 second is also executed after clearing a zero cross error Povver ON 1s Example 1 Stabilization Normal operation Q Outputs stopped Error cleared Example 2 Stabilization Normal operation Outputs stopped Error cleared Example 3 Stabilization j Normal operation Zero cross error Stabilization Normal operation Outputs stopped Outputs stopped Connecting More Than 16 Controllers If more than 16 G3ZA Controllers are connected set SVV2 to betvveen 8 and B for the 17th Controller on The relationship betvveen the settings of SVV1 and SVV2 is shovvn in the follovving table T 17 19 120 121 122 123 124 125 126 28 129 130 2 11 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 follovving settings vvould be used to set a Controller to communications unit number 7 and a baud rate of 38 4 kbit s SVV1 7 and SVV2 2 64 Appendix Status Lists Use the status listed in the follovving tables to check G3ZA status Status Bt Status OFF ON 31 to 13 Not used
2. 53 4 15 Monitoring the Effective Current 3 54 29 Setup Procedure Section 4 1 4 1 Setup Procedure The follovving flovvchart shovvs the setup procedure for the G3ZA Make the settings required for the application being used Set the SSR control method page 31 Select the control method appropriate for the SSR being used il Set the current range page 33 Set a displayable current range appropriate for the CT being used Jl Set CT allocation in 4 channel models only page 35 1 Detect heater burnout Set which channel s current will be used for error detection s N page 36 Detect heater overcurrent page 43 Jl Detect SSR short circuit page 45 Detect communications timeout page 48 Set the time to use to determine if a communications error has occurred Set the MV after communications Set the manipulated variable MV to output when a communications error page 49 error occurs When Using Soft start Optimum Cycle Control Set soft increase and soft decrease times The output value can be page 49 Note Default values can also be used changed smoothly ba 7 gt MV threshold Svvitches between phase control page i a Note Default values can also be used and optimum cycle control Change the MV page 50 0 Selecting the SSR Control Method 4 or 8 channel Models Section 4 2 4 2 Selecting the SSR Con
3. 26 5 0 Controller Status Read ust Ri vam red data a OE a 21 750 SBoho DdCk T S asel RM mac Es Ie So ES dX ka e 28 A o amp gt Gc os cc O m Q 3 gc 17 Communications Settings Section 3 1 3 1 Communications Settings G3ZA settings and operation are performed using RS 485 communications The communications functions use the program created in the host computer Descriptions of communications in this manual are therefore vvritten from the vievvpoint of the host computer For example references to reading and vvrit ing mean reading data from the G3ZA to the host computer and writing data from the host computer to the G3ZA Communications Stop bite Vtozus 0 Flow control lm 7 Communications settings are made as shown in the following table Seting Setting range Defaut Setting method Communications unit O 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 5 o E gt Gc os ai Q 3 8g SV 0 1 2 3 4 5 6 7 8 9 A B C D E F Unit number 100 01102 03 04 105 06 07 108 109110 11 12 13 14 15 Su fo at 2 8 Baud rate kbit s 9 6 19 2 38 4 57 6 Note 1 Refer to Connecting More Than 16 Controllers on page 64 in the
4. 5 8 mm max v 5 8 mm max Jk Use wires that are rated to withstand 70 C minimum 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 6 E 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 e The G3ZA detects the zero cross point of the load power supply Use a load power supply with the same phase as the G3ZA Controller s input power supply e The system will not be controlled correctly if the control power supply is phase controlled or has a different frequency from the input power supply To communicate with a host system connect the communications line to terminals 7 and 8 as follows 7 8 9 C 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 e The maximum cable length is 500 m total Hov To Use the Terminals Alarm Output vvith 200 V Rating Terminals 9 and 11 NJ 0 Alarm Output vvith 400 V Rating Connector Pins A and B Trigger Ou
5. Alarm output 30 V 50 mA i i 000 890 9 0 09 0 RS 485 Alarm output 30 V 50 mA P i s Control power supply Load power supply O 5 o 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 GS3ZA L Il 1203 FLK UTU GS3ZA L 1 1403 FLK UTU 11 Section 2 2 Hov To Use the Terminals VViring Diagrams VViring Precautions Control Povver Supply Terminals 1 and 2 o G p Ls Q t 14 16 16 1718 49 20 21 22 23 24 13 14 16 18 17 18 Load Povver Suppiy Input Terminals 4 and 6 sO 19 20 2122 23 24 19 1415161718 19 20 21 22 23 24 13 14 16 18 17 1 8 311 RS 485 Communications Terminals 7 and 8 19 20 2122 23 24 KO 19 2 2 2 23 24 13 14 1616 7 18 READY all a B o OCC omkon 9 G3ZA N ERROR gt SA i a J LT OMO 0021 004 68 1 6 12 To avoid the effects of noise wire signal lines separately from power lines Use cables with wires that have sufficient capacity Attach solderless crimp terminals on wires that connect to the terminal block Use one of the following M3 solderless terminals for wiring
6. Ri m Connect the G3ZA Connecting Cable to the CN1 connector on the bottom of the TC Unit Port A connector USB connection can be made using the CX Thermo for setting E58 CIFQ1 order separately G3ZA NJ AN P d 5 05 05 ad PT Computer o E im Lum Q OL ND ND Ge ae IN f 15 PS PS 2 1 PIS P E NU NY NA AU NAN ANAT 19 20 21 2 13 14 15 16 READY SD RD OCC omkon G3ZA ERROR Set SW to 3 57 6 kbit s Connect the black line with a white stripe to terminal 7 on the G3ZA and the black line with no stripe to terminal 8 EJ1C CBLAO050 order separately cable length 5 m 15 Hov To Use the Terminals Section 2 2 o EX dm o Bu Q 16 SECTION 3 Communications CompoWay F This section describes application information including settings communications and controlling operation 3 1 Communications Settings dp X E Re RD A AAA 18 3 2 Fame C oniizutatioflin qetsi in da dd b quaa 19 Kv e Re Hee aS 21 3 4 Vamable Area e i e eS Saw EO RRA GROSS Cae RES 23 00 sNariables Mea Reid a AE E N E hed 24 3 0 Op ration Command ss siki ede HERE Vatic ea SE 25 3 7 Controller Attribute Read
7. Lum Q Connection Examples Example Connection with the PLC Section 2 2 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 SSH CH6 S h 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 CH1 CH3 CT CHD CT CH CT CT There are four current transformer inputs that can be used Use the E54 CT1 the E54 CT3 or the G3ZA CT150L from OMRON as the current transformer Heater o 000 OOO OOO 6 1 B 14 1 aS 1 Alarm output SS Er Far Ll 7 O v SO 7 OQO O L 20 mm min See note SSR Power Controller Load power supply RS 232C 485 power supply for zero cross detection 14 Note When installing next to an SSR CS CJ series PLC provide sufficien
8. O 2 o O Ka o 2 O p H 60 Appendix Appendix Specifications Specifications Ratings Control povver 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 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 Indications LED indicators Ambient operating temperature 10 to 55 C with no icing or condensation Ambient operating humidity 25 to 85 Storage temperature 25 to 65 C with no icing or condensation Elevation 2 000 m max Accessories Instruction Sheet E54 CT1 E54 CT3 G3ZA CT150L CT input Single phase between 0 and 50 A AC Single phase between O and 150 A AC Performance Current accuracy Current range 0 to 50 A 3 A max O to 150 A 9 A max 0 to 10096 6 max 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
9. Burnout current 2 Heater burnout detection value 15 10 12 5 121A 2 Three phase Heaters a Delta VViring Example Using Three 4 kVV Heaters 200 V AC Normal Operation 34 6 A gt Load such 200 V Each phase s normal current is 34 6 A 34 6 A J 3 x20A Burnout Occurred VVire break 20 A Load such VVire break as a heater Load such as a heater 200 V 40 Detecting Heater Burnouts 4 channel Models Only Section 4 5 Burnout current 20Ax4 3 x 3 Burnout current 20 A x Y 3 x 2 1 T 30 A 20 The follovving formula yields the heater burnout current vvhen there is a break in the load vviring 34 6 30 Heater burnout detection value 32 3 gt 32 A The following formula yields the heater burnout current when there is a break in the load itself 34 6 20 Heater burnout detection value 27 3 gt 27 A To detect a wire break at either location set a heater burnout detection value of 32 A b Star Wirin Example Using three 6 kW heaters 200 V AC Normal Operation 17 3 A Q Load such 200 V as a heater 200 V K D FA 17 3 A KE isi CT 200 V Uu input KO 17 3 A gt O CT To CT input Each phase s normal current is 17 3 A 17 3 A 2 30 Ax 4 3 Burnout Occurred Wire break 15A gt Load such as a heater Load such as a heater 200 V 200 V 200 V 200
10. Loads Connected to Channel 2 17 3 A CT3 Measures the current of channel 2 Load such 4 Measures the current of channel 2 200 V To CT3 input 17 3 A To CT4 input For details on heater burnout detection refer to 4 5 Detecting Heater Burn outs 4 channel Models Only 4 5 Detecting Heater Burnouts 4 channel Models Only Setting Procedure 36 A heater burnout is detected by determining if the heater current is below the heater burnout detection value when a control output is ON In addition the abnormal current detection delay can be set to prevent noise from causing false burnout detection Make the following settings to detect heater burnout If these settings are not made heater burnout may not be detected properly e Wire the CTs Calculate the detection value as described under the heading Calculating the Heater Burnout Detection Value on page 39 and set the heater burn out detection value e Set the abnormal current detection delay as described in 4 13 Setting the Abnormal Current Detection Delay 4 and 8 channel Models Vk3 on page 52 Detecting Heater Burnouts 4 channel Models Only Section 4 5 Heater Burnout Detection Timing Load current SSR output Dr m Note This example shows operation with the following settings Abnormal current detection delay O immediate alarm Operation at error 2 O Continue with error clear Heater burnout is detected at point
11. cHasaus 0011 rt heater ON current 1 00000000 1 HOQODOAS 016 165 0 Jaor 0012 heater ON current H 00000000 to H 000000A5 016 165 0 Aor t 0013 CTS heater ON current H00000000 to H00000045 0 to 165 10 Jaor 0014 CTA ester ON current H 00000000 to 000000 01o 16 0 Taare 0015 TT heater OFF current 1 00000000 to 000000 016 165 0 JAor 0016 CT2 heater OFF current H 00000000 te H00000045 0 to 165 10 Jaorse 0017 CTS heater OFF current H 00000000 to 0000045 016 16 0 JAor 0018 CT heater OFF current 1 00000000 to 0000045 01o 165 0 JAor ooo Hi control variable H00000000 1o 0 016 1000 00 s O00 CH2 control variable 00000000 to H 000003E 0 0 to 1000 00 0002 ora contol variable H00000000 to H000003E8 0 0 to 100 0 00 J H 00000000 to H 000003E8 to 100 0 00 196 bor orrsas Jo C C oos fesas 0 os oka sana Je LLM e n x 0008 rt effective current 1H00000000 to H00000677 0 0 to 1650 00 Aar 0009 T effecive current 0000000 to H 00000672 00 to 1650 100 A or H 00000000 to H 00000672 7 0 to 165 0 0 0 1Aor 96 0008 Ta effective current 1H00000000 to H00000677 0 0 to 165 0 00 JA or H 00000000 to H 000000A5 to 165 0 JAorsl r O o lt 69 Appendix type Opora CE BE 000 CT2 heater ON c
12. 0 to 100 m Control switchover hystere H 00000000 to H 0000012C 0 0 to 30 0 See note 1 000B Communications timeout H 00000000 Disabled time 2 See note 1 H 00000001 H 0 00000E10 1 to 3600 000C CT1 7737 See H 00000000 Disabled note 1 H 00000001 ch1 H 00000002 ch2 000D Ale sg See H 00000003 ch3 H 00000004 ch4 000E CT3 assignment See note 1 OOOF CT4 assignment See note 1 H 00000000 SSR for single phase heater with zero cross function Optimum cycle control H 00000001 SSR for single phase heater without zero cross function Soft start optimum cycle control H 00000002 SSR for three phase heater with zero cross function Three phase optimum cycle con trol o o lt 71 x I x x x x x nnjolno n1 gnngojonjojojolgjo0 Appendix EE e isi ype Opera 5 85 0000 CHT soft increase time 1 0000000010 H000003E7 0010 999 1200 0002 CHS soft increase time H 00000000 to H 000003 7 0 0 to 999 200 s 10003 Jona soft increase time H00000000 to H 000003E7 0 0 to 999 1200 s fo004 1085 soft increase time 90000000 to H000003E7 0 0 to 99 9 1200 s 0008 1086 soft increase time H 00000000 to H000003E7 0010999 1200 s 0006 CH7 soft increase time H00000000 to H 000003E7 0 0 to 999 1200 s 0007 CH8 soft increase time 9000000010 H000003E7 6010999 1
