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OMRON Corporation
Industrial Automation Company
Industrial Devices and Components Division H.Q.
Measuring Components Department
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 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,
239920 Singapore
Tel: (65)6835-3011/Fax: (65)6835-2711
OMRON CHINA CO., LTD.
BEIJING OFFICE
Room 1028, Office Building,
Beijing Capital Times Square,
No. 88 West Chang'an Road,
Beijing, 100031 China
Tel: (86)10-8391-3005/Fax: (86)10-8391-3688
Authorized Distributor:
Cat. No. Z200-E1-01 Note: Specifications subject to change without notice.
Printed in Japan
0404-0.5M (0404)(B)
G3ZA
Multi-channel
Power Controller
User's Manual
Cat. No. Z200-E1-01
G3ZA
Multi-channel Power Controller
User’s Manual
Produced April 2004
iv
Preface
OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual.
This manual describes the functions, performance, and application methods needed for optimum use of the G3ZA.
Please observe the following items when using the G3ZA.
• This product is designed for use by qualified personnel with a knowledge of electrical systems.
• Read this manual carefully and make sure you understand it well to ensure that you are using the
G3ZA correctly.
• 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 constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.
v
vi
Read and Understand this Manual
Please read and understand this manual before using the product. Please consult your OMRON representative if you have any questions or comments.
Warranty and Limitations of Liability
WARRANTY
OMRON's exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-
INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS.
ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED
THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE.
OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES,
LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS,
WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT
LIABILITY.
In no event shall the responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS
REGARDING THE PRODUCTS UNLESS OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS
WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO
CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.
Application Considerations
SUITABILITY FOR USE
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer's application or use of the products.
At the customer's request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product, machine, system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for the products.
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this manual.
• 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.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR
PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO
ADDRESS THE RISKS, AND THAT THE OMRON PRODUCTS ARE PROPERLY RATED AND INSTALLED
FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user's programming of a programmable product, or any consequence thereof.
Disclaimers
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other reasons.
It is our practice to change model numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the products may be changed without any notice. When in doubt, special model numbers may be assigned to fix or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual specifications of purchased products.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.
PERFORMANCE DATA
Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a 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.
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
■ 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.
WARNING
Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, or may result in serious injury or death. Additionally there may be significant property damage.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or in property damage.
■ Symbols
Caution
Symbol Meaning
General Caution
Indicates non-specific general cautions, warnings, and dangers.
Electrical Shock Caution
Indicates possibility of electric shock under specific conditions.
Prohibition
Mandatory
Caution
General Prohibition
Indicates non-specific general prohibitions.
General Caution
Indicates non-specific general cautions, warnings, and dangers.
viii
■ 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. 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 damage to the equipment.
Terminal screws: 0.40 to 0.56 N·m
ix
x
Precautions for Safe Use
(1) Do not use the product in the following locations.
• Locations subject to direct radiant heat from heating equipment
• Locations where the product may come into contact with water or oil
• Locations subject to direct sunlight
• Locations where dust or corrosive gases (in particular, sulfuric or ammonia gas) are present
• Locations subject to extreme temperature changes
• Locations where icing or condensation may occur
• 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 forcedcooling if required.
(5) Minimum mounting distance of G3ZA is 10 mm.
When mounting the G3ZA near the SSRs, mount the G3ZA so as to not interfere with the heat dissipation of the SSR.
(6) Use the specified size of insulated type crimp terminals (M3, width: 5.8 mm max.) for wiring and attach insulative sleeves. To connect bare wires, use AWG22
(cross section: 0.326 mm
2
) to AWG14 (cross section: 2.081 mm
2
) to wire the power supply terminals and AWG22 (cross section: 0.326 mm
2
) to AWG16 (cross section: 1.039 mm
2
) for other terminals.
(7) Be sure to confirm the correct terminal and polarity when wiring the terminal block and connectors.
(8) Do not connect any conductors to unused terminals.
(9) In order to prevent inductive noise, wire the lines connected to the product separately from power lines carrying high voltages or currents. Do not wire in parallel with or in the same cable as power lines. Other measures for reducing noise include running lines along separate ducts and using shield lines.
(10) Attach a surge suppressor or noise filter to peripheral devices that generate noise
(in particular, motors, transformers, solenoids, magnetic coils or other equipment that have an inductance component).
Do not install the product near devices generating strong high-frequency fields or surges. When using a noise filter, check the voltage and current and install it as close to the product as possible.
(11) For a safety disconnection of the power-line in the application the equipment shall be provided with disconnecting devices suitable for isolation.
(e.g. circuit breakers IEC60947-2, power switches IEC60947-3, power plugs etc.)
(12) The G3ZA is for single-phase loads only. Connect only single-phase zero-cross
SSRs.
Do not connect three-phase SSRs, magnetic relays, or SSRs that do not have zero-cross function.
TABLE OF CONTENTS
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the G3ZA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xi
xii
About this Manual:
This manual describes the installation and operation of the G3ZA Multi-channel Power Controller and includes the sections described below.
Please read this manual carefully and be sure you understand the information provided before attempting to install or operate the G3ZA. Be sure to read the precautions provided at the beginning of this manual.
The Preface provides precautions for using the G3ZA and information on using this manual.
Section 1 introduces the G3ZA and its features.
Section 2 describes preparations for using the G3ZA, including installation and wiring.
Section 3 describes application information, including settings, communications, and controlling operation.
Section 4 describes the functions of the G3ZA so that these functions can be used effectively according 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.
!WARNING
Failure to read and understand the information provided in this manual may result in personal injury or death, damage to the product, or product failure. Please read each section in its entirety and be sure you understand the information provided in the section and related sections before attempting any of the procedures or operations given.
xiii
xiv
This section introduces the G3ZA and its features.
SECTION 1
Overview
1
Features
1-1 Features
Section 1-1
The G3ZA is a Multi-channel Power Controller with externally connected
SSRs. It can receive manipulated variables from a PLC or other host via RS-
485 communications and control heater power with high precision via the
SSRs.
Overview
Optimum Cycle Control
• Optimum cycle control is performed by driving SSRs according to load power detection and trigger signals. (Zero-cross SSRs are used.)
• Noise is suppressed while ensure high-speed response by turning outputs ON and OFF each half cycle to achieve high-precision temperature control.
1/5th ON (20%)
Manipulated variable: 20%
Offset Control
Manipulated Value
Calculations
Error Detection (4-channel
Controllers Only)
Number of Outputs
Connected
Alarm Output
Installation
• The timing of turning ON the control outputs for G3ZA channels can be offset.
• The manipulated variable can be calculated for one channel and the calculated value can be output for another channel.
• The current flowing through the heater can be monitored to detect heater burnouts, heater overcurrents, and SSR short circuits.
• Between one and four outputs can be connected to 4-channel Controllers and between one and eight outputs can be connected to 8-channel Controllers.
• 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 of wiring required between the G3ZA and host.
• Up to 31 Controllers can be connected to one communications line. With
4-channel Controllers, up to 124 channels can be controlled, and with 8channel Controllers, up to 248 channels can be controlled.
The following four models are available.
