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G3PW Power Controller User`s Manual

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1. 154 5 1 188 171 5 22 Installation Section 3 2 G3PW A245E 1 C A260E 1 C 45 60 A Models with Screwless Clamp Terminal Block 171 5 Mounting Hole Dimensions m G3PW A220 m G3PW A245 pL h A ice min T 100 min 158 0 2 176 0 2 Two M5 38 0 2 51 min 57 6 0 2 71 min 23 Installation Section 3 2 Mounting Screws Control Panel Ventilation 24 m G3PW A260 176 0 2 Two M5 57 6 0 2 90 min Modei Tightening torque Screw size All models 2 3 to 2 5 Nem M5 length 10 mm min The G3PW Power Controller generates a lot of heat and it uses natural heat convection for cooling Mounting the Power Controller in the wrong direction may obstruct heat radiation and cause malfunctions or accidents To increase cooling efficiency mount the Power Controller in the correct direction and take control panel ventilation and the installation location into consideration to avoid obstructing heat dissipation Installation Section 3 2 Mounting Position in Relation to Wiring Duct 155 mm min Wiring duct y Airflow Mounting surface
2. If a device with a depth of 155 mm or Use short wiring ducts or other de If tall devices or wiring ducts must be used more blocks the top or bottom of the Pow vices around the Power Controller take measures such as mounting the Power er Controller the flow of air will be ob Controller to a mounting base to improve structed and heat will not dissipate ventilation Control Panel Ventilation When mounting the Power Controller in a control panel consider measures such as installing louvers or fans for ventilation in the control panel e If the air intake and outlet ports have filters perform periodic maintenance to prevent the filters from becoming clogged e Install devices in such a way that airflow is not blocked inside or outside of the air intake and outlet ports e If using a heat exchanger for cooling inside the panel it is most effective to mount it on the front of the Power Controller Control panel la Louver axial S flow ventilation fan etc Louver 25 Wiring Section 3 3 3 3 Wiring 3 3 1 Wiring the Power Supply and Load Circuits N WARNING N Caution N Caution e First connect the load to load terminal T1 and to the power supply and then connect the power supply to load terminal L1 through a fast acting fuse e Connect the AC power supply to power supply terminals 4 N and 5
3. Output mode Parameter External Duty Input Enable Disable das P01 Internal Duty only o Setting enabled by external variable resistor P01 0 P01 1 Set the Input Digital Filter Time Constant 0 0 to 100 ms P03 0 0 Input Digital Filter Time Constant P03 Event Input Assignment P11 l Phase Control and Optimum Main Setting No Assignment Or Cycle Control Selection or Automatic Manual Selection P11 O P11 1 P11 2 CL o U0 0 J N Default Setting disabled Main Setting Input Parameter Settings The following table shows the relationship between the parameters related to inputting the main settings Main Setting Main Setting Automatic Input Manual Input Selection P05 Selection P06 Event Input 0 No assignment Main Setting 0 Automatic O 4 to 20 mA or 1 to Assignment or Automatic Main setting input using 9 V P11 1 Control method BSA linear input or commu selection efault P08 nications 1 Manual Main setting input using an external variable resistor or using key operation 2 Main setting Event input O 4 to 20 mA or 1 to automatic manual Open Automatic 5 V 1 selection Communications External variable resistor 0 1 Key input Event input nn O External variable Closed Manual resistor 1 Key input 44 Setting Parameters in the Initial Setting Level Section 4 6 Parameter Settings Related to Protective
4. Increase the set value or initialize the total run time Use the alarm reset see note to clear the error Communications Time A communications timeout Check whether the communications lines are dis out Alarm occurred connected Check whether the host device is operating cor rectly The error is cleared by correctly writing the main setting from the host Note To reset the alarm press the ENT RST Key or turn ON the RESET input Errors for Which the Output Continues Alarm Level 2 Display Errorname Probable cause Countermeasures Heater Burnout Alarm The heater resistance rate of change Reset the error by using the ENT RST when assigned to exceeded value set for the Heater Burnout Key execute a reset input from the alarm level 2 Threshold HBR parameter for more cycles RESET terminal or execute a reset than the value set for the Number of Alarms command via communications for Heater Burnout Detection parameter If more than one error has occurred P09 consecutively for the output all of the External Input Range A 4 to 20 mA or 1 to 5 V input signal was out errors will be cleared for one reset Alarm when assigned of the input range operation to alarm level 2 External Duty Input The external duty variable resistor is discon Alarm when assigned nected to alarm level 2 EF BLU Total Run Time Alarm The total run time exceeded the set value for when assigned to the Total Run Time Threshold param
5. Main Setting Automatic Manual 0 Automatic See note Default Event Input Assignment 0 No assignment 1 Control method selection See note You can use external contacts to switch between manual input using an external variable resistor or key input and communications Set the Event Input Assignment parameter P11 to 2 main setting automatic manual selec tion Moving to the Communications Parameters in the Initial Setting Level Procedure 66 1 23 Move to the communications settings in the Initial Setting Level by performing the following procedure with the keys on the front panel 1 When the power is turned ON the 7 segment display level indicators monitoring indicators and communication indicator will all light and then the current input value for the MV will be displayed on the 7 segment dis play Confirm this status Current input value for MV will be displayed on 7 segment display El N EOUM E aoun E PHASE EJ A ENT El COMM RST ZY 2 Press the Level Key for at least 2 seconds The Power Controller will move from Run Mode to Initial Setting Mode and P01 will be displayed on the 7 segment display dela 8 5 ADJ SEI E a KV UY Press the Level Key for at least 2 seconds E IN EJ DUTV E E OUT E PHASE EJ A Communications Settings Section 6 1 3 Press the Up Key or Down Key repeatedly until the desired p
6. Main Setting Automatic Manual Selection Automatic Manual Semen eee Control Method Phase Control Optimum Cycle Control AAA AAA AAA AAA AAA AAA DENIA Not used AAA AAA AAA AAA AAA AAA BRBRBRBRBRBRBRBRBRBRBRBRBRBRBRBRBRBRBRBRBRBRBRBRRRBRBRRRRRRRRR Not used Pe A A el SAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA 80 Variable Area Read Section 6 6 6 6 Variable Area Read This command reads set values Command Variable Bit MR type Read start address position No of elements C SRC A aa 2 2 2 4 2 4 Note ln the G3PW the bit position is not used Set it to OO Response MRC SRC Response code Set values vor feo fT aaa a S lee ae 2 2 4 No of elements x 8 or 4 E Variable Type and Read Start Address Refer to the 6 4 Services and Addresses E Number of Elements Specify the number of elements for which the set value is to be read Up to 8 elements can be specified E Response Code Response code Errormame Cause 1001 Command length too long The command is too long 1002 Command length too short The command is too short 1101 Area type error The specified variable type does not exist 110B Response length too long The number of elements is larger than the maximum number allowed 1100 Parameter error The bit position specification is not 00 2203 Operation error An error occurred in nonvola tile memory Normal end Proce
7. External Contact Input Functions Section 5 1 Switching between Automatic and Manual Operation with the Event Input Set the parameter to 2 automatic manual selection The event input can be used to switch between automatic and manual operation as shown below Automatic opera The input value is set by the linear input 4 to 20 mA or 1 to 5 V tion or by using communications Manual operation The input value is set by the external variable resistor or by key operation RS 485 Event input status Meaning RS 485 ie Open Automatic operation Main setting Main setting COM Closed Manual operation Duty setting Duty setting COM Alarm output 1 Automatic Alarm output 1 operation J W K M Alarm output 2 10 Alarm output 2 11 Event input 12 Event input 13 Reset input 14 Reset input For standard models 1 and 2 are not used Note When 1 control method selection is set for the Event Input Assign ment parameter P11 the Control Method Selection TYP will not be displayed In addition ifthe Control Method Selection parameter is changed by using communications an operation error response will be returned Alarm Reset If any of the following alarms occurs it can be cleared by using the reset input e Overcurrent error E20 flashing e Zero cross error E30 flashing e Frequency error E31 flashing e Heater burnout alarm E40 flashing e External
8. G3PW Power Controllers User s Manual Cat No Z280 E1 01 G3PW Power Controllers User s Manual Produced November 2008 Preface This manual describes the G3PW Power Controllers including information on functions performance and application methods Observe the following precautions in using the G3PW e Allow only a specialists with sufficient knowledge of electrical systems to handle the G3PW e Read this manual thoroughly be sure you understand the contents and use the G3PW correctly e Keep this manual in a safe location where it will be readily available when needed 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 opera tion of the product 1 2 3 1 Indicates lists of one sort or another such as procedures checklists etc OMRON 2008 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 con stantly striving to improve its high quality products the information contained in this manual is subject to change without notice Every precaut
9. 3 Hz Load current 1to 20A 7 AZGOEL inrush current 0 to 98 Input signal for Analog input 4 to 20 mA DC input impedance 100 Q or 1 to 5 VDC input impedance control 30 1 kQ Voltage ON OFF Input 5 VDC input impedance 30 1 KQ External main setting Specified Variable Resistor G32X V2K 2 kQ 2 W External duty setting _ External duty setting _ setting Output value Main setting 0 0 to 100 0 to 100 Setting range 0 0 to 100 Default ean Upper lower limits Output upper limit 0 0 to 100 Default 100 Doper wer is Output lower limit 0 0 to 100 Default 0 0 Duty setting Duty setting Internal duty setting x External duty setting Internal duty setting range set using front panel keys or communica tions 0 to 100 Default 100 External duty setting range set using external variable resistor 0 to 100 Default 100 Soft start up time and soft start down time 0 0 to 99 9 s Default 0 5 s Either phase control or optimum cycle control can be used Constant current TTT Current fluctuation 2 FS Load current upper limit 0 0 to 66 0 Default 0 0 OFF Overcurrent detection time 500 ms max QO Specifications Section 2 1 ltem Standard Models Constant current Models Model SSCP EU G3PW A2 T EC FLK Current detection Current transformer Built in CT Current detection 10 FS of rated current accuracy Minimum detected load 1A current Burnout detection 10