13. 1 0 to 50 A See note 50 Disabled cuit detection value CT 1 to 4 SSR short circuit Oto 165A or See 165 Dis 57 value mod note 7 83 03 10 A or Note f set to 50 A or 165 A in the models SSR short circuit will not be detected If set to O A detection is forced Use these settings to confirm oper ation during installation Detecting SSR Short Circuits 4 channel Models Only Section 4 7 Note 1 2 3 Precautions Operation after Error Detection Calculating the SSR Short Circuit Detection Value Setting Ranges Supported in the Models 0 to 165 A or 96 The current range and units are determined by the Current Monitor Selector setting Variable type _ Parameter name T Setting Curenirange Unis Current Monitor Selector Detection values of 0 to 165 A or max can be detected but set the detec tion value appropriate for the current range If the detection value is set above the current range errors will not be detected Refer to 4 3 Selecting the CT 4 channel Models Only on page 33 for details on detection values Example Setting the CT1 SSR short circuit detection value to 20 A 1 Setthe CT1 SSR short circuit detection value to 20 with a Variable Area Write command 2 The current is detected in CT1 and SSR short circuits are detected with the timing shown in the diagram on the preceding page 3 Once the CT1 SSR short circuit detection value is written the
14. ASCII table 73 baud rate 18 C calculating the heater overcurrent detection value 45 communications specifications 18 communications terminals 12 communications unit number 18 CompoWay F 19 end codes 20 connection examples 14 control channels maximum number 2 control povver supply terminals 12 controller attributes reading 26 controller status reading 27 crimp terminals 12 current monitor selector 33 current transformer 62 input terminals 14 selecting the CT 33 D data length 18 dimensions 8 E E54 CT1 62 E54 CT3 63 echo back test 28 error detection 2 ERROR indicator 4 Index errors table 58 F FINS mini command and response text 21 functional upgrades xiii G G3ZA CTISOL 63 H heater OFF current 46 heater ON current 37 43 initializing settings 25 installation 2 8 mounting 8 removing 9 using screws 10 L load power supply input 12 M manipulated variable calculations 2 saving 25 model numbers 62 monitoring the effective current 54 MRC 21 O OCC indicator 4 offset control 2 operation command 25 75 16 P parameter list 66 R READY indicator 4 resetting softvvare reset 25 RS 485 communrcations 12 S SD RD indicator 4 send standby time 18 19 set values reading 24 vvriting 23 setting the abnormal current detection delay 52 setup procedure 30 soft increase a
15. Even H 00000002 Odd Send standby time See H 00000000 to H 00000063 0 to 99 note 2 Communications timeout H 00000000 Disabled i time See note 2 H 00000001 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 2 0006 Offset value H 00000000 to H 000003E8 0 0 to 100 0 Note These settings are valid after the G3ZA is reset with an operation command or after the power is turned ON again 2 Only the channel vvith the error vvill stop a o 68 Appendix Parameter List for V2 Controllers type Opera CO 80 E In 0002 CH2 contol variable Hi00000000 to 00101000 100 0003 CHS contol variable Hi00000000 to 0 0 to 1000 100 Je 0004 CHA contol variable Hi00000000 to 0 0 to 1000 00 Je 0005 CHS contol variable Hi00000000 to 00101000 so Je AMAN 0 weer Ne es eS 0006 control variable H 00000000 to H 000003E 00 to 100 0 00 0007 CH7 control variable Hi00000000 te 8 0010 1000 00 H 00000000 to H 000003E8 0 0 to 100 0 00 196 owe femsas o wa cH sus 0008 fesses 0 0 w femsas 0 0 0000 cHbsau 0 Je w Jo status 0 0 0 oor osmu 0 ouo
16. than 9 A For a Current Monitor Selector setting of 2 0 to 100 Heaters of less than 10 A Normal current Overcurrent setting 2 4 Detection will not be stable if the difference is less than 4 Heaters of 10 A or more Normal current Overcurrent setting 2 6 Detection will not be stable if the difference is less than 6 Each channel s status can be read individually to check it for heater over current detection It is possible to select the Controller s operation after a heater overcurrent is detected For details on selecting operation after an error refer to 4 14 Setting Opera tion at Error 4 and 8 channel Models on page 53 Set a heater overcurrent detection value appropriate for the customer s appli cation 4 7 Detecting SSR Short Circuits 4 channel Models Only Setting Procedure An SSR short circuit is detected by determining whether the heater current is above the SSR short circuit detection value when a G3ZA control output is OFF The abnormal current detection delay can be set to prevent false SSR short circuit detection due to noise Make the following settings to detect an SSR short circuit If these settings are not made SSR short circuits may not be detected properly Wire the CTs Calculate the detection value as described under the heading Calculating the SSR Short Circuit Detection Value on page 47 and set the SSR short circuit detection value e Set the abnormal curren
17. 0 to 165 A or detection value SSR short circuit H 00000000 to H 000000A5 0 to 165 A or e n value 0027 CT4 SSR short circuit H 00000000 to H 000000A5 0 to 165 A or detection value 0028 CT1 heater overcurrent H 00000000 to H 000000A65 0 to 165 A or 96 detection value 0029 CT2 heater overcurrent H 00000000 to H 000000A65 0 to 165 A or 96 detection value 002A CT3 heater overcurrent H 00000000 to H 000000A65 0 to 165 A or 96 detection value 002B CT4 heater overcurrent H 00000000 to H 000000A65 0 to 165 A or 96 detection value Offset control H 00000000 Disabled H 00000001 Enabl d 0005 Operation at error H 00000000 Continue with error clear H 00000001 vvith no error ui H 00000002 So See note 2 0006 Offset value H 00000000 to H 000003E8 0 0 to 100 0 3 83 m Communications data H 00000000 7 length See note 1 H 00000001 0001 Communications stop bits H 00000000 1 See note 1 H 00000001 2 0002 Communications pH H 00000000 Note See note 1 H 00000001 bi N 00000002 Odd 0003 Communications send H 00000000 to H 00000063 0 to 99 standby time See note 1 0004 Communications timeout H 00000000 Disabled time See note 1 H 00000001 200056 1 to 60 0007 H 00000001 to H 0000000A 1 to 10 0008 SSR drive selection See note 1 m Current monitor display H 00000000 0 to 50 A selection See note 1 H 00000001 0 to 150 A H 00000002
18. Appen dix when connecting more than 16 Controllers 2 The default settings are shaded in the above table 3 When connecting to the EJ1 set SW2 to 3 18 Frame Configuration Section 3 2 Other Communications Settings Note Send Standby Time Communications are used to set the data length number of stop bits parity and send standby time To change the settings use communications vvith the default communications settings Refer to 3 4 Variable Area VVrite on page 23 for the procedure for changing these settings The settings will be enabled only when the power is turned ON again or the G3ZA is software reset 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 Heceive Heceive Send G3ZA Send status Response created gt E 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 3 2 Frame Configuration Command Frame Format Response Frames The communications protocol is the OMRON CompoWay F 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 In the following explanations
19. CT1 and heater overcurrent is detected with the timing shown in the diagram on the preceding page 3 Once the CT1 heater overcurrent detection value is written the setting is saved and will also be effective the next time that the power is turned ON Precautions The actual current flowing in the heater may not be the same as the heater s rated current Check the heater current under actual conditions using the CT1 to CT4 Heater ON currents Detection will be unstable if there is only a small difference between the normal current and the overcurrent setting To achieve stable detection set the parameters as follows For a Current Monitor Selector setting of 0 0 to 50 A Heaters of less than 10 A Normal current Overcurrent setting 22 A Detection will not be stable if the difference is less than 2 A Heaters of 10 A or more Normal current Overcurrent setting 2 3 A Detection will not be stable if the difference is less than 3 A For a Current Monitor Selector setting of 1 0 to 150 A Heaters of less than 10 A Normal current Overcurrent setting 2 6 A Detection will not be stable if the difference is less than 6 A 44 Detecting SSR Short Circuits 4 channel Models Only Section 4 7 Operation after Error Detection Calculating the Heater Overcurrent Detection Value Heaters of 10 A or more Normal current Overcurrent setting gt 9 A Detection vvill not be stable if the difference is less
20. ON Timing 4 and 8 channel Models 51 4 12 Turning OFF a Control Output 4 and 8 channel Models 92 4 13 Setting the Abnormal Current Detection Delay 4 and 8 channel Models 52 4 14 Setting Operation at Error 4 and 8 channel Models 53 4 15 Monitorine the Effective Current ecole 54 SECTION 5 Troubleshooting e 0 OS 0 OS 0 0 0 09 09 0o 9 0909 oO 57 I eae 58 3 2 Handling Problems se xS a ik e dt R De eb axe sued ue 59 XV XVI About this Manual This manual describes the installation and operation of the G3ZA Multi channel Povver Controller and includes the sections described belovv 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 vviring Section 3 descrides how to use the G3ZA Controller s communications functions focusing on the CompoWay F communications commands Section 4 describes the functions of the G3ZA so that these functions can be used effecti
21. Section 4 15 In the follovving cases the display vvill indicate a value other than the effective current Operation is stopped or a communications error occurred 0 0 A is dis played Power is turned ON or a zero cross error occurred 0 0 A is displayed 55 Monitoring the Effective Current Section 4 15 56 SECTION 5 Troubleshooting This section provides information on problems that may occur during operation and corrective measures for them Sel Eros a e tr dau deeds 58 952 JHandline Problems 235292 sa eld e ewe e Rw be ew oe ews 59 O o O Ka m 2 o Som 57 O 2 o O Ka o o 2 p Errors 5 1 Error Table Errors Section 5 1 ERROR Operation Correction indicator Flashing 58 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 h
22. V 200V input 200V input 15 A To CT input To CT input 41 Detecting Heater Burnouts 4 channel Models Only Section 4 5 d Y Burnout current 30 A x Js 2 15A 15A 1 Burnout current 30 A x x x al 3 2 ki The follovving formula yields the heater burnout current for the main vviring 17 3 15 Heater burnout detection value uu 16 15 gt 16 A c V VViring Example Using two 2 kVV heaters 200 V AC Normal Operation 10 A o Load such ON heater To CT input Burnout Occurred Load such Load such as a heater as a heater 1 Burnout current 10 A x gt Burnout current 0 A 5A The following formula yields the heater burnout current when there is a break in the common wire 1045 Heater burnout detection value un 7 5 7 A The following formula yields the heater burnout current when there is a break in the load wire 1040 Heater burnout detection value 5 A To detect a wire break at either location set a heater burnout detection value of 7 A 42 Detecting Heater Overcurrent 4 channel Models Only Section 4 6 4 6 Detecting Heater Overcurrent 4 channel Models Only Heater overcurrents are detected by determining whether the heater current is above the heater overcurrent detection value when a G3ZA control output is ON The abnormal current detection delay can be set to pr