No. of channels
4 channels
8 channels
Error detection
Supported
Not supported
Load power supply
100 to 240 V
400 to 480 V
100 to 240 V
400 to 480 V
2
Features
Connections
Section 1-1
Host
G3ZA
Trigger signal
SSR
RS-485
Control power supply
CT
Note
Load power supply
Load (e.g., heater)
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
OCC
SW1
SW2
READY
SD/ RD
OCC
ERROR
SW1
SW2
ERROR
Operation Indicators
Operation indicator
READY
SD/RD
OCC
ERROR
Meaning
Lit while power is being supplied.
Lit while communicating with the host.
Lit while a control output is ON.
Lights or flashes when an error is detected.
Switches SW1 and SW2
SW1 and SW2 are used to set the communications unit number and baud
rate. Refer to 3-1 Communications Settings on page 14 for details.
3
Features
Section 1-1
4
This section describes preparations for using the G3ZA, including installation and wiring.
SECTION 2
Preparations
5
Installation
2-1 Installation
Dimensions (Unit: mm)
Section 2-1
7
×5=35
READY
SD/RD
OCC
ERROR
SW 1
SW 2
R
4.5
111 max. (110 typical)
35
±0.3
45 max.
R2.
3
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.
• DIN Track: PFP-50N (50 cm) or PFP-100N (100 cm)
• End Plates: PFP-M
6
Installation
Mounting the G3ZA
Removing the G3ZA
Section 2-1
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).
(2)
(3)
(1)
(4)
Use a flat-blade screwdriver to pull down the DIN Track mounting hook (1) and then pull out on the bottom of the G3ZA (2).
Mounting End Plates
(2)
(1)
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.
(2)
(1)
READY
SD/RD
OCC
ERROR
SW 1
SW 2
Note
Always mount one End Plate on each side of the G3ZA.
7
Installation
Mounting the G3ZA with Screws
Mounting Hole
Dimensions (Unit: mm)
Two, 4.2 dia. or M4 holes
84
±0.3
35
±0.3
Section 2-1
8
How To Use the Terminals
2-2 How To Use the Terminals
+
Trigger output
12 V, 21 mA
−
+
Trigger output
12 V, 21 mA
−
+
Trigger output
+
Trigger
12 V,
21 mA output
12 V,
21 mA
19 20 21 22 23 24
CH5
CH6 COM CH7 CH8 COM
+
Trigger output
12 V, 21 mA
Trigger
−
+
Trigger output −
+ output
12 V,
21 mA
12 V, 21 mA
+
Trigger output
12 V,
21 mA
13 14 15 16 17 18
CH1 CH2 COM CH3 CH4 COM
G3ZA-8A
@03-FLK-UTU
Section 2-2
CT CT CT CT
19 20 21 22 23 24
CH1 CH2
COM
CH3 CH4 COM
+
Trigger output
12 V, 21 mA
Trigger
+ output
12 V,
−
+
Trigger output
12 V, 21 mA
+
Trigger output
−
21 mA
12 V,
21 mA
13 14 15 16 17 18
COM COM
CH1
CH2 CH3 CH4
G3ZA-4H
@03-FLK-UTU
READY
SD/RD
OCC
ERROR
SW 1
SW 2
+
7 8 9
RS-485
−
Alarm output
30 V, 50 mA
11
1 2 4 6
+
7 8
RS-485 −
1 2 4 6
Control power supply
100 to 240 VAC
50/60 Hz
Load power supply
100 to 240 VAC
50/60 Hz
G3ZA@@203-FLK-UTU
Wiring Diagrams
Control power supply
100 to 240 VAC
50/60 Hz
Load power supply
400 to 480 VAC
50/60 Hz
G3ZA@@403-FLK-UTU
Use one of the following M3 solderless terminals for wiring.
5.8 mm max.
A
B
Alarm output
30 V, 50 mA
5.8 mm max.
Use wires that are rated to withstand 70
°C minimum.
9
How To Use the Terminals
Controller Power Supply
Terminals
Section 2-2
In the wiring diagrams, the area within the lines indicating terminals numbers is inside the G3ZA and the area outside the lines are outside the G3ZA.
• Connect terminals 1 and 2 as follows:
1 2
READY
SD/ RD
OCC
ERROR
SW1
SW2
• The input power is 100 to 240 VAC.
Load Power Supply Input
Terminals
READY
SD/ RD
OCC
ERROR
SW1
SW2
Communications
Terminals
READY
SD/ RD
OCC
ERROR
SW1
SW2
• To detect the zero-cross point of the load supply, connect the load power supply to terminals 4 and 6 as follows:
4 6
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
• The G3ZA detects the zero cross point of the load power supply.
• To communicate with a host system, connect the communications line to terminals 7 and 8 as follows:
7 8
B
(+)
RS-485
A
(- )
• The connection type can be 1: 1 or 1: N. For 1: N connections, up to 32
Units can be connected, including the host.
• The maximum cable length is 500 m total.
Cable Diagram (Reference)
• Use shielded twisted-pair cables (AWG28 to AWG16).
AWG28
Cross-sectional area of core:
0.081 mm
2
min.
• A terminator must be connected to both ends of the communications path
(including the PLC). Use a resistance of 100 to 125
Ω (1/2 W) in the terminators.
• Use an RS-232C/RS-485 converter to connect to a personal computer or other host with an RS-232C connection.
10
How To Use the Terminals
Alarm Output Terminals for the G3ZA-
@@203-FLK-
UTU
READY
SD/ RD
OCC
ERROR
SW1
SW2
Section 2-2
Converter: K3SC RS-232C/RS-485 Interface Converter
RS-232C
D-sub, 9-pin
(straight)
K32-23209
Adapter
K3SC-10
RS-232C/RS-485
Converter
Terminator
100 to 125
Ω (1/2 W)
(B) (A)
G3ZA
Terminator
(No. 0)
100 to 125
Ω (1/2 W)
(B)
(A)
G3ZA
3ZA
(No. 1)
• Alarms are output on terminals 9 and 11.
9 11
SUB
• The alarm output specifications are as follows:
Maximum load voltage: 30 VDC
Maximum load current: 50 mA
Maximum residual voltage: 1.5 V
Maximum leakage current: 1 mA
(B) (A)
G3ZA
(No. 31)
Terminator
100 to 125
Ω (1/2 W)
Alarm Output Terminals for the G3ZA-
@@403-FLK-
UTU
READY
SD/ RD
OCC
ERROR
SW1
SW2
• Alarms are output on pins A and B of the connector.
• The alarm output specifications are as follows:
A
B
SUB
Maximum load voltage: 30 VDC
Maximum load current: 50 mA
Maximum residual voltage: 1.5 V
Maximum leakage current: 1 mA
• The C-Grid SL connector for Molex Incorporated can be used for the connector.
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.
11
How To Use the Terminals
Trigger Output Terminals
READY
SD/ RD
OCC
ERROR
SW1
SW2
Current Transformer Input
Terminals
READY
SD/ RD
OCC
ERROR
SW1
SW2
Section 2-2
• The trigger outputs for channels 1 to 4 are output on terminals 13 to 18.
CH1
SSR
CH2
SSR
CH3
SSR
CH4
SSR
+
13 14 15 16 17 18
+
−
+ +
−
12 VDC,
12 VDC,
12 VDC,
21 mA
12 VDC,
21 mA
21 mA 21 mA
Output voltage: 12 VDC
±15%
PNP
Maximum load current: 21 mA
Short-circuit protection circuit provided.
