OMRON ZEN User Manual
Cat. No. Z183-E1-01A
OPERATION MANUAL
ZEN Programmable Relay
ZEN Programmable Relay
Operation Manual
Produced May 2003
Terms and Conditions of Sale
1. Offer; Acceptance. These terms and conditions (these "Terms") are deemed
part of all quotes, agreements, purchase orders, acknowledgments, price lists,
catalogs, manuals, brochures and other documents, whether electronic or in
writing, relating to the sale of products or services (collectively, the "Products
by Omron Electronics LLC and its subsidiary companies (“Omron
objects to any terms or conditions proposed in Buyer’s purchase order or other
documents which are inconsistent with, or in addition to, these Terms.
2. Prices; Payment Terms.
out notice by Omron. Omron reserves the right to increase or decrease prices
on any unshipped portions of outstanding orders. Payments for Products are
due net 30 days unless otherwise stated in the invoice.
3. Discounts.
sent to Buyer after deducting transportation charges, taxes and duties, and will
be allowed only if (i) the invoice is paid according to Omron’s payment terms
and (ii) Buyer has no past due amounts.
Omron, at its option, may charge Buyer 1-1/2% interest per month or
4. Interest.
the maximum legal rate, whichever is less, on any balance not paid within the
stated terms.
. Omron will accept no order less than $200 net billing.
5. Orders
6. Governmental Approvals.
costs involved in, obtaining any government approvals required for the importation or sale of the Products.
. All taxes, duties and other governmental charges (other than general
7. Taxes
real property and income taxes), including any interest or penalties thereon,
imposed directly or indirectly on Omron or required to be collected directly or
indirectly by Omron for the manufacture, production, sale, delivery, importation, consumption or use of the Products sold hereunder (including customs
duties and sales, excise, use, turnover and license taxes) shall be charged to
and remitted by Buyer to Omron.
8. Financial.
to Omron, Omron reserves the right to stop shipments or require satisfactory
security or payment in advance. If Buyer fails to make payment or otherwise
comply with these Terms or any related agreement, Omron may (without liability and in addition to other remedies) cancel any unshipped portion of Products sold hereunder and stop any Products in transit until Buyer pays all
amounts, including amounts payable hereunder, whether or not then due,
which are owing to it by Buyer. Buyer shall in any event remain liable for all
unpaid accounts.
9. Cancellation; Etc.
unless Buyer indemnifies Omron against all related costs or expenses.
10. Force Majeure
resulting from causes beyond its control, including earthquakes, fires, floods,
strikes or other labor disputes, shortage of labor or materials, accidents to
machinery, acts of sabotage, riots, delay in or lack of transportation or the
requirements of any government authority.
11. Shipping; Delivery.
a.Shipments shall be by a carrier selected by Omron; Omron will not drop ship
except in “break down” situations.
b.Such carrier shall act as the agent of Buyer and delivery to such carrier shall
constitute delivery to Buyer;
c. All sales and shipments of Products shall be FOB shipping point (unless oth-
erwise stated in writing by Omron), at which point title and risk of loss shall
pass from Omron to Buyer; provided that Omron shall retain a security inter-
est in the Products until the full purchase price is paid;
d.Delivery and shipping dates are estimates only; and
e.Omron will package Products as it deems proper for protection against nor-
mal handling and extra charges apply to special conditions.
Any claim by Buyer against Omron for shortage or damage to the
12. Claims.
Products occurring before delivery to the carrier must be presented in writing
to Omron within 30 days of receipt of shipment and include the original transportation bill signed by the carrier noting that the carrier received the Products
from Omron in the condition claimed.
13. Warranties
Products will be free from defects in materials and workmanship for a period of
twelve months from the date of sale by Omron (or such other period expressed
in writing by Omron). Omron disclaims all other warranties, express or implied.
(b) Limitations
EXPRESS OR IMPLIED, ABOUT NON-INFRINGEMEN T, MERCHANTABIL-
All prices stated are current, subject to change with-
Cash discounts, if any, will apply only on the net amount of invoices
Buyer shall be responsible for, and shall bear all
If the financial position of Buyer at any time becomes unsatisfactory
Orders are not subject to rescheduling or cancellation
. Omron shall not be liable for any delay or failure in delivery
Unless otherwise expressly agreed in writing by Omron:
. (a) Exclusive Warranty. Omron’s exclusive warranty is that the
. OMRON MAKES NO WARRANTY OR REPRESENTATION,
”). Omron
ITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCTS.
BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE
PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR
")
INTENDED USE. Omron further disclaims all warranties and responsibility of
any type for claims or expenses based on infringement by the Products or otherwise of any intellectual property right. (c) Buyer Remedy
gation hereunder shall be, at Omron’s election, to (i) replace (in the form
originally shipped with Buyer responsible for labor charges for removal or
replacement thereof) the non-complying Product, (ii) repair the non-complying
Product, or (iii) repay or credit Buyer an amount equal to the purchase price of
the non-complying Product; provided that in no event shall Omron be responsible for warranty, repair, indemnity or any other claims or expenses 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. Return of any Products by
Buyer must be approved in writing by Omron before shipment. Omron Companies shall not be liable for the suitability or unsuitability or the results from the
use of Products in combination with any electrical or electronic components,
circuits, system assemblies or any other materials or substances or environments. Any advice, recommendations or information given orally or in writing,
are not to be construed as an amendment or addition to the above warranty.
See http://oeweb.omron.com or contact your Omron representative for published information.
14. Limitation on Liability; Etc
FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES,
LOSS OF PROFITS OR P RODUCTION OR COM MERCIAL LOSS IN AN Y
WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS
BASED IN CONTRACT, WARRANTY, NEGLIGENCE OR STRICT LIABILITY.
Further, in no event shall liability of Omron Companies exceed the individual
price of the Product on which liability is asserted.
15. Indemnities
16. Property; Confidentiality.
17. Export Controls.
18. Miscellaneous
. Buyer shall indemnify and hold harmless Omron Companies and
their employees from and against all liabilities, losses, claims, costs and
expenses (including attorney's fees and expenses) related to any claim, investigation, litigation or proceeding (whether or not Omron is a party) which arises
or is alleged to arise from Buyer's acts or omissions under these Terms or in
any way with respect to the Products. Without limiting the foregoing, Buyer (at
its own expense) shall indemnify and hold harmless Omron and defend or settle any action brought against such Companies to the extent based on a claim
that any Product made to Buyer specifications infringed intellectual property
rights of another party.
sive property of Omron Companies and Buyer shall not attempt to duplicate it
in any way without the written permission of Omron. Notwithstanding any
charges to Buyer for engineering or tooling, all engineering and tooling shall
remain the exclusive property of Omron. All information and materials supplied
by Omron to Buyer relating to the Products are confidential and proprietary,
and Buyer shall limit distribution thereof to its trusted employees and strictly
prevent disclosure to any third party.
licenses regarding (i) export of products or information; (iii) sale of products to
“forbidden” or other proscribed persons; and (ii) disclosure to non-citizens of
regulated technology or information.
and no course of dealing between Buyer and Omron shall operate as a waiver
of rights by Omron. (b) Assignment
without Omron's written consent. (c) Law.
law of the jurisdiction of the home office of the Omron company from which
Buyer is purchasing the Products (without regard to conflict of law principles). (d) Amendment
Buyer and Omron relating to the Products, and no provision may be changed
or waived unless in writing signed by the parties. (e) Severability
sion hereof is rendered ineffective or invalid, such provision shall not invalidate
any other provision. (f) Setoff
against the amount owing in respect of this invoice. (g) Definitions
herein, “including
nies” (or similar words) mean Omron Corporation and any direct or indirect
subsidiary or affiliate thereof.
. OMRON COMPANIES SHALL NOT BE LIABLE
Any intellectual property in the Products is the exclu-
Buyer shall comply with all applicable laws, regulations and
. (a) Waiver. No failure or delay by Omron in exercising any right
. Buyer may not assign its rights hereunder
. These Terms constitute the entire agreement between
. Buyer shall have no right to set off any amounts
” means “including without limitation”; and “Omron Compa-
Certain Precautions on Specifications and Use
1. 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 H AS BEEN DESIGNED TO
ADDRESS THE RISKS, AND THAT THE OMRON’S PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN TH E
OVERALL EQUIPMENT OR SYSTEM.
2. Programmable Products.
user’s programming of a programmable Product, or any consequence thereof.
3. Performance Data
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
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.
checked and is believed to be accurate; however, no responsibility is assumed
for clerical, typographical or proofreading errors or omissions.
Omron Companies shall not be responsible for the
. Data presented in Omron Company websites, catalogs
. Product specifications and accessories may be
Information presented by Omron Companies has been
. Omron’s sole obli-
These Terms are governed by the
. If any provi-
. As used
Notice:
OMRON products are manufactured for use according to proper procedures by a
qualified operator and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always heed the information provided with them. Failure to heed precautions
can result in injury to people or damage to property.
!DANGER Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
!WARNING Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
!Caution Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury, or property damage.
v
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it refers to an OMRON product, regardless of whether or not it appears in
the proper name of the product.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of information.
Note
Indicates information of particular interest for efficient and convenient
operation of the product.
1,2,3... 1. Indicates lists of one sort or another, such as procedures, check-
lists, etc.
Precaution Indicates precautionary information that should be heeded in using
the ZEN.
RUN
PARAMETE R
SET CL OCK
LANGUAGE
▲▼
Indicates that the display (the word “LANGUAGE” in this case) is
flashing. In this manual, this state is described by saying that the
“flashing cursor” is at the word “LANGUAGE”. In this state it is possible to change settings and the position of the cursor.