10. Use the alarm reset see note to clear the error Heater Burnout Alarm A heater burnout was detected Refer to 5 9 Heater Burnout Detection check for burnout and check the set values Use the alarm reset see note to clear the error External Input Range A disconnected line was A disconnected line was detected for the 4 to 20 mA Alarm detected for the 4 to 20 mA or 1 or 1 to 5 V input signal input or external variable to 5 V input signal input or resistor Check the location of the disconnection external variable resistor If the 4 to 20 mA or 1 to 5 V input signal inout and external variable resistor are not being used refer to the auxiliary input related parameters and make the setting Use the alarm reset see note to clear the error External Duty Input External duty input disconnec A disconnected line was detected for the external Alarm tion duty variable resistor Check the location of the disconnection If the external duty variable resistor is not being used set the External Duty Input Enable Disable parameter P01 to Disable Use the alarm reset see note to clear the error 89 Error Displays Section 7 2 Display Errorname Probable cause Countermeasures Total Run Time Thresh The total run time exceeded the The internal total run time has exceeded the set old Exceeded Alarm set value of the Total Run Time value of the Total Run Time Alarm Set Value param Alarm Set Value parameter eter
11. preventing xi initial setting level 41 43 initial settings 2 input signal 5 input signal type 2 input system 39 input value 38 input value output value relation 51 inrush current resistance 8 20 installation xi installation environment xi 18 installation in control panels 24 installation location 18 25 insulation resistance 10 K key input main setting 39 L leakage current 9 10 level indicators 14 load capacity maximum 8 load current 38 load current limit 8 56 load terminal block 15 26 Index main setting external variable resistor 50 main setting input 39 44 manual operation external variable resistor 33 input 39 input wiring 33 Modular Temperature Controller 4 monitor level 38 41 monitored items 38 monitoring indicators 14 mounting hold dimensions 23 mounting screws 24 N noise filter 19 31 noise immunity improving 19 nonmetal heaters 3 O ON OFF control 2 8 36 ON OFF output 2 ON OFF voltage input 27 operating humidity humidity 10 operating temperature ambient 10 18 operation keys 15 operation level 41 operation selection input 30 optimum cycle control 2 8 36 output limit 3 54 output mode 2 8 output modes 37 output phase angle 38 output value 38 output value setting range 8 output voltage adjustable range 8 overcurrent detection 10 overcurrent error 93 P parameter settings 41 protective f
12. 50 100 200 500 1 000 5 000 Power ON time ms 20 Installation Section 3 2 3 2 Installation Installation Direction For cooling efficiency install the Power Controller in the correct direction The Power Controller generates a lot of heat and it uses natural heat convection for cooling Installing the Power Controller in the wrong direction may cause it to malfunction or to be damaged N WARNING Install the Power Controller in the direction shown in this manual The Power Controller generates a lot of heat and it uses natural heat convection for cool ing Installing the Power Controller in the wrong direction may cause in mal functions or accidents N WARNING Leave at least 100 mm of space above and below the Power Controller when installing it to allow heat to dissipate Do not obstruct the area around the Power Controller and especially the area around the heat sink Natural convection Mounting surface Specified dis 4 fance or longer j 100 mm min 21 Installation Section 3 2 External Dimensions and Mounting Hole Dimensions G3PW A220E_ S 20 A Models with Terminal Block with Small Slotted Screws Wea O D Kh 170 137 BBS s 170 146 4
13. Char This parameter is displayed only when the control method is set to optimum cycle acteristics for Opti control lt is used to record the heater characteristics resistance for optimum mum Cycle Control cycle control Heater Characteristic This parameter is displayed only when the control method is set to optimum cycle Resistance for Opti control It is used to check and correct the heater characteristic resistance set by mum Cycle Control teaching 0 0 to 99 9 2 Default 0 0 Heater Burnout Sets the lower limit of the output value for judging heater burnout Detection Lower 0 0 to 100 Default 0 0 Total Run Time Moni Displays the total time power is turned ON to the Power Controller in units of tor 0 1 kh 0 0 to 99 9 Default 0 0 function disabled 1 Constant current Models only 97 Parameter Settings in the Adjustment Level Appendix B 98 Index Numerics 7 segment display 14 A adjustment level 41 alarm level 45 alarm outputs 5 9 29 alarm reset 49 analog input 8 automatic operation input 39 automatic operation input wiring 32 B base up function 3 53 C checking safety Xi cleaning xii command input and power supply terminal block 14 15 27 communications indicator 14 communications settings 64 communications specifications 11 64 communications terminals 31 32 communications timeout alarm 94 CompoWay F 5 63 64 73 end codes 74 c
14. Fuses fuses recommended for external connection Fast acting fuses Super rapid Fuse Fuji Electric Fuse Holder Fuji Electric OMS Weight G3PW A220E 0 O0 O000 1 0 kg max G3PW A245E0 0 0000 1 9 kg max G3PW A260E0 0 O0J01 1 9 kg max 10 Specifications Section 2 1 Serial Communications Specifications Constant current Models Onl ltem Constant current Models G3PW A2 1 JEC _1 FLK Communications CompoWay F Slave protocol Communications Reading and writing all parameters functions Transmission path Multipoint connections Communications method Maximum RS 485 transmission distance Number of 31 Multi drop connections nodes Sync method Start stop synchronization 9 6 19 2 38 4 or 57 6 kbit s Default 57 6 kbit s ASCI 7 or 8 bits Default 7 bits Stop bits 1 or 2 bits Default 2 bits Vertical parity None even odd Default Even Flow control None gl O O 1 pd Specifications Section 2 1 Comparison with Previous Model G3PX G3PX G3PW Simple Advanced Simple Advanced Standard Constant models models current Oo Mode BUN EH EAN Ec DU DH Dc Eu Ec Number of heater phases Single phase Single phase Control object Alloy nichrome Alloy nichrome Alloy nichrome Load voltage 200 V 100 110 200 220 VAC 200 220 VAC 100 to 240 VAC Load current 1 to 20 1 to 40 or 1 to60A 1 to200r1to60A 1
15. ON OFF voltage input connect the positive and negative sig nal wires to terminals 1 and 3 respectively 1 4 5 SEE EE A SS 9 S IS O or 5 V output PLC or other controller 27 Wiring Section 3 3 The G3PW may be damaged if a command voltage that is higher than 5 V is applied If it is necessary to apply more than 5 V split the voltage as shown below by inserting resistance in the line to terminal 1 and applying the voltage across terminals 1 and 3 The internal impedance between terminals 1 and 3 is 30 1 KQ Internal impedance 30 1 kQ 1 2 3 N L 5 E OK IG Siz al voltage Ft t trie t Not required Output of 5 V or higher PLC or other controller Oor12V 42 KQ 1 5 W min Oor24V 120 kQ 1 5 W min Resistance Command Input and Power Supply Wire Sizes Recommended wire Tightening torque Terminal screws diameter All models AWG 14 to 18 0 8 to 1 0 Nm Recommended Crimp Terminals Always use the following crimp terminals for M3 5 to wire to the command input and power supply terminals 7 2 mm mas OA 7 2 mm ma Dm 3 3 3 Wiring the Control Terminal Block Recommended Wire Sizes and Connection Method e GBPW A2LILIELI S Models with terminal blocks with small slotted screws e G3PW A2L 11 JEL C Models with screwless clamp terminal block e Wire Sizes for Control Terminals Models with Small Slotted or Screwless Clamp
16. Terminals Recommended Tightening torque Terminal screws wire diameter See note All models AWG26 to AWG16 0 22 N m Note Only models with terminal blocks with small slotted screws have terminal screws e Use copper AWG26 to AWG16 twisted pair cable when connecting the wires directly e Strip the wire sheathing for the following lengths according to the connec tor type e Small slotted terminals 7 mm e Screwless clamp terminals 9 mm e When using twisted wires it is recommended that you attach a ferrule with an insulating cover that conforms to DIN 46228 4 and connect the ferrule to the terminal 28 Wiring Section 3 3 e Use shielded twisted pair wires for RS 485 communications wires A maximum of 500 m total of wiring can be used Terminal Names A screwless clamp terminal block is shown as an example Multi drop See note Max of 31 nodes RS 485 RS 485 Main setting Main setting COM Duty setting Duty setting COM Alarm output 1 EJ1 Modular Temperature Controller CJ series Serial Communications Unit etc CON OOF WN Alarm output 1 9 Alarm output 2 10 Alarm output 2 11 Event input 12 Event input 13 Reset input 14 Reset input For standard models 1 and 2 are not used Note A terminator must be connected at each end of the RS 485 trans mission path The terminators must be at least 54 Q combined Wiring Inputs f
17. 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 OMRON MAKES NO WARRANTY OR REPRESENTATION EXPRESS OR IMPLIED ABOUT NON INFRINGEMENT MERCHANTABIL 14 15 16 17 18 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 oth erwise of any intellectual property right c Buyer Remedy Omron s sole obli 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 responsi ble for warranty repair indemnity or any other claims or expenses regarding the Products unless Omron s analysis confirms that the Products were prop erly handled stored installed and maintained and not subject to contamina tion abuse misuse or inappropriate modification Return of any Products by Buyer must be approved in writing b
18. current control control Parameter Operation for Operation for a AS e NO contacts or NC contacts See note 2 P12 0 P12 14 When the external main setting variable resistor is disconnected External Input Range Alarm or when outside the range of 4 to 20 mA or 1 to 5 V P17 No alarm Alarm level 1 Alarm level 2 P17 0 P17 1 P17 2 When the external duty variable resistor is disconnected or when External Duty Input Alarm Operation outside the range of 4 to 20 mA or 1 to 5 V P18 No alarm Alarm level 1 Alarm level 2 P18 0 P18 1 P18 2 Function OFF Function sp Current limit setting OFF P10 0 1 P10 0 1 to 66 0 f P10 0 0 to 66 0 Load Current Upper Limit Function OFF 0 Current limit P10 P10 0 04 specification Number of Alarms for Heater Burnout Number of errors to detect before a heater mo Detection P09 See note 1 1 Power supply half cycle P09 0 to 999 150 errors AMES ZA AE e A Heater Burnout Alarm Operation No alarm r Alarm level 1 Alarm level 2 P14 See note 1 P14 0H P14 1 Or P14 2 Default Setting disabled Note 1 Constant current Models only Note 2 The alarm status is not determined for 1 s after startup 45 Setting Parameters in the Initial Setting Level Section 4 6 46 SECTION 5 Descriptions of Functions This section describes the functions you can use when operating the G3PW Power Controllers 5 1 External Conta
19. detected Display Name T Range HBL Heater Burnout Detection Lower Limit 0 0 to 100 Number of Alarms for The Number of Alarms for Heater Burnout Detection parameter is used to set Heater Burnout Detection the number of cycles for which heater burnout is to continue until an alarm will be output The default setting is 150 Display Name TO age Number of Alarms for Heater Burnout Detection O to 999 Note Ta number of 10 or lower is set for the Number of Alarms for Heater Burnout Detection parameter the alarm may operate incorrectly with a sudden change in the MV 60 Heater Burnout Detection Section 5 9 Parameter Settings Flowchart Set each parameter correctly in order for heater burnout to be clearly detected and to avoid false detections Start the operation Confirm that at least 10 of the rated current is flowing and that control is stable Set the Heater Burnout Alarm Operation parameter P14 toa value other than 0 Setting Examples Execute teaching TPC or TCC for Number of Set the heater characteristics heaters value Set the Heater B t Threshold et tine neater burnou resno HBR parameter Guideline 90 number of heater elemerfts Are alarms Raise the Heater Burnout Detection occurring at small Lower Limit HBL setting by output values approximately 10 End 61 Heater Burnout Detection Section 5 9 62 SECTION 6 CompoWay F Communications This section provides information