Controllers without a Current Transformer Input Circuit (G3ZA-8A
@03-
FLK-UTU)
• The trigger outputs for channels 5 to 8 are output on terminals 19 to 24.
CH5
SSR
CH6
SSR
CH7
SSR
CH8
SSR
+
19 20 21 22 23 24
+
−
+ +
−
12 VDC,
12 VDC,
21 mA
12 VDC,
21 mA
12 VDC,
21 mA
21 mA
Controllers with Built-in Current Transformer Circuits (G3ZA-4H
@03-
FLK-UTU)
• Connect terminals 19 to 24 to the current transformers (no polarity) to detect heater burnouts, heater overcurrents, and SSR short circuits.
CH1
CT
CH2
CT
CH3
CT
CH4
CT
19 20 21 22 23 24
There are four current transformer inputs that can be used.
Use the E54-CT1 or the E54-CT3 from OMRON as the current transformer.
Wiring Example
(G3ZA-4H
@03-FLK-
UTU)
Heater
CT
Alarm
Host PLC
READY
SD/RD
OCC
ERROR
SW 1
SW 2
Power Controller power supply
Load power supply
(for zero cross detection)
SSR
12
SECTION 3
Using the G3ZA
This section describes application information, including settings, communications, and controlling operation.
13
Communications Settings
Section 3-1
3-1 Communications Settings
G3ZA settings and operation are performed using RS-485 communications.
Communications
Specifications
Transmission path connections
Multipoint
Communications method
RS-485
Sync method
Stop-start sync
Baud rate
Transmission code
Data length
Stop bits
Error detection
Flow control
9.6, 19.2, 38.4 or 57.6 kbit/s
ASCII
7 or 8 bits
1 or 2 bits
Vertical priority: None, even, or odd
None
Communications settings are made as shown in the following table.
Setting
Communications unit number
Baud rate
Setting range
0 to 31
Data length
9.6, 19.2, 38.4 or
57.6 kbit/s
7 or 8 bits
Stop bits
Parity
Send standby time
1 or 2 bits
None, even, odd
0 to 99 ms
1
Default
9.6 kbit/s
7 bits
2 bits
Even
20 ms
Setting method
SW1
SW2
Communications
Communications
Communications
Communications
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.
SW1 SW2
SW1
Unit number
0 1 2 3 4 5 6 7 8 9 A B C D E F
00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
Note
SW2 0 1 2 3
Baud rate (kbit/s) 9.6
19.2 38.4 57.6
(1) Refer to Connecting More Than 16 Controllers on page 38 in the Appen-
dix when connecting more than 16 Controllers.
(2) The default settings are shaded in the above table.
Other Communications Settings
Communications are used to set the data length, number of stop bits, parity, and send standby time. To change the settings, use communications with the
default communications settings. Refer to 3-4 Variable Area Write on page 17
for the procedure for changing these settings.
Note
The settings will be enabled only when the power is turned ON again or the
G3ZA is reset.
14
CompoWay/F Frame Structure
Send Standby Time
Section 3-2
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
Receive status
Receive
G3ZA
Response created
Receive
Send
Receive status
Send status
Send standby time
If switching time will not cause problems, the send standby time can be shortened to reduce the communications time with the host.
3-2 CompoWay/F Frame Structure
The propriety OMRON communications protocol called CompoWay/F is used as the communications protocol. Commands from the host and responses from the G3ZA are sent in data packets called frames. The structures of the command and response frames are shown below.
Command Frames
STX
Node No.
Subaddress
SID
02H "00" "0"
1 2
FINS-mini command text
2 1
BCC calculation range
ETX
BCC
03H
1 1
Response Frames
STX Node No.
Subaddress End code
02H "00"
FINS-mini response text
1 2 2 2
ETX
BCC
03H
1 1
STX
Node No.
Code that indicates the beginning of the communications frame. Always set 02H.
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 command text
The text of the command. Refer to 3-6 Operation Command on page 19 for details.
ETX
BCC
Code that indicates the end of the communications frame.
Always set 03H.
This stores the result of the BCC calculation from the Node
No. to EXT.
STX Node No.
Subaddress
SID
FINS-mini command text
ETX
BCC
02H 30H 30H 30H 30H 30H 30H 35H 30H 30H 03H 36H
+ indicates an exclusive OR.
15
CompoWay/F Frame Structure
Section 3-2
End Codes (CompoWay/F Communications)
End code
“0F”
“10”
“11”
“12”
“13”
“14”
“16”
“18”
“00”
Name
FINS command error
Parity error
Description
Could not execute the specified FINS command.
Framing error
Overrun error
BCC error
Sum of bits that are “1” in received data does not agree with the set communications parity value.
Stop bit is “0”.
The next data was received when the received data buffer was full.
Calculated BCC differs from received BCC.
Format error Characters other than “0” to “9” or “A” to “F” in
FINS-mini command text. (Refer to 3-9 Echo-
back Test on page 22 for echo-back tests.)
Subaddress error One or more of the subaddresses is missing.
Frame length error The received frame exceeds the required number of bytes.
Normal end Command was executed normally without error.
Data Type Notation
In this manual, hexadecimal and ASCII characters are expressed as shown in the following table.
Hexadecimal
ASCII characters
An H is added to the end of the hexadecimal number.
Example: 02H
ASCII characters are given in quotation marks.
Example: “00”
16
FINS-mini Text
Section 3-3
3-3 FINS-mini Text
The structure of FINS
1
command and response text is shown below.
Command Text
STX
02H
Node No.
Subaddress
SID
"00" "0"
FINS-mini command text
ETX
BCC
03H
MRC
SRC Data
2 2
Response Text
STX
Node No.
End code
Subaddress
02H "00"
FINS-mini response text
ETX
BCC
03H
MRC
SRC
Response code Data
2 2 4
List of FINS-mini Service Commands
MRC
“01”
“01”
“30”
“05”
“06”
“08”
SRC
“02”
“01”
“05”
“03”
“01”
“01”
Service name
Variable Area Write
Description
Changes set values.
Variable Area Read
Operation Command
Reads set values.
Executes commands such as start/stop, manipulated variable save and software reset.
Controller Attribute Read Reads the model number of the
Controller.
Controller Status Read Reads the operating status.
Echo-back Test Performs an echo-back test.
3-4 Variable Area Write
This command changes set values.
Command
Note
MRC
"01"
2
SRC Variable type
"02"
2 2
Write start address Bit position
No. of elements
"00"
4 2 4
Set values
No. of elements x 8 or 4
The bit position is not used. Set it to “00”.
Response
MRC
"01"
2
SRC
"02"
2
Response code
4
■ Variable Type and Write Start Address
Refer to the Parameter Tables on page 38 in the Appendix.
1.FINS: Short for Factory Interface Network Service.
The FINS protocol is used for message communications between controllers on
OMRON FA networks.
17
Variable Area Read
Section 3-5
■ 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
“1002”
“1101”
“1003”
“1100”
“2203”
“0000”
Error name Cause
Command length too short The command is too short.
Area type error
Number of elements/Number of data do not agree
The specified variable type does not exist.
The specified number of elements does not agree with the actual number of data elements.
Parameter error
Operation error
Normal end
The bit position specification is not “00”.
