Omron G3ZA - MANUAL 2 User Manual
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Omron G3ZA - MANUAL 2 User Manual

Omron G3ZA - MANUAL 2 User Manual

Multi-channel power controller
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Cat. No. Z200-E1-02
G3ZA
Multi-channel
Power Controller
USER'S MANUAL

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  • Page 1 Cat. No. Z200-E1-02 G3ZA Multi-channel Power Controller USER’S MANUAL...
  • Page 2 G3ZA Multi-channel Power Controller User’s Manual Produced February 2007...
  • Page 4  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.
  • Page 5 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.
  • Page 6 PERFORMANCE DATA 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.
  • 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.
  • 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 • Locations subject to excessive shocks or vibration (2) Use this product within the rated load and power supply. (3) Ensure that the rated voltage is achieved no longer than 2 s after turning the power ON. (4) Use/store within the rated temperature and humidity ranges. Provide forced-cooling if required.
  • Page 10 • SSR for single-phase heater without zero-cross function • SSR for three-phase heater Do not connect an electromagnetic relay. • When wiring the CT, check the G3ZA's settings and select the correct CT from the following supported CTs. • E54-CT1 •...
  • Page 11 Conventions Used in This Manual ■ 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 Channel Note The EJ1 Series is a series of OMRON Tempera- ture Controllers.
  • Page 12 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 Unit's label or the box label. If there is no unit version number, the Controller's version is 1.0. Box Label Version...

  • Page 14: Table Of Contents

    SECTION 2 Preparations ........
  • Page 15 Appendix ........
  • Page 16 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 17 xviii...

  • Page 18: Overview

    SECTION 1 Overview This section introduces the G3ZA and its features. Features ..........

  • Page 19: Features

    SSRs. SSR Drive Selection 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 control can be selected to reduce inrush power when starting.
  • Page 20 Phase T Load power supply Trigger signal G3ZA ..Control power supply CT (4 channel models only) Load Load Note Connect a power supply with the same phase as the SSRs to the load power supply input terminals on the G3ZA.
  • Page 21 Trigger signal G3ZA Control power supply CT (4 channel models only) Load Note Out of the three phases, connect any one phase to the G3ZA Controller's load power supply input terminals. Component Names and Functions Terminal block READY SD/RD READY SD/RD...
  • Page 22 Alarm Output Outputs an alarm to the output terminal (open collector). For details, refer to Alarm Output with 200 V Rating (Terminals 9 and 11) or Alarm Output with 400 V Rating (Connector Pins A and B) on page 13.
  • Page 23 Features Section 1-1...

  • Page 24: Preparations

    How To Use the Terminals ........

  • Page 25: Installation

    45 max. Mounting to DIN Rail DIN Rail Products When installing a DIN Rail inside a control panel, secure the DIN Rail with screws in at least three locations. • DIN Rail: PFP-50N (50 cm) or PFP-100N (100 cm) • End Plates: PFP-M...
  • Page 26 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 27 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 28: How To Use The Terminals

    How To Use the Terminals Section 2-2 How To Use the Terminals Trigger output Trigger output − − 12 V, 21 mA 12 V, 21 mA Trigger Trigger output output 12 V, 12 V, 21 mA 21 mA Trigger output...
  • Page 29 READY (- ) SD/RD RS-485 ERROR • The connection type can be 1: 1 or 1: N. For 1: N connections, up to 32 Units can be connected, including the host. • The maximum cable length is 500 m total.
  • Page 30 • The C-Grid SL connector for Molex Incorporated can be used for the con- nector. Model number: 51030-0630 C-Grid SL Housing Trigger Outputs • The trigger outputs for channels 1 to 4 are output on terminals 13 to 18. (Terminals 13 to 18) 20 21 22 23 24 − −...
  • Page 31 How To Use the Terminals Section 2-2 Controllers without a Current Transformer Input Circuit (G3ZA-8A@03- FLK-UTU) • The trigger outputs for channels 5 to 8 are output on terminals 19 to 24. − − 12 VDC, 12 VDC, 21 mA...
  • Page 32 SD/RD ERROR Set SW2 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. Connect the G3ZA EJ1C-CBLA050 (order separately) (cable Connecting Cable to the...
  • Page 33 How To Use the Terminals Section 2-2...

  • Page 34: Communications (Compoway/F)

    Communications Settings ........

  • Page 35: Communications Settings

    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 36: Frame Configuration

    Refer to 3-4 Variable Area Write on page 23 for the procedure for changing these settings. Note The settings will be enabled only when the power is turned ON again or the G3ZA is software reset. Send Standby Time The send standby time is used to adjust the time required for the host to switch from sending to receiving status.
  • Page 37 This code indicates the beginning of the communications frame. Always set 02H. Unit. No. • Set the unit number that is set on SW1 on the front of the G3ZA. • No response will be received if another unit number is set. Sub-address and Not used by the G3ZA.