23. V V V V V ea L YA EN Y AA A N JS V VV VVN V V V V V V WAY VN FFF VV V Note 1 The waveforms are current waveforms of the SSR load power supply volt age 2 The amount of overlapping depends on the control variables and the tim ing of control variable changes 4 12 Turning OFF a Control Output 4 and 8 channel Models Use the startistop operation command to turn OFF control outputs The starti stop command can control individual channels not just all channels at once For details on operation commands refer to 3 6 Operation Command on page 25 N Caution Since the start stop status is written to non volatile memory a channel will still be stopped when power is turned back ON if the power is turned OFF while the control output is stopped To restart operation use the Start Stop opera tion command again 4 13 Setting the Abnormal Current Detection Delay 4 and 8 channel Models The abnormal current detection delay can be set to prevent false detection of current errors Such as heater burnout due to noise or other causes Set a suitable number of detections for the usage conditions Variable type Parameter name Selling range Default 85 C5 Abnormal current detection O to 200 detections 13 See note delay Note output an alarm immediately when an error is detected set the delay to disabled When heater burnouts heater overcurrents and SSR short circuits are being detected an a
24. acceleration 50 m s in X Y Z directions EEPROM non volatile memory write life 100 000 writes installation environment Approved standards UL508 Listing CSA22 2 No 14 EN50178 EN61000 6 4 EN55011 1998 A1 1999 Class A Group 1 EN61000 6 2 2001 6 ln lt o o lt Appendix Model Numbers Model Numbers G3ZA 1X2X3X4 X5 6 7 No of control points 4 4 channels parma fos a fono transformer input None Load power supply voltage 100 to 240 VAC 4 400 to 480 VAC Communications specifications RS 485 Communications protocol CompoWay F International standards Approved by T V Current Transformer Specifications Rem Specification 98 ris 50Hz S Vibration resistance 98 mis 50 Hz Approx 11 5g Approx 50 g Approx 130 g Accessories None Connection terminals 2 Plugs 2 Note The maximum continuous current of the G3ZA together with the E54 C T3 is 50 A Dimensions Unit mm E54 CT1 75 p s 25 10 5 Two 3 8 dia 62 Appendix E54 CT3 30 am 26MAX gt o o 63
25. again CT Current Monitors CT for 0 to 50 A Detection E54 CT1 or E54 CT3 Selected The follovving table shovvs representative currents that are detected Current Monitor Selector 0 0to 50A 1 0to 150A 2 0 to 100 setting See note 1 See note 2 Maximum monitored value o OA 00 34 Allocating CTs 4 channel Models Only o Section4 4 Note 1 When a CT for 0 to 50 A detection is selected do not set the Current Mon itor Selector to 1 0 to 150 A The correct current value cannot be detect ed if it is set to 1 2 When the Current Monitor Selector is set to 2 076 to 100 the current will be displayed as a percentage of the connected CT s range For ex ample the current will be 100 for a 50 A current flowing through a CT for O to 50 A detection as shown in the table above CT for 0 to 150 A Detection G3ZA CT150L Selected The following table shows representative currents that are detected Current Monitor Selector 0 0to50A 1 0to 150A 2 0 to 100 setting See note 1 See note 2 Minimum monitored value Maximum monitored value Note 1 When a CT for 0 to 150 A detection is selected do not set the Current Monitor Selector to 0 0 to 50 A The correct current value cannot be de tected if it is set to 0 2 When the Current Monitor Selector is set to 2 076 to 100 the current will be displayed as a percentage of the connected CT s range For ex ample the current will be 100 for a 150 A cu
26. also be set to output an MV to each channel after a communications error is detected With the upgraded models the communications timeout time can be set in seconds Host device Communications Communications timeout time Variable type Setting range Default 83 C3 Communications timeout time 0 Disabled 0 Disabled 1 to 60 min Communications timeout time 0 Disabled 0 Disabled 2 See note 1 T only 1 to 3 600 s Note 1 When the communications timeout time minutes is set the same time will be reflected in communications timeout time 2 seconds For exam ple a setting of 1 minute will become 60 s 2 Communications timeouts will not be detected if the time is set to 0 3 The new setting will become valid and detection of communications tim eouts will start after executing a software reset with an Operation Com mand or turning the power OFF and then ON again When a communications timeout is detected operation will stop and the com munications error flag in the status the ERROR indicator and the alarm out put will turn ON To clear the error execute a software reset or start command with an Operation Command All channels ON Auxiliary output Control output Run All channels stopped The MV after com munications error value will be output Clearing method Execute a software reset or start command with an Operation Command Example Setting the communications timeout
27. command frame Unit No SID FINS mini BC STX Subaddress command text ETX e Per MRC SRC Data Response Text The MRES main response code and SRES sub response code are trans ferred in the response frame following the above MRC SRC Data is then transferred follovving the MRES and SRES Unit No End code FINS mini ETX STX Subaddress response text BCC pd H MRC SRC Response code Data l CompoWay F 2 o E E o O Variable Type and Address Note Refer to Parameter List on page 66 Number of Elements The number of elements is expressed in 2 byte hexadecimal format The range for specifying the number of elements differs for each command Refer to 3 4 Variable Area VVrite or 3 5 Variable Area Read Communications Data Setting monitor value Communications data 1 Negative values Decimal point See note Hexadecimal Double vvord 8 digits 2 s complement The decimal point is removed and the result is VVord 4 digits converted to hexadecimal Example 105 0 1050 0000041A 8 digits 105 0 1050 041A A digits Note Refer to Parameter List on page 66 21 0 c 9 E E O O gom gt o Q E O O if FINS mini Text 22 Note Section 3 3 List of FINS mini Service Commands 01 1402 Variable Area Write Changes set values 017 1401 Variable Area Read Reads set values 30 140
28. conductors to unused terminals 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 and power plugs Precautions vvhen Using Unit Version 1 0 Unit version 1 0 is for use vvith single phase loads only Connect single phase zero cross SSRs Do not connect three phase SSRs electromagnetic relays or single phase SSRs without the zero cross function Precautions when Using Unit Version 2 0 e When wiring the SSR check the G3ZA s settings and select the correct SSR from the following supported SSRs e SSH for single phase heater with zero cross function e SSH for single phase
29. elements For double vvord 8 digit variable iype 25 max 0019H For vvord 4 digit variable type 50 max 0032H m 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 allovved 1100 Parameter error The bit position specification is not 00 2203 Operation error An error occurred in nonvola tile memory 0000 Normal end Processing vvas completed normally Example The following command reads the control variable for channel 1 set value 8 digits Command STX 0100001010C00001000001 ETX BCC Response STX 0100000101000000000000 ET X 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 M Precautions O is set when an address with no data set is read 24 Operation Command Section 3 6 3 6 Operation Command This command is used to start and stop operation save the manipulated vari able execute a softvvare reset or initialize settings Command Operation Related MRC Se code information sav ls 2 2 2 2 Response MRC SRC Response code Ku a 2
30. heater without zero cross function e SSR for three phase heater Do not connect an electromagnetic relay e When wiring the CT check the G3ZA s settings and select the correct CT from the following supported CTs e E54 CT1 e E54 CT3 e G3ZA CT150L Note For details on checking the G3ZA s unit version refer to dentifying an Upgraded Controller on page xili xi Conventions Used in This Manual E Meanings of Abbreviations The following abbreviations are used in parameter names figures and in text in this manual These abbreviations mean the following Abbreviation Term ch Channel Note The EJ1 Series is a series of OMRON Tempera MV Manipulated variable ture Controllers For details on the functions of EJ1 EJ1 series Temperature Con these Temperature Controllers refer to the EJ1 troller See note Modular Temperature Controller User s Manual Cat No H142 or the EJ1G Modular Tempera ture Controllers for Gradient Temperature Control User s Manual Cat No H143 xii E Functional Upgrades in G3ZA Version 2 0 Functions vvere added to control halogen heaters and three phase heaters Descriptions of these functional upgrades have been added to this manual and are indicated by the symbol Identifying an Upgraded Controller The Controller s version can be identified on the Units label or the box label If there is no unit version number the Controller s version is 1 0 Box Label Version TYPE G3ZA 4H403 FL
31. hexadecimal values are expressed by adding the suffix H after the number e g O2H All other alohanumeric values in the explanations indicate ASCII characters Text STX Unit No Sub address SID FINS mini command text ETX BCC MN Poo 1 2 2 1 1 1 BCC calculation range Text STX Unit No Sub address End code FINS mini command text ex BCC n BCC calculation range 19 2 es O qo o es E E o O CompoWay F o o 9 c E E O O gom gt o o E O O e Frame Configuration Section 3 2 Always set 02H Unit No e Set the unit number that is set on SW1 on the front of the G3ZA S TAS response ibe v d archer unt number ie set o SID FINS mini This text is the command For details refer to 3 6 Operation command text Command on page 25 ETX This code indicates the end of the communications frame Always set to 03H This stores the result of the BCC calculation from the Unit No to EXT STX Unit No Sub address SID FINS mini command text ETX BCC 30H 30H 30H 30H uu 35H 30H 30H BCC 30H 380H 30HH30HG30HG30HH35H 03H 36H XOR exclusive OR calculation BCC Calculation Example Note response will be returned unless the frame contains all elements up to the ETX and BCC End Codes CompoWav F Communications Endcodel Name Beseripien Error detection priority FINS comma
32. is 0 0 by default when the power supplied is turned ON but this value can be changed to a non zero value vvith the Manip ulated Variable Save operation command Example Changing the manipulated variable to 20 0 when the power is turned ON 1 Set the manipulated variables to 20 0 for all channels with a Variable Area Write command 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 Manipulated variable calculations can be used to set a channel s control vari able based on another channel s manipulated variable Set the control vari able with the channel 1 to 8 source channel channel 1 to 8 slope and channel 1 to 8 offset settings The following calculation method and set values can be used Control variable Source channel s MV X Slope 100 0 Offset The following table shows the default values which will output 100 of each channel s MV as the control variable Variable type Parameter name Setting range Default Channel 1 to 8 source channel Channel 1 to 8 Set the channel to use as the source for calculation Channel 1 to 8 slope 0 0 to 400 0 100 0 Channel 1 to 8 offset 400 0 to 400 0 1 If the control variable exceeds the range of 0 to 100 it will be clamped at 0 or 100 2 The control variable can be read using the Variable Area Read command Example Setting the Other Channels Control V