A set value is outside of the setting range.
An error occurred in nonvolatile memory.
Processing was completed normally.
Example: The following command changes the manipulated variable for channel 1 to 50% (set value: 8 digits).
Command: [STX]010000102C10000000001000001F4[ETX][BCC]
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[ETX][BCC]
3-5 Variable Area Read
This command reads set values.
Command
Note
MRC
"01"
2
SRC
"01"
2
Variable type
Read start address
Bit position No. of elements
"00"
2 4 2 4
The bit position is not used. Set it to “00”.
Response
MRC
"01"
2
SRC
"01"
2
Response code
Set values
4 No. of elements x 8 or 4
■ Variable Type and Read Start Address
Refer to the Parameter Tables on page 38 in the Appendix.
■ Number of Elements
Specify the number of elements for which the set value is to be read. Up to 8 elements can be specified.
18
Operation Command
Section 3-6
■ Response Code
Response code
“1001”
“1002”
“1101”
“110B”
“1100”
“2203”
“0000”
Error name
Command length too long
Command length too short
Area type error
Response length too long
Parameter error
Operation error
Normal end
Cause
The command is too long.
The command is too short.
The specified variable type does not exist.
The number of elements is larger than the maximum number allowed.
The bit position specification is not “00”.
An error occurred in nonvolatile memory.
Processing was completed normally.
Example: The following command reads the control variable for channel 1
(set value: 8 digits).
Command: [STX]010000101C00001000001[ETX][BCC]
Response: [STX]0100000101000000000000[ETX][BCC]
Example: The following command reads the control variable for channel 1
(set value: 4 digits).
Command: [STX]010000101800001000001[ETX][BCC]
Response: [STX]010000010100000000[ETX][BCC]
3-6 Operation Command
This command is used to start and stop operation, save the manipulated variable, execute a software reset, or initialize settings.
Command
MRC
"30"
2
SRC
Operation
Related code information
"05"
2 2 2
Response
MRC
"30"
2
SRC
"05"
2
Response code
4
19
Controller Attribute Read
Section 3-7
1. Operation Code and Related Information
Operation code
“01”
Description
Start/stop
Related information
“05”
“06”
“0B”
Manipulated variable save
Software reset
Initialize settings
Operation
Upper digit: Channel specification
“0”: Channel 1
“1”: Channel 2
“2”: Channel 3
“3”: Channel 4
“4”: Channel 5
“5”: Channel 6
“6”: Channel 7
“7”: Channel 8
“F”: All channels
Lower digit: Start/stop
“0”: Start
“1”: Stop
“00”
Refer to 4-3 Turning OFF the Control Output on page 25.
“00”
“00”
Refer to 4-1 Changing the Manipulated Vari-
Performs the same processing as when the
G3ZA is turned ON.
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
“1001”
“1002”
“1100”
“2203”
“0000”
Error name
Command length too long
Command length too short
Parameter error
Operation error
Normal end
Cause
The command is too long.
The command is too short.
The operation code or related information is not correct.
An error occurred in nonvolatile memory.
Processing was completed normally.
Example: The following command starts operation for channel 1.
Command: [STX]0100030050100[ETX][BCC]
Response: [STX]01000030050000[ETX][BCC]
3-7 Controller Attribute Read
This command reads the model number of the Controller and the communications buffer size.
Command
MRC
"05"
2
SRC
"03"
2
Response
MRC
"05"
2
SRC
"03"
2
Response code
4
Model number
"G3ZA"
10
Buffer size
"00D9"
4
20
Controller Status Read
1. Model Number
Section 3-8
G 3 Z A
–
1
2 3
4 5
A
Number
B
C
DE
“4”
“8”
“H”
“A”
“2”
“4”
“03”
Code Meaning
4 channels
8 channels
With current transformer input
No current transformer input
Load power supply: 100 to 240 V
Load power supply: 400 to 480 V
RS-485
The buffer size is 217 bytes (D9H).
2. Buffer Size
3. Response Code
Response code
“1001”
“2203”
“0000”
Error name
Command length too long
Operation error
Normal end
Cause
The command is too long.
An error occurred in nonvolatile memory.
Processing was completed normally.
Example: The following command reads the model number and buffer size.
The response shows the Controller has four channels, supports a current transformer, and has a load power supply of 400 to 480 V.
Command: [STX]010000503[ETX][BCC]
Response: [STX]01000005030000G3ZA-4H40300D9[ETX][BCC]
3-8 Controller Status Read
This command reads the operating status of the Controller.
Command
MRC
"06"
2
SRC
"01"
2
Response
MRC
"06"
2
SRC
"01"
2
Response code
Operating
Related status information
4 2 2
1. Operating Status
2. Related Information
Note
Operating status
“00”
“01”
Meaning
The control output is ON for one or more channels.
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 Parameter Tables 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.
21
Echo-back Test
3. Response Code
Section 3-9
Response code
“1001”
“2203”
“0000”
Error name
Command length too long
Operation error
Normal end
Example:
Command: [STX]010000601[ETX][BCC]
Response: [STX]010000060100000100[ETX][BCC]
Cause
The command is too long.
An error occurred in nonvolatile memory.
Processing was completed normally.
3-9 Echo-back Test
This command performs an echo-back test.
Command
MRC
"08"
2
SRC
"01"
2
Test Data
0 to 200
Response
1. Test Data
MRC
"08"
2
SRC
"01"
2
Response code
Test Data
4
0 to 200
Set the test data within the following ranges according to the communications data length setting.
Data length
7 bits
8 bits
Text data
ASCII 20H to 7EH
ASCII 20H to 7EH or A1H to FEH
2. Response Codes
Response code
“1001”
“2203”
“0000”
Error name
Command length too long
Operation error
Normal end
Cause
The command is too long.
An error occurred in nonvolatile memory.
Processing was completed normally.
Example:
Command: [STX]010000801123[ETX][BCC]
Response: [STX]01000008010000123[ETX][BCC]
22
SECTION 4
Functions
This section describes the functions of the G3ZA so that these functions can be used effectively according to the application.
4-2 Offsetting Control Output ON Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4 Detecting Heater Burnout (4-channel Models Only) . . . . . . . . . . . . . . . . . . .
4-5 Detecting Heater Overcurrent (4-channel Models Only) . . . . . . . . . . . . . . . .
4-6 Detecting SSR Short Circuits (4-channel Models Only) . . . . . . . . . . . . . . . .
4-8 Detecting Communications Timeouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
Changing the Manipulated Variable
Section 4-1
4-1 Changing the Manipulated Variable
The Variable Area Write command is used to change the manipulated variable. 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 Manipulated Variable Save operation command.
Example: The following procedure can be used to change the manipulated variable to 20.0% whenever the power supply is turned ON.
1,2,3...
Using Manipulated
Variable Calculations
Note
1.
Execute the Variable Area Write command to set the manipulated variable to 20.0% for all channels.
2.
Execute the Manipulated Variable Save operation command.
3.
The manipulated variables will be set to 20.0% the next time power is turned ON.
Manipulated variable calculations can be used to set the control variable for one change based on the manipulated variable for another channel. The following calculation method and set values can be used.
Control variable =
Manipulated variable of source channel x Slope/100.0 + Offset
Set value Setting
Channels 1 to 8: Source channel Channel 1 to 8 (Set the channel to use as the source for calculation.)