20. eee eee eens 32 SECTION 4 Control Methods and I O Configuration 35 dl Control Metodista ab awed alee nes ees 36 A QUMI ModS e soe R R Rea Meds Bae Pen TR eae o BSR oa a a dey IMoOnttored Henson Sot SM a atric pa dani 38 eas GID UE Sy SUC IL osa A tase ee wae ane nes 39 4 5 Procedures for Operation and Setting Parameters 0 0 0 0 eee eee 40 4 6 Setting Parameters in the Initial Setting Level nenene arana 43 SECTION 5 Descriptions of Functi0NS oooooooooooooooooo 47 521 External Contact Input Functions 4406408 ss A AR N hone N 48 5 2 Inputting the Main Setting with an External Variable Resistor 50 e DUYOS e AS A E 51 524 Basesip PUNO rs shoe acts ae Rae A Recs Oh ek dR ee Aa Oe Pk SRA Gee 53 A O re sicet A ddtadtves eaten tee eaekee ele ee ules 54 5 6 Soft start Up and Soft start Down Functions 0 0 ccc eee eens 55 5 7 Load Current Limit Constant current Models Only o oooooooooooooooooo 56 JS Monitoring Total Run Time seriernes RARA AE ATA ps dad 57 509 Heater Burnout Detection cuina sb berri ee aa a 58 xiii TABLE OF CONTENTS SECTION 6 CompoWay F Communications oooooooooooo 63 G21 Communications Sets iaa sii ERG RCR A bel ERE ds she d R de ERRER R ER ands 64 02 ramo CONS Ia ON cocci io aed ebsites E ste he de Sie Sens 73 6 3 FINS MD Text dos jamie a acne shore Y EIA A iio 75 6 4 Servicesand Addresses sd A are oe ae ie We Od Se Oe ES
21. input range alarm E50 flashing e External duty input alarm E51 flashing e Total run time alarm E60 flashing RS 485 Alarms can also be cleared by using RS 485 the ENT RST Key on the front of the Main setting Power Controller Main setting COM Duty setting Duty setting COM Alarm output 1 Alarm output 1 O te ee eS D Alarm output 2 10 Alarm output 2 11 Event input 12 Event input 13 Reset input 14 Reset input For standard models 1 and 2 are not used 49 Inputting the Main Setting with an External Variable Resistor Section 5 2 9 2 50 Inputting the Main Setting with an External Variable Resistor 1 23 The setting procedure shown here is for when the main setting is input by using an external variable resistor 1 In the initial setting level set the Event Input Assignment parameter P11 to O no assignment or 1 control method selection In the initial setting level set the Main Setting Automatic Manual Default parameter P08 to 1 manual If automatic or manual operation is select ed using the event input the setting for the event input will be given priority Set the Main Setting Manual Input Selection P06 to 0 external variable resistor input Use the ENT RST Key to reset the Power Controller and set the Main Set ting Automatic Manual Default parameter P08 to Enable If automatic or manual operation is selected using the e
22. model with a terminal block with small slotted screws is shown as an exam ple Level indicators a LA IA E S 7 segment display Reset event indicator LVL Key Monitoring UP Key indicators Communications DOWN Key indicator ENT RST Key Command input and power supply terminal block with cover 1 1 to 5 V 0 or 5 V input 2 4 to 20 mA input 3 Current voltage input COM 4 100 to 240 VAC 5 100 to 240 VAC Control terminal block a sila 5 s he a G j il Ltv N L Protective cover removable Load terminal block under protective cover 100 to 240 VAC Indicators Level Indicators Indicator Description S ADJ Lit when in the adjustment level Mi SET Lit when in the initial setting level Lit when an external contact reset input or an event input is ON Monitoring Indicators Indicator Description Wi DUTY Lit when the duty value is monitored in the monitor level Communications Indicator Indicator _ Description _ Z COMM Lit when the serial communications are in progress 14 Nomenclature and Operations Section 2 2 Operation Keys Key symbol Name Description Enabling condition LVL Level Key Level Changes Changing from monitor level to adjust e Monitor level lt gt Adjustment level ment level or from monitor level to ini tial setting level is possible even when an error occurs e Monitor level lt Initial setting leve
23. on using CompoWay F communications 6 1 Communications Sete eR sedate laica 64 G lel Introducion traia a 64 6 1 2 Communications SettingS ooo 64 6 1 3 Connection RXample eri aeneo 68 02 Fame COnMeuraons raosira T AE R AE E RAK 73 e SUNS Sia E cao oes tenst oat ews eon Be Dd wi doe Sw eect ae 75 6 4 Services and Addresses nish ws Re SERS 76 6 3 VariablesArcaW TIE N tc ne A AAA 79 6 6 Varlable Arca Read TTT 81 O27 Operation Command isse ada added 82 6 8 Controller Attribute Read 83 6 9 Controller Status Read 84 6 10 Echo sback Lestat usd a ra dad ds 85 AT ASCII able o ds ia il atrapa 86 63 Communications Settings Section 6 1 6 1 Communications Settings 6 1 1 Introduction G3PW Constant current Models can perform serial communications with EJ1 Modular Temperature Controllers or SYSMAC CS CJ CP series PLCs The CompoWay F communications protocol is used CompoWay F is a generic serial communications protocol from OMRON An RS 485 interface is used at the G3PW Communications RS 485 2 wire half duplex Data length 7 or 8 bits Stopbits tor bits Error detection Vertical parity None even or odd Ban sanal None OO O Note CompoWay F CompoWay F is OMRON s standard communications format for general serial communications lt uses commands compliant with the well established FINS used exten sively with OMRON Programmable Controllers together with a consistent frame
24. or 0 V The input value is set manually Manual Input m External Variable Resistor Main Setting Use an external G32X V2K Variable Resistor to set the input value m Key Input Main Setting Use the keys on the front of the G3PW Power Controller to directly set the input value Key input main setting 4 to 20 mA 1 to Voltage Commu 5 V analog input ON OFF input nications RS 485 Relationship between Input Signal and Input Value There is a linear relationship i e a proportional relationship between an analog input signal and the input value Input value 100 Input value 100 0 0 4 mA 20 mA Input signal 1V 5 V Input signal 39 Procedures for Operation and Setting Parameters Section 4 5 4 5 Procedures for Operation and Setting Parameters Operating Procedure Installation and Wiring Turning ON the Power x When the power is turned ON output will start immediately Be careful not to allow large values to be input for current or voltage signal until the parameter settings have been completed If the power is turned ON with no load connected an SSR short circuit E10 alarm will occur but you will still be able to set the parameters X The default for the main setting is 4 to 20 mA or 1 to 5 V The output mode is for an output proportional to phase angle of the input the same mode as the G3PX Parameter Settings in the Initial Setting Level Press the LVL Key for at least 2 s
25. the manipulated variable for channel 1 to 50 set value 4 digits Command STX 01000010281000000000101F4 ETX BCC Response STX 01000001020000 E I X BCC 79 Variable Area Write Section 6 5 Status Protection Error Operation 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 SERB RRP Heater Burnout No error BEPC Not used External Input Range Alarm No error o CI Status 0 OFF a CI SSR Short circuit No error O S 2 Va muun SSR Open Failure No error n n n UE GT Failure No error n 5 n O EEEE E Heater Overcurrent No error S os os Zero Cross Error No error n S R Frequency Error No error d d BERBER BRE RRR REPRE RRR Ree eee eee ee RRR RR External Duty Input Alarm No error Cee Otal Run Time Alarm No error PA BERR ERR BRE RRP RRR RR RR RRR RRR RRR ee eee eee Communications Timeout No error Not used Fl BRE BBR RB RRB RRR RRP RRR RRR RRR RRR Ree eee eee eee Not used BRE BRR RRR RRP RRR REP RP RRR eee ee eee ee eee Not used MB RRR RRR RRR PRR RRR RRR BERBER RRR RPE RRP BRR RR RRP RRR RRR RRR Ree eee eee eee eee Not used Operating status Bit positions 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 Alarm Output 1 OFF ON 0 OFF MERE RRR eee eee pennn sss l Alarm Output 2 OFF ON BEEBE EERE Event Input OFF ON MBB RPP RPP RRR eee eee eee eee er Getting Level See note Operation Level Initial Setting Level
26. to move to the initial setting level Then set the following parameters in order using the parameter setting procedure e Settings related to I O mode e Settings related to auxiliary input functions e Settings related to alarms After the parameter settings have been completed press the LVL Key for at least 2 s to return to the monitor level Parameter Settings in the Adjustment Level Use the following procedure to set the parameters in the adjustment level as needed Press the LVL Key to move to the adjustment level Set the parameters in the adjustment level Such as the Soft start Up Time and the Output Upper Limit After the parameter settings have been completed press the LVL Key to return to the monitor level Actual Operation 40 Procedures for Operation and Setting Parameters Section 4 5 Parameter Settings Operation Level Monitor level J O D L ADJ SET EV Press for at least 2 s Initial setting level HE Se ADJ SET EV The indicator for the unit will light Adjustment level The SET indicator will light The ADJ indicator will light e The level when power is turned ON is the monitor level Normal operation is performed in the monitor level e Press the LVL Key to move to the adjustment level In the adjustment level parameter settings can be changed during operation Press the LVL Key again to return to the monitor level While in the monitor level or the adjustmen
27. transmission and switching to send sta tus Host Send status Send 5 Receive Receive Send G3PW Send status Response created gt gt gt l Send wait time If switching time will not cause problems the send wait time can be shortened to reduce the communications time with the host Frame Configuration Section 6 2 6 2 Frame Configuration The communications protocol is the OMRON CompoWay F protocol Commands from the host and responses from the G3PW are sent in data packets called frames The structures of the command and response frames are shown below Command Frame Format Text STX UnitNo Sub address SID FINS mini command text ETX BCC a AA de 1 BCC calculation range Response Frames Text STX Unit No Sub address End code FINS mini command text ETX BCC ay O ACI 1 2 2 2 1 1 BCC calculation range STX This code indicates the beginning of the communications frame Always set 02H e Set the unit number that is set on SW1 on the front of the G3PW e No response will be received if another unit number is set Sub address and Not used by the G3PW Always set to 0 SID FINS mini This text is the command For details refer to 6 3 FINS mini Text command text ETX This code indicates the end of the communications frame Always set to 03H This stores the result of the BCC calculation from the Unit No to EXT STX Unit No Sub address SID FINS mini command tex
28. will occur if P11 is set to 0 3 To use operation code OA switching the control method not be assigned to an event input i e P11 must not be set to 1 Always set P11 to O before using this operation code An operation error will occur if P11 is set to 0 4 Parameters and the total time can be initialized only in Initial Setting Lev el 5 Execute an error reset to release the pause Response Codes Response code Erorname Cas 1001 Command length too long The command is too long 1002 Command length too short The command is too short 1100 The operation code or related information is not correct 2203 An error occurred in nonvolatile memory 0000 Processing was completed normally Example The following command executes a software reset Command STX 0100030050600 ETX BCC Response None 82 Controller Attribute Read Section 6 8 6 8 Controller Attribute Read This command reads the model number of the Controller and the communica tions buffer size Command MRC SRC 2 2 Response MRC SRC Response code Model number Buffer size 3 2 4 10 4 Model Number A Constant Current Always 1 o o oa zo qea s oa w myo o Fe wys Buffer Size The buffer size is 113 bytes 071 hex Response Code Response code Errorname Cause 1001 Command length too long The command is too long Normal end Proce