33. is not being used set it to 0 0 s disabled 2 Only the Soft Increase Time is set to 20 0 as a default setting Soft Increase and Soft The Soft Increase Time sets the time it takes for the MV to go from 0 to Decrease Times Settings 100 of its value and the Soft Decrease Time sets the time it takes for the MV to go from 100 to 0 of its value Since these are continuously changed parameters they can be changed dur ing operation Soft Increase Time Soft Decrease Time Manipulated variable MV Manipulated variable MV Time Time lt a gt Soft Increase Time Soft Decrease Time Example Setting the channel 1 Soft Increase Time to 50 0 s and the channel 1 Soft Decrease Time to 30 0 s 1 2 3 1 Set the channel 1 Soft Increase Time to 50 0 with a Variable Area Write command 2 Set the channel 1 Soft Decrease Time to 30 0 vvith a Variable Area VVrite command 3 When the settings are written they are stored and become effective the next time that the povver is turned ON 49 Changing the Manipulated Variable 4 and 8 channel Models Section 4 10 Manipulated variable MV 100 Time gt lt gt Soft Increase Soft Decrease Time Time 4 10 Changing the Manipulated Variable 4 and 8 channel Models 1 2 3 Using Manipulated Variable Calculations 50 Note The Variable Area VVrite command is used to change the manipulated vari able The manipulated variable
34. 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 e Up to 8 G3ZA Multi channel Power Controllers can be connected to the communications port of an EJ1l TC2 4 In addition it is not necessary to create a communications program for communications between the EJ1 and G3ZA Features Section 1 1 Setting an Abnormal An abnormal current detection delay can prevent noise from causing false Current Detection Delay detection by requiring a fixed number of consecutive error detections heater burnout heater overcurrent or SSR short circuit detections before an error is actually detected 2 gt ho o Available Models The follovving four models are available 6 Model number Number of Error detection Load power supply channels G3ZA 4H203 FLK UTU 4H203 FLK UTU 4 channels Supported 100t0240V to 240 V EE 4H403 FLK UTU 400 to 480 LIII G3ZA 8A203 FLK UTU 8 channels Not supported 100 to 240 V G3ZA 8A403 FLK UTU 8A403 FLK UTU 400 to 480V to 480 V Connections Single phase SSRs Phase R Phase S PhaseT Load povver supply Control povver supply CT 4 channel models only Ter Load Note Connect a power supply with the same phase as the SSRs to the load power supply input terminals on the G
35. 00 019 4000 00 0015 offset HFFFFFOSO to HOOOOOFAO 400 0 400 0 Joo 0016 CHrofse HFFFFFO60 to HOOOOOFAO 400 0 o 4000 Jo 0 7 H FFFFFO60 to H 00000FA0 400 0 to 400 0 10 0 0018 CHT source channel H00000001 to H 0000008 8 i Je 0019 source channel 0000 0 1 to H 00000008 108 2 J 001A source channel 00000001 to H00000008 108 3 J OB CH source channel 00000001 to H00000008 i 16 8 14 0010 CHS source channel 00000001 to 0000008 108 s J 0010 CHS source channel HOO0000019HO000008 1108 ls J OE CH7 source channel H00000001 to H 0000008 10 8 7 0012 source channel 00000001 to H o0000008 1t08 8 J 0020 CT1 heater burnout detec H 00000000 to H 000000A5 0 to 165 A or Yo tion value 0021 CT2 heater burnout detec H 00000000 to H 000000A5 0 to 165 A or 96 tion value 0022 CT3 heater burnout detec H 00000000 to H 000000A5 0 to 165 A or 96 tion value 0023 CT4 heater burnout detec H 00000000 to H 000000A5 0 to 165 od A or 96 tion value 0 1 me om Vo Al lt lt 1 ON 1 0 yr N S N S AJOJN o o lt 70 Appendix type Opera C1 81 10024 CT1 SSR short circuit H 00000000 to H 000000A5 0 to 165 A or 96 tion detection value 0025 CT2 SSR short circuit H 00000000 to H 000000A5
36. 00000 to H 00000037 0 to 55 CH1 heater OFF current H 00000000 to H 00000037 0 to 55 CH2 heater OFF current H 00000000 to H 00000037 0 to 55 CH3 heater OFF current H 00000000 to H 00000037 0 to 55 CH4 heater OFF current H 00000000 to H 00000FAO 0 0 to 400 0 Appendix Level Address Parameter Settingjmonitor range Default Unit type Opera C1 81 1000E CH7 slope H 00000000 to H 00000FA0 0 0 to 400 0 100 0 Yo ton CH8 slope H 00000000 to H 00000FA0 0 0 to 400 0 100 0 CH1 offset 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 CH4 offset H FFFFFO60 to H 00000FAO0 400 0 to 400 0 CH5 offset H FFFFFO60 to H 00000FA0 400 0 to 400 0 CH6 offset H FFFFFO060 to H 00000FA0 400 0 to 400 0 CH7 offset H FFFFFO060 to H 00000FA0 400 0 to 400 0 CH8 offset H FFFFFO060 to H 00000FA0 400 0 to 400 0 CH1 source channel H 00000001 to H 00000008 CH2 source channel H 00000001 to H 00000008 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 H 00000001 to H 00000008 1 to 8 a Sa Sa e e a O O Ojo jo Oc im Cco PM lt 1to8 1to8 CH6 source channel H 00000001 to H 00000008 1 to 8 CH7 source channel H 00000001 t
37. 1 in the diagram above The detection condition is as follows Heater ON current see note 1 x Heater burnout detection value e The heater burnout alarm is cleared at point 2 in the diagram above The clearing condition is as follows Heater ON current see note 1 gt Heater burnout detection value Hyster esis see note 2 Note 1 The heater ON current is the peak load current that flows when the G3ZA s output is ON 2 The hysteresis setting applies a dead zone between the detection condi tion and clearing condition which prevents ON OFF chattering of the alarm The same hysteresis setting is used for the heater burnout detec tion heater overcurrent detection and SSR short circuit detection func tions Variable type Parametername Setmgrange Deiau 81 C1 Channel 1 to 4 heater burnout 1 O to 50 A See note 0 Disabled detection value CT 1 to 4 heater burnout O to 165 A or 96 0 Disabled detection value See note 8303 Hysteress tO TOA o t Note If set to 0 A heater burnout vvill not be detected If set to 50 A or 165 A in the models detection is forced Use these set tings to confirm operation during installation 37 Detecting Heater Burnouts 4 channel Models Only Section 4 5 Precautions 38 Note 1 2 3 Setting Ranges Supported in the Models 0 to 165 A or 96 The current range and units are determined by the Current Monitor Selector setting Variab
38. 2 4 1 Operation Code and Related Information code 01 Start stop Upper digit Channel specification Refer to 4 12 Turning OFF a Control Output 4 0 Channel 1 and 8 channel Models on page 52 1 Channel 2 2 Channel 3 3 Channel 4 4 Channel 5 b Channel 6 6 Channel 7 7 Channel 8 F All channels Lovver digit Start stop O Start 1 Stop 05 Manipulated variable Refer to 4 10 Changing the Manipulated Vari save able 4 and 8 channel Models on page 50 Software reset Performs the same processing as when the G3ZA is turned ON OB Initialize settings 1 settings 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 Erorname 1 Case 1001 Command length too long The command is too long 1002 Command length too short The command is too short 1100 The operation code or related information is not correct 2203 An error occurred in nonvolatile memory 0000 Processing vvas completed normally Example The follovving command starts operation for channel 1 Command STX 0100030050100 E TX BCC Response STX 01000030050000 ETX BCC 25 2 o E E o O CompoWay F Controller Attribute Read Section 3 7 3 7 Controller A
39. 200 s bonos r sot decrease ime 100000000 e H oooosE 0016 589 Joo s 0009 GHZ soft decrease time H00000000 to 000003 7 0 010999 Joo fs 000A 1083 soft decrease time H00000000 to H000003E7 0 010999 joo s 0008 1084 soft decrease time 9000000010 H000003E7 0 010999 joo s 000C CH soft decrease time H 00000000 to 000003 7 0 010999 Joo fs 0005 CH6 soft decrease time H00000000 to H000003E7 0 010999 joo 000E CH7 soft decrease time H 00000000 to H000003E7 0 010999 joo s Se e jj H 00000000 to H 000003E8 to 100 0 lil ul r al e NE ia a p e meme s S O El san Tas s O pw ren e Tas Ts NE A Tas s uH Gn nsan iso T R cations error ul Ki NN NN cations error h Tutu s cations error ul Kod poe s m s cations error hee ya m s cations error uli ZR s m s cations error ull n iN CNN cations error di HN Tn s cations error El me elay Note These settings are valid after the G3ZA is reset with an operation command or after the power is turned ON again 2 Only the channel with the error will stop o o lt 72 Appendix ASCII Table Leftmost digit n digit NL DLE SPACE 0 L3 pepe patet ES z m o 73 Appendix x pu ddy 74 A alarm output 2 terminals on 200 V Controllers 13 terminals on 400 V Controllers 13
40. 3E8 0 0 to 100 0 CH5 manipulated variable H 00000000 to H 000003E8 0 0 to 100 0 CH6 manipulated variable H 00000000 to H 000003E8 0 0 to 100 0 CH7 manipulated variable H 00000000 to H 000003E8 0 0 to 100 0 CH8 manipulated variable CH1 slope H 00000000 to H 000003E8 H 00000000 to H 00000FAO 0 0 to 100 0 0 0 to 400 0 CH2 slope H 00000000 to H 00000FAO 0 0 to 400 0 CH3 slope H 00000000 to H 00000FAO 0 0 to 400 0 CH4 slope H 00000000 to H 00000FAO 0 0 to 400 0 CH5 slope H 00000000 to H 00000FAO 0 0 to 400 0 CH6 slope 66 Opera CO 80 en CH1 control variable H 00000000 to H 000003E8 dy 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 CH4 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 variable H 00000000 to H 000003E8 0 0 to 100 0 CH8 control variable H 00000000 to H 000003E8 0 0 to 100 0 CH1 status CH2 status CH3 status CH4 status CH5 status CH6 status CH7 status CH8 status CH1 heater ON current H 00000000 to H 00000037 0 to 55 CH2 heater ON current H 00000000 to H 00000037 0 to 55 CH3 heater ON current H 00000000 to H 00000037 0 to 55 CH4 heater ON current H 000
41. 3ZA Features Section 1 1 Three phase SSRs Phase R Phase S Phase T 101 Load povver I supply SSR GazA Trigger signal Control Ed power supply CT 4 channel models only a i Load Z O Note Out of the three phases connect any one phase to the G3ZA Controller s load povver supply input terminals Component Names and Functions Terminal block LS L TT e a 6 Se St s d 1 1 t le Ss DY NU MUZ N 1L J QU ANIL NU SVV1 Alarm output SVV1 sw2 637 PINS A A N 7 dich 44 I r E S IN TN NN 7 N aura terminals gpa 260 Jap G3ZA IL 1403 FLK T I block pe erminal bloc Si ai UTU models only Operation Indicators Operation indicator Meaning READY Lit while power is being supplied SD RD Lit while communicating with the host OCC Lit while a control output is ON ERROR Lights or flashes when an error is detected Switches SW1 and SW2 SVV1 and SW2 are used to set the communications unit number and baud rate Refer to 3 1 Communications Settings on page 18 for details Features Section 1 1 Alarm Output Terminal Block Outputs an alarm to the output terminal open collector For details refer to Alarm Output vvith 200 V Rating Terminals 9 and 11 or Alarm Output vvith 400 V Rating Connector Pins A and B on page 13 O signals connect to the termina
42. 5 Operation Command Executes commands such as start stop manipulated variable save and software reset Controller Attribute Read Reads the model number of the Controller 506 Io Controller Status Read 1 Reads the operating status 08 por Echo back Test Performs an echo back test FINS is an acronym for Factory Interface Netvvork Service FINS is a protocol used for message communications betvveen controllers on OMRON FA net vvorks Variable Area VVrite Section 3 4 3 4 Variable Area Write This command changes set values Command VVrite start MRC SRC Variable yp address Bit GM No of elements Set values ETT EE 20 EREN ER iu No of elements x 8 or 4 Note ln the G3ZA the bit position is not used Set it to 00 Response MRC SRC Response code DE il 2 2 4 B Variable Type and Write Start Address Refer to the Parameter List on page 66 in the Appendix B Number of Elements Specify the number of elements for vvhich the set value is to be changed Up to 24 0018H elements can be specified VVrite data length No of elements For double vvord 8 digit variable type 24 max 0018H For vvord 4 digit variable type 48 max 0030H M Response Code Response code Emornam 1 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 o