Channels 1 to 8: Slope
Channels 1 to 8: Offset
0.0% to 400.0%
−400.0% to 400.0%
(1) The control variable will be clamped at 0% or 100% if it exceeds the range of 0% to 100%.
(2) The control variable can be read using the Variable Area Read command.
Example:
Channel
Manipulated variable
Source channel
Slope
Offset
Control variable
1
0.0
2
175.0
15.0
50.0
20.0
2
2
100.0
0.0
20.0
3
0.0
2
125.0
5.0
30.0
4
0.0
2
150.0
10.0
40.0
Control variable (%)
80.0
60.0
40.0
20.0
ch1 ch2 ch3 ch4
24
Offsetting Control Output ON Timing
Section 4-2
4-2 Offsetting Control Output ON Timing
The ON timing of control outputs for all of the channels can be adjusted to reduce overlapping with each other. Set the Offset Control to perform this.
(Offset Control is enabled by default.)
Disabled (No Offset)
In the following diagram, the ON timing overlaps between the channels. ch1 ch2 ch3 ch4
Enabled (Offset)
In the following diagram, overlapping of the ON timing has been reduced. ch1 ch2 ch3 ch4
Note
Overlapping will vary with the control variables and changes to the control variables.
4-3 Turning OFF the Control Output
Use the start/stop operation command to turn OFF control outputs. The start/ stop command can be used for all channels or for individual channels.
Note
The start/stop status is written to nonvolatile memory. If the power is turned
OFF when a control output is stopped, it will still be stopped when power is turned back ON. Use the Start/Stop operation command to enable operation again.
25
Detecting Heater Burnout (4-channel Models Only)
Section 4-4
4-4 Detecting Heater Burnout (4-channel Models Only)
A heater burnout is detected by determining if the heater current is below the heater burnout detection value when a control output is ON.
Heater Burnout
Detection Timing
Heater ON current
Hysterisis
Heater burnout detection value
Operating Conditions
ON
OFF
Note
Status (heater burnout bit)
ERROR indicator
Alarm output
Set value
Channels 1 to 4: Heater burnout detection value
Hysteresis (See note 2.)
Setting range Default
0 to 50 (See note 1.) 0 (disabled)
1 to 10 1
(1) Heater burnouts will not be detected if the detection value is set to 0.
Detection status will be forced ON if the detection value is set to 50. Use these to check operation during installation.
(2) Hysteresis is used to prevent chattering at the detection point. The same hysteresis setting is used for all heater burnout detection, heater overcurrent detection, and SSR short-circuit detection functions.
• 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. Check the heater current under actually conditions using the Heater ON Current parameters for channels 1 to 4.
• Keep the total normal heater current to 50 A or less. If 55 A is exceeded, the Heater ON Current parameters for channels 1 to 4 will be 55.
• Detection will be unstable if there is only a small difference between the normal current and burnout current. To achieve stable detection, set the parameters so that there will be a difference of at least 2 A for heaters of less than 10 A and a difference of 3 A or more for heaters of 10 A or more.
Heaters of less than 10 A: Normal current - burnout current
≥ 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
≥ 3 A
Detection will not be stable if the difference is less than 3 A.
If the conditions for stable detection cannot be met, increase the number of turns of the heater wire through the current transformer. The monitor value for the heater ON current is proportional to the number of turns.
26
Detecting Heater Burnout (4-channel Models Only)
Example:
Section 4-4
• Heater burnout detection status can be confirmed by reading the status for individual channels.
Calculating the Detection Current for Heater Burnout
Use the following formula to calculate the detection current.
Normal current + Burnout current
Set value =
2
When two or more heaters are connected through the current transformer, set the detection current to detect burnouts on the heater with the smallest current. If the heater currents are all the same, set the detection current for one wire.
Application Example
Example 1: Using one 1-kW heater (200 VAC)
Heater
1 kW
CT
SSR
19 21
Normal current =
1000
200
= 5 A (< 10 A)
Burnout current = 0 A
200 VAC
Set value =
5+0
2
= 2.5 A
≅ 2 A
(Normal current
− Burnout current = 5 − 0 = 5 A (≥ 2 A))
The above calculation produces 2.5 A. The minimum setting unit is
1 A, so 2.5 is truncated and 2 A is used.
Example 2: Using three 1-kW heaters (200 VAC)
Heater
SSR
1 kW
× 3
CT
200 VAC
19 21
Normal current =
1000
200
× 3 = 15 A (≥ 10 A)
Current for 1 heater =
1000
200
15+10
Set value =
2
× 2 = 10 A
= 12.5 A
≅ 12 A
(Normal current
− Burnout current = 15 − 10 = 5 A ≥ 3 A)
The calculation produces 12.5 A. This is truncated to 12 A, as explained above.
27
Detecting Heater Overcurrent (4-channel Models Only)
Section 4-5
4-5 Detecting Heater Overcurrent (4-channel Models Only)
A heater overcurrent is detected by determining if the heater current is above the heater overcurrent detection value when a control output is ON.
Heater Overcurrent
Detection Timing
Heater overcurrent detection value
Hysteresis
Heater ON current
Status (SSR short-circuit bit)
ERROR indicator (flashing)
Alarm output
ON
OFF
Note
Set value
Channels 1 to 4:
Heater overcurrent detection value
Hysteresis
(See note 2.)
Setting range
0 to 50 (See note 1.)
1 to 10
Default
50 (disabled)
1
(1) Heater overcurrents will not be detected if the detection value is set to 50.
Detection status will be forced ON if the detection value is set to 0. Use these to check operation during installation.
(2) Hysteresis is used to prevent chattering at the detection point. The same hysteresis setting is used for all heater burnout detection, heater overcurrent detection, and SSR short-circuit detection functions.
Operating Conditions
• The actual current flowing in the heater may not be the same as the heater's rated current. Check the heater current under actually conditions using the Heater ON Current parameter for the relevant channel.
• Detection will be unstable if there is only a small difference between the normal current and overcurrent current. To achieve stable detection, set the parameters so that there will be a difference of at least 2 A for heaters of less than 10 A and a difference of 3 A or more for heaters of 10 A or more.
• Heater overcurrent detection status can be confirmed by reading the status for individual channels.
Calculating the Detection Current for Heater Overcurrent
Set the detection current according to the needs of the application.
4-6 Detecting SSR Short Circuits (4-channel Models Only)
An SSR short-circuit is detected by determining if the heater current is above the SSR short-circuit detection value when a control output is OFF.
28
Detecting SSR Short Circuits (4-channel Models Only)
SSR Short-circuit
Detection Timing
SSR short-circuit detection value
Heater OFF current
Hysteresis
Section 4-6
Status (SSR short-circuit bit)
ERROR indicator
Alarm output
ON
OFF
Note
Set value
Channels 1 to 4:
SSR short-circuit detection value
Hysteresis
(See note 2.)
Setting range
0 to 50 (See note 1.)
1 to 10
Default
50 (disabled)
1
(1) SSR short-circuits will not be detected if the detection value is set to 50.
Detection status will be forced ON if the detection value is set to 0. Use these to check operation during installation.
(2) Hysteresis is used to prevent chattering at the detection point. The same hysteresis setting is used for all heater burnout detection, heater overcurrent detection, and SSR short-circuit detection functions.
