Omron G3ZA-4H203-FLK-UTU, G3ZA-4H403-FLK-UTU, G3ZA-8A203-FLK-UTU, G3ZA-8A403-FLK-UTU User Manual

Multi-channel Power Controller G3ZA 1

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.

• 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.

Version Upgrade for Improved Functionality (V2)

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

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

Control
method

Phase Control

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

• Harmonics and noise are problems.

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.

Power Controller Power Controlle

r

Power Controller

Multi-channel Temperature Controller

EJ1N

-HFU

EJ1N-TC4 or

EJ1N-TC2

Modular Temperature
Controller (EJ1)

EJ1C

-EDU

COM1
COM2
COM3

PWR
RUN
ERR
ALM

SW1

ON

SW2

21345678

EJ1-TC4

0

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

COM1
COM2
COM3

PWR
RUN
ERR
ALM

SW1

ON

SW2

21345678

EJ1-TC4

0

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

COM1
COM2
COM3

PWR
RUN
ERR
ALM

SW1

ON

SW2

21345678

EJ1-TC4

0

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

COM1
COM2
COM3

PWR
RUN
ERR
ALM

SW1

ON

SW2

21345678

EJ1-HFU

0

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

SW2

SW1

ERROR

OCC

SD/RD

READY

SW2

SW1

ERROR

OCC

SD/RD

READY

SW2

SW1

ERROR

OCC

SD/RD

READY

G3ZA

Eight SSRs

G3ZA

Eight SSRs

G3ZA

Eight SSRs

Power controller Power controller Power controller Power controller

8 total

Programmable Controller

4 to 20 mA commands

G3ZA-8 SSR SSR SSR SSR

8 total

Programmable Controller

RS-485 commands

Serial Communications Unit (RS-485

)

2 Multi-channel Power Controller G3ZA

Model Number Structure

■ Model Number Legend

Ordering Information

■ List of Models

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

■ Accessories (Order Separately)

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

8 8 channels 4 400 to 480 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

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

CSA.

12 34

G3ZA- @ @ @ @ @ - @ - @

567

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

Multi-channel Power
Controller

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”.

Name Hole diameter Detection

current

Model

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

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)

Multi-channel Power Controller G3ZA 3

Specifications

■ Ratings

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.)

■ Performance

Note: When measured with percentage selected for the current monitor

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

■ Communications Specifications

■

Current Transformer Specifications
(Order Separately)

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

with the E54-CT3.

Item

Load power supply

voltage range

100 to 240 VAC 400 to 480 VAC

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)

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

Trigger output One voltage output for each channel, 12 VDC

±15%, Max. load current: 21 mA

(with built-in short-circuit protection circuit)

Alarm output NPN open collector, one output

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

Indications LED indicators
Control method Optimum cycle control

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

Ambient operating temperature

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

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

V2

V2

V2

Current indication
accuracy

Current Range

0 to 50 A,

±3 A

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

(for models with heater burnout detection)

Insulation resistance 100 M

Ω min. (at 500 VDC) between primary and

secondary

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

and secondary

Vibration resistance Vibration frequency: 10 to 55 Hz,

acceleration: 50 m/s

2

in X, Y, and Z directions

Shock resistance

300 m/s

2

three times each in six directions along

three axes

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

writes: 100,000)

Installation environment Overvoltage category III,

pollution degree 2 (according to IEC 60664-1)

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

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

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,

Default: 9.6 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,

Default: Even

Flow control None

Item Specification

Model number E54-CT1 E54-CT3 G3ZA-CT150L

Max. continuous
heater current

50 A 120 A (See note.) 150 A

Detection current
with G3ZA
connected

50 A 150 A

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

min

Vibration resistance

98 m/s

2

, 50 Hz

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

terminals (2)
Plugs (2)

None

4 Multi-channel Power Controller G3ZA

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.

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.

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.

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%.

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.

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 three-

phase 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.