LANGUAGE
Indicates that the display (the letter “H” in this case) is flashing in
reverse video. In this manual, this state is described by saying that
ENGLISH
the “highlighted cursor” is at the word “H”. In this state it is not possible to change settings but the cursor can be changed to the flashing
cursor by pressing the OK button.
Indicate the buttons that needs to be pressed in operating procedures. Press each button once.
Indicate buttons that needs to be pressed in operating procedures.
Press one of the buttons once or more.
Ó OMRON, 2003
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.
vi
TABLE OF CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
2 Application Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
3 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
4 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
5 Operating Mode at Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
6 Memory Backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx
7 Version Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
SECTION 1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 Features and Part Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-3 Display Screen and Basic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1-4 Memory Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1-5 Allocating I/O Bit Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1-6 Preparations for Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 2
Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2-1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2-2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 3
Programming and Operating Methods . . . . . . . . . . . . . . . . . . . . .49
3-1 Selecting Display Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3-2 Setting the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3-3 Creating Ladder Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3-4 Confirming Ladder Program Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3-5 Correcting Ladder Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3-6 Using Timers (T) and Holding Timers (#). . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3-7 Using Counters (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3-8 Using Weekly Timers (@) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3-9 Using Calendar Timers (*). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3-10 Analog Inputs (Analog Comparators (A)). . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3-11 Comparing Timer/Counter Present Values Using Comparators (P) . . . . . . . 79
3-12 Displaying Messages (Display Bits (D)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3-13 Using Button Switches (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
vii
TABLE OF CONTENTS
SECTION 4
Special Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4-1 Protecting Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4-2 Stabilizing Input Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4-3 Changing Backlight Automatic Cutout Time. . . . . . . . . . . . . . . . . . . . . . . . . 92
4-4 Adjusting LCD Screen Contrast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4-5 Setting Summertime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4-6 Reading System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
SECTION 5
Optional Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5-1 Mounting Battery Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5-2 Using Memory Cassettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5-3 Connecting the ZEN Support Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
SECTION 6
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6-2 Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6-3 Deleting Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Appendices
A Product Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
C Ladder Program Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
D Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
E Allocations and Setting Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
viii
About this Manual:
This manual describes the installation and operation of the ZEN Programmable
Relay 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 ZEN. Be sure to read the
precautions provided in the following section.
Precautions provides general precautions for using the ZEN and related
devices.
Section 1 gives an outline of the ZEN, including example applications, the system configurations and basic operations.
Section 2 explains how to mount and wire the ZEN CPU Units and Expansion
I/O Units.
Section 3 explains how to create and edit ladder programs and how to use the
timers, counters, comparators, display function and buttons switches.
Section 4 describes how to protect ladder programs, stabilize inputs, make
LCD screen adjustments, and make summer time settings.
Section 5 describes how to mount Battery Units, use Memory Cassettes, and
how to connect the ZEN Support Software.
Section 6 lists the error messages and provides probable causes and countermeasures for troubleshooting.
The following two manuals are provided for the ZEN Programmable Relay.
Refer to them as required in operation.
Manual Contents Cat. No.
ZEN Programmable Relay
Operation Manual
ZEN Support Software
Operation Manual
ZEN specifications, functions, and operating methods.
Installation and operating procedures for
the ZEN Support Software
Z183
Z184
!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.
ix
PRECAUTIONS
This section provides general precautions for using the ZEN Programmable Relay.
The information contained in this section is important for the safe and reliable application
of the ZEN. You must read this section and understand the information contained before
attempting to set up or operate the ZEN.
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
2 Application Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
2-1 Circuit Design and Ladder Programming . . . . . . . . . . . . . . . . . . . xiii
2-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
2-3 Wiring and Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
2-4 I/O Connections and Startup Precautions . . . . . . . . . . . . . . . . . . . xiv
2-5 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
2-6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
2-7 Transportation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
3 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
4 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
4-1 Applicable Directives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
4-2 Concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
4-3 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
4-4 Relay Output Noise Reduction Methods . . . . . . . . . . . . . . . . . . . . xvii
5 Operating Mode at Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
6 Memory Backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx
7 Version Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
7-1 Application Precautions for Differences between Versions. . . . . . xxii
7-2 CPU Units Covered in this Manual . . . . . . . . . . . . . . . . . . . . . . . . xxiii
xi
Safety Precautions 1
1 Safety Precautions
!WARNING Never attempt to disassemble any Units while power is being
supplied. Doing so may result in serious electrical shock or electrocution.
!WARNING Never touch the I/O terminals, computer connector, Expansion
Unit connector, or Battery Unit connector while power is being
supplied. Doing so may result in serious electrical shock or electrocution.
!WARNING Provide safety measures in external circuits (i.e., not in the ZEN),
including the following items, to ensure safety in the system if an
abnormality occurs due to malfunction of the ZEN or another
external factor affecting the ZEN operation. Not doing so may
result in serious accidents.