Operating Conditions
• The actual current flowing in the heater may not be the same as the heater's rated current. Check the heater current under actually conditions using the Heater OFF Current parameters for channels 1 to 4.
• SSR short-circuit detection status can be confirmed by reading the status for individual channels.
Calculating the Detection Current for SSR Short-circuits
Set the detection current to the value calculated with the following formula or higher.
Set value > Normal leakage current x 2
29
Setting Operation for Errors
Section 4-7
4-7 Setting Operation for Errors
The operation to be used when the following errors occur can be set.
• Zero cross error (See note 2.)
• Heater burnout detection
• Heater overcurrent detection
• SSR short-circuit detection
Operation at error
Continue with error clear
Continue without error clear
Stop
Operation
Continues.
Continues.
Stops for the channel with an error. (See note.)
Clearing the error
The error is cleared when normal status is recovered (i.e., the status ERROR indicator and alarm output are turned OFF).
The error is not cleared even if normal status is recovered. Restore normal status and then use an Operation Command
Start operation again.
The error is not cleared even if normal status is recovered and operation will remained stopped. Restore normal status and then use an Operation Command
Start operation.
Note
(1) Operation will stop for all channels if a zero cross error occurs.
(2) Zero cross error: A zero cross error will occur when there is an error in
the load power supply voltage, frequency, or waveform. Refer to SEC-
TION 5 Troubleshooting for details.
4-8 Detecting Communications Timeouts
Operation can be stopped if the time when normal communications cannot be performed exceeds the communications timeout time.
Host
Communications
G3ZA
Operating
Communications timeout time
Stopped
Note
Set value
Communications timeout time
Setting range
0 to 60 min
Default
0 (disabled)
(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 communications error bit in status, the ERROR indicator, and the alarm output will turn ON. Use an Operation Command to clear the error.
30
SECTION 5
Troubleshooting
This section provides information on problems that may occur during operation and corrective measures for them.
31
Errors
Section 5-1
5-1 Errors
Error Table
ERROR indicator
Lit
Lit
Lit
Lit
Lit
Flashing
Status Operation Error Correction
No response or an error response
Communications error bit is
ON.
Zero cross error bit is ON.
Heater burnout bit is ON.
Heater overcurrent bit is ON.
SSR short-circuit bit is ON.
Stops
Stops
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 communications timeout has occurred.
A zero cross error has been detected.
A heater burnout has been detected.
A heater overcurrent has been detected.
According to the operation at error setting
An SSR shortcircuit has been detected.
Cycle the power supply.
If operation does not recover, use the following procedure, noting that all settings will be returned to their default values.
• 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 broken.
• Check to see if a communications error has occurred.
• Check the host to see if it is functioning correctly.
• Check the information provided in 4-8 Detecting
Communications Timeouts on page 30.
• 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.
• Check the information provided in 4-4 Detecting
Heater Burnout (4-channel Models Only) on page 26.
• An overcurrent has occurred to the heater.
Return the current to the correct range.
• Check the information provided in Wiring Dia-
grams on page 9 and in 4-5 Detecting Heater
Overcurrent (4-channel Models Only) on page 28.
• The SSR has short-circuited. Replace the SSR.
• Check the information provided in Wiring Dia-
grams on page 9 and in 4-6 Detecting SSR
Short Circuits (4-channel Models Only) on page 28.
32
Handling Problems
Section 5-2
5-2 Handling Problems
Handling Problems
Preliminary Checks
Check item
Is the power supply turned ON?
Was wiring performed correctly?
Were settings performed correctly?
Items to check
If the power supply is turned ON, the READY indicator will be lit.
Check all of the wiring.
• Check the switches to see if they are set 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
Condition Correction
Communications cannot be performed.
Outputs do not turn
ON.
Returning settings to default values
• If the SD/RD indicator does not light when communications are attempted, there is a problem with the communications line. Check the wiring of the communications line.
• If a communications converter is being used, check the settings 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.
• Check the data length, number of stop bits, and parity to see if they are the same as the host. If any of the settings are incorrect or if any are unknown, use the following method for communications.
1. Set SW2 to 7. (If more than 16 communications unit numbers are used, set SW2 to F.)
2. Set the baud rate, data length, number of stop bits, and parity 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.
• Check the communications line to see if it is correct.
• Unless the OCC indicator is lit or the control variable is set to
0.0%, then there is a problem in the wiring. Check the wiring of the control outputs.
• If the ERROR indicator is lit or flashing, refer to the correc-
tions given in the Error Table on page 32.
• Initialize the settings with an Operation Command. All of the settings can be returned to their default values. Refer to the
Parameter Tables on page 38 in the Appendix for default val-
ues.
33
Handling Problems
Section 5-2
34
Appendix
Specifications
Specifications
Ratings
Control power supply voltage
100 to 240 VAC (50/60 Hz)
Control power supply voltage range 85 to 264 VAC
Power consumption
Load power supply voltage
Approx. 5.9 W
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
Manipulated variable inputs
0.0% to 100.0% (via RS-485 communications)
Current transformer inputs
Trigger outputs
Alarm output
Indications
Ambient operating temperature
Ambient operating humidity
Storage temperature
Elevation
Accessories
Single-phase AC, 0 to 50 A
One for each channel, 12 VDC
±15%, max. load current: 21 mA (with built-in short-circuit protection circuit)
NPN open collector, one output
(Max. load voltage: 30 VDC, max. load current: 50 mA, max. residual voltage:
1.5 V, max. leakage current: 1.0 mA)
LED indicators
−10 to 55°C (with no icing or condensation)
25% to 85%
−25 to 65°C (with no icing or condensation)
2,000 m max.
Instruction Sheet
Performance
Current accuracy
Insulation resistance
Dielectric strength
Vibration resistance
Shock resistance
Weight of main body
Degree of protection
Memory backup
Installation environment
Approved standards
±3 A
100 M
Ω min. (at 500 VDC) between primary and secondary
2,000 VAC, 50/60 Hz for 1 min between primary and secondary
Vibration frequency: 10 to 55 to 10 Hz, acceleration: 50 m/s
2
in X, Y, Z directions
300 m/s
2
three times each in six directions along three axes
Approx. 200 g (including terminal cover)
IP20
EEPROM (non-volatile memory), write life: 100,000 writes
Overvoltage category III, pollution degree 2 (according to IEC 60664-1)
UL508 (Listing), CSA22.2 No. 14
EN50178
EN61000-6-4 (EN55011: 1998, A1: 1999 Class A, Group 1)
EN61000-6-2: 2001
35
D
E
F
G
Model Numbers
Model Numbers
G3ZA-
ABCDE-F-G
A
Number
No. of control points
B
C
Control method
Current transformer input
Load power supply voltage
Communications specifications
Communications protocol
International standards
Code
4
8
None
2
4
H
A
03
FLK
UTU
Specifications
4 channels
8 channels
Ideal cycle control
Yes
None
100 to 240 VAC
400 to 480 VAC
RS-485
CompoWay/F
Approved by TÜV.