43. CS LLC 1 East Commerce Drive Schaumburg IL 60173 U S A Tel 1 847 843 7900 Fax 1 847 843 8568 OMRON ASIA PACIFIC PTE LTD 83 Clemenceau Avenue 11 01 UE Square 239920 Singapore Tel 65 6835 301 1 Fax 65 6835 271 1 OMRON CHINA CO LTD Room 2211 Bank of China Tower 200 Yin Cheng Road M Shanghai 200120 China Tel 86 21 5037 2222 Fax 86 21 5037 2200 Authorized Distributor Note Specifications subject to change without notice Printed in Japan 0404 0 5M 0404 B LTIiAAXALTL BA IALIIMIIIMA IAN II IALILIDIINCLITLNAIAL m a aa IDALILIDIA Aen A A 6277
44. Cat No Z200 E1 02 Multi channel Power Controller USER S MANUAL G3ZA Multi channel Povver Controller User s Manual Produced February 2007 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 follovving items vvhen 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 of this manual Nevertheless OMRON assumes no responsibility for errors or omissions Neither is
45. Command length too long The command is too long Goo Operation error An error occurred in nonvola tile memory Normal end Processing vvas completed normally Example Command fSTX1010000801123 ETX LBCC Response STX 01000008010000123 E TX BCC 28 SECTION 4 Functions This section describes the functions of the G3ZA so that these functions can be used effectively according to the application del Setup Procedure ous vod at 7 keen i een sean dns 30 4 2 Selecting the SSR Control Method 4 or 8 channel Models WJ 31 4 3 Selecting the CT 4 channel Models Only ME 33 4 4 Allocating CTs 4 channel Models Only V 295 4 5 Detecting Heater Burnouts 4 channel Models Only 36 4 6 Detecting Heater Overcurrent 4 channel Models Only 43 4 7 Detecting SSR Short Circuits 4 channel Models Only 45 4 8 Detecting Communications Timeouts 4 and 8 channel Models 48 4 0 Setting the Soft Increase and Soft Decrease Times 4 and 8 channel Models 49 4 10 Changing the Manipulated Variable 4 and 8 channel Models 50 4 11 Offsetting the Control Output s ON Timing 4 and 8 channel Models 51 4 12 Turning OFF a Control Output 4 and 8 channel Models 52 4 13 Setting the Abnormal Current Detection Delay 4 and 8 channel Models 22 4 14 Setting Operation at Error 4 and 8 channel Models
46. Communications Sel iig S uc Ka NT AIM es 18 23 2 Frame Conlzurationu ence ere Toe err Pa tee hh ta dri d 19 20 FINS MN LEKU e varet odo eta hare SEO A ol ES CBAR abba 21 354 Manabe Area WIG e T S ed OREN OS See 29 25 24 2 0 Operation GConhimand 4 254 oh Satir Swe t a b B ak R Che Re y a 25 5 7 Controller Attribute Read ame bak EU du SUN DEP b b Sees 26 3 5 Controller us Red secondo ep bibe Heo Bo qun Ra adds 27 3 9 iBeho Dack lu wows ae a n oe ees he ae b E ERA ln il 28 SECTION 4 LUHCUODSuu josie dda b e 29 4 1 Setup SS Sd aqva visu uu 30 4 2 Selecting the SSR Control Method 4 or 8 channel Models 31 4 3 Selecting the CT 4 channel Models Only 33 4 4 Allocating CTs 4 channel Models Only 33 4 5 Detecting Heater Burnouts 4 channel Models Only 36 4 6 Detecting Heater Overcurrent 4 channel Models Only 43 4 7 Detecting SSR Short Circuits 4 channel Models Only 45 4 8 Detecting Communications Timeouts 4 and 8 channel Models 48 4 0 Setting the Soft Increase and Soft Decrease Times 4 and 8 channel Models 49 4 10 Changing the Manipulated Variable 4 and 8 channel Models 50 4 11 Offsetting the Control Output s
47. K UTU SOLID STATE RELAY VOLTS 100 240 LOT QTY No 1 OMRON Corporation MADE IN JAPAN 1 ade Power Controller Label omnon G3ZA 4H403 FLK UTU POWER CONTROLLER 100 240V AC 9 ev iA a La 12V 21mA 12V 21mA T 12V CH1 CH2 COM CH3 CH4 43 qarmaq T 748 dup nud 100 240VAC 400 480VAC 50 60Hz 5 9W 50 60Hz POWER SUPPLY LOAD VOLTAGE INPUT IND CONT EQ ADA C EE 05 LOT No See Manual LISTED OMRON Corporation MADE IN JAPAN XIV TABLE OF CONTENTS SECTION 1 Overview e o ee OO I 10000 UP ds n s on 2 SECTION 2 Preparations e e o O0 Oo e 7 2 13101 1000 c a PATCH 8 242 How ou ce the Terminals ma sa be BS ee BERE Uo nn ECCO CER ti 11 SECTION 3 Communications CompoWay F 17 JEL
48. Load povver supply i G3ZA Trigger signal SSR IM Control power supply CT 4 channel models only Load When the G3ZA is connected as shown above and the MV is 50 the phases will have the current waveforms shown in the following diagram Load power supply Phase R S Phase S T Phase R T 4 3 Selecting the CT 4 channel Models Only The selected CT setting determines the displayable current range as shown in the following table Variable 1 Parameter name Min monitor Max monitor type value value See note 3 Current Monitor 0 to 50 A 55 A See 0 Selector See note note 3 0 to 50 A 1 0 to 150 A x See on 3 2 076 to 0 110 See See note 3 note gt 33 Selecting the CT 4 channel Models Only Section 4 3 Note 1 The resolution of the monitor display is as follovvs O to 50 A range selected 1A O to 150 A range selected 3A 076 to 100 range selected 2 2 The heater burnout detection heater overcurrent detection and SSR short circuit detection values must be set as percentages 3 VVhen the input exceeds the maximum value the display vvill overflovv at the maximum value Example If the range is O to 50 A and the input is 60 A the display vvill overflovv at 55 A Example If the range is O to 150 A and the input is 170 A the display will overflovv at 165 A Example the range is 0 to 100 and the input is 115 the display will overflow at 110 When the
49. ORED 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 equipment that could present a risk to life or property Please know and observe all prohibitio
50. Start stop 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 SSH short circuit Heater burnout Output Error oO Example Condition Status Alarm output and zero cross error bit are ON H 00000210 Stopped with no errors H 00001000 65 ES z m o Appendix Parameter List If variables vvithout parentheses are used in communications the set values vvill be eight digit double vvord data If variables vvith parentheses are used in communications the set values vvill be four digit vvord data Example Variable type C4 Double vvord 8 digits Variable type 84 VVord 4 digits Parameter List for Pre V2 Controllers Note Refer to Parameter List for V2 Controllers on page 69 for parameters for upgraded Controllers ype o o o t CH1 manipulated variable H 00000000 to H 00000037 0 to 55 H 00000000 to H 000003E8 0 0 to 100 0 2055555 CH2 manipulated variable H 00000000 to H 000003E8 0 0 to 100 0 CH3 manipulated variable H 00000000 to H 000003E8 0 0 to 100 0 CH4 manipulated variable H 00000000 to H 00000
51. amage to the equipment Terminal screws 0 40 to 0 56 N m IX Precautions for Safe Use 1 Do not use the product in the follovving locations 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 ocations subject to excessive shocks or vibration Use this product within the rated load and power supply Ensure that the rated voltage is achieved no longer than 2 s after turning the power ON Use store within the rated temperature and humidity ranges Provide forced cooling if required 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 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 AVVG22 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 AVVG16 cross section 1 039 mm for other terminals Be sure to confirm the correct terminal and polarity when wiring the terminal block and connectors Do not connect any
52. annel Models Only on page 36 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 12 and in 4 6 Detecting Heater Overcurrent 4 channel Models Only on page 43 e The SSR has short circuited Replace the SSR Check the information provided in Wiring Dia grams on page 12 and in 4 7 Detecting SSH Short Circuits 4 channel Models Only on page 45 Handling Problems Section 5 2 5 2 Handling Problems Handling Problems Preliminary 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 f 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 If 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 hos
53. 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 VVarranty and Limitations of Liability VVARRANTY 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 VVARRANTY OR REPRESENTATION EXPRESS OR IMPLIED REGARDING NON INFRINGEMENT MERCHAN TABILITY OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS ANY BUYER OR USER ACKNOVVLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS VVILL 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 INNO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY REPAIR OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED ST
54. ariables Based on Channel 2 s MV The following values are set for each parameter with Variable Area Write com mands Gems rl l sl a Manipulated variable 00 200 100 Offsetting the Control Output s ON Timing 4 and 8 channel Models Section 4 11 Channel T 1 2 3 4 Offset iso foo s0 ice Control varlable 1800 1200 1400 1600 Control variable 96 ch1 ch2 ch3 ch4 4 11 Offsetting the Control Output s ON Timing 4 and 8 channel Models Offset Control can be set to adjust the time when each channel s control out put goes ON in order to reduce overlapping ON states Offset Control is enabled by default Variable type Setting range Default 81 C1 Offset control 0 Disabled 1 Enabled 1 Enabled Disabled No Offset The ON timing will overlap ai ZN YA IN N N N A N N N UN V V V V V V V v no LIEN IN NN N A N N N UN V V V V V V UV as LV N IN AN FN N N JS YAM VY FY YE YS V V ona LN VA IN AN AN A N N N AW YY VVVVV VY Note 1 The waveforms are current waveforms of the SSR load power supply volt age 2 The amount of overlapping depends on the control variables and the tim ing of control variable changes 51 Turning OFF a Control Output 4 and 8 channel Models Section 4 12 Enabled Offsets Overlapping of the ON outputs is reduced Applied en L V N N N AN LN A AAA V V VVN V NN NN VY ene LN YA EN TY A N A V V VIN V
55. as 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 Error Response Received Initialize the settings and perform a software reset with an Operation Command 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 software reset with an Operation Command If operation still does not recover the G3ZA needs to be repaired Check to see if the communications line is bro ken e Check to see if a communications error has occurred Check the host to see if it is functioning cor rectly e Check the information provided in 4 8 Detecting Communications Timeouts 4 and 8 channel Models on page 48 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 5 Detecting Heater Burnouts 4 ch
56. bnormal current detection delay can be set to output an alarm only when the number of consecutive errors exceeds the set number of detec tions If the number of detections is set to 0 an alarm will be output immediately when an error is detected 52 Setting Operation at Error 4 and 8 channel Models Section 4 14 Use the follovving example as a reference vvhen setting the number of detec tions Example Setting the Abnormal Current Detection Delay to 3 Detections 1 2 3 1 Setthe abnormal current detection delay to 3 detections 0000 0003 hex with a Variable Area Write command 2 Whenthe setting is written it is stored and becomes effective the next time that the power is turned ON 3 An alarm is not output even if heater burnout is detected 3 times consecu tively A heater burnout will be detected and the alarm will be output only when the heater burnout is detected consecutively 4 times or more Error value detected 4 consecutive times gt Alarm is output Heater burnout detection value Error value Detected detected once 3 times Alarm is not output Heater burnout detection value Note 1 The image shows a current waveform 2 During optimum cycle control or soft start optimum cycle control the op eration of the abnormal current detection delay is as follows Output ON OFF control and Current error detection are performed each half cycle so the errors are detected and counted each half