• Emergency stop circuits, interlock circuits, limit circuits, and similar safety measures must be provided in external control circuits.
• The ZEN will turn OFF all outputs when its self-diagnosis function detects any error. As a countermeasure for such errors,
external safety measures must be provided to ensure safety in
the system.
• The ZEN outputs may remain ON or OFF due to deposition or
burning of the output relays or destruction of the output transistors. As a countermeasure for such problems, external safety
measures must be provided to ensure safety in the system.
• Provide double safety mechanisms to handle incorrect signals
that can be generated by broken signal lines or momentary
power interruptions.
!WARNING Do not short the battery terminals or charge, disassemble, heat,
or incinerate the battery. Do not subject the battery to strong
shocks. Doing any of these may result in leakage, rupture, heat
generation, or ignition of the battery. Dispose of any battery that
has been dropped on the floor or otherwise subjected to excessive shock. Batteries that have been subjected to shock may leak
if they are used.
!Caution Tighten the AC power supply terminal block screws to the torque
specified in the manual. Loose screws can result in fire or faulty
operation.
xii
Application Precautions 2
2 Application Precautions
Observe the following precautions when using the ZEN.
2-1 Circuit Design and Ladder Programming
• Provide external interlock circuits, limit circuits, and other safety
circuits in addition to any provided within the ZEN to ensure
safety.
• The output relays or the output transistors may remain ON due to
faults in internal circuits such as output relays or output transistors. As a countermeasure for such problems, external safety
measures must be provided to ensure safety in the system.
• Always turn ON power to the ZEN before turning ON power to
the I/O circuits. If the ZEN power supply is turned ON after the I/
O power supply, temporary errors may result in operation.
• The life of the output relays is largely affected by the switching
conditions. Confirm the operation of the system under actual
operating conditions and set the switching frequency to ensure
that adequate performance will be provided. Insulation faults and
burning in the ZEN may result if relays are used after their performance has deteriorated.
2-2 Installation
• Install the ZEN according to instructions in the operation manual.
Improper installation may cause faulty operation.
• Do not install the ZEN in locations subject to excessive noise.
Malfunction may occur.
• Do not allow the ZEN to fall during installation.
• Be sure that all the mounting screws on the ZEN and Expansion
I/O Unit are tightened to the torque specified in the manual.
Incorrect tightening torque may result in malfunction.
• Use with the cover of the computer connector mounted. Using
without the cover may result in malfunction due to dust or other
foreign matter.
• Be sure that the DIN rail mounting levers, Expansion I/O Units,
Memory Cassettes, Battery Units, cable connectors, and other
items with locking devices are properly locked into place.
Improper locking may result in malfunction.
2-3 Wiring and Connections
• Use the wires specified in this manual when wiring. Use straight
crimp terminals when connecting loose wires.
xiii
Application Precautions 2
• Provide circuit breakers and other safety measures to provide
protection against shorts in external wiring.
• Use separate wiring ducts for signal wires from those used for
power supply and high-voltage lines.
• Always check polarity when connecting cables.
• Leave the label attached to the Unit when wiring. Removing the
label may result in malfunction if foreign matter enters the Unit.
• Remove the label after the completion of wiring to ensure proper
heat dissipation. Leaving the label attached may result in malfunction.
• Tighten the terminal block screws to the torque specified in the
manual.
• Wire the ZEN according to instructions in the operation manual.
Improper installation may cause faulty operation.
2-4 I/O Connections and Startup Precautions
• Use the Units only with the power supplies and voltages specified in the operation manual. Other power supplies and voltages
may damage the Units.
• Take measures to stabilize the power supply to conform to the
rated supply if it is not stable.
• Do not apply voltages exceeding the rated input voltage to input
circuits. The input circuits may be destroyed.
• Do not apply voltages exceeding the maximum switching capacity to output circuits. The output circuits may be destroyed.
• Double-check all wiring before turning ON the power supply.
Incorrect wiring may result in burning.
• Check the user program for proper execution before actually running it on the Unit. Not checking the program may result in an
unexpected operation.
2-5 Handling
• Use, store, and transport the ZEN under the limits given for general specifications in this manual.
• Do not attempt to disassemble, repair, or modify any Units. Any
attempt to do so may result in malfunction, fire, or electric shock.
• Always turn OFF the power supply to the ZEN before attempting
any of the following.
xiv
• Assembling the ZEN.
• Attaching or removing the Expansion I/O Unit.
• Connecting or disconnecting any cables or wiring.
Application Precautions 2
• Attaching or removing the Memory Cassette.
• Attaching or removing the Battery Unit.
• Confirm that no adverse effect will occur in the system before
attempting any of the following. Not doing so may result in an
unexpected operation.
• Changing the operating mode.