Current Transformer
Specifications
Model number
Item
E54-CT1
Max. continuous heater current 50 A
Dielectric strength
Vibration resistance
1,000 VAC for 1 min
98 m/s
2
, 50 Hz
Specification
E54-CT3
120 A (See note.)
Weight
Accessories
Approx. 11.5 g
None
Approx. 50 g
Connection terminals (2)
Plugs (2)
Note The maximum continuous current of the G3ZA is 50 A.
Dimensions (Unit: mm)
E54-CT1
21
15
2.8
5.8 dia.
40
30
Two, 3.8 dia.
36
Appendix
Appendix
E54-CT3
30
2.36 dia.
12 dia.
40
Two, M3 holes, depth: 4
30
Startup Operation
It takes about 1 second for the load power supply to stabilize after the power supply to the G3ZA is turned ON.
Outputs will not turn ON during this period. A stabilization period of 1 second is also executed after clearing a zero cross error.
Power ON
1 s
Example 1
Stabilization
Normal operation
Example 2
Outputs stopped
Error cleared
Zero cross error
Stabilization
Outputs stopped
Normal operation
Error cleared
Example 3
Stabilization Normal operation
Outputs stopped
Zero cross error Stabilization
Normal operation
Outputs stopped
37
Appendix
Connecting More Than 16 Controllers
9.6
19.2
38.4
57.6
---
9.6
19.2
38.4
57.6
---
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.
kbit/s sw1 sw2
2
3
0
1
9
A
4 to 7
8
B
C to F
0 1 2 3 4 5 6 7 8 9 A B C D E F
00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Note
(1) Up to 31 Controllers can be connected.
(2) Do not set SW2 to between 4 and 7 or C and F.
(3) It's easiest to set the communications unit number first and then the baud rate.
Setting example: The following settings would be used to set a Controller to communications unit number 7 and a baud rate of 38.4 kbit/s.
SW1 = 7 and SW2 = 2
Parameter Tables
Parameter Tables
Status
2
1
0
4
3
6
5
8
7
10
9
Bit
31 to 13 Not used.
12
11
Start/stop
Not used.
Not used.
Status
Alarm output (applies to all channels)
Control output
Not used.
Not used.
Communications error (applies to all channels)
Zero cross error (applies to all channels)
Not used.
Heater overcurrent
SSR short circuit
Heater burnout
Example:
Condition
Alarm output and zero cross error bit are ON.
Stopped with no errors
OFF
No
No
OFF
No
No
No
OFF
OFF
Operating
OFF
OFF
OFF
OFF
OFF
H’00000210
H’00001000
Status
---
Yes
Yes
---
Yes
Yes
Yes
---
ON
ON
---
ON
---
Stopped
---
Operating
Output
Error
38
Level Variable type
Address
Operation
C0 (See note 1.)
0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
000A
000B
000C
000D
000E
000F
0010
0011
Parameter Setting/monitor range
Version ---
CH1 control variable H’00000000 to H’000003E8 (0.0 to 100.0)
CH2 control variable H’00000000 to H’000003E8 (0.0 to 100.0)
CH3 control variable H’00000000 to H’000003E8 (0.0 to 100.0)
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
---
---
---
---
---
---
---
---
H’00000000 to H’00000037 (0 to 55)
0012
0013
0014
0015
0016
CH7 status
CH8 status
CH1 heater ON current
CH2 heater ON current
CH3 heater ON current
CH4 heater ON current
CH1 heater OFF current
CH2 heater OFF current
H’00000000 to H’00000037 (0 to 55)
H’00000000 to H’00000037 (0 to 55)
H’00000000 to H’00000037 (0 to 55)
H’00000000 to H’00000037 (0 to 55)
H’00000000 to H’00000037 (0 to 55)
0017 H’00000000 to H’00000037 (0 to 55)
C1 (See note 1.)
0018
0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
CH3 heater OFF current
CH4 heater OFF current
CH1 manipulated variable
CH2 manipulated variable
CH3 manipulated variable
CH4 manipulated variable
CH5 manipulated variable
CH6 manipulated variable
CH7 manipulated variable
CH8 manipulated variable
CH1 slope
CH2 slope
H’00000000 to H’00000037 (0 to 55)
H’00000000 to H’000003E8 (0.0 to 100.0)
H’00000000 to H’000003E8 (0.0 to 100.0)
H’00000000 to H’000003E8 (0.0 to 100.0)
H’00000000 to H’000003E8 (0.0 to 100.0)
H’00000000 to H’000003E8 (0.0 to 100.0)
H’00000000 to H’000003E8 (0.0 to 100.0)
H’00000000 to H’000003E8 (0.0 to 100.0)
H’00000000 to H’000003E8 (0.0 to 100.0)
H’00000000 to H’00000FA0 (0.0 to 400.0)
H’00000000 to H’00000FA0 (0.0 to 400.0)
Appendix
0.0
0.0
0.0
0.0
0.0
0
0
0.0
0.0
0.0
%
100.0
%
100.0
%
%
%
A
A
%
%
%
%
%
0
0
0
0
0
0
Default Unit
---
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
---
---
---
---
%
%
---
---
---
---
A
%
%
%
%
---
%
%
A
A
A
A
A
39
Appendix
Level Variable type
Operation
C1 (See note 1.)
Address
000A
000B
000C
000D
000E
000F
0010
0011
0012
0013
0014
0015
0016
0017
0018
0019
001A
001B
001C
001D
001E
001F
0020
0021
0022
0023
0024
Parameter Setting/monitor range
CH2 source channel H’00000001 to H’00000008 (1 to 8)
CH3 source channel H’00000001 to H’00000008 (1 to 8)
CH4 source channel H’00000001 to H’00000008 (1 to 8)
CH5 source channel H’00000001 to H’00000008 (1 to 8)
CH6 source channel H’00000001 to H’00000008 (1 to 8)
CH7 source channel H’00000001 to H’00000008 (1 to 8)
CH8 source channel H’00000001 to H’00000008 (1 to 8)
CH1 heater burnout detection value
H’00000000 to H’00000032 (0 to 50)
H’00000000 to H’00000032 (0 to 50) CH2 heater burnout detection value
CH3 heater burnout detection value
CH4 heater burnout detection value
CH1 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)
Default
CH3 slope
CH4 slope
CH5 slope
H’00000000 to H’00000FA0 (0.0 to 400.0)
H’00000000 to H’00000FA0 (0.0 to 400.0)
H’00000000 to H’00000FA0 (0.0 to 400.0)
100.0
%
100.0
%
100.0
%
CH6 slope
CH7 slope
H’00000000 to H’00000FA0 (0.0 to 400.0)
H’00000000 to H’00000FA0 (0.0 to 400.0)
100.0
100.0
%
%
CH8 slope
CH1 offset
CH2 offset
CH3 offset
CH4 offset
CH5 offset
CH6 offset
CH7 offset
CH8 offset
H’00000000 to H’00000FA0 (0.0 to 400.0) 100.0
%
H’FFFFF060 to H’00000FA0 (
−400.0 to 400.0)
0.0
H’FFFFF060 to H’00000FA0 (
−400.0 to 400.0)
0.0
H’FFFFF060 to H’00000FA0 (
−400.0 to 400.0)
0.0
H’FFFFF060 to H’00000FA0 (
−400.0 to 400.0)
0.0
H’FFFFF060 to H’00000FA0 (
−400.0 to 400.0)
0.0
H’FFFFF060 to H’00000FA0 (
−400.0 to 400.0)
0.0
H’FFFFF060 to H’00000FA0 (
−400.0 to 400.0)
0.0
H’FFFFF060 to H’00000FA0 (
−400.0 to 400.0)
0.0
CH1 source channel H’00000001 to H’00000008 (1 to 8) 1
%
%
%
%
%
%
%
%
---
2
3
4
5
8
0
6
7
0
0
0
50
Unit
---
---
---
A
---
---
---
---
A
A
A
A
0025
0026
0027
0028
0029
002A
002B
002C
CH2 SSR short-circuit detection value
CH3 SSR short-circuit detection value
CH4 SSR short-circuit detection value
CH1 heater overcurrent detection value
CH2 heater overcurrent detection value
CH3 heater overcurrent detection value
CH4 heater overcurrent detection value
Offset control
H’00000000 to H’00000032 (0 to 50)
H’00000000 to H’00000032 (0 to 50)
H’00000000 to H’00000032 (0 to 50)
H’00000000 to H’00000032 (0 to 50)
H’00000000 to H’00000032 (0 to 50)
H’00000000 to H’00000032 (0 to 50)
H’00000000 to H’00000032 (0 to 50)
H'00000000 (Disabled)
H'00000001 (Enabled)
50
50
50
50
50
50
50
A
A
A
A
A
A
A
Enabled ---
40
Appendix
Level Variable type
Operation
C3 (See note 1.)