29. you can use when operating the G3PW Power Controllers Section 6 provides information on using CompoWay F communications Section 7 provides troubleshooting information The Appendices provide lists of the parameters in the initial setting level and the adjustment level N WARNING Failure to read and understand the information provided in this manual may result in per sonal 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 XV XVI SECTION 1 Overview This section provides an overview of the G3PW Power Controllers 1 1 Overview of G3PW Power Controller ooooooooooo 15 GPW Fe IUES a is EA a eee 1 2 1 Features of Constant current and Standard Models 1 2 2 Features of Constant current Models Only EF DO Block Did rae TTT l 4 Models and Specifications 0 0 cece eee ene O mM WwW W DW N Overview of G3PW Power Controller Section 1 1 1 1 Overview of G3PW Power Controller The G3PW Power Controller is a thyristor type single phase power controller that enables precise temperature control It accepts a continuous proportional output of 4 to 20 mA or 1 to 5 V from a temperature controller to execute phase control or optimum cycle control Measured temperature Temp
30. 018 G3PW A245 AWG 6 2 8 Nm G3Pw az60 See note Note Crimp terminals that conform to UL and CSA specifications must be used Wiring Section 3 3 N Caution Be sure to keep terminal screws tightened to the torque specified below Recommended Crimp Terminals Recommended Fuses Loose screws may occasionally cause a fire e Either use insulated crimp terminals or cover the crimp terminals with insulating sleeves e Always use the following crimp terminals to wire the load terminals e Do not connect more than two crimp terminals to one terminal screw A GaPW AZA0 G3PW A245 A260 12 mm max Fuse Holder Fuji Super rapid Fuse Fuji Electric Electric Fastacting fuse CMS 4 250 VAC 2A 3 3 2 Command Input and Power Supply Terminal Wiring Command Input and Power Supply Terminal Wirin Voltage Input 1 to 5 VDC Current Input 4 to 20 mA DC ON OFF Voltage Input 0 or 5 VDC When using a voltage input connect the positive and negative signal wires to terminals 1 and 3 respectively 2 3 4 5 EA LALA gal EA Temperature controller or other controller 1 to 5 V output When using current input connect the positive and negative signal wires to terminals 2 and 3 respectively 1 2 3 4 5 SIS SIS fa NAN ANIZ E Gc GG H O CiT ee Temperature controller or other controller 4 to 20 mA output When using an
31. 0H to 7EH ASCII 20H to 7EH or A1H to FEH 2 Response Codes Response code Emormame anas 1001 Command length too long The command is too long 0000 Normal end Processing was completed normally Example Command STX 010000801123 ET X BCC Response STX 01000008010000123 ET X BCC 85 ASCII Table Section 6 11 6 11 ASCII Table Leftmost digit digit NUL DLE space O OS 0 IO IO CI a a RT 2 TK e BR b r o 3 TX oes 3 e s e s S O E A BENQ NAK esi CO IO A IC CT o 7 8 ETB ga po EM po A BUR IE DOI H IO H HTS gt ee eee LE A E a D Se gt M o m A T E E A E A E RA F MEF ME OR LiL T ree HI T l lt TEN H IT Z lt T A 86 SECTION 7 Error Processing This section provides troubleshooting information TE hecking Possible ENOS sois caera eles oe ke 88 9 2 Eror Display Ss Sire eee Hew ne eso ew ENT te he eee ee 89 7 3 Detailed Descriptions of Errors 200s 91 87 Checking Possible Errors Section 7 1 7 1 Checking Possible Errors Troubleshooting Check Flow When There Is No Output Output occurs Check the output value OUT on the 7 value not 0 0 Check for problems in the load wiring segment display No output occurs value is 0 0 Check for problems in the input signal wiring No problem The setting whether the duty setting DUTY i
32. 100 Q or less There are no ground terminals provided so use the heat sink mounting screws as ground terminals e Check the terminal number and polarity for each input before connecting it e Use copper twisted wire in the sizes specified in this Instruction Sheet e Use insulated crimp terminals with insulation sleeves If using crimp terminals that are not insulated cover them with insulation sleeves Also use terminals of the sizes specified in this Instruction Sheet e Insert connectors all the way e Do not connect anything to unused terminals O Safety Measures and Checking e Install a switch or circuit breaker so that the operator can immediately turn OFF the power and provide a Suitable display e Apply the power supply voltage through the contacts of a switch relay or similar device so it reaches the rated voltage within 2 s If the voltage is increased gradually the power supply may not be reset or outputs may malfunction e Use a power supply voltage input voltage input current and load within the specifications and rated ranges for the Power Controller Use a load that draws a current at the maximum output that is within the rated current range of the Power Controller If the current drawn by the load is not within the rated current range malfunction or fire may occur e To prevent electric shock damage or malfunction complete all the wiring before turning ON the power e Make sure that the protective cover is attached
33. 2 Event input 13 14 12 13 Reset input 14 Reset input Number of event inputs 2 event inputs Contact input conditions ON 1 KQ max OFF 100 kQ min Non contact input conditions ON residual voltage 1 0 V min OFF leakage current 0 1 mA max Current flow Approx 1 1 mA per input 30 Wiring Section 3 3 Communications Terminals Multi drop Max of 31 nodes EJ1 Modular Tempera 1 RS 485 ture Controller CJ ser gt 2 RS 485 les Serial Communica tions Unit etc 14 For standard models 1 and 2 are not used e The terminating resistance is 54 Q min combined e Both ends of the transmission path including the host computer if it is at one end must be specified as end nodes terminating resistance Use a combined terminating resistance of at least 54 Q e The EJ1 has an internal terminating resistance of 120 Q Install terminat ing resistance 110 to 125 Q 1 2 W at only the end G3PW Power Con troller 3 3 4 Grounding Always ground the Power Controller to 100 Q or less There are no ground ter minals provided so use the heat sink mounting screws as ground terminals 3 3 5 Wiring an External Noise Filter Always insert a noise filter in the power supply lines to the GBPW Command TN AO AJO ADN AD eee supply SIDO Ep I terminal block y y ee Load Noise Filter terminal block RSMN 2030 2060 TDK Lambda Corporation Power supply 100 t
34. 7 to 63 Hz and the frequency fluctuates at a rate of 3 Hz s or greater Confirm that the power supply frequency is stable and then perform a reset operation using the ENT RST Key a reset input or a reset command via communications When a heater burnout alarm error E40 occurs use the following procedure to remove the problem Set the Heater Burnout Threshold parameter HBR according to the number of heaters Burnout detection becomes more difficult as the value is increased Restart operation Is an alarm occurring before the output value has finished rising No Yes Incorrect detection may be occurring at small output values Increase the Heater Burnout Detection Limit HBL little by little by approx 10 and The resistance may be unstable Extend the time until burnout is determined Set a larger value in the Number of Alarms for Heater Burnout Detection parameter P09 narrow the burnout detection range If the conditions do not change re teach the heater characteristics 93 Detailed Descriptions of Errors Section 7 3 E50 External Input Range Alarm E51 External Duty Input Alarm E60 Total Run Time Alarm E70 Communications Timeout Alarm 94 An external input range alarm occurs when a 4 to 20 mA or 1 to 5 V input sig nal or variable resistor main setting input is outside of the input range Check whether the input signal range is correct and whether the e
35. 76 G25 Variable Arca W Mesa aie ia R oa ea ae EWG e RS 79 6 6 Vatiablo Atrea Read rroan deste ak oe hws ASAS 81 0 7 Operator Command eree ibn a ad ee 82 0S Controller Attribule Read sas IA S RS 83 6 9 Controller Status Radisson AE AAA 84 As A aids Sond ahaa he ov aaa Oe SL Oe aS 85 OL ASCE Tables ta A dla risa 86 SECTION 7 Error a K iras O Jal Checking Possible T ies grani a TE E RERE TSE T NRE T A E 88 12 Eror Display Sidi it ii e r a a bi E i 89 7 3 Detailed Descriptions of Emors nanana a ai 91 Appendices A Parameters Set in Initial Setting Level sng RR RRR riesi iaca aaa RRR RA a 95 B Parameter Settings in the Adjustment Level anneau raaa 97 Md rr riadas 99 Revision History sss s s s e s lt e e aeaaaee 103 XIV About this Manual This manual describes the G3PW Power Controllers and includes the sections described below Please read this manual carefully and be sure you understand the information provided before attempting to set up or operate a G3PW Power Controllers Section 1 provides an overview of the G3PW Power Controllers Section 2 provides the specifications of the G3PW Power Controllers and describes the part names and functions Section 3 describes how to install and wire the G3PW Power Controllers Section 4 describes the control methods that you can use the I O configuration and how to set parameters for the G3PW Power Controllers Section 5 describes the functions
36. ANTY 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 e Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses not described in this manual e 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 regula
37. ChJ MV EEE dy CELU Ch1 MV Ch2 MV Ch3 mv X Ch4 MV GaPW Unit 3 Japu Un 2 9 1 2 The MV for the channel with the same number G3PW Unit 1 G3PW Unit 2 it 4 as the communications Heater J EET unit number of the E S G3PW is received Note The MV for communications unit number 1 will be received if there are more than 9 communications unit numbers Communi Communica Communi Communica cations tions Main cations tions Main Main Setting Setting Main Setting Setting Number 0 Number 0 Number 0 Number 0 Note Refer to the note on page 72 for information on the Communica tions Main Setting Numbers Note The EJ1 will automatically send the MV for the maximum number of G3PW channels User programming is not required e The CompoWay F communications frame sent from the EJ1 for G3PW communications unit 2 is shown below 1 2 E 4 6 7 8 Note 1 to 8 are the channel numbers When the G3PW communica tions channel number is set to 2 the MV for channel 2 is obtained The number of the EJ1 channel is the same as the G3PW channel number Setting Any G3PW Communications Unit Numbers for the EJ1 Channel Numbers The EJ1 channel number from which to receive the MV can be set as desired for each communications unit number 1 2 3 1 Set any communications unit numbers P19 for the G3PW Power Control lers 69 Communications Settings Section 6 1 Note Connecting to a Serial Communicat
38. FS at rated current Not applicable to loads with variable resistance Heater burnout alarm accuracy Detection method According to heater resistance with heater resistance teaching and Heater Burnout Threshold parame ter Note The accuracy of heater burn out detection will be lower for heaters for which the resis tance significantly changes depending on the tempera ture Setting range for heater 1 to 100 Default 100 burnout detection Burnout detection Detects a burnout at or above the output lower limit specified output value 0 0 to 100 Default 0 0 Number of alarms for O to 999 Default 150 heater burnout detection Multiple heater burnout detections Burnout of 1 of 10 heater elements can be detected at the rated cur rent Event inputs Number of event inputs 2 event inputs Event input 1 The function of the event input can be changed with a parameter setting in the initial setting level The event input can be used for one of the following functions e Switching the main setting between automatic and man ual operation e Switching between phase control and optimum cycle control Event input 2 Alarm reset Contact input ON 1 kQ max OFF 100 kQ min conditions Non contact input ON residual voltage 1 0 V min OFF leakage current 0 1 mA max conditions Current flow Approx 1 1 mA per input Alarm outputs Number of alarm 2 alarm outputs outputs A