• Using the button switches.
• Changing bit status or parameter settings.
• Before touching a Unit, be sure to first touch a grounded metallic
object in order to discharge any static build-up.
• Do not pull on the cables or bend the cables beyond their natural
limit. Doing either of these may break the cables.
• Do not place objects on top of the cables or other wiring lines.
Doing so may break the cables.
• Do not short the battery terminals or charge, disassemble, heat,
or incinerate the battery. Do not subject the battery to strong
shocks. Doing any of these may result in leakage, rupture, heat
generation, or ignition of the battery. Dispose of any battery that
has been dropped on the floor or otherwise subjected to excessive shock. Batteries that have been subjected to shock may
leak if they are used.
• Abide by all local ordinances and regulations when disposing of
the ZEN.
2-6 Maintenance
• When replacing parts, be sure to confirm that the rating of a new
part is correct.
• When replacing a Unit, transfer to the new Unit and confirm all
settings for clock data, internal holding bits, holding timers, and
counter before starting operation again.
2-7 Transportation and Storage
• Use special packaging boxes when transporting the ZEN and do
not subject it to excessive shock or vibration or drop it during
shipment.
• Store the ZEN in the following temperature and humidity ranges
without condensation or icing.
Model Ambient
temperature
LCD –20 to 75°C 10% to 90%
LED –40 to 75°C
Humidity
xv
Operating Environment Precautions 3
3 Operating Environment Precautions
Do not operate the control system in the following places.
• Where the ZEN is exposed to direct sunlight.
• Where the ambient temperature or humidity is beyond the specified ranges.
• Where the ZEN may be affected by condensation due to radical
temperature changes.
• Where there is any corrosive or inflammable gas.
• Where there is excessive dust, saline air, or metal powder.
• Where the ZEN is affected by vibration or shock.
• Where any water, oil or chemical may splash on the ZEN.
• Any other place with conditions beyond those specified in the
general specifications.
Take appropriate and sufficient countermeasures when installing systems in the following locations:
• Locations subject to static electricity or other forms of noise.
• Locations subject to strong electromagnetic fields.
• Locations subject to possible exposure to radioactivity.
• Locations close to power supplies.
4 Conformance to EC Directives
4-1 Applicable Directives
•EMC Directives
• Low Voltage Directive
4-2 Concepts
EMC Directives
OMRON devices that comply with EC Directives also conform
to the related EMC standards so that they can be more easily
built into other devices or the overall machine. The actual
products have been checked for conformity to EMC standards
(see the following note). Whether the products conform to the
standards in the system used by the customer, however, must
be checked by the customer.
EMC-related performance of the OMRON devices that comply
with EC Directives will vary depending on the configuration,
xvi
Conformance to EC Directives 4
wiring, and other conditions of the equipment or control panel
on which the OMRON devices are installed. The customer
must, therefore, perform the final check to confirm that devices
and the overall machine conform to EMC standards.
Note Applicable EMC (Electromagnetic Compatibility) standards are as
follows:
EMS (Electromagnetic Susceptibility): EN61000-6-2
EMI (Electromagnetic Interference): EN50081-2
(Radiated emission: 10-m regulations)
Low Voltage Directive
Always ensure that devices operating at voltages of 50 to
1,000 VAC and 75 to 1,500 VDC meet the required safety
standards for the ZEN (EN61131-2).
4-3 Conformance to EC Directives
The ZEN complies with EC Directives. To ensure that the machine or
device in which the ZEN is used complies with EC Directives, the
ZEN must be installed as follows:
1,2,3... 1. The ZEN must be installed within a control panel.
2. You must use reinforced insulation or double insulation for the DC
power supplies used for the communications power supply and I/
O power supplies.
3. ZEN models complying with EC Directives also conform to the
Common Emission Standard (EN50081-2). Radiated emission
characteristics (10-m regulations) may vary depending on the
configuration of the control panel used, other devices connected
to the control panel, wiring, and other conditions.
You must therefore confirm that the overall machine or equipment
complies with EC Directives.
4-4 Relay Output Noise Reduction Methods
The ZEN conforms to the Common Emission Standards (EN50081-2)
of the EMC Directives. However, noise generated by relay output
switching may not satisfy these Standards. In such a case, a noise filter must be connected to the load side or other appropriate countermeasures must be provided external to the ZEN.
Countermeasures taken to satisfy the standards vary depending on
the devices on the load side, wiring, configuration of machines, etc.
Following are examples of countermeasures for reducing the generated noise.
xvii
Conformance to EC Directives 4
Countermeasures
(Refer to EN50081-2 for more details.)
Countermeasures are not required if the frequency of load switching
for the whole system with the ZEN included is less than 5 times per
minute.
Countermeasures are required if the frequency of load switching for
the whole system with the ZEN included is more than 5 times per
minute.