57. cy cle During three phase optimum cycle control the operation of the abnormal current detection delay is as follows Output ON OFF control and Current error detection are performed ev ery two cycles so the errors are detected and counted once every two cycles 4 14 Setting Operation at Error 4 and 8 channel Models This setting can select the operation of the Controller after one of the following errors has occurred Zero cross error See note 2 Heater burnout detection e Heater overcurrent detection 53 Monitoring the Effective Current Section 4 15 e SSR short circuit detection Variable type Setting range 1 Defa 83 C3 Operation at Error Continue with error clear 1 Continue vvithout error clear 2 Stop The follovving table shovvs the error clearing methods vvhen an error is detected Setting 1 Operation at Error clearing method Error Continue vvith 1 Continues VVhen the Controller returns to normal error clear status the error is cleared i e the sta tus flag ERROR indicator and alarm output are turned OFF Continue vvith 1 Continues The error is not cleared even vvhen the out error clear Controller returns to normal status Restore normal status and then execute a Start command vvith the Operation Command Affected chan 1 The error is not cleared and operation nel stops See remains stopped even when the Con note 1 troller returns to normal status Restore norma
58. e G3ZA Use a flat blade screvvdriver to pull dovvn the DIN Track mounting hook 1 and Q then pull out on the bottom of the G3ZA 2 pa Jz 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 and then pull down on the End Plate Tighten the screw on the End Plate to secure it READY TD ANY 24 18 fo O O O O NS o 4 6 Note Always mount one End Plate on each side of the G3ZA Installation Section 2 1 Mounting the G3ZA vvith Screvvs Mounting Hole Dimensions Unit mm Two 4 2 dia or M4 holes 84 40 3 o G p Ls Q 10 Hov To Use the Terminals Section 2 2 2 2 Hov To Use the Terminals Trigger output Trigger output z 12 V 21 mA 12 V 21 mA Der m 12 v Y Y 19 20 2 29 24 CHI CH2 COM CH CH4 COM CH8 COM Trigger output Trigger output Trigger output _ Trigger output 4 12 21 aa oe oe 4 12V 21mA 117 12V 21mA 1 Trigger i Trigger Trigger Trigger G3ZA 8AI 103 FLK UTU G3ZA 4H 103 FLK UTU o pur Sh o Q up
59. event false overcur rent detection due to noise Setting Procedure Make the following settings to detect heater overcurrent If these settings are not made heater overcurrent may not be detected properly Heater Overcurrent Detection Timing e Wire the CTs e Calculate the detection value that is appropriate for the application and set the heater overcurrent detection value e Set the abnormal current detection delay as described in 4 13 Setting the Abnormal Current Detection Delay 4 and 8 channel Models Vp on page 52 Load current SSR output Hysteresis Heater overcurrent detection value G3ZA output G3ZA alarm Note iy 2 Note This example shovvs operation vvith the follovving settings Abnormal current detection delay O immediate alarm Operation at error 0 Continue vvith error clear e Heater overcurrent is detected at point 1 in the diagram above The detec tion condition is as follovvs Heater ON current see note 1 gt Heater overcurrent detection value The heater overcurrent alarm is cleared at point 2 in the diagram above The clearing condition is as follovvs Heater ON current see note 1 x Heater overcurrent detection value Hysteresis see note 2 1 The heater ON current is the peak load current that flovvs vvhen the G3ZA s output is ON 2 The hysteresis setting applies a dead zone betvveen the detection condi tion and clearing condition which prevent
60. f 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 vvas completed normally Example The folloving command changes the manipulated variable for channel 1 to 50 set value 8 digits Command STX 010000102C10000000001000001 FAJETXIIBCCGI Response STX 01000001020000 ETX BCC Example The following command changes the manipulated variable for channel 1 to 50 set value 4 digits Command STX 01000010281000000000101F4 ETX BCC Response STX 01000001020000 ET X BCC 23 2 o E E o O CompoWay F o o 9 c E E O O gom gt o o E O O e Variable Area Read Section 3 5 3 5 Variable Area Read This command reads set values Command Variable Bit type Read start address position No of elements 4 2 4 Note ln the G3ZA the bit position is not used Set it to 00 Response uru code Set values No of 2 x8or4 B Variable Type and Read Start Address Refer to the Parameter List on page 66 in the Appendix B Number of Elements Specify the number of elements for which the set value is to be read Up to 25 0019H elements can be specified Read data length No of
61. l block For details refer to 2 2 Hov To Use the Terminals on page 11 2 Z gt O Features Section 1 1 o gt O SECTION 2 Preparations This section describes preparations for using the G3ZA including installation and vviring Zel qusr llutomu du doe c he hw e It RE RU Re e li 8 2 2 How To Use the Terminals sellem si ala sabi 11 02 pur LE o Bu Q Installation Section 2 1 2 1 Installation Dimensions Unit mm 91 o O pruri x SoS Ed uu E G 3 1 Q 0 7x5 35 b zl o l gt is 2127 s t UN L 111 max 110 typical Mounting to DIN Rail DIN Rail Products VVhen installing a DIN Rail inside a control panel secure the DIN Rail vvith screvvs in at least three locations e DIN Rail 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 8 o BY E 1 4 o Removing th
62. l status and then execute a Start command vvith the Operation Com mand Note 1 Operation vvill stop for all channels if a zero cross error occurs 2 A zero cross error occurs when there is an error in the load power supply voltage frequency or vvaveform Refer to SECTION 5 Troubleshooting tor details Example Setting the Operation at Error Setting to Continue vvithout Error Clear 1 2 3 1 Set the Operation at Error to 1 with a Variable Area Write command 2 VVhen the setting is vvritten it is stored and becomes effective the next time that the povver is turned ON 4 15 Monitoring the Effective Current The G3ZA can monitor the current read by the CT sensor as the effective cur rent The follovving formula is used to calculate the effective current that is actually displayed Effective current A CT Current A v 100 Control variable Note 1 The display shows the current in 0 1 A units 2 The CT current is the heater ON current the current flowing through the heater when the control output is ON The effective current is monitored with the Variable Area Read command Variable type Parameter name Monitor range Default 8E CE CT1 to CT4 effective current 0 0 to 165 0 A or See note Note The setting range is determined by the Current Monitor Selector setting For details refer to 4 3 Selecting the CT 4 channel Models Only VE on page 33 54 Monitoring the Effective Current
63. le type Parametr name Setting Curentrange Unis Current Monitor Selector Detection values of 0 to 165 A or 96 max can be detected but set the detec tion value appropriate for the current range If the detection value is set above the current range errors will not be detected Refer to 4 3 Selecting the CT 4 channel Models Only on page 33 for details on detection values Example Setting the CT1 Heater Burnout Detection Value to 20 A 1 Set the CT1 heater burnout detection value to 20 with a Variable Area Write command 2 Thecurrentis detected in CT1 and heater burnout is detected with the tim ing shown in the diagram on the preceding page 3 Once the CT1 heater burnout detection value is written the setting is saved and will also be effective the next time that the power is turned ON Turn ON the heater power supply at the same time or before turning ON the G3ZA power supply 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 actual conditions using the CT1 to CT4 Heater ON currents 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 as follows For a Current Monitor Selector setting of 0 0 to 50 A Heaters of less than 10 A No
64. n RC SRC E EOM B NUR 2 2 2 2 4 Operating status Meaning 000 oe The control output is ON for one or more channels 01 The Controller is stopped or a zero cross error has occurred during operation An OR of status bits 0 to 7 for all channels Refer to the Status in the Status Lists on page 65 in the Appendix To read the status of individual channels use the Variable Area Read com mand for the desired channel Refer to 3 5 Variable Area Read for details Response code Errorname 1 1001 Command length too long The command is too long 2203 Operation error An error occurred in nonvola tile memory 0000 Normal end Processing vvas completed normally Example Command STX 010000601 ETX BCC Response STX 010000060100000100 ETX BCC 27 o 9 c 5 E CompoWay F o o 9 c E E O O gom gt o o E O o e Echo back Test Section 3 9 3 9 Echo back Test This command performs an echo back test Command Test Data Response nn code Test Data Tel Tr 0 to 200 1 Test Data The test data can contain up to 200 00C8H bytes Set the test data vvithin the follovving ranges according to the communications data length setting Data length Test data ASCII 20H to 7EH ASCII 20H to 7EH or A1H to FEH 2 Response Codes Response code Errorname Cause 1 10017
65. nd error The specified FINS command could not be executed 8 10 Parity error The OR of 1 bits in received data does not match the set 12 ting for the communications parity Stop bitis 0 12 Overrun error The next data was received when the reception data buffer 13 vvas full calculated BCC value is different from the received BCC value Sub address error The sub address is not included Frame length error The received frame exceeds the required number of bytes o Normal completion Command processing was completed normally mM End Code Example 14 Format error The FINS mini command text contains characters other 1 than O to 9 and A to F For details on the echoback test refer to 3 9 Echo back Test on page 28 SID and the FINS mini command text are not included When the Sub address SID and FINS mini Command Text Are Not Included e Command STX UnitNo ETX BCC ka ZN a e Response S Unit No Subaddress End code ETX BCC TX Se ee ee The sub address is 00 and the end code is 16 sub address error 20 FINS mini Text Section 3 3 3 3 FINS mini Text The FINS mini command and response text is the text that form the command and response communications The structure of FINS command and response text is shown below Command Text An MRC main request code and SRC sub request code follovved by the various required data is transferred in the
66. nd soft decrease times 49 soft start optimum cycle control 2 31 specifications 61 SRC 21 SSR 2 calculating the SSR short circuit detection value 47 detecting SSR short circuits 45 drive selection 2 starting operation 25 startup operation 64 status lists 65 stop bits 18 stopping operation 25 switches SW1 4 SW2 4 switching MV threshold for channels 32 T three phase optimum cycle control 2 32 trigger outputs 13 troubleshooting 57 handling problems 59 Index V V2 Version 2 xiii variable type 21 W wiring example 14 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 02 Revision code The follovving 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 02 February 2007 1 Made additions and changes for upgraded version V2 of the Controller 77 78 Revision History Cat No Z200 E1 02 OMRON OMRON Corporation Industrial Automation Company Control Devices Division H Q Analog Controller Division Shiokoji Horikawa Shimogyo ku Kyoto 600 8530 Japan Tel 81 75 344 7080 Fax 81 75 344 7189 Regional Headquarters OMRON EUROPE B V Wegalaan 67 69 NL 2132 JD Hoofddorp The Netherlands Tel 31 2356 81 300 Fax 31 2356 81 388 OMRON ELECTRONI
67. ns 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 Hovvever some specifications of the producis may be changed vvithout any notice VVhen in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult vvith your OMRON representative at any time to confirm actual specifications of purchased products DIMENSIONS AND VVEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes even when tolerances are shovvn PERFORMANCE DATA Periormance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty It may represent the result of OMRON s test conditions and the users must c