SSR Control

method

CT (4-channel

models only)

Example of

supported

heater

Single-phase
heater SSR
with zero­cross function

Optimum cycle
control

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

SIngle-phase
heater

Single-phase
heater SSR
without zero­cross function

Soft-start
optimum cycle
control

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

Single-phase
halogen
heater

Three-phase
heater SSR
with zero­cross function

Three-phase
optimum cycle
control

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

Three-phase
heater

V2

V2

V2

1/5th ON (20%)

Manipulated
variable: 20%

V2

Variable

type

Parameter Setting

range

Default

85/C5 Ch1 to Ch8 Control

Switching MV
Threshold

0.0% to

100.0%

20.0

Phase control Optimum cycle control

Soft startup time (20 s)

100.0%

MV

Tim

e

40.0%

V2

Load power
supply

R-S phase

S-T phase

R-T phase

Multi-channel Power Controller G3ZA 5

Connections

■ Terminal Arrangement

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.

Operation Indicators

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.

Communications Unit Number

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

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.

+

+

+

+

−

+

+

+

−

+

−

+

+

+

−

+

−

Trigger output
12 VDC, 21 mA

Trigger output
12 VDC, 21 mA

Trigger output
12 VDC, 21 mA

Trigger output
12 VDC, 21 mA

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

Trigger output
12 VDC, 21 mA

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

Trigger output
12 VDC, 21 mA

Alarm output
30 VDC, 50 mA

Power supply voltage
100 to 240 VAC
50/60 Hz

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

Models with Load Power Supply Voltage
of 100 to 240 V

Power supply voltage
100 to 240 VAC
50/60 Hz

Models with Load Power
Supply Voltage of 400 to 480 V

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

19 20 21 22 23 24

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

13 14 15 16 17 18

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

19 20 21 22 23 24

13 14 15 16 17 18

CT

CT

CT

CT

7

B (+) A (−)

RS-485

89 11

12 4 6

7

RS-485

8

12 4 6

B

A

SW2

SW1

ERROR

OCC

SD/RD

READY

ERROR

OCC

SD/RD

READY

SW1

SW2

−

B (+) A (−)

(See note 1.)

(See note 1.)

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

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

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: 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.

30 VDC, 50 mA

Alarm output

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

Trigger output

12 VDC,
21 mA

C-Grid SL Housing
Model: 51030-0630

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.

SW1 SW2

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

▲

Default

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

▲

Default

6 Multi-channel Power Controller G3ZA

■ Connection Configuration

Single-phase SSR

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

the load power supply terminals on the G3ZA.

Three-phase SSR

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

Example of Connection to PLC

Trigger
signal

G3ZA

Example for Connecting Two SSRs

R phase
S phase
T phase

Host device

Control
power
supply

SSR

CT (4-channel model only)

SSR

Load

(e.g., heater)

Load

(e.g., heater)

Load power
supply

V2

G3ZA

R phase
S phase
T phase

Host device

Control
power
supply

Load

Trigger signal

SSR
(three­phase)

CT (4-channel model only)

Load power
supply

Eight SSRs Eight SSRs Eight SSRs

SW2

SW1

ERROR

OCC

SD/RD

READY

G3ZA

PC

PLC PT

PC

EJ1N-TC4

or

EJ1N-TC2

EJ1C-EDU

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

Port B: RS-485 (CompoWay/F)

COM1
COM2
COM3

PWR
RUN
ERR
ALM

SW1

ON

SW2

21345678

EJ1-TC4

0

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

COM1
COM2
COM3

PWR
RUN
ERR
ALM

SW1

ON

SW2

21345678

EJ1-TC4

0

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

COM1
COM2
COM3

PWR
RUN
ERR
ALM

SW1

ON

SW2

21345678

EJ1-TC4

0

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

SW2

SW1

ERROR

OCC

SD/RD

READY

SW2

SW1

ERROR

OCC

SD/RD

READY

G3ZAG3ZA

Host Devices

G3ZA
Connection port

G3ZA
Connection port

G3ZA
Connection port

CX-Thermo for setup

PLC

Alarm output

Load power supply
(for zero-cross detection)

Power supply for
Multi-channel
Power Controller

RS-485

Heater

G3ZA

SSR