Omron G3ZA User Manual

Multi-channel Power Controller

)

G3ZA

Optimum Cycle Control for High-precision Control with Low Noise

• Smaller than a Normal Power Controller.

• Enables low-noise power control in combination with zero-cross SSRs. (See note.)

• One Controller can control up to 8 SSRs.

• RS-485 communications to set manipulated variables and heater burnout detection. The Smart FB Library for the G3ZA can also be used.

•CE Marking

Main Upgraded Functions

• Soft-start function added for lamp heaters.

• Three-phase optimum cycle control added for three-phase heaters.

Version Upgrade for Improved Functionality (V2)

• Combining with special CT for150-A current detection.

Note: The G3ZA must be used in combination with an SSR without the zero cross

function when the soft-start function is used.

Refer to Safety Precautions on page 9 for safety information.

Features

Comparison between the G3ZA and Normal Power Controllers

Item Normal Power Controllers G3ZA

Connections

Power Controllers Controlled Using Current Output of 4 to 20 mA Control Using Communications from a Host Device

Multi-channel Temperature Controller

• Direct connection is possible using an EJ1 Modular Temperature Controller.

EJ1N

EJ1N-TC4 or

-HFU

PWR

COM1

RUN

COM2

EJ1-HFU

ERR

COM3

ALM

SW1

Modular Temperature Controller (EJ1)

SW1

21345678

SW2

EJ1N-TC2

PWR

COM1

RUN

COM2

EJ1-TC4

ERR

COM3

ALM

SW1

21345678

SW2

EJ1C

-EDU

PWR

COM1

RUN

COM2

EJ1-TC4

ERR

COM3

ALM

SW1

21345678

SW2

Control method

Power Controller

4 to 20 mA commands

Power Controller Power Controlle

Programmable Controller

Power controller Power controller Power controller Power controller

8 total

Phase Control

• Response is fast and high-precision temperature control is possible.

• Harmonics and noise are problems.

READY

SD/RD

SW1

OCC

SW2

ERROR

Eight SSRs

G3ZA

RS-485 commands

READY

SD/RD

SW1

OCC

SW2

ERROR

Eight SSRs

G3ZA

Programmable Controller

READY

SD/RD

SW1

OCC

SW2

ERROR

G3ZA

Eight SSRs

Serial Communications Unit (RS-485

G3ZA-8 SSR SSR SSR SSR

8 total

Optimum Cycle Control (High-precision Zero Cross Control)

• Outputs are turned ON and OFF each half cycle.

• Zero-cross control is performed.

• Noise is suppressed while achieving high-speed response with high-

precision temperature control.

Multi-channel Power Controller G3ZA 1

Model Number Structure

■ Model Number Legend

G3ZA- @ @ @ @ @ - @ - @

12 34

No. Meaning Code Specifications No. Meaning Code Specifications 1 No. of control points 4 4 channels 4 Load power supply voltage 2 100 to 240 VAC

2 Control method None Optimum cycle control 5 Communications specifications 03 RS-485 3 Heater burnout detection H Yes 6 Communications protocol FLK CompoWay/F

567

8 8 channels 4 400 to 480 VAC

A None 7 International standards UTU Approved by TÜV, UL, and

CSA.

Ordering Information

■ List of Models

Name Number of control channels Heater burnout detection Load power supply voltage Model

Multi-channel Power Controller

Note: When using the heater burnout detection function, CTs must be ordered separately.

4 Supported 100 to 240 VAC G3ZA-4H203-FLK-UTU

400 to 480 VAC G3ZA-4H403-FLK-UTU

8 Not supported 100 to 240 VAC G3ZA-8A203-FLK-UTU

400 to 480 VAC G3ZA-8A403-FLK-UTU

Upgraded Functionality

Refer to page 7 for details. Upgrade functions are marked with “V2”.

■ Accessories (Order Separately)

Name Hole diameter Detection

Current Transformer (CT)

5.8 dia. 0 to 50 A E54-CT1

12.0 dia. 0 to 50 A E54-CT3

30.0 dia. 0 to 150 A G3ZA-CT150L

current

Model

Name Model

DIN Track PFP-100N

PFP-50N

End Plates (stoppers) PFP-M

Be sure to read the precautions for correct use and other precautions in the following user’s manual before using the Power Controller.