Address
0000
0001
0002
0003
0004
0005
0006
0007
Parameter Setting/monitor range
Data length
(See note 2.)
H’00000000 (7)
H’00000001 (8)
Stop bits (See note 2.) H’00000000 (1)
H’00000001 (2)
Parity (See note 2.) H'00000000 (None)
H'00000001 (Even)
H'00000002 (Odd)
H’00000000 to H’00000063 (0 to 99) Send standby time
(See note 2.)
Communications timeout time (See note 2.)
Operation at error
Offset value
H'00000000 (Disabled)
H'00000001 to H'0000003C (1 to 60)
H'00000000 (Continue with error clear)
H'00000001 (Continue with no error clear)
H'00000002 (Stop) (See note 3.)
H’00000000 to H’000003E8 (0.0 to 100.0)
Hysteresis H’00000001 to H’0000000A (1 to 10)
Note
(1) If C in the variable type is changed to 8, 4-digit data can be set or monitored.
(2) These settings are valid until the G3ZA is reset or the power is turned ON again.
(3) Only the channel with the error will stop.
Default Unit
7
2
Even
20
0
0
20.0
1 bits bits
--ms min
---
%
A
ASCII Character Table
D
E
F
9
A
B
C
7
8
5
6
3
4
1
2
Upper byte
Lower byte
0 NUL
0
SOH
STX
ETX
EOT
ENQ
ACK
BEL
BS
HT
LF
VT
FF
CR
SO
SI
DLE
DC1
DC2
DC3
DC4
NAK
SYN
ETB
CAN
EM
SUB
ESC
FS
GS
RS
US
1 2
m n o l k j i g h f e c d a b
\
[
Y
Z
U
V
W
X
]
^
_
P
S
T
Q
R
K
L
I
J
E
F
G
H
M
N
O
@
A
B
C
D
;
<
:
9
7
8
5
6
=
>
?
0
3
4
1
2
,
+
)
*
(
’
%
&
.
-
/
SPACE
#
$
“
!
3 4 5 6 7
u v w x y z
|
{
}
~
DEL p t s r q
41
42
Appendix
A-B
alarm output
terminals on 200-V Controllers
terminals on 400-V Controllers
baud rate
,
C
communications specifications
,
communications terminals
,
communications timeout time
,
communications timeouts
communications unit number
,
CompoWay/F
,
end codes
,
control channels maximum number
,
control outputs turning OFF
,
control power supply terminals
controller attributes reading
,
controller status reading
,
crimp terminals
current transformer
input terminals
,
D
data length
detecting heater burnout
,
detecting heater overcurrent
,
detecting SSR short-circuits
,
E
E54-CT1
,
E54-CT3
,
echo-back test
error detection
ERROR indicator
,
errors setting operation for errors
,
Index
table
F-H
FINS-mini command and response text
,
heater burnout
,
calculating the detection current
detection
,
detection value
heater overcurrent calculating the detection current
detection
,
detection value
hysteresis
,
I-L
ideal cycle control
initializing settings
installation
,
mounting
,
removing
,
using screws
,
load power supply terminals
,
M
manipulated variable calculations
,
calculations using
changing
,
saving
model numbers
O
OCC indicator
offset control
,
offset for manipulated variable calculations
,
offsetting ON timing
,
disabled
,
enabled
,
operation command
43
44
R
READY indicator
,
resetting software reset
,
S
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
SW1
,
SW2
,
T-Z
trigger output terminals
,
troubleshooting
handling problems
,
wiring example
,
zero cross errors
,
Index
Revision History
A manual revision code appears as a suffix to the catalog number on the front cover of the manual.
Cat. No. Z200-E1-01
Revision code
The following table outlines the changes made to the manual during each revision. Page numbers refer to the previous version.
Revision code
01
Date
April 2004 Original production
Revised content
45
46
Revision History
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Suitability of Use. Omron Companies shall not be responsible for conformity with any standards, codes or regulations which apply to the combination of the
Product in the Buyer’s application or use of the Product. At Buyer’s request,
Omron will provide applicable third party certification documents identifying ratings and limitations of use which apply to the Product. This information by itself is not sufficient for a complete determination of the suitability of the Product in combination with the end product, machine, system, or other application or use. Buyer shall be solely responsible for determining appropriateness of the particular Product with respect to Buyer’s application, product or system.
Buyer shall take application responsibility in all cases but the following is a non-exhaustive list of applications for which particular attention must be given:
(i) Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this document.
(ii) Use in consumer products or any use in significant quantities.
(iii) Energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety equipment, and installations subject to separate industry or government regulations.
(iv) Systems, machines and equipment that could present a risk to life or property. Please know and observe all prohibitions of use applicable to this Product.
NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS
RISK TO LIFE OR PROPERTY OR IN LARGE QUANTITIES WITHOUT
ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO
ADDRESS THE RISKS, AND THAT THE OMRON’S PRODUCT IS PROP-
ERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE
OVERALL EQUIPMENT OR SYSTEM.
2.
Programmable Products. Omron Companies shall not be responsible for the user’s programming of a programmable Product, or any consequence thereof.
3.
Performance Data. Data presented in Omron Company websites, catalogs and other materials 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 user must correlate it to actual application requirements. Actual performance is subject to the Omron’s Warranty and Limitations of Liability.
4.
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 part numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the Product may be changed without any notice. When in doubt, special part numbers may be assigned to fix or establish key specifications for your application. Please consult with your Omron’s representative at any time to confirm actual specifications of purchased Product.
5.
Errors and Omissions. Information presented by Omron Companies has been checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical or proofreading errors or omissions.
OMRON ELECTRONICS LLC
1
Commerce Drive
Schaumburg, IL
60173
847.843.7900
For US technical support or other inquiries:
800.556.6766
OMRON CANADA, INC.
885
Milner Avenue
Toronto, Ontario M
1
B
5
V
8
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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