  • Page 38: Fins-Mini Text

    FINS-mini Text Section 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) followed by the various required data is transferred in the command frame.
  • Page 39 Controller Status Read Reads the operating status. “08” “01” Echo-back Test Performs an echo-back test. Note FINS is an acronym for Factory Interface Network Service. FINS is a protocol used for message communications between controllers on OMRON FA net- works.

  • Page 40: Variable Area Write

    Refer to the Parameter List on page 66 in the Appendix . ■ Number of Elements Specify the number of elements for which the set value is to be changed. Up to 24 (0018H) elements can be specified. Write data length No.

  • Page 41: Variable Area Read

    Refer to the Parameter List on page 66 in the Appendix . ■ 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.

  • Page 42: Operation Command

    Operation Command Section 3-6 Operation Command This command is used to start and stop operation, save the manipulated vari- able, execute a software reset, or initialize settings. Command Operation Related code information "30" "05" Response Response code "30" "05" 1. Operation Code and Related Information...

  • Page 43: Controller Attribute Read

    Controller Attribute Read Section 3-7 Controller Attribute Read This command reads the model number of the Controller and the communica- tions buffer size. Command "05" "03" Response Response code Model number Buffer size "05" "03" "G3ZA- " "00D9" 1. Model Number –...

  • Page 44: Controller Status Read

    2. Related Information 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 . Note To read the status of individual channels, use the Variable Area Read com- mand for the desired channel.

  • Page 45: Echo-Back Test

    "08" "01" 0 to 200 1. Test Data The test data can contain up to 200 (00C8H) bytes. Set the test data within the following ranges according to the communications data length setting. Data length Test data 7 bits ASCII 20H to 7EH...

  • Page 46: Functions

    Setup Procedure ........

  • Page 47: Setup Procedure

    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.

  • Page 48: Selecting The Ssr (Control Method) 4 Or 8-Channel Models)

    1,2,3... 1. Set the SSR Selector to 1 with a Variable Area Write command. 2. After setting the SSR Selector, enable the new setting by executing a soft- ware reset with an Operation Command or turning the power OFF and then ON again.
  • Page 49 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.

  • Page 50: Selecting The Ct (4-Channel Models Only)

    G3ZA 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...
  • Page 51 (3) When the input exceeds the maximum value, the display will overflow at the maximum value. Example: If the range is 0 to 50 A and the input is 60 A, the display will overflow at 55 A. Example: If the range is 0 to 150 A and the input is 170 A, the display will overflow at 165 A.

  • Page 52: Allocating Cts (4-Channel Models Only)

    Section 4-4 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.

  • Page 53: Detecting Heater Burnouts (4-Channel Models Only)

    (4-channel Models Only). Detecting Heater Burnouts (4-channel Models Only) 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.
  • Page 54 Heater ON current (see note 1) ≤ Heater burnout detection value. • 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) ≥ Heater burnout detection value + Hyster-...
  • Page 55 0 to 110 Note 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.
  • Page 56 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 follows: (Normal current + Burnout current) Heater burnout detection value = 5 + 0 = 2.5 →...
  • Page 57 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 follows: (Normal current + Burnout current) Heater burnout detection value = 15 + 10 = 12.5 A →...
  • Page 58 34.6 + 20 = 27.3 → 27 [A] Heater burnout detection value = To detect a wire break at either location, set a heater burnout detection value of 32 A. b. Star Wiring Example: Using three 6-kW heaters (200 V AC) Normal Operation: 17.3 A...
  • Page 59 The following formula yields the heater burnout current when there is a break in the load wire. 10 + 0 Heater burnout detection value = = 5 [A] To detect a wire break at either location, set a heater burnout detection value of 7 A.

  • Page 60: Detecting Heater Overcurrent (4-Channel Models Only)

    Abnormal current detection delay = 0 (immediate alarm) Operation at error = 0 (Continue with error clear) • Heater overcurrent is detected at point 1 in the diagram above. The detec- tion condition is as follows: Heater ON current (see note 1) ≥ Heater overcurrent detection value.
  • Page 61 0 to 110 Note 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.

  • Page 62: Detecting Ssr Short-Circuits (4-Channel Models Only)

    Detecting SSR Short-Circuits (4-channel Models Only) Section 4-7 Heaters of 10 A or more: (Normal current - Overcurrent setting) ≥ 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 - Overcurrent setting) ≥...
  • Page 63 Heater OFF current (see note 1) 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) SSR short-circuit detection value - Hys-...
  • Page 64 0 to 110 Note 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.

  • Page 65: Detecting Communications Timeouts (4 And 8-Channel Models)

    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.

  • Page 66: Setting The Soft Increase And Soft Decrease Times (4 And 8-Channel Models)

    Time note.) Note (1) If the Soft Increase or Soft Decrease Time 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...

  • Page 67: Changing The Manipulated Variable (4 And 8-Channel Models)

    Channel 1 to 8 offset 400.0 to 400.0% Note (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.