39. Functions Alarm Level The G3PW Power Controller has two alarm contact outputs Alarm output 1 ALARM1 and alarm output 2 ALARM2 For the following alarms the contacts to which to output an alarm when an error occurs can be selected with a parameter setting in the initial setting level Alarm level Parameter Operation setting level Noaarm 0 Noaror s detected Alarm level 1 1 The alarm is output to alarm output 1 The output to the load is stopped when a fatal error is detected and the error is displayed on the 7 segment display Alarm level 2 2 The alarm is output to alarm output 2 The error is displayed on the 7 segment display and operation continues Note Errors will not be detected if no alarm output is assigned Alarms for which Alarm e Heater burnout alarm E40 Output Contacts Can Be e External input range alarm external variable resistor disconnection Assigned detection E50 e External duty input alarm external variable resistor disconnection detec tion E51 e Total run time exceeded alarm E60 Note 1 If multiple errors occur the most recent error will be displayed on the 7 segment display For details on error numbers refer to 7 2 Error Dis plays 2 Errors other than the above are set to alarm level 1 and cannot be changed Setting Procedure Output mode S Sane nra Proponionalto Proportional Constant Optimum cycle Te ae GOP square voltage ON OFF control same as G3PX to voltage
40. INS command and response text is shown below An MRC main request code and SRC sub request code followed by the various required data is transferred in the command frame Unit No SID FINS mini BCC STX Subaddress command text ETX oat oo fro E SRC Data hey The MRES main response code and SRES sub response code are trans ferred in the response frame following the above MRC SRC Data is then transferred following the MRES and SRES Unit No End code FINS mini ETX S Subaddress response text BCC oH for n HO MRC gRC Response code Data gt dl 2 2 4 FINS Factory Interface Network Service The FINS protocol provides message communications between controllers in OMRON FA networks FINS mini text is based on the FINS specifications 75 Services and Addresses Section 6 4 6 4 Services and Addresses FINS mini Command Services Variable Area Read Reads data from the variable area Variable Area Write Writes data to the variable area E Controller Attribute Read Reads the model number and communica tions buffer size of the Controller oe Joa Controller Status Read Reads operating status 08 01 Echo back Test Performs an echo back test 30 05 Operation Command Performs operation commands such as resetting and changing areas Note Service requests will not be accepted and no response will be re turned if there is a RAM error or the Controller is in standby status Standby status exists f
41. K Variable Resistor to adjust the main setting ofr 3 Main setting 4 Main setting COM m m e m m q m Use a G32X V2K Variable Resistor to adjust the duty setting 5 Duty setting 6 Duty setting COM p o mm ma m m m m 33 Wiring for Specific Applications 34 Section 3 4 SECTION 4 Control Methods and I O Configuration This section describes the control methods that you can use the I O configuration and how to set parameters for the G3PW Power Controllers del Control Metodo t d0 0c tore CMe aire eye anal Meee Be 36 4 2 OuputlMOdES ince neni Mate aeado ia hae eee 37 des Monitored ems iaa iodo 38 A AA hee neds iment Ree 4 39 4 5 Procedures for Operation and Setting Parameters o 40 4 6 Setting Parameters in the Initial Setting Level o o ooo 43 35 Control Menos Section 4 1 4 1 Control Methods Any of the following methods can be used as the output mode for the G3PW Power Controller Phase control optimum cycle control or ON OFF control In addition it is possible to switch between phase control and optimum cycle control during operation Phase Control With phase control the phase angle range for the AC voltage supplied to the load is changed by the switching element to continually change the power supplied to the load Phase control is suitable for precise temperature control or for contro
42. L e The AC power supply ground polarity and the G3PW terminal block polar ity are not related but connect the 4 N and 5 L terminals on the com mand input power supply terminal block and the T1 and L1 terminals of the load terminal block to power supplies with the same phases e Always connect the load to load terminal T1 Command input power supply terminal block Load terminal block Power supply 100 to 240 VAC 50 60 Hz Fast acting fuse LO90 circuit L1 Make sure that the phases match for load terminal T1 and power supply ter minal 4 N and for load terminal L1 and power supply terminal 5 L If the connections are incorrect the Power Controller will not operate normally or the load may be damaged When connecting from line connected to load terminal T1 to power supply ter minal 4 N connect it from a point that is as close as possible to the power supply If the connection is incorrect the output operation will be stopped by the Power Controller failure detection functions When using the Power Controller to control the power to the primary side of a transformer do not open the circuit on the secondary side of the transformer during Power Controller operation Wiring the Load Terminal Block Recommended Wires 26 When connecting to the load terminals use the specified wire size for each model of Power Controller Recommended Tightening torque Terminal screws wire size GSPWA220 AWG 101
43. Output value In this mode the output volt age is proportional to the output value 80 60 100 Output value In this mode the load cur rent is proportional to the output value The duty set ting changes with the load resistance To suppress the output current use the duty setting function to suppress the duty 60 80 100 Output value 37 Monitored Items Section 4 3 4 3 Monitored Items Values for the following five items can be monitored on the 7 segment display during operation in monitor level 8 Input Value The main setting that was set by automatic or manual input is displayed m Duty Value The duty calculated from the internal and external duty settings is displayed Duty value Internal duty setting x External duty setting m Output Value The output value in relation to the input value is displayed after applying the base up value output limits soft start up down settings and load current limit If no processing is performed the output value will be the same as the input value m Output Phase Angle The thyristor module output phase angle calculated from the output value is displayed according to the output mode When the proportional to phase angle mode is used as the output mode the output value and the output phase angle will be the same m Load Current A The load current A detected by the built in CT is displayed This feature is support
44. Products Taxes All taxes duties and other governmental charges other than general 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 importa tion 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 Financial If the financial position of Buyer at any time becomes unsatisfactory 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 liabil ity and in addition to other remedies cancel any unshipped portion of Prod ucts 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 Cancellation Etc Orders are not subject to rescheduling or cancellation unless Buyer indemnifies Omron against all related costs or expenses Force Majeure Omron shall not be liable for any delay or failure in delivery resulting from causes beyond its control including earthquakes fires floods strikes or ot
45. al to Constant Opt hase angle Proportional ptimum cycle same as G3PX naiiai to voltage current control control ONOFF CANTO Voltage ON OFF input Parameter Input Signal Type P04 Linear Input P04 O P04 1 Automatic input 4 to 20 mA or 1 to 5 V or Automatic inout or Manual input communications P08 OF a Manual input External variable resistor or Manual input only key operation _ SZ Main Setting Automatic Manual Default P08 Manual input only Main Setting Automatic Input Selection Automatic input M ct anual input P05 4 to 20 mA or 1 to 5 V or communications External variable resistor or key input E e a Main Setting Manual Input Selection POS O or POS 1 P06 09 or P06 1 P06 O P06 1 P06 Control Method Selection P07 Phase Control Ra T di Phase Control only Proportional to Proportional to Phase Proportional to Proportional Constant Optimum Cycle Control same Square Voltage to Voltage Current Control Control only as G3PX P02 1 P02 2 P02 3 P02 P02 04 tT I 0 I j Default Setting disabled Output Mode Selection P02 Voltage Control only 2 43 Setting Parameters in the Initial Setting Level Section 4 6 Parameter Settings Related to Auxiliary Inputs Pe a Proportional to Proportional Constant Optimum cycle leans pa G3PX square voltage to voltage current control control ON OFF control
46. anges in heater resistance An alarm is output if a change exceeds the set value The Controller can be set to stop or hold the output status when an alarm occurs With previous heater burnout detection functions heater burnout was deter mined based on the rate of change of the electric current flowing to the heater The command value and the load current do not have a linear relationship so faulty detection can occur when the command value is changed With the G3PW Power Controllers heater burnout is determined based on the rate of change of the heater resistance enabling more accurate heater burnout detection when the command value changes Serial Control from an EJ1 Modular Temperature Controller Up to eight G3PW Power Controllers can be connected to a Basic Unit in an EJ1 Modular Temperature Controller via RS 485 Using multiple Power Con trollers enables a wire saving temperature control system CX Thermo Enables setting and EJ1 Modular monitoring Power Temperature Controller parameters Controller Connected to End Unit Connected to Basic Unit Input value RS 485 Measured temperature 000000000 Temperatu re sensors a 00 G3PW Power Controllers Heater 8 max Power Controller parameters can be set and monitored and the control status of items such as the load current can be monitored from CX Thermo Support Software running on a personal computer that is connecte
47. anual Note If the Event Input Assignment parameter P11 is set to 2 main setting automatic manual selection the control method selected with the event inputs will be used regardless of the setting of this parameter Number of Alarms for An alarm is output when an error status continues for more than the specified Heater Burnout number of cycles Detection O to 999 Default 150 Load Current Upper Sets the upper limit for the current that can flow to the load Limit 0 0 to 66 0 ti This function stops when the parameter is set to 0 Default Event Input Assign Sets the event input application ment U No assignment Default i Control method selection phase control or optimum cycle control c Main setting automatic manual selection Alarm Output Open in Sets the alarm output operation Alarm ti Close in alarm NO contact operation i Open in alarm NC contact operation Default Alarm Output Test Used to perform an alarm output test U No test output Default Test output on ALARM1 terminal c Test output on ALARM2 terminal 3 Test output on ALARM1 and ALARM2 terminals Heater Burnout Alarm Operation ih Disable Default Alarm level 1 fatal error Alarm level 2 nonfatal error 95 Parameters Set in Initial Setting Level Display Total Run Time Exceeded Alarm Operation Total Run Time Alarm Set Value External Input Range Alarm Operation External Duty Input Alarm Operation Comm
