Omron G3ZA User Manual
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Omron G3ZA User Manual

Omron G3ZA User Manual

Multi-channel power controller
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G3ZA
Multi-channel
Power Controller
User's Manual
Cat. No. Z200-E1-01

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Summary of Contents for Omron G3ZA

  • Page 1 G3ZA Multi-channel Power Controller User's Manual Cat. No. Z200-E1-01...
  • Page 2 G3ZA Multi-channel Power Controller User’s Manual Produced April 2004...
  • Page 4 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.
  • Page 5 WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. In no event shall the responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted. IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS...
  • Page 6 Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of OMRON's test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON Warranty and Limitations of Liability.
  • Page 7 Safety Precautions ■ 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.
  • Page 8 ■ Precautions 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. CAUTION Do not allow pieces of metal, wire clippings, or fine metallic chips or filings from installation to enter the product.
  • Page 9 (5) Minimum mounting distance of G3ZA is 10 mm. When mounting the G3ZA near the SSRs, mount the G3ZA so as to not interfere with the heat dissipation of the SSR. (6) Use the specified size of insulated type crimp terminals (M3, width: 5.8 mm max.) for wiring and attach insulative sleeves.

  • Page 10: Table Of Contents

    SECTION 3 Using the G3ZA........
  • Page 12 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.

  • Page 14: Overview

    Overview This section introduces the G3ZA and its features. Features ............

  • Page 15: Features

    1/5th ON (20%) Manipulated variable: 20% Offset Control • The timing of turning ON the control outputs for G3ZA channels can be offset. Manipulated Value • The manipulated variable can be calculated for one channel and the cal- Calculations culated value can be output for another channel.
  • Page 16 Load power supply Load (e.g., heater) Note Connect a power supply with the same phase as the SSRs to the load power supply input terminals on the G3ZA. Component Names and Functions READY SD/RD RE ADY SD/ RD...
  • Page 17 Features Section 1-1...

  • Page 18: Preparations

    Preparations This section describes preparations for using the G3ZA, including installation and wiring. Installation........... .

  • Page 19: Installation

    Installation Section 2-1 Installation Dimensions (Unit: mm) 7×5=35 READY SD/RD SW 1 SW 2 ERROR 111 max. (110 typical) 35±0.3 45 max. Mounting to DIN Track DIN Track Products When installing a DIN Track inside a control panel, secure the DIN Track with screws in at least three locations.
  • Page 20 G3ZA (2). 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.
  • Page 21 Installation Section 2-1 Mounting the G3ZA with Screws Mounting Hole Dimensions (Unit: mm) Two, 4.2 dia. or M4 holes 84 ±0.3 35 ±0.3...

  • Page 22: How To Use The Terminals

    Trigger output output output output 12 V, 12 V, 12 V, 12 V, 21 mA 21 mA 21 mA 21 mA G3ZA-4H@03-FLK-UTU G3ZA-8A@03-FLK-UTU READY SD/RD SW 1 SW 2 ERROR Alarm output 30 V, 50 mA RS-485 − RS-485 −...
  • Page 23 Controller Power Supply In the wiring diagrams, the area within the lines indicating terminals numbers Terminals is inside the G3ZA and the area outside the lines are outside the G3ZA. • Connect terminals 1 and 2 as follows: RE ADY...
  • Page 24 ERRO R • The C-Grid SL connector for Molex Incorporated can be used for the con- nector. Model number: 51030-6030 C-Grid SL Housing Model number: 52109-0660 C-Grid SL Housing/Press-fit Type • The G3ZA-A300C Cable from OMRON also can be used.
  • Page 25 RE ADY SD/ RD SW 1 SW 2 ERRO R There are four current transformer inputs that can be used. Use the E54-CT1 or the E54-CT3 from OMRON as the current transform- Wiring Example (G3ZA-4H@03-FLK- Heater UTU) RE ADY SD/RD...

  • Page 26: Using The G3Za

    SECTION 3 Using the G3ZA This section describes application information, including settings, communications, and controlling operation. Communications Settings ........

  • Page 27: Communications Settings

    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 SW2 on the front of the G3ZA. Unit number 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 Baud rate (kbit/s) 19.2 38.4 57.6...