  • Page 68: Offsetting The Control Output's On Timing (4 And 8-Channel Models)

    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.

  • Page 69: Turning Off A Control Output (4 And 8-Channel Models)

    !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.

  • Page 70: Setting Operation At Error (4 And 8-Channel Models)

    1. Set the abnormal current detection delay to 3 detections (0000 0003 hex) with a Variable Area Write command. 2. When the setting is written, it is stored and becomes effective the next time that the power is turned ON.

  • Page 71: 4-15 Monitoring The Effective Current

    Note (1) Operation will 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 waveform. Refer to SECTION 5 Troubleshooting for details.
  • Page 72 Monitoring the Effective Current Section 4-15 In the following cases, the display will 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.
  • Page 73 Monitoring the Effective Current Section 4-15...

  • Page 74: Troubleshooting

    Handling Problems ........

  • Page 75: Errors

    • Check to see if a communications error has occurred. • Check the host to see if it is functioning cor- rectly. • Check the information provided in 4-8 Detecting Communications Timeouts (4 and 8-channel Models) on page 48.

  • Page 76: Handling Problems

    • If a communications converter is being used, check the set- tings of the converter to see if they are correct. • Check the settings of SW1 and SW2 to see if they agree with the settings of the host.
  • Page 77 Handling Problems Section 5-2...
  • Page 78 Controllers for 400 to 480 VAC: 340 to 528 VAC Manipulated variable inputs 0.0% to 100.0% (via RS-485 communications) One for each channel, 12 VDC ±15%, max. load current: 21 mA (with built-in Trigger outputs short-circuit protection circuit) Alarm output NPN open collector, one output (Max.
  • Page 79 Approx. 11.5 g Approx. 50 g Approx. 130 g Accessories None Connection terminals (2) None Plugs (2) Note The maximum continuous current of the G3ZA together with the E54-CT3 is 50 A. Dimensions (Unit: mm) E54-CT1 5.8 dia. Two, 3.8 dia.
  • Page 80 Appendix E54-CT3 2.36 dia. 12 dia. Two, M3 holes, depth: 4 G3ZA-CT150L 26MAX Four, M4 × 6 13.5 34.5 81.5 33.5 14.5 14.5...
  • Page 81 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 82 Appendix Status Lists Use the status listed in the following tables to check G3ZA status. Status Status 31 to 13 Not used. Start/stop Operating Stopped Operating Not used. Not used. Alarm output (applies to all channels) Output Control output Not used.
  • Page 83 Parameter List If variables without parentheses are used in communications, the set values will be eight-digit (double-word) data. If variables with parentheses are used in communications, the set values will be four-digit (word) data. Example: Variable type C4: Double word (8 digits)
  • Page 84 Address Parameter Setting/monitor range Default Unit type Opera- C1 (81) 000E CH7 slope H’00000000 to H’00000FA0 (0.0 to 400.0) 100.0 tion 000F CH8 slope H’00000000 to H’00000FA0 (0.0 to 400.0) 100.0 0010 CH1 offset H’FFFFF060 to H’00000FA0 (−400.0 to 400.0)
  • Page 85 0007 Hysteresis H’00000001 to H’0000000A (1 to 10) Note (1) 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.
  • Page 86 Opera- C0 (80) 0000 Version tion 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 H’00000000 to H’000003E8 (0.0 to 100.0)
  • Page 87 Setting/monitor range Default Unit type Opera- CE (8E) 000D CT2 heater ON current H’00000000 to H’000000A5 (0 to 165) A or % tion 000E CT3 heater ON current H’00000000 to H’000000A5 (0 to 165) A or % 000F CT4 heater ON current H’00000000 to H’000000A5 (0 to 165)
  • Page 88 Parameter name Setting/monitor range Default Unit type Opera- C1 (81) 0024 CT1 SSR short-circuit H’00000000 to H’000000A5 (0 to 165) A or % detection value tion 0025 CT2 SSR short-circuit H’00000000 to H’000000A5 (0 to 165) A or % detection value...
  • Page 89 H’00000000 to H’000000C8 (0 to 200) Times delay Note (1) 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.
  • Page 90 Appendix ASCII Table Leftmost digit Rightmost digit SPACE ‘ ‘ & ‘ < ¥ >...
  • Page 91 Appendix...
  • Page 92 400-V Controllers ASCII table FINS-mini command and response text functional upgrades xiii baud rate G3ZA-CT150L calculating the heater overcurrent detection value communications specifications communications terminals heater OFF current communications unit number heater ON current CompoWay/F end codes connection examples...
  • Page 93 RS-485 communications SD/RD indicator send standby time set values reading writing setting the abnormal current detection delay setup procedure soft increase and soft decrease times soft-start optimum cycle control specifications calculating the SSR short-circuit detection value detecting SSR short-circuits...
  • Page 94 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 following table outlines the changes made to the manual during each revision. Page numbers refer to the previous version.
  • Page 95 Revision History...
  • Page 96 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 ELECTRONICS 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,...

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