Countermeasure Examples
When switching an inductive load, connect an surge protector,
diodes, etc., in parallel with the load or contact as shown below.
Circuit Current Characteristic Required element
AC DC
CR method Yes Yes If the load is a relay or
Powe r
supply
Inductive
load
solenoid, there is a time
lag between the moment
the circuit is opened and
the moment the load is
reset.
If the supply voltage is 24
or 48 V, insert the surge
protector in parallel with
the load. If the supply voltage is 100 to 200 V, insert
the surge protector
between the contacts.
The capacitance of the capacitor must be 1 to 0.5
contact current of 1 A and
resistance of the resistor must
be 0.5 to 1
age of 1 V. These values, however, vary with the load and
the characteristics of the relay.
Decide these values from
experiments, and take into
consideration that the capacitance suppresses spark discharge when the contacts are
separated and the resistance
limits the current that flows
into the load when the circuit is
closed again.
The dielectric strength of the
capacitor must be 200 to 300
V. If the circuit is an AC circuit,
use a capacitor with no polarity.
W per contact volt-
mF per
xviii
Operating Mode at Startup 5
Circuit Current Characteristic Required element
AC DC
Diode method No Yes The diode connected in
Powe r
supply
Varistor method Yes Yes The varistor method pre-
Powe r
supply
Inductive
load
Inductive
load
parallel with the load
changes energy accumulated by the coil into a current, which then flows into
the coil so that the current
will be converted into
Joule heat by the resistance of the inductive
load.
This time lag, between
the moment the circuit is
opened and the moment
the load is reset, caused
by this method is longer
than that caused by the
CR method.
vents the imposition of
high voltage between the
contacts by using the constant voltage characteristic of the varistor. There is
time lag between the
moment the circuit is
opened and the moment
the load is reset.
If the supply voltage is 24
or 48 V, insert the varistor
in parallel with the load. If
the supply voltage is 100
to 200 V, insert the varistor between the contacts.
The reversed dielectric
strength value of the diode
must be at least 10 times as
large as the circuit voltage
value. The forward current of
the diode must be the same as
or larger than the load current.
The reversed dielectric
strength value of the diode
may be two to three times
larger than the supply voltage
if the surge protector is
applied to electronic circuits
with low circuit voltages.
---
5 Operating Mode at Startup
The operating mode at startup depends on the model and the presence of a user program as shown in the following table.
User
program
LCD model (with LCD and
operation buttons)
LED model (with LED and
no operation buttons)
In CPU No Yes No Yes
In Memory
Cassette
No No Yes Yes
STOP
mode
STOP
mode
RUN mode with
program in CPU
RUN mode with
program in CPU
RUN mode with program
in Memory Cassette
RUN mode with program
in Memory Cassette
RUN mode with
program in CPU
RUN mode with
program in CPU
xix
Memory Backup 6
6 Memory Backup
The ladder program and settings are stored in EEPROM and thus will
not be lost even if the power supply is turned OFF for an extended
period of time (e.g., 2 days at 25°C). The status of the following data,
however, is backed up by an internal capacitor, and may be lost if
power is turned OFF for an extended period of time: ON/OFF status
of holding bits (H), holding timers (#), and counters (C) and the prevent value areas. For models equipped with a clock/calendar, the
time and date may be reset. Always reconfirm system operation
before restarting operation after the power has been turned OFF for
an extended period of time. We recommend that a Battery Unit be
(optional) connected in any system in which power may be interrupted for an extended period of time.
xx
Version Upgrades 7
7 Version Upgrades
The following table shows the relationship between the versions and
functionality of the ZEN CPU Unit and ZEN Support Software
Date of
upgrade
January
2002
May
2003
System
software
version
Ver. 1.10 The following functions were added to the CPU
Ver. 2.00 • The number of timers, counters, weekly tim-
Units with LCD displays.
• A Clear Display function
• A Day/Month display object (DAT1)
ers, calendar timers, and display areas was
increased from 8 to 16 each and the number
of holding timers was increased from 4 to 8.
(See note 2.)
• A new CPU Unit with 20 I/O points was
added. (See note 2.)
• The input circuits of CPU Units with DC
power supply were made compatible with
both PNP and NPN.
• A password input was added to the memory
all clear function for CPU Units with LCDs.
Note The model numbers of CPU Units with
CPU Unit Support Software
Main changes
The following functions
were added to version
2.00 (ZEN-SOFT01-V2).
• Support for changes to
display function
• Simulation function
• Improvements to functions, operating procedures, and displays
The following functions
were added to version
3.00 (ZEN-SOFT01-V3).
• Support for V1 CPU
Units with 20 I/O points
• Support for V1 CPU
Units with 10 I/O points
10 or 20 I/O points end in “-V1.”