  • Page 28: Compoway/F Frame Structure

    This number specifies the destination. This is the same as the communications unit number set on SW1 and SW2. Subaddress and SID These are not used by the G3ZA. Set them to all zeros. FINS-mini The text of the command. Refer to 3-6 Operation Command command text on page 19 for details.
  • Page 29 CompoWay/F Frame Structure Section 3-2 End Codes (CompoWay/F Communications) End code Name Description “0F” FINS command Could not execute the specified FINS command. error “10” Parity error Sum of bits that are “1” in received data does not agree with the set communications parity value. “11”...

  • Page 30: Fins-Mini Text

    "02" ■ Variable Type and Write Start Address Refer to the Parameter Tables on page 38 in the Appendix. 1.FINS: Short for Factory Interface Network Service. The FINS protocol is used for message communications between controllers on OMRON FA networks.

  • Page 31: Variable Area Read

    Variable Area Read Section 3-5 ■ Number of Elements Specify the number of elements for which the set value is to be changed. Up to 8 elements can be specified. ■ Response Code Response code Error name Cause “1002” Command length too short The command is too short.

  • Page 32: Operation Command

    Operation Command Section 3-6 ■ Response Code Response code Error name 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.

  • Page 33: Controller Attribute Read

    24. “06” Software reset “00” Performs the same processing as when the G3ZA is turned ON. “0B” 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.

  • Page 34: Controller Status Read

    Controller Status Read Section 3-8 1. Model Number – Number Code Meaning “4” 4 channels “8” 8 channels “H” With current transformer input “A” No current transformer input “2” Load power supply: 100 to 240 V “4” Load power supply: 400 to 480 V “03”...

  • Page 35: Echo-Back Test

    Echo-back Test Section 3-9 3. Response Code Response code Error name Cause “1001” Command length too long The command is too long. “2203” Operation error An error occurred in nonvola- tile memory. “0000” Normal end Processing was completed normally. Example: Command: [STX]010000601[ETX][BCC] Response: [STX]010000060100000100[ETX][BCC] Echo-back Test...

  • Page 36: Functions

    SECTION 4 Functions This section describes the functions of the G3ZA so that these functions can be used effectively according to the application. Changing the Manipulated Variable ....... .

  • Page 37: Changing The Manipulated Variable

    Changing the Manipulated Variable Section 4-1 Changing the Manipulated Variable The Variable Area Write command is used to change the manipulated vari- able. The manipulated variable is 0.0% by default when the power supplied is turned ON. This value can be changed to another value by using the Manipu- lated Variable Save operation command.

  • Page 38: Offsetting Control Output On Timing

    Offsetting Control Output ON Timing Section 4-2 Offsetting Control Output ON Timing The ON timing of control outputs for all of the channels can be adjusted to reduce overlapping with each other. Set the Offset Control to perform this. (Offset Control is enabled by default.) Disabled (No Offset) In the following diagram, the ON timing overlaps between the channels.

  • Page 39: Detecting Heater Burnout (4-Channel Models Only)

    Operating Conditions • Turn ON the power supply to the heater either simultaneously with or before the power supply to the G3ZA. False detection will occur if the heater power supply is turned ON after the G3ZA power supply. • The actual current flowing in the heater may not be the same as the heater's rated current.
  • Page 40 Detecting Heater Burnout (4-channel Models Only) Section 4-4 Example: • Heater burnout detection status can be confirmed by reading the status for individual channels. Calculating the Detection Current for Heater Burnout Use the following formula to calculate the detection current. Normal current + Burnout current Set value = When two or more heaters are connected through the current transformer, set...

  • Page 41: Detecting Heater Overcurrent (4-Channel Models Only)

    Detecting Heater Overcurrent (4-channel Models Only) Section 4-5 Detecting Heater Overcurrent (4-channel Models Only) A heater overcurrent is detected by determining if the heater current is above the heater overcurrent detection value when a control output is ON. Heater Overcurrent Detection Timing Heater overcurrent Hysteresis...
  • Page 42 Detecting SSR Short Circuits (4-channel Models Only) Section 4-6 SSR Short-circuit Detection Timing SSR short-circuit Hysteresis detection value Heater OFF current Status (SSR short-circuit bit) ERROR indicator Alarm output Set value Setting range Default Channels 1 to 4: 0 to 50 (See note 1.) 50 (disabled) SSR short-circuit detection value...

  • Page 43: Setting Operation For Errors

    (1) Communications timeouts will not be detected if the time is set to 0. (2) The setting is not valid and communications timeout detection will not start until the G3ZA is reset or until the power supply is cycled. Operation will stop when a communications timeout is detected and the com- munications error bit in status, the ERROR indicator, and the alarm output will turn ON.