G3ZA Multi-channel Power Controller User’s Manual (Cat. No. Z200)

2 Multi-channel Power Controller G3ZA

Specifications

■ Ratings

Item Power supply voltage 100 to 240 VAC (50/60 Hz) Operating voltage range 85 to 264 VAC Power consumption 16 VA max. Load power supply voltage 100 to 240 VAC 400 to 480 VAC Load power supply voltage range 75 to 264 VAC 340 to 528 VAC Manipulated variable input 0.0% to 100.0% (via RS-485 communications) Current transformer input (See note 1.) Single-phase AC, 0 to 50 A (primary current of CT)

Trigger output One voltage output for each channel, 12 VDC

Alarm output NPN open collector, one output

Indications LED indicators Control method Optimum cycle control

Ambient operating temperature Ambient operating humidity 25% to 85% Storage temperature −25 to 65°C (with no icing or condensation) Elevation 2,000 m max. Accessories Instruction Sheet

Note: 1. CT inputs are provided only on Models with heater burnout detection.

2. Use an SSR without the zero-cross function (G3PA-@BL-VD) for soft-start optimum cycle control. (Refer to page 11.)

Load power supply

voltage range

Single-phase AC, 0 to 150 A (primary current of CT)

(with built-in short-circuit protection circuit)

Max. applicable voltage: 30 VDC, Max. load current: 50 mA Residual voltage: 1.5 V max., Leakage current: 0.4 mA max.

Soft-start optimum cycle control (See note 2.) Three-phase optimum cycle control

−10 to 55°C (with no icing or condensation)

■ Performance

100 to 240 VAC 400 to 480 VAC

±15%, Max. load current: 21 mA

■ Communications Specifications

Current indication accuracy

Insulation resistance 100 M

Dielectric strength 2,000 VAC, 50/60 Hz for 1 min between primary

Vibration resistance Vibration frequency: 10 to 55 Hz,

Shock resistance

Weight Approx. 200 g (including terminal cover) Degree of protection IP20 Memory protection EEPROM (non-volatile memory) (number of

Installation environment Overvoltage category III,

Approved standards UL508 (Listing), CSA22.2 No. 14

Note: When measured with percentage selected for the current monitor

parameter and the maximum current measurable with the CT at 100%.

Current Range

0 to 50 A, 0 to 150 A, ±9 A 0 to 100%, ±6% (See note.)

(for models with heater burnout detection)

secondary

and secondary

acceleration: 50 m/s 300 m/s

three axes

writes: 100,000)

pollution degree 2 (according to IEC 60664-1)

EN50178 EN61000-6-4 (EN55011: 1998, A1: 1999 Class A, Group 1) EN61000-6-2: 2001

±3 A

Ω min. (at 500 VDC) between primary and

three times each in six directions along

in X, Y, and Z directions

Transmission line connections Multipoint Communications method RS-485

Max. transmission distance 500 m

No. of nodes 31 (via multidrop connections) Synchronization method Stop-start synchronization Communications baud rate 9.6, 19.2, 38.4 or 57.6 kbps,

Transmission code ASCII Communications data length 7 or 8 bits, Default: 7 Communications stop bits 1 or 2 bits, Default: 2 Communications parity Vertical parity: None, even, or odd,

Flow control None

Current Transformer Specifications

■

(Order Separately)

Item Specification

Model number E54-CT1 E54-CT3 G3ZA-CT150L

Max. continuous heater current

Detection current with G3ZA connected

Dielectric strength 1,000 VAC for 1 min 2,000 VAC for 1

Vibration resistance Weigh t Approx. 11.5 g Approx. 50 g Approx. 130 g Accessories None Connection

Note: The maximum continuous current is 50 A for the G3ZA in combination

with the E54-CT3.

50 A 120 A (See note.) 150 A

50 A 150 A

98 m/s

Default: 9.6 kbps

Default: Even

, 50 Hz

terminals (2) Plugs (2)

min

None

Multi-channel Power Controller G3ZA 3

Applicable SSR and Control

Methods

The G3ZA can be used for a variety of applications by selecting the SSR drive. For example, inrush current can be reduced at startup by selecting soft-start optimum cycle control if a single-phase halogen heater is used.