Note 1. The number of the system software version in the CPU Unit is not
related to the model number. The system software version of
CPU Units with LCDs can be read by selecting SYSTEM INFO
from the OTHER Menu. “V02.00” will be displayed as the system
software version for V1 CPU Units.
xxi
Version Upgrades 7
2. Memory Area Comparison between V1 and Pre-V1 CPU Units
Area V1 CPU Units Pre-V1 CPU Units
ZEN-10C@@@-@-V1 ZEN-20C@@@-@-V1 ZEN-10C@@@-@
CPU Unit input bits I0 to I5 (6 bits) I0 to Ib (12 bits) I0 to I5 (6 bits)
CPU Unit output bits Q0 to Q3 (4 bits) Q0 to Q7 (8 bits) Q0 to Q3 (4 bits)
Timers T0 to Tf (16 bits) T0 to T7 (8 bits)
Holding timers #0 to #7 (8 bits) #0 to #3 (4 bits)
Counters C0 to Cf (16 bits) C0 to C7 (8 bits)
Weekly timers @0 to @f (16 bits) @0 to @f7(8 bits)
Calendar timers
Displays D0 to Df (16 bits) D0 to D7 (8 bits)
Work bits M0 to Mf (16 bits)
Holding bits H0 to Hf (16 bits)
Expansion I/O Unit
input bits
Expansion I/O Unit
output bits
Analog comparators A0 to A3 (4 bits)
Comparators P0 to Pf (16 bits)
0 to f (16 bits) 0 to 7 (8 bits)
X0 to Xb (12 bits)
Y0 to Yb (12 bits)
7-1 Application Precautions for Differences between
Versions
Memory Cassette Compatibility
Be aware of the following restrictions when using a Memory Cassette
containing a program that was stored from a CPU Unit with a different
version of system software.
Version of CPU Unit used to
write the Memory Cassette
Ver. 1.00 OK OK OK OK
Ver. 1.10 Restrictions
Ver. 2.00
(V1 CPU Units)
10 I/O points Restrictions
20 I/O points Restrictions
Version of CPU Unit used to read the Memory Cassette
Ver. 1.00 Ver. 1.10 Ver. 2.20 (V1 CPU Units)
10 I/O points 20 I/O points
(See note 1.)
(See note 1.)
(See notes 1,
2, and 3.)
OK OK OK
Restrictions
(See note 2.)
Restrictions
(See notes 2
and 3.)
OK OK
Restrictions
(See note 3.)
OK
xxii
Note 1. The new display functions (display clear: -CD@ and day/month
display: DAT1) cannot be used and will be ignored.
Version Upgrades 7
2. Only the memory area ranges supported by the pre-V1 CPU
Units can be used for Timers, Holding Timers, Counters, Weekly
Timers, Calendar Timers, and Displays (i.e., only half of each).
3. Only 6 inputs and 4 outputs can be used in the CPU Unit I/O bits.
Any others will be ignored.
Compatibility of Programs Depending on Support Software Version
CPU Unit system software Support Software
Ver. 1.00
ZEN-SOFT01
Ver. 1.00 OK OK Restrictions
Ver. 1.10 Restrictions
Ver. 2.00
(V1 CPU Units)
10 I/O points Restrictions
20 I/O points Not applicable. Not applicable. OK
(See note 1.)
(See notes 1 and
2.)
Ver. 2.00
ZEN-SOFT01-V2
OK Restrictions
Restrictions
(See note 2.)
Ver. 3.00
ZEN-SOFT01-V3
(See notes 1 and
2.)
(See note 2.)
OK
Note 1. The new display functions (display clear: -CD@ and day/month
display: DAT1) cannot be used and will be ignored.
2. Only the memory area ranges supported by the pre-V1 CPU
Units can be used for Timers, Holding Timers, Counters, Weekly
Timers, Calendar Timers, and Displays (i.e., only half of each).
7-2 CPU Units Covered in this Manual
The material in this manual is based on the memory areas of the V1
CPU Units. If you are using a pre-V1 CPU Unit, the sizes of some of
the memory areas will be different. Refer to page xxii for details.
Also, the I/O circuits and I/O terminal arrangements for CPU Units for
DC power supply different between V1 and pre-V1 CPU Units, as
described in the following table. Refer to page 38 for details
CPU Unit I/O circuits
V1 CPU Units With CPU Units for DC power supply, the common is
Pre-V1 CPU Units The negative size of the power supply for input circuits
separated from the power supply circuit in the I/O circuits, and a COM (common) terminal is provided for
input terminals. This enables connecting devices with
sourcing outputs (+ common) in addition to connecting
devices with sinking outputs (
is connected internally to the negative side of the DC
power supply. The input circuits can thus be used only
with a
- common.
- common).
xxiii
Version Upgrades 7
xxiv
SECTION 1
Outline
This section gives an outline of the ZEN, including example applications, the system
configurations and basic operations.