68. o H 00000008 1 to 8 CH8 source channel H 00000001 to H 00000008 1 to 8 CH1 heater burnout detec H 00000000 to H 00000032 0 to 50 tion value CH2 heater burnout detec H 00000000 to H 00000032 0 to 50 tion value CH3 heater burnout detec H 00000000 to H 00000032 0 to 50 tion value 1 a Xa e a a Sa CH4 heater burnout detec tion value CH1 SSR short circuit detection value CH2 SSR short circuit detection value CH3 SSR short circuit detection value CH4 SSR short circuit detection value H 00000000 to H 00000032 0 to 50 H 00000000 to H 00000032 0 to 50 H 00000000 to H 00000032 0 to 50 50 H 00000000 to H 00000032 0 to 50 50 H 00000000 to H 00000032 0 to 50 50 H 00000000 to H 00000032 0 to 50 50 H 00000000 to H 00000032 0 to 50 50 H 00000000 to H 00000032 0 to 50 50 H 00000000 to H 00000032 0 to 50 50 002C Offset control H 00000000 Disabled Enabled H 00000001 Enabled CH1 heater overcurrent detection value CH2 heater overcurrent detection value CH3 heater overcurrent detection value CH4 heater overcurrent detection value lt 67 Appendix type Opera C3 83 Data length H 00000000 7 i tion 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
69. orrelate 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 PANS 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 Caution Indicates non specific general cautions warnings and dangers Mandatory Ca
70. percentage input is selected the maximum current value measur able with the CT is measured as 100 For example the following percentages will be displayed when a 30 A current is flowing in the heater e Ifa E54 CT1 0 to 50 A CT is being used 60 is displayed e Ifa G3ZA CT150L 0 to 150 A CT is being used 20 is displayed Similarly the heater burnout detection heater overcurrent detection and SSR short circuit detection values are also detected as percentages Setting Procedure The following examples show how to select a suitable CT and set the Current Monitor Selector e Select the CT e Detecting current in the O to 50 A range Select a CT for O to 50 A detection E54 CT1 or E54 CT3 Detecting current in the O to 150 A range Select a CT for O to 150 A detection G3ZA CT150L e Set the Current Monitor Selector to match the CT selected above e If a CT for O to 50 A detection is selected Set the Current Monitor Selector to 0 0 to 50 A or 2 096 to 10092 e f a CT for O to 150 A detection is selected Setthe Current Monitor Selector to 1 0 to 150 A or 2 096 to 10092 Example Setting the Current Monitor Selector to the 0 to 150 A Range 1 2 3 1 Setthe Current Monitor Selector to 1 vvith a Variable Area VVrite command 2 After setting the Current Monitor Selector enable the nevv setting by exe cuting a softvvare reset vvith an Operation Command or turning the povver OFF and then ON
71. rmal current Burnout current 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 2 3 A Detection will not be stable if the difference is less than 3 A For a Current Monitor Selector setting of 1 0 to 150 A Heaters of less than 10 A Normal current Burnout current 26 A Detection will not be stable if the difference is less than 6 A Heaters of 10 A or more Normal current Burnout current 2 9 A Detection will not be stable if the difference is less than 9 A For a Current Monitor Selector setting of 2 0 to 100 Heaters of less than 10 A Normal current Burnout current gt 496 Detection will not be stable if the difference is less than 4 Heaters of 10 A or more Normal current Burnout current gt 6 Detection vvill not be stable if the difference is less than 6 If the conditions for stable detection cannot be met increase the number of turns of the heater wire through the current transformer and increase the detection value The monitored heater ON current value is proportional to the number of turns Detecting Heater Burnouts 4 channel Models Only Section 4 5 Operation after Error Detection Calculating the Heater Burnout Detection Value Application Examples 1 Single phase Heaters Example PP e Each channel s status be read individually to check it for heater burn out de
72. rol can be selected to reduce inrush power when starting Control method Application example SSR for single phase heater with Optimum cycle control Single phase zero cross function heaters SSR for single phase heater without Soft start optimum cycle Single phase zero cross function control halogen heaters SSR for three phase heater with zero cross function Three phase optimum cycle Three phase control heaters Refer to 4 2 Selecting the SSR Control Method 4 or 8 channel Models for details on selecting the SSR and the control method e The timing of turning ON the control outputs for G3ZA channels can be offset to help prevent control outputs from being turned ON at the same time e The manipulated variable can be calculated for one channel and the cal culated value can be output for another channel The effective current flowing to a heater can be monitored to one decimal place e The current flowing through the heater can be monitored to detect heater burnouts heater overcurrents and SSR short circuits This function can be used for SSRs with ratings of up to 150 A Between one and four outputs can be connected to 4 channel Controllers and between one and eight outputs can be connected to 8 channel Con trollers An open collector output terminal can be used to inform the host of errors without using communications RS 485 communications can be used to set and operate the G3ZA reducing the amount
73. rrent flowing through a CT for O to 150 A detection as shown in the table above 4 4 Allocating CTs 4 channel Models Only The CT allocation settings specify which currents are measured for the out puts of channels 1 to 4 When detecting abnormal current in a single phase heater leave these settings at their default settings A heater burnout can be detected in a three phase heater by allocating two CTs to one output Variable type Parameter name Setting range Defaut 83 C3 CT1 Allocation 0 Disabled CT2 All ti 1 Channel 1 7 57 CT3 Allocation 3 Channel 3 CT4 Allocation 4 Channel 4 Example Settings for Detection of Three phase Heater Burnout The following measurements can be made when the CTs are connected as shown in the following diagram CT1 Allocation is set to 1 channel 1 CT2 Allocation is set to 1 channel 1 CT3 Allocation is set to 2 channel 2 and CT4 Allocation is set to 2 channel 2 e The channel 1 outputs are synchronized and the current inputs to CT1 and CT2 are measured e The channel 2 outputs are synchronized and the current inputs to CT3 and CT4 are measured In this example all of the CT inputs 4 inputs are allocated to channels 1 and 2 so a three phase heater burnout cannot be detected in channels 3 and 4 35 Detecting Heater Burnouts 4 channel Models Only Section 4 5 Loads Connected to Channel 1 17 3 A CT1 Measures the current of channel 1 Load such
74. s ON OFF chattering of the alarm The same hysteresis setting is used for the heater burnout detec 43 Detecting Heater Overcurrent 4 channel Models Only Section 4 6 tion heater overcurrent detection and SSR short circuit detection func tions Variable type Setting range Default 81 C1 Channel 1 to 4 heater overcur 0 to 50 A See note 50 Disabled rent detection value CT 1 to 4 heater overcurrent O to 165 A or 96 165 Dis detection value IZ See note abled Tio 10 A or Note If set to 50 A or 165 A in the models heater overcurrent will not be detected If set to O detection is forced Use these settings to confirm opera tion during installation Setting Ranges Supported in the Models 0 to 165 A or 96 The current range and units are determined by the Current Monitor Selector setting Variable type Parameiername J Setting Current range Unts Current Monitor Selector Note Detection values of O to 165 A or max can be detected but set the detec tion value appropriate for the current range If the detection value is set above the current range errors will not be detected Refer to 4 3 Selecting the CT 4 channel Models Only on page 33 for details on detection values Example Setting the CT1 Heater Overcurrent Detection Value to 20 A 1 Set the CT1 heater overcurrent detection value to 20 vvith a Variable Area Write command 2 The current is detected in
75. se e Use SSRs for single phase heaters with zero cross function for optimum cycle control ON for 1 5 half cycles 20 mo MV 20 Note The image shows a current waveform with an MV of 20 Soft start Optimum Soft start optimum cycle control is a control method that combines phase Cycle Control control and optimum cycle control e By smoothly switching between phase control and optimum cycle control it is possible to control the output and suppress the inrush current even with loads with characteristics like halogen heaters e Use SSRs for single phase heaters without zero cross function for soft start optimum cycle control The control method is switched at the Switching MV threshold 31 Selecting the SSR Control Method 4 or 8 channel Models Section 4 2 e Set the soft increase and soft decrease times to control the output For details on these settings refer to 4 9 Setting the Soft Increase and Soft Decrease Times 4 and 8 channel Models on page 49 Current detection is not performed during phase control The current val ues heater ON current heater OFF current and actual current vvill be 0 A and the current alarms heater burnout detection heater overcurrent detection and SSR short circuit detection vvill alvvays be OFF Setting the Switching MV The Switching MV Threshold is used in soft start optimum cycle control By Threshold setting the Switching MV Threshold the control method can be
76. setting is saved and will also be effective the next time that the power is turned ON The actual current flowing in the heater may not be the same as the heater s rated current Check the heater current under actual conditions using the CT1 to CT4 Heater OFF currents It is possible to select the Controller s operation after an SSR short circuit is detected For details on selecting operation after an error refer to 4 14 Setting Opera tion at Error 4 and 8 channel Models on page 53 When an SSR short circuit has been detected it is possible that the SSR has failed in the always ON state so that it cannot control operation Consider installing a failsafe circuit to cut off the power supply to the heater Set an SSR short circuit detection value appropriate for the customer s appli cation As a rule set a detection value that is at least two times the normal heater OFF current Proper detection may not be possible if a value that is less than two times the normal heater OFF current is set In additions short circuit detection value is set to O A so set a detection value of at least 1 A 47 Detecting Communications Timeouts 4 and 8 channel Models Section 4 8 4 8 Detecting Communications Timeouts 4 and 8 channel Models Operation can be stopped if communications cannot be performed normally for longer than the communications timeout time In addition to stopping oper ation the MV after communications error setting can