SSR Control

Single-phase heater SSR with zerocross function

Single-phase heater SSR without zerocross function

Three-phase heater SSR with zerocross function

method

Optimum cycle control

Soft-start optimum cycle control

Three-phase optimum cycle control

CT (4-channel

models only)

0 to 50 A or 0 to 150 A: 4 Units

0 to 50 A or 0 to 150 A: up to 2 Units

Example of

supported

heater

SIngle-phase heater

Single-phase halogen heater

Three-phase heater

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%

Setting the Control Switching MV Threshold

The Control Switching MV Threshold function is enabled when softstart optimum cycle control is used. Setting the Control Switching MV Threshold enables switching to phase control when the current value is below the set value, and switching to optimum cycle control when the current value is above the set value. The default setting is 20.0%.

Variable

type

85/C5 Ch1 to Ch8 Control

Example: For channel 1, soft-start optimum cycle control is performed under the following conditions: control switching MV:

40.0%, MV: 100.%, soft startup time: 20 s. (1) Ch 1 Control Switching MV Threshold is set to 40.0% and Ch1

MV is set to 100.0% by writing to the variable area.

(2) Ch1 Soft Startup Time remains at the default. Setting is not

required.

(3) Once the Control Switching MV Threshold is written, the

changes are saved and become enabled the next time the power is turned ON.

100.0%

40.0%

Parameter Setting

Switching MV Threshold

Soft startup time (20 s)

range

0.0% to

100.0%

Default

20.0

Tim

Note: Refer to Connection Configuration on page 6 for connecting to

an SSR.

Soft-start Optimum Cycle Control

• Soft-start optimum cycle control is a control method that combines phase control and optimum cycle control.

• Smooth switching for phase control and optimum cycle control enables control of outputs with limited inrush current even for loads with characteristics like halogen heaters.

• Use a single-phase heater SSR (without the zero-cross function) for soft-start optimum cycle control. Refer to G3PA on page 11 for details on SSRs without the zero-cross function.

• Control is switched according to the Control Switching MV Threshold.

• Set the Soft-start Up/Down Time to control output.

• Current is not detected during phase control. The current value

(heater ON current value, heater OFF current value, and effective current value) will be 0 A, and the current error alarm (heater burnout detection, SSR short-circuit detection, and heater overcurrent detection) will always turn OFF.

Phase control Optimum cycle control

Three-phase Optimum Cycle Control

• Three-phase optimum cycle control is a control method that turns the output ON and OFF every two cycles.

• Turning the output ON and OFF every two cycles enables optimum cycle control for three-phase heaters.

• Use a three-phase heater SSR with a zero-cross function for threephase optimum cycle control.

Note: Refer to page 6 for details on connecting to three-phase

heaters.

The following figure shows the current waveform of each phase for a MV of 50% when a three-phase heater SSR is connected.

Load power supply

R-S phase

S-T phase

R-T phase

4 Multi-channel Power Controller G3ZA

Connections

■ Terminal Arrangement

Models with 8 Channels (Control Points), No CT Inputs, and No Heater Burnout Detection

Trigger output 12 VDC, 21 mA

Trigger output

12 VDC, 21 mA

19 20 21 22 23 24

CH5 CH6 COM CH7 CH8 COM CH1 CH2 COM CH3 CH4 COM

Trigger output 12 VDC, 21 mA

Trigger output

12 VDC, 21 mA

Trigger output

−

12 VDC, 21 mA

Trigger output

−

12 VDC, 21 mA

Trigger output

12 VDC, 21 mA

−

13 14 15 16 17 18

CH1 CH2 COM CH3 CH4 COM CH1 CH2 COM CH3 CH4 COM

READY

SD/RD

OCC

Models with Load Power Supply Voltage

ERROR

of 100 to 240 V

89 11

RS-485

B (+) A (−)

Alarm output 30 VDC, 50 mA

12 4 6

Power supply voltage 100 to 240 VAC 50/60 Hz

Load power supply voltage 100 to 240 VAC 50/60 Hz

Note: Connect the power supply (100 to 240 VAC) for the

G3ZA across terminals 1 and 2 and the load power supply for the SSR loads across terminals 4 and 6.