1-1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 Features and Part Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-2-1 Features and System Configuration. . . . . . . . . . . . . . . . . . . . . . . . 8
1-2-2 Part Names. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-3 Display Screen and Basic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1-3-1 Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1-3-2 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1-4 Memory Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1-5 Allocating I/O Bit Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1-6 Preparations for Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1
Outline Section 1-1
1-1 Outline
The ZEN Programmable Relay is an extremely small programmable
controller that provides 10 programmable I/O points (6 inputs and 4
outputs) to enable low-cost, small-scale automation. There is also a
new model that provides 20 programmable I/O points (12 inputs and
8 outputs) along with 16 of each of the following: Timers, counters,
displays, etc.
In this manual, the ZEN Programmable Relay is referred to as merely
the “ZEN.”
The ZEN comes in basically two types: LCD and LED.
• LCD Type: LCD screen and operation buttons
• LED Type: No LCD screen or operation buttons
The following pages provide a few examples of the way the ZEN
meets a wide variety of application needs.
Low-cost, Small-scale Automatic Control
One CPU Unit provides 12 inputs and 8 outputs (with CPU Unit with
20 I/O points).
Water-supply facilities in
apartments, lighting control in
Easy Operation with an Inexpensive Controller
Ladder programming is possible directly from a LCD-type CPU Unit.
Ladder programs can be easily copied to low-cost LED-type CPU
Units by using Memory Cassettes (optional).
2
Outline Section 1-1
Smaller Control Panels
The ZEN is very small at 90 x 70 x 56 mm (H x W x D) and mounts
essentially anywhere.
Note Dimensions are 90 x 122.5 x 56 mm (H x W x D) for CPU Units
with 20 I/O points.
70 mm
90 mm
CPU Unit with
10 I/O points
Less Assembly and Wiring Time Required for Control Panels
Simple one-touch DIN Track mounting. Built-in timers and counters
so only power supply and I/O circuit wiring required.
Solid wires can be easily connected using only a screwdriver.
Refer to page 33.
Future System Expandability
I/O capacity can be expanded to up to 24 inputs and 20 outputs by
connecting 3 Expansion I/O Units.
Refer to page 9 and 33.
CPU Unit
12 inputs/8outputs + (4 inputs/4outputs)
Expansion I/O Units (up to 3)
´ 3
3
Outline Section 1-1
Power Failure Countermeasures
EEPROM backs up the program and system settings data when no
power is supplied to the ZEN.
Use a Battery Unit (optional) to back up work bits, holding timers,
counters, and date/time data.
Refer to page 96.
Battery
Unit
Easy Saving and Copying of Programs
Use an optional Memory Cassette to easily save and copy programs.
Refer to page 97.
Ladder program
data/settings.
Memory Cassette
Programming and Monitoring from a Personal Computer
Windows-based ZEN Support Software is available and provides a
complete simulation function.
Refer to page 99.
ZEN Support
Software
(CD-ROM)
Greater Switching Capacity
The output contacts have 8-A switching capacity (250 VAC). All contacts are independent (for CPU Units with 10 I/O points).
4
Outline Section 1-1
Refer to page 45.
8 A max.
250 V
AC Inputs
For CPU Units with AC power supply inputs, 100 to 240 VAC can be
directly connected.
Refer to page 35.
100 to 240 VAC
LN
Easy Program Design
There are 4 different operations that can be set for bit outputs. Selfholding bits also can be easily programmed.
Refer to page 58.
Ry
-[Q0 Normal operation
-SQ0 Set operation
-RQ0 Reset operation
-AQ0 Alternate operation
MC
Circuit protector
Complicated Timers without Additional Programming
Any of the 16 timers support 4 types of operation and 3 timing
ranges.
There are also 8 built-in holding timers that hold data during power
interruptions.
Refer to page 67.
TIM
ON delay
OFF delay
One-shot pulse
Flashing pulse
0.01 to 99.99 s
1 s to 99 min 59 s
1 min to 99 h 59 min
5
Outline Section 1-1
Incremental and Decremental Counters
There are 16 built-in counters that can be switched between incrementing and decrementing.
Use Comparators to enable programming multiple outputs from a
counter.
Counters: Refer to page 70.
Comparators: Refer to page 79.
C
CNT
D
R
Control number of cars entering
and leaving a car park.
Season- or Day-dependent Operating Times
CPU Units with built-in calendar and clock functions have 16 weekly
timers and 16 calendar timers. Seasonal control is possible using calendar timers and day/time control is possible with weekly timers.
Weekly timers: Refer to page 72.
Calendar timers: Refer to page 74.
MO FR
−
SA SU
−
For gardens, parks, and
recreational ponds.
Direct Analog Inputs
CPU Units with DC power supply inputs have 2 analog input points (0
to 10 V) and 4 analog comparators.
Refer to page 75.
6
Temperature control for hot
houses and tanks. Prevent
freezing of swimming pools.
Loading...