77. switched to phase control below the set value and optimum cycle control above the set value The default value is set to 20 type Switching MV threshold for 0 0 to 100 0 channels 1 to 8 Example Performing Soft start Optimum Cycle Control in Channel 1 with a Switching MV Threshold of 40 0 an MV of 100 0 and a Soft Increase Time of 20s 1 2 3 1 Set the Channel 1 Switching MV Threshold to 40 0 and the Channel 1 MV to 100 0 with a Variable Area Write command 2 The channel 1 Soft Increase time is kept at its default value so it is not nec essary to set this value 3 Once the Channel 1 Switching MV Threshold is written the setting is saved and will also be effective the next time that the power is turned ON MV 100 0 Soft increase time 20 s ARRARARAAR VVVVVVV VV V Phase control Optimum cycle control Note image shovvs a current vvaveform Three phase e Three phase optimum cycle control is a control method in which the out Optimum Cycle puts are turned ON OFF every tvvo cycles Control e Turning the outputs ON OFF every two cycles allows optimum cycle con trol to be used with three phase heaters e Use SSRs for three phase heaters with zero cross function for three phase optimum cycle control 32 Selecting the CT 4 channel Models Only Section 4 3 The follovving diagram shovvs an example connection to a three phase heater 1 Phase R 2 Phase S Y
78. t If any of the settings are incorrect or if any are unknown use the following method for communications 1 Set SW2 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 turn e Unless the OCC indicator is lit and the control variable is set ON to 0 0 then there is a problem in the wiring Check the wir ing of the control outputs f the ERROR indicator is lit or flashing refer to the correc tions given in the Error Table on page 58 Returning settings to e Initialize the settings with an Operation Command All of the default values settings can be returned to their default values Refer to the Status Lists on page 65 in the Appendix for default values Current cannot be Check to see if the CT setting in the G3ZA matches the CT detected correctly that is connected Refer to 4 3 Selecting the CT 4 channel Models Only IPA An output is not sta Je Check to see if the SSR setting in the G3ZA matches the ble SSR that is connected Refer to 4 2 Selecting the SSR Con trol Method 4 or 8 channel Models YI Troubleshooting 59 Handling Problems Section 5 2
79. t detection delay as described in 4 13 Setting the Abnormal Current Detection Delay 4 and 8 channel Models Wp on page 52 45 Detecting SSR Short Circuits 4 channel Models Only Section 4 7 SSR Short Circuit Detection Timing Hysteresis Load current SSR short circuit SSR outpu N N detection value IKA AA MAT G3ZA output br EE A G3ZA alarm Im 46 A A Note This example shows operation with the following settings Abnormal current detection delay 0 immediate alarm Operation at error 0 Continue with error clear An SSR short circuit is detected at point 1 in the diagram above The detection condition is as follows Heater OFF current see note 1 x SSR short circuit detection value The heater short circuit alarm is cleared at point 2 in the diagram above The clearing condition is as follows Heater OFF current see note 1 lt SSR short circuit detection value Hys teresis See note 2 Note 1 The heater OFF current is the peak load current that flows when the G3ZA s output is OFF 2 The hysteresis setting applies a dead zone between the detection condi tion and clearing condition which prevents ON OFF chattering of the alarm The same hysteresis setting is used for the heater burnout detec tion heater overcurrent detection and SSR short circuit detection func tions Variable type Parameter name Setting range Defaut 81 C1 Channel 1 to 4 SSR short cir
80. t spacing Example When a current of 10 A 100 of the control capacity flows in a G3PA 210B VD SSR a mini mum spacing of 20 mm is required between the G3ZA Controller and the SSR Hov To Use the Terminals Section 2 2 Example Connection vvith the EJ1 EJ1L TC4 or EJ1L TC2 EJ1C EDU Md I m lan lan sil gl ie ge lum a l ol oli c l Be Lace ES ea Lee See e ee BS 2429 1165 olan sl jep Cie CHO CHES eH KG AIS SAEN d SAEY ES 00600 008605 00090 IGE 99990 ese OC G D G3ZA G3ZA EJ1 e go l aS mni
81. tection It is possible to select the Controller s operation after a heater burnout is detected For details on selecting operation after an error refer to 4 14 Setting Opera tion at Error 4 and 8 channel Models on page 53 Use the following formula to calculate the heater burnout detection value Normal current Burnout current 2 Heater burnout detection value Note The result is an integer display When two or more heaters are connected through the current transformer set the burnout detection value to detect burnouts on the heater with the smallest current If the heater currents are all the same set the value for burnout of one wire Example 1 Using One 1 kW Heater 200 V AC Normal operation Burnout occurred AC line AC line 200 V VVire break To CT input To CT input If the normal heater current is 5 A and the burnout heater current is 0 A the heater burnout detection value is calculated as follovvs Normal current Burnout current 2 Heater burnout detection value 5 0 5 2 5 o 2 A 39 Detecting Heater Burnouts 4 channel Models Only Section 4 5 Example 2 Using Three 1 kVV Heaters 200 V AC Normal operation Burnout occurred 15 A AC line 10 A AC line To CT input To CT input If the normal heater current is 15 A and the burnout heater current is 10 A the heater burnout detection value is calculated as follovvs Normal current
82. time to 20 seconds 1 2 3 1 Set communications timeout time 2 to 20 with a Variable Area Write com mand 2 After setting communications timeout time 2 enable the new setting by ex ecuting a software reset with an Operation Command or turning the power OFF and then ON again 48 Setting the Soft Increase and Soft Decrease Times 4 and 8 channel Models Section 4 9 Setting the MV after VVhen a communications timeout has been detected the preset MV after Communications communications error value can be output at each channel Error Use a Variable Area VVrite command to set the Channel 1 to 8 MV after com munications error settings Variable type Parameter name Selling range Default 85 C5 Channel 1 to 8 MV after com 0 0 to 100 096 munications error Note The Soft Increase and Soft Decrease times are applied to the MV after com munications error outputs 4 9 Setting the Soft Increase and Soft Decrease Times 4 and 8 channel Models The Soft Increase Time and Soft Decrease Time can be set to smoothly change the output level The Soft Increase and Soft Decrease times can be set for each channel Also either one of the times can be set and used alone Variable type Parameter name Setting range Default 85 C5 Channel 1 to 8 Soft Increase 10 0 to 99 9 s 20 0 See Time note Channel 1 to 8 Soft Decrease 0 0 to 99 9 s 0 0 See Time ne Note 1 If the Soft Increase or Soft Decrease Time
83. tputs Terminals 13 to 18 19 20 21 22 23 24 Section 2 2 Cable Diagram Reference Use shielded twisted pair cables AWG16 to AWG22 AWG22 Cross sectional area of core 0 326 mm min e Terminators must be connected at both ends of the transmission line including the PLC Use terminators with a combined resistance of at least 54 Q e Alarms are output on terminals 9 and 11 The alarm output specifications are as follows Maximum load voltage 30 VDC Maximum load current 50 mA o E im o Q 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 E B Maximum load current 50 mA e The C Grid SL connector for Molex Incorporated can be used for the con nector Model number 51030 0630 C Grid SL Housing e 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 13 Hov To Use the Terminals Current Transformer Inputs 4 channel Models Oniy Terminals 19 to 24 131415161718 24 19 20 21 22 13 14 15 o p Ls
84. trol Method 4 or 8 channel Models The follovving kinds of SSRs can be selected to control operation SSRs for single phase heaters vvith zero cross function SSRs for single phase heaters vvithout zero cross function SSRs for three phase heaters vvith zero cross function The default setting is for SSRs for single phase heaters vvith zero cross func tion Select the appropriate control method for the application being used Variable Parameter Setting range Example type name application SSR Selector 10 SSH for single phase heater Single phase 0 with zero cross function heater Optimum cycle control SSR for single phase heater 1 Single phase without zero cross function halogen Soft start optimum cycle con heater trol SSR for three phase heater Three phase with zero cross function heater Three phase optimum cycle control Example Setting the SSR Selector to an SSR for Single phase Heaters with out Zero cross Function 1 2 3 1 Setthe SSH Selector to 1 with a Variable Area Write command 2 After setting the SSH Selector enable the new setting by executing a soft ware reset with an Operation Command or turning the power OFF and then ON again Optimum Cycle Optimum cycle control is a control method in which the outputs are turned Control ON OFF each half cycle e Turning the outputs ON OFF each half cycle can provide high speed response and high precision temperature control while suppressing noi
85. ttribute 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 a ae 2 2 4 10 4 1 Model Number 4 4 channels 8 8 channels HW With current transformer input No current transformer input E Load power supply 100 to 240 V 2 Size The communications buffer size is expressed in 2 byte hexadecimal and read after being converted to 4 byte ASCII The buffer size is 217 bytes D9H 5 o E gt Gc os ai Q 8g 3 Response Code Response code Errorname Cave 1001 Command length too long The command is too long 2203 Operation error An error occurred in nonvola tile memory 0000 Normal end Processing vvas 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 010000503 ETX BCC Response STX 01000005030000G3ZA 4H40300D9 E T X BCC 26 Controller Status Read Section 3 8 3 8 Controller Status Read Command Response 1 Operating Status 2 Related information Note 3 Response Code This service reads the operating status and error status MRC SRC 7 2 2 Operating Related M Response code status informatio
86. urrent H 00000000 to H 0000045 0 to 168 asr 002 GTa heater ON current H 00000000 to 000000 5 01o 165 0 JAor 0010 Tt heater OFF current H 00000000 to 4000000 5 0 t0165 0 Aor t 0011 CTZ heater OFF current H00000000 to 000000 016 16 0 JAor 0012 CTS heater OFF current 00000000 to 000000 016 16 Ja JAor H 00000000 to H 000000A5 0 to 165 0 Jaorsl oua Vemm f SSS GT 81 0000 CH1 manipulated variable Hi00000000 to H 0000388 0 0 to 1000 joo Je 0001 CH2 manipulated variable H 00000000 to 000003 8 0 0 1o 1000 100 0002 CH manipulated variable H 00000000 to 000003 00 to 100 0 00 0003 CH manipulated variable H 00000000 to H 000003E 0 0 to 100 0 00 0004 CHS manipulated variable H 00000000 to H000003E8 0 0 1o 1000 100 0005 CH manipulated variable H 00000000 to H 000003E 0 0 to 100 0 00 0006 manipulated variable H 00000000 to 00000 00 to 100 0 00 0007 JOH manipulated variable H 00000000 to H0O0003E 0 0 1o 100 0 0 H 00000000 to H 00000FA0 0 0 to 400 0 0010 CH1 offset HFFFFFO60 to HOOOOOFAO 400 0 to 4000 100 7 0011 H ofset H FFFFF060 to WOOO00FAO 4000104000 00 7 012 HFFFFFOSO to HOOOOOFAO 400 0 o 4000 Joo 0013 CH ofiset_ HFFFFFO60 to HOOOOOFAO 40040 o 4000 Jo 0 7 0014 CHS ofset HFFFFF060 to WOOO00FAO 4
87. ution Vill M 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 Loose screws may occasionally cause fire resulting in minor or moderate injury or d
88. vely 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 AN 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 given xvii xviii SECTION 1 Overvievv Oo gt O This section introduces the G3ZA and its features 1 1 Features WEM Ad 2 Features Section 1 1 1 1 Features SSR Drive Selection Main Functions Offset Control Manipulated Value Calculations Effective Current Monitor Error Detection 4 channel Controllers Only Number of Outputs Connected Alarm Output Installation The G3ZA is a Multi channel Power Controller with externally connected SSRs It can receive manipulated variables from a PLC EJ1 Temperature Controller or other host via RS 485 communications and control heater power with high precision via the SSRs The control method used to drive the SSRs can be selected to enable using the G3ZA for a variety of applications For example to use a single phase halogen heater soft start optimum cycle cont

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