  • Page 44: Troubleshooting

    SECTION 5 Troubleshooting This section provides information on problems that may occur during operation and corrective measures for them. Errors............Handling Problems .

  • Page 45: Errors

    • 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.

  • Page 46: Handling Problems

    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.
  • Page 47 Handling Problems Section 5-2...

  • Page 48: Appendix

    Appendix Specifications Specifications Ratings Control power supply voltage 100 to 240 VAC (50/60 Hz) Control power supply voltage range 85 to 264 VAC Power consumption Approx. 5.9 W Load power supply voltage 100 to 240 VAC 400 to 480 VAC Load power supply voltage range Controllers for 100 to 240 VAC: 75 to 264 VAC Controllers for 400 to 480 VAC: 340 to 528 VAC...
  • Page 49 Vibration resistance 98 m/s , 50 Hz Weight Approx. 11.5 g Approx. 50 g Accessories None Connection terminals (2) Plugs (2) Note The maximum continuous current of the G3ZA is 50 A. Dimensions (Unit: mm) E54-CT1 5.8 dia. Two, 3.8 dia.
  • Page 50 Startup Operation It takes about 1 second for the load power supply to stabilize after the power supply to the G3ZA is turned ON. Outputs will not turn ON during this period. A stabilization period of 1 second is also executed after clearing a zero cross error.
  • Page 51 Connecting More Than 16 Controllers If more than 16 G3ZA Controllers are connected, set SW2 to between 8 and B for the 17th Controller on. The relationship between the settings of SW1 and SW2 is shown in the following table.
  • Page 52 Appendix Level Variable Address Parameter Setting/monitor range Default Unit type Opera- C0 (See 0000 Version tion note 1.) 0001 CH1 control variable H’00000000 to H’000003E8 (0.0 to 100.0) 0002 CH2 control variable H’00000000 to H’000003E8 (0.0 to 100.0) 0003 CH3 control variable H’00000000 to H’000003E8 (0.0 to 100.0) 0004 CH4 control variable...
  • Page 53 Appendix Level Variable Address Parameter Setting/monitor range Default Unit type Opera- C1 (See 000A CH3 slope H’00000000 to H’00000FA0 (0.0 to 400.0) 100.0 tion note 1.) 000B CH4 slope H’00000000 to H’00000FA0 (0.0 to 400.0) 100.0 000C CH5 slope H’00000000 to H’00000FA0 (0.0 to 400.0) 100.0 000D CH6 slope...
  • Page 54 (1) If C in the variable type is changed to 8, 4-digit data can be set or monitored. (2) These settings are valid until the G3ZA is reset or the power is turned ON again. (3) Only the channel with the error will stop.
  • Page 55 Appendix...

  • Page 56: Index

    Index table alarm output terminals on 200-V Controllers terminals on 400-V Controllers FINS-mini baud rate command and response text heater burnout calculating the detection current detection communications specifications detection value communications terminals heater overcurrent calculating the detection current communications timeout time detection communications timeouts detection value...
  • Page 57 Index READY indicator resetting software reset SD/RD indicator send standby time set values reading writing slope for manipulated variable calculations source channel for manipulated variable calculations specifications SSR short-circuit calculating the detection current detection detection value SSRs starting operation startup operation stop bits stopping operation switches...

  • Page 58: Revision History

    Revision History A manual revision code appears as a suffix to the catalog number on the front cover of the manual. Cat. No. Z200-E1-01 Revision code The following table outlines the changes made to the manual during each revision. Page numbers refer to the previous version.
  • Page 59 Revision History...
  • Page 60 Buyer indemnifies Omron against all related costs or expenses. rights of another party. 10. Force Majeure. Omron shall not be liable for any delay or failure in delivery 16. Property; Confidentiality. Any intellectual property in the Products is the exclu-...
  • Page 61 For US technical support or other inquiries: 800.556.6766 OMRON CANADA, INC. Milner Avenue Toronto, Ontario M 416.286.6465 OMRON ON-LINE Global - http://www.omron.com USA - http://www.omron.com/oei Canada - http://www.omron.ca Z200-E1-01 6/06 ©2006 OMRON ELECTRONICS LLC Specifications subject to change without notice. Printed in the U.S.A.

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