Note: 1. The following CTs can be used (sold separately):

0 to 50 A: E54-CT1 and E54-CT3 0 to 150 A: G3ZA-CT150L

2. Use C-Grid SL connectors from Molex Inc. C-Grid SL Housing

Model: 51030-0630

READY

SD/RD

OCC

ERROR

Models with 4 Channels (Control Points), CT Inputs, and Heater Burnout Detection

(See note 1.)

(See note 1.) (See note 1.)

(See note 1.)

19 20 21 22 23 24

Trigger output 12 VDC, 21 mA

Trigger output

12 VDC, 21 mA

Trigger output

−

12 VDC, 21 mA

Trigger output

12 VDC, 21 mA

−

13 14 15 16 17 18

SW1

SW2

Alarm output connector (See note 2.) (only models with load power supply voltage of 400 to 480 V)

SW2

Models with Load Power Supply Voltage of 400 to 480 V

RS-485

B (+) A (−)

A B

30 VDC, 50 mA

Alarm output

12 4 6

Power supply voltage 100 to 240 VAC 50/60 Hz

Load power supply voltage 400 to 480 VAC 50/60 Hz

Note: Connect the power supply (100 to 240 VAC) for the

G3ZA across terminals 1 and 2 and the load power supply for the SSR loads across terminals 4 and 6.

Operation Indicators

Operation indicator Meaning

READY (Green) Lit while power is being supplied. SD/RD (Orange) Lit while communicating with the host. OCC (Orange) Lit while a control output is ON. ERROR (Red) Lights or flashes when an error is detected.

Setting Switches

• Always turn OFF the power supply before setting the switches. The

switch settings are read only when the power supply is turned ON.

• Use a flat-blade screwdriver to set the switches and be sure not to leave a switch set between two settings.

SW1 SW2

Communications Unit Number

Set a communications unit number on SW1 so that the host system can identify the Controller.

SW1 0123456789ABCDEF Unit No. 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15

▲

Default

Note: A unique unit number must be set for each node (Controller) on

the same communications line. Do not set the same unit number for more than one node. If 17 or more Units must be connected, refer to the G3ZA Multichannel Power Controller User’s Manual (Cat. No. Z200).

Communications Baud Rate

Set the baud rate for communicating with the host system on SW2.

SW2 01234 to F Baud rate 9.6 19.2 38.4 57.6 Do not set.

▲

Default

Multi-channel Power Controller G3ZA 5

■ Connection Configuration

Single-phase SSR

R phase S phase T phase

Host device

Control power supply

Load power supply

G3ZA

Trigger signal

SSR

Three-phase SSR

R phase S phase T phase

Load power supply

Host device

Control power supply

G3ZA

Trigger signal

CT (4-channel model only)

Example for Connecting Two SSRs

Note: Connect a power supply with the same phase as the SSRs to

the load power supply terminals on the G3ZA.

Load

(e.g., heater)

Load

(e.g., heater)

Note: Connect to one of the three phases on the load power supply

input terminals of the G3ZA.

■ Host Device Connection Example

Example of Connection to EJ1 Modular Temperature Controller

EJ1N-TC4

PWR RUN ERR ALM

SW1

SW2

21345678

EJ1N-TC2

PWR

COM1

RUN

COM2

EJ1-TC4

ERR

COM3

ALM

SW1

SW2

21345678

EJ1C-EDU

PWR

COM1

RUN

COM2

EJ1-TC4

ERR

COM3

ALM

SW1

21345678

SW2

Port A (connector): USB connection possible using a E58-CIFQ1 (sold separately)

Port B: RS-485 (CompoWay/F)

Host Devices

SSR (threephase)

Load

CX-Thermo for setup

G3ZA Connection port

READY

SD/RD

SW1

OCC

SW2

ERROR

G3ZA Connection port

READY

SD/RD

SW1

OCC

SW2

ERROR

G3ZA

Example of Connection to PLC

PLC

RS-485

G3ZA

Power supply for Multi-channel Power Controller

Load power supply (for zero-cross detection)

G3ZA Connection port

READY

SD/RD

SW1

OCC

SW2

ERROR

G3ZAG3ZA

Alarm output

Eight SSRs Eight SSRs Eight SSRs

Heater

SSR

PLC PT

6 Multi-channel Power Controller G3ZA

+ 14 hidden pages