48. arameter is displayed Parameters P20 to P26 contain the communications settings Press the Up Key or 2 1ND Down Key until the E DUTY desired communications E OUT IPHASE E SIA ENT E COMM RST The setting of the parameters can be read and changed as required Moving to Communications Parameters lt Power ON RUN Mode Screen Display Input value monitor gt 4 lt F Initial Settings Mode Screen Display b gt d Communications unit number fp lt q Communications baud rate p A Communications data length 4 Communications Communications stop bits parameters p A Communications parity Pp 4 Send wait time lt q Communications main setting number 4 Communications timeout time Be 4 Reset total run time Initialize set values 67 Communications Settings Section 6 1 Example Setting Communications Parameters Display the initial settings mode screen and then use the Up and Down Keys to display B 3 the parameter for which the setting is to be changed in this example alii Je Y When the ENT RST Key is pressed the present set value for A the selected aT will be displayed Use the Up and Down Keys to set a new value A 4 Y The data display will flash Press the ENT RST Key to enter t
49. cause a fire Precautions for Safe Use O Installation Environment e Use the Power Controller within the rated ambient temperature and humidity ranges If multiple Power Con trollers are installed side by side or vertically the heat that is generated will cause the internal tempera tures of the Power Controllers to rise and will shorten their service life In these kinds of installations take suitable measures such as installing fans for forced cooling The Power Controller is designed for indoor use only Also do not use the Power Controller in the following environments e Locations subject to water oil or chemicals e Locations subject to direct sunlight e Locations where dust or corrosive gases in particular sulfuric or ammonia gas are present e Locations subject to extreme temperature changes e Locations where icing or condensation may occur e Locations subject to excessive shocks or vibration e Locations subject to direct heat radiated from heating devices O Installation and Wiring e When installing the Power Controller always securely tighten the top mounting screws first When remov ing the Power Controller always remove the bottom mounting screws first e Take safety measures such as wearing safety shoes in case the Power Controller falls e Touch the Power Controller only after first touching a grounded metal object to discharge any static elec tricity from your body e Always ground the Power Controller to
50. ct Input Functions 0 0 ccc cece ee ees 48 5 2 Inputting the Main Setting with an External Variable Resistor 50 A NN 51 4 Base p FUNCOM e currada dice 53 Io A ean toes SIN eae ewe ee OLae Seria 54 5 6 Soft start Up and Soft start Down Functions ooo oo 55 5 7 Load Current Limit Constant current Models Only 56 5 8 Monitoring Total Run Time nananana A A A 57 5 9 Hear Burnout TGT 6 9 95 dales a RETLA USARA 58 47 External Contact Input Functions Section 5 1 5 1 External Contact Input Functions Event Inputs When Not Using the Event Input Note Selecting the Control Method with the Event Input Note 48 There are two external contact inputs the event input terminals 11 and 12 and reset input terminals 13 and 14 The event input terminals 11 and 12 is an external contact input that can be used for one of the following functions e Switching the control method between phase control and optimum cycle control e Switching between automatic and manual operation selection In the initial setting level set the Event Inout Assignment parameter P11 as follows to assign one of the above functions to the event input Pit setting Meaning Function of event input o Noassignment Does not function as event input 1 Control method selection Switches between phase contro and optimum cycle control 2 Automatic manual selection Switches between automatic and manual ope
51. d to the EJ1 End Unit For details refer to the EJ1 Modular Temperature Controller User s Man ual Cat No H142 I O Block Diagram Section 1 3 1 3 1 0 Block Diagram G3PW Power Controller Input signal 4 to 20 mA 1 Control method cy eee cae to 5 V or voltage ON OFF caa input 5 VDC O VDC Phase control roportional to square voltage Automatic tela e Proportional to voltage e Constant current control See note External main setting 2 kQ External duty e Current limit See note e Heater burnout alarm setting 2 kQ See note gt Alarm output 1 contacts Event input automatic manual setting or control method gt Alarm output 2 selection contacts EJ1 Modular Temperature External contacts RS 485 Controller or See note CompoWay F Master alarm reset Note Constant current Models only Models and Specifications Section 1 4 1 4 Models and Specifications G3PW A2 El il ll 01 234567 8 Symbol Meaning of symbol G3PW_ Power Controller 2 Degree of pro A tection E Voltage class i 200 VAC Maximum rated 20A current 45A 60 60A ramp ri type Current control U Standard Model no constant current control 9 Z Constant current Model Control terminal so Terminal block with small slotted screws i block Co Screwless clamp terminal block RS 485 com Communications not supported munications Communications support
52. e ENT RST Key to display the parameter set values 3 Use the UP and DOWN Keys to change a set value When the UP or DOWN Key is pressed the display will start flashing 4 Press the ENT RST Key to enter the setting and return to the previous pa rameter External Duty Input Enable Disable parameter P01 to Initialize Set Values parameter P28 42 Setting Parameters in the Initial Setting Level Section 4 6 4 6 Setting Parameters in the Initial Setting Level Settings Related to I O Parameters Determining the Output Mode Setting the Main Setting Typical Output Mode Automatic Input e Automatic operation 4 to 20 mA based Ema Proportional to phase angle on the analog current output from a same as G3PX temperature controller e Automatic operation 1 to 5 V based on P TEE the voltage output from a temperature as D paliaou a controller e Automatic operation based on a voltage ON OFF output from a temperature ON OFF control controller e Automatic operation based on communications using the CompoWay F dA A 10 phase angie same as G3PX e Constant current control protocol for devices such as EJ1 Modular Temperature Controllers Manual Input ewe set using external variable gt Proportional to phase angle same as G3PX e Main setting set using keys on front panel Proportional to phase angle same as G3PX Parameter Setting Procedure Output mode Proportional to Proporti portion
53. e Products without regard to conflict of law princi ples d Amendment These Terms constitute the entire agreement between Buyer and Omron relating to the Products and no provision may be changed or waived unless in writing signed by the parties e Severability If any provi sion hereof is rendered ineffective or invalid such provision shall not invalidate any other provision f Setoff Buyer shall have no right to set off any amounts against the amount owing in respect of this invoice g Definitions As used herein including means including without limitation and Omron Compa nies or similar words mean Omron Corporation and any direct or indirect subsidiary or affiliate thereof 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 Prod uct 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 Bu
54. e duty using an external variable resistor Enable Disable U Disable Default i Enable Output Mode Selec Selects the output mode for phase control tion for Phase Control 0 Proportional to phase angle same as G3PX Default i Proportional to square voltage c Proportional to voltage 3 Constant current Constant current Models only Input Digital Filter Sets the software filter time constant in relation to the input command value when Time Constant automatic input is set for the main setting 0 0 to 100 ms Default 0 0 Input Signal Type Sets the type of input signal from a temperature controller U Linear input Default Voltage ON OFF input Main Setting Auto Sets the input source when automatic input is set for the main setting matic Input Selection 4 to 20 mA or 1 to 5 VDC Default i Communications Main Setting Manual Sets the input source for when manual input is set for the main setting Input Selection ti External variable resistor input Default i Key input Control Method Sets the control method to use after a reset Default ti Phase control Default Optimum cycle control Note If the Event Input Assignment parameter P11 is set to 1 control method selection the control method selected with the event inputs will be used regardless of the setting of this parameter Main Setting Auto Sets the main setting input mode to use after a reset matic Manual Default U Automatic Default i M
55. e exposure to radioactivity e Locations close to power supplies When installing in a control panel consider the ease of operation ease of maintenance and environmental factors Leave at least 100 mm of space above and below the Power Controller when installing it to allow heat to dissipate Do not obstruct the area around the Power Controller and especially the area around the heat sink The ambient operating temperature range is 15 to 55 C but take the follow ing considerations into account When the ambient temperature exceeds 40 C reduce the maximum load current as shown below m Current and Temperature Characteristics G3PW A220E A245E 18 Load current 100 80 60 40 20 10 20 30 40 50 55 60 Ambient temperature C Installation Environment Section 3 1 Improving Noise Immunity m Current temperature Characteristic G3PW A260E Load current 4 Installation with 20 mm 60 Pf fy fy dy between Power Controllers 2 Close mounting 10 20 30 40 50 5560 Ambient temperature C e At least 20 mm must be provided on the left and right sides of the G3PW A260E Refer to 3 2 Installation lf you must use side by side mounting then reduce the maximum load current when the ambient temperature is over 30 C e Certification for safety standards was obtained with a mounting interval of 20 mm e Leave sufficient space for ventilation e Do not install the Power Controller above devices tha
56. e initial setting level and initialize the total Error Total Run Time nonvolatile memory run time If this does not remove the error the oper ation of the Power Controller must be checked by OMRON SSR Short Circuit The SSR is short circuited or Check that the heater is not burned out Turn ON the the heater is totally burned out power again If this does not remove the error the operation of the Power Controller must be checked by OMRON SSR Open Failure An SSR open failure occurred Check whether the heater is connected to terminal or the heater is not connected T1 on the load terminal block If this does not to terminal T1 on the load termi remove the error the operation of the Power Con nal block troller must be checked by OMRON CT Failure The built in CT Unit has failed or Check that the heater is not burned out Turn ON the the heater elements are all power again If this does not remove the error the burned out operation of the Power Controller must be checked by OMRON Heater Overcurrent An overcurrent was detected An overcurrent is flowing to the heater Check the Error load and use the alarm reset see note to clear the error E30 ZeroCross Error A zero cross error or frequency Check whether the load power supply voltage and Frequency Error error was detected the frequency are within the specified ranges Check whether noise is occurring in the load power supply line or in the surroundings
57. ed phases nal block Single phase Terminal block Standard aal Screwless clamp Standard bernie bine G3PW A260EC C FLK List of Models Optional Products Variable Resistor G32X V2K specified model SECTION 2 Specifications and Nomenclature This section provides the specifications of the G3PW Power Controllers and describes the part names and functions el sSpeCiiCaHOns usara bo ee a aoe eek Sele ee lea ieee 8 2 2 Nomenclature and Operations 0 0 eee eens 14 Specifications Section 2 1 2 1 Specifications Specifications O tem Standard Models Constant current Models ma RT EU G3PW A2 T ECT FLK Control method Analog input Phase control or optimum cycle control Voltage ON OFF input ON OFF control Maximum load capacity e Phase control Linear resistive load transformer primary side control Magnetic flux E 1 25 T max e Optimum cycle control Linear resistive load Transformer primary side control is not supported Output Analog input Phase Proportional to phase angle same Proportional to phase angle same mode control as G3PX proportional to square as G3PX proportional to square voltage proportional to voltage voltage proportional to voltage con stant current control Optimum Optimum cycle control Output is switched to 100 or 0 each half cycle cycle control Voltage ON OFF ON OFF Proportional to voltage control oo control AAN Single 15 t0 10 50 60 Hz
58. ed ported ported ported ported Spores Supporied _ Supported Output upper lower Supported Supported limits Total run time Supported Supported exceeded detection 2 U alarm reset auto Duty settings Internal setting Supported Supported Supported Supported Supported Supported Supported Sup ported Keys or communi cations S matic manual selection or control method selection I O functions Event inputs 1 alarm reset Serial communica Supported tions RS 485 ke 2 Specifications Section 2 1 models models current Pp Model S EN EH EmN Ec bu w be Eu Ec Error monitor Overcurrent detection ENE EN Supported ENE Supported EN Supported m Single heater burnout Supported Supported Supported El Supported Supported I Supported detection Multiple heater burn up out detection Ta 1 element out of 10 SSR short circuit ele Supported Supported Supported Supported Supported ment ON failure a tion ssRopentaiore df i send Supported forraie eo i id i id ES E zoss f E df f seed Supported External input range Supported Supported error external input disconnection detec tion Power supply fre Supported Supported quency error X The soft start down time is the same as the soft start up time 13 Nomenclature and Operations Section 2 2 2 2 Nomenclature and Operations Nomenclature A
59. ed for Constant current Models only Main Setting 4 to 20 mA P03 Input OF P05 Main Setting Au dal 1to5V Digital Filter tomatic Input Selection 79 See Automatic setting e cations i Variable P03 Input O 4 R S Setting j Digital Filter utomatic Manua resistor g Elaun Manual setting Key input P06 Main Set P01 External ting Manual Input Selection Key com munications O Duty Input Ena ble Disable Variable P03 Input External duty resistor Digital Filter 1 Base up value Key Input Output upper lower limits Duty Setting Internal duty Thyristor gt control cir cuit Output phase angle calcu lation Output value Figure 1 Signal Flow Diagram for Other than ON OFF Control Output phase angle Default 38 Input System Section 4 4 4 4 Input System Main Setting Input The main setting can be selected from the following five input systems Automatic Input m Analog input 4 to 20 mA or 1 to 5 V Used to connect to outputs such as the linear output from a Temperature Con troller Communications RS 485 Used to connect with a device that uses the CompoWay F protocol such as for the EJ1 Modular Temperature Controller m Voltage ON OFF input 0 or 5 VDC Used to connect to outputs such as a time proportional control output from a temperature controller Only for commands for switching outputs ON and OFF with 5 V
60. el it is possible to distinguish between E10 SSR short circuit and E40 heater burnout alarm errors by assigning 1 Alarm level 1 or 2 Alarm level 2 to the Heater Burnout Alarm Operation parameter P14 This error occurs if there is an SSR open failure or the heater is not connected to terminal T1 on the load terminal block and the output phase angle is 28 min If the heater is connected to terminal L1 connect it to terminal T1 Turn ON the power again If this does not remove the error there is an SSR open failure and the operation of the Power Controller must be checked by OMRON A CT failure error occurs when either the built in CT has failed or the output mode is set to constant current mode and all of the heaters connected to the Power Controller have burned out Turn OFF the power to the Power Controller and to the heaters and check for heater burnout If there is no heater burnout then it means that the CT has failed In that case the operation of the Power Controller must be checked by OMRON Consult with your OMRON representative If heater burnout cannot be easily confirmed the following procedure can be used to distinguish between CT failure and heater burnout First check whether the problem continues when the output mode is change and then perform this procedure Procedure for Distinguishing CT Failure and Heater Burnout 92 1 2 3 1 Set the input value to 0 Detailed Descriptions of Errors E20 Hea
61. el or by using communications Constant current Models only Base up value setting range 0 0 to 100 The output value is found with the following formula Output value Duty setting x input value Base up value m Example Setting the Base up Value to 30 Output value 100 DO T A E N CO a Base up setting 30 1 2 3 1 While in the monitor level during operation press the LVL Key once to move to the adjustment level 2 Press the DOWN Key for 2 s to display the BUP base up value and press the ENT RST Key to enter the value 0 50 100 Input value 3 Use the UP and DOWN Keys to display 30 0 and then press the ENT RST Key to enter the value 4 Press the LVL Key once to return to the monitor level 53 Output Limits Section 5 5 5 5 Output Limits 54 The output limit function can be used to set upper and lower limits for the out put value The output value is found with the following formula Output value Duty setting x Input value Base up value The output limit is set in the Output Upper Limit OLU and Output Lower Limit OLL parameters in the adjustment level from 0 0 to 100 in each case If the output lower limit is set higher than the output upper limit then the out put lower limit will be used as the output upper limit and the output upper limit will be used as the output lower limit In other words the higher value will always be taken as the upper limit and the lower
62. ent input 13 Reset input 14 Reset input For standard models 1 and 2 are not used Description of function Terminals for connecting external variable resistor for main setting RS 485 RS 485 communications RS 485 COS Duty setting COM Terminals for connecting external variable resistor for duty setting Alarm output 1 Alarm output for fatal errors The output to ENS Alarm output 1 the load is stopped 9 4 Alarm output 2 Alarm output non fatal errors The output Alarm output 2 to the load is not stopped Event input Terminals for connecting event inputs The functions for event inputs are selected with parameter settings in the initial setting level using the Event Input Assignment parameter P11 16 Event input Reset input Reset input The reset input is valid only for alarm level 2 alarm output 2 SECTION 3 Installation and Wiring The section describes how to install and wire the G3PW Power Controllers 321 Installation Environment traia cower dete ee aie RTE cade 18 5 2 Wins tallagions ir a kn aa 21 si 51 ehot os a cae eee aca a ee wn ce eee oe eee ee oe 26 3 3 1 Wiring the Power Supply and Load Circuits 26 3 3 2 Command Input and Power Supply Terminal Wiring 2J 3 3 3 Wiring the Control Terminal Block 28 Jo A O 31 3 3 5 Wiring an External Noise Filter o ooooooooooo
63. er characteristic resistance Select TPC for phase control or TCC for optimum cycle control The present heater characteristic resistance will be displayed A teaching error occurred Her gg After the setting has Remove the cause of the been made the menu error and then try again will again be displayed Teaching cannot be executed when the current T to the CT is less than 10 of the rated current Perform teaching only when the current is at least 10 of the rated current and when control is stable When teaching is not possible 0 0 will be displayed EE Operation Teach Heater STS ES for Sets the present resistance as the Phase Control heater characteristic resistance for phase control Teach Heater Characteristics for Sets the present resistance as the Optimum Cycle Control heater characteristic resistance for optimum cycle control To set the parameter directly without teaching or to make an adjustment after teaching select the Heater Characteristic Resistance parameter HPR or HCR 59 Heater Burnout Detection Section 5 9 Display Name T Range Heater Characteristic Resistance for Phase Control 0 0 to 99 9 Heater Characteristic Resistance for Optimum Cycle 0 0 to 99 9 Control Parameters for Heater Burnout Judqment Conditions The following parameters are used to set the conditions for detecting a heater burnout Use them according to the load environment e Heater Burnout T
64. erature controller Input value 4 to 20 mA or 1 to 5 V Temperature sensor Continuous proportional current output phase control or optimum cycle control G3PW Power Controller Heater Just as with a solid state relay SSR ON OFF control can be executed by inputting a time proportional output or ON OFF output i e voltage ON OFF signals from a temperature controller Initial settings output mode input signal type event input settings etc and adjustments duty settings soft start up down settings etc can be made by using keys on the front panel The 7 segment display on the front panel can also be used to monitor items such as the input value output value phase angle and load current A see note Note Constant current Models only G3PW Power Controllers come in two models Constant current Models and Standard Models Constant current Models provide current detection func tions constant current current limit overcurrent detection and heater burn out detection and serial communications including connections to the EJ1 Modular Temperature Controller Heater burnout detection is based on the heater resistance rather than on the load current making detection more accurate G3PW Features Section 1 2 1 2 G3PW Features 1 2 1 Features of Constant current and Standard Models Phase control or optimum cycle control can be selected by using either event inputs or the keys on the front panel Inr
65. eter alarm level 2 P17 Pm 90 Detailed Descriptions of Errors Section 7 3 7 3 Detailed Descriptions of Errors E01 RAM Error E02 EEPROM Checksum Error E03 EEPROM Checksum Error Setting Error Note Recovery Procedure 1 2 3 An error occurred in the internal memory Consult with your OMRON repre sentative An error occurred in the system area in EEPROM The operation of the Power Controller must be checked by OMRON Consult with your OMRON represen tative An error occurred in the user set parameter area in EEPROM Initialize the parameters set in the initial setting level and the adjustment level and then turn the power OFF and back ON After restarting set the correct values for the parameters in the initial setting level and the adjustment level Until the correct parameter settings are made unintended outputs may occur While initializing the user set parameters and making the settings again lower the input value and take sufficient precautions 1 Move to the initial setting level Press the LVL Key for at least 2 s The Initialize Set Values parameter P28 in the initial setting level will be displayed 2 Enter the Initialize Set Values Menu Press the ENT RST Key 3 Select the Initialize Set Values Menu Press the UP Key once to display C oc INI on the display 4 Initialize the set values Press the ENT RST Key to initialize the set values After 0 5 s the display will auto
66. format to facilitate communications between more than one compo nent and between personal computers and components FINS Factory Interface Network Service The FINS protocol provides message communications between control lers in OMRON FA networks 6 1 2 Communications Settings This section describes the communications settings for the GBPW 64 Communications Settings Section 6 1 Communications Settings in the Initial Setting Level Display Setting range Default BIR oO Communications Unit Number 0 la 99 E Communications Baud Rate fs U L fu D 9 6 k bit s 57 6 k bit s 19 2 k bit s 38 4 k bit s 1 57 6 k bit s Communications Data Length 7 bit 7 bit al c 2 bit EVN EVEN D ot Ja US lal pu L m hog De a 1 00 N Ern R vp Lm S LD TU IN h Communications Main Set ting Number Automatic assignment recommended Default CH1 control output heating CH2 control output heating CH3 control output heating CH4 control output heating 5 CH1 control output cooling L Nr Nr wad LL M a q gt Ner See note b CH2 control output cooling See note 1 CH3 control output cooling See note H CH4 control output cooling See note EE to an OMRON PLC 1 i Automatic assignment Fixed POE Communications Timeout 4 Communications timeout function disabled 10s Note Refer to 6 4 Se
67. he new setting The data display will stop flashing and the parameter display will return 6 1 3 Connection Example Setting the G3PW Communications Unit Numbers to the Same Numbers as the EJ1 Channel Numbers An EJ1 TC4 Unit has four channels It can thus be connected to up to four G3PW Power Controllers Setting Example 1 2 3 1 The G3PW communications unit numbers P19 can be set to the same numbers as the EJ1 channel numbers as shown below 68 Communications Settings Section 6 1 2 Set the Communications Main Setting Number parameter P25 to the de fault value 0 Automatic assignment The EJ1 will create communications frames for the MVs for the maximum number of channels i e four chan nels for the TC4 Unit The Communications Main Setting Number param eter of the G3PW is set to specify automatic assignment so the channel number for the MV will be the same as the communications unit number for each channel Communications Main Setting Number Automatic Assignment 1 Communications frames for the MV for all channels are sent from the EJ1 to the G3PW according to the unit numbers User programming is not required Chi MV Ch2 MVI Ch3 MM Ch4 MV Communications frame for Unit 1 Cht MV Ch2 MV Ch3 MV Ch4 MV Communications frame for Unit 2 Chd MVI Ch2 Ch3 MV ICh4 MV Communications frame for Unit 3 Cn MV Ch2 Mv Ch3 MV Ch3 104 EDU g TMVICRAMV CR3 VIG MV Communicavons tame dor Unita ighi MV
68. her 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 Shipping Delivery Unless otherwise expressly agreed in writing by Omron 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 Claims Any claim by Buyer against Omron for shortage or damage to the 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 trans portation bill signed by the carrier noting that the carrier received the Products from Omron in the condition claimed Warranties a Exclusive Warranty Omron s exclusive warranty is that the Products will be free from defects in materials
69. hreshold HBR Adjustment level e Heater Burnout Detection Lower Limit HBL Adjustment level e Number of Alarms for Heater Burnout Detection P09 Initial setting level Rate of Change in The threshold for determining a heater burnout when the resistance increases Resistance for Heater must be set as a percentage of the present resistance using the Heater Burn Burnout Detection out Threshold parameter HBR The following formula is used to determine heater burnouts 100 Present resistance gt Characteristic resistance of heater x _________ wee S 100 Heater Burnout Threshold An approximate value for the Heater Burnout Threshold can be calculated with the following formula Heater Burnout Threshold 90 Number of heater elements For example if you want to detect the burnout of one element for a heater with three elements set the Heater Burnout Threshold to 30 Note 1 If the default value of 100 is used burnout of all heater elements will be detected 2 If the Heater Burnout Threshold is too small the alarm output may be un stable Display T Name T Rane HBH Heater Burnout Threshold 1 to 100 Heater Burnout Detection The Heater Burnout Detection Lower Limit parameter is used to limit the Lower Limit range of output values for heater burnout detection The default setting is 0 0 If alarms are frequently occurring for small outputs in normal operation then limit the range of output values to be
70. ion 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 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 INNO EVENT SHALL OMRON BE RESPONSIBLE FOR WARR
71. ions Unit Board in a PLC G3PW Settings 1 2 3 PLC Settings 70 2 Set the Communications Main Setting Number parameter P25 to any number between 1 and 8 The G3PW with each communications unit num ber will receive the MV from the Temperature Controller channel specified by the Communications Main Setting Number Communications Main Setting Number Specific Settings 1 Communications frames for the MV for all channels are sent from the EJ1 to the G3PW according to the unit numbers User programming is not required Ch1 bO Ch2 M Communications frame for Unit 1 Gn ht MV MV Ch2 MV MV Communications frame for Unit 2 Chi MV MV pe Communications frame for Unit 3 TC2 EDU cary T VIV Cre mv Communications frame for Unit 4 CompoWay F RS 485 capw Unit 1 qgpw Unit 2 faapw Unit3 pw Unit 4 2 The G3PW with each communi gt gt cations unit number will receive the MV from the Temperature l Heater Heater ale me Controller channel specified by the Communications Main Set ting Number Note The MV for Ere unit bol 1 will be P if there are more than 9 communications unit numbers Communica Communica Communica Comunica tions Main tions Main tions Main tions Main Setting Setting Setting Setting Number 1 Number 2 Number 1 Number 2 Note Refer to the note on page 72 for information on the Communica tions Main Setting Numbers The EJ1 will automatically send the MV for the maximum number of G3PW chan
72. ions nan None n Even Default dd Odd Sets the send wait time O to 99 ms Default 1 Sets the MV input channel e Connection to an OMRON EJ1 Modular Temperature Controller Automatic assignment recommended Default CH1 control output heating 5 CH1 control output CH2 control output heating b CH2 control output CH3 control output heating i CH3 control output CH4 control output heating CH4 control output e Connection to an OMRON PLC i CH1 a L m L fo D e qu qu PU m j IS U m l Lm A ua Cm pu Ex cooling cooling Le Lu TU nn cooling cooling m D la Communications Tim 0 to 999 s Default 10 eout Time U Communications timeout function disabled Reset Total Run Time Used to reset the total run time AE Do not reset Default Initialize Used to initialize parameter settings ABE Do not initialize Default C nc Initialize LaL Appendix B Parameter Settings in the Adjustment Level Depay enn O nH Key Input Main Set Sets the input value ting 0 0 to 100 Default 0 0 Internal Duty Setting Sets the proportion of the input value to the output value as a duty 0 0 to 100 Default 100 Base Up Value Sets the amount to increase the output value so that the output value does not go to 0 even when the input value is 0 0 0 to 100 Default 0 0 ret Soft start Up Time Sets the ti
73. ions 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 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 Prices Payment Terms All prices stated are current subject to change with 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 Discounts Cash discounts if any will apply only on the net amount of invoices 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 Interest Omron at its option may charge Buyer 1 1 2 interest per month or the maximum legal rate whichever is less on any balance not paid within the stated terms Orders Omron will accept no order less than 200 net billing Governmental Approvals Buyer shall be responsible for and shall bear all costs involved in obtaining any government approvals required for the impor tation or sale of the
74. ions frames are given in the following table when G3PW Power Controllers with communications unit numbers 1 3 and 5 are connected to the PLC CompoWay F communications frame Operation sent from the PLC STX 010000102810000000001 03E6 Writes an MV of 03E6 to the G3PW with communications unit number 1 STX 030000102810000000001 01F4 Writes an MV of 01F4 to the G3PW with communications unit number3 STX 050000102810000000001 OOFA Writes an MV of OOFA to the G3PW with communications unit number 5 Note The shaded portions of the communications frames are the MVs 71 Communications Settings Section 6 1 Send Wait Time 72 Note Communications Main Setting Numbers The Communications Main Setting Number is set in a G3PW Power Controller to specify the EJ1 channel from which the MV is to be received for the com munications unit number As shown below the communications frame sent by the EJ1 contains the MVs in the order of the channel numbers MV for four channels for a TC4 Unit The Communications Main Setting Number specifies the channel number from which the G3PW is to received the MV as input data Normally the Communications Main Setting Number parameter P25 is set to specify automatic assignment so that the channel number will be the same as the communications unit number For example the MV from channel 1 is received by the G3PW with communications unit number 1 The Communica tions Main Setting Number ca
75. ire power lines together with or parallel to Power Control ler wiring Using shielded cables and using separate conduits or ducts is recommended e 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 e When a noise filter is used at the power supply first check the voltage or current and attach the noise filter as close as possible to the Power Controller O Cleaning e Do not use paint thinner or similar chemical to clean with Use commercially available standard grade alco hol O Storage e Store the Power Controller within the rated ambient temperature xii TABLE OF CONTENTS SECTION 1 VOICE Wenas TENEIS ees 1 1 1 Overview of G3PW Power Conroler ooo Z E2 W SC AUC So gre oc estes O hk GLARE DR EEA are ee aE 3 ES MO Block Distrito cack n hehe eek Weick ww cote ds eee wee eae wwe eee oem seats 5 1 4 Models and Specifications a A RR R e R e eee eee Ra RA 6 SECTION 2 Specifications and Nomenclature ooooooooo o 7 Dell SPECIACAMONS 2 AA A eta ea dat Ue Sates eee hee eee 8 222 Nomenclature and Operations a a E A R td iA wt A ee R es 14 SECTION 3 Installation and Wiring ooooooooooomooooo 17 3 1 Installation Environment A A AA A SAS A te 18 A E AAA O Bae Oh a aes 21 Fo A 26 3 4 Wiring for Specific Applications 0 0 0 ce
76. l e Software is reset when moving from the initial setting level to monitor level ENT RST Enter Set value display In the monitor level the ENT RST Key Reset Key Set value change and entry functions as a Reset Key only when an error occurs It does not function as a Reset Key when there is no error Error reset UP Key Set value change Monitor item set value number change DOWN Key Command Input and Power Supply Terminal Block 1 1 to 5 V input 2 4 to 20 mA input 3 Current voltage input COM 4 100 to 240 VAC 5 100 to 240 VAC Load Terminal Block Under Protective Cover Load circuit output terminal T1 Load circuit output terminal L1 15 Nomenclature and Operations Control Terminal Block mScrewless Clamp Terminal Block RS 485 RS 485 Main setting Main setting COM Duty setting Duty setting COM Alarm output 1 St eS oS SI ES Alarm output 1 9 Alarm output 2 10 Alarm output 2 11 Event input 12 Event input 13 Reset input 14 Reset input For standard models 1 and 2 are not used Main setting COM Duty setting Section 2 2 Terminal Block with Small Slotted Screws ARRRRRRRRRBRARRE RS 485 RS 485 Main setting Main setting COM Duty setting Duty setting COM Alarm output 1 ON ooh WD Alarm output 1 9 Alarm output 2 10 Alarm output 2 11 Event input 12 Ev
77. la omron com Santiago 56 9 9917 3920 OMRON ELECTRONICS DE MEXICO SALES OFFICE OTHER OMRON LATIN AMERICA SALES Apodaca N L s 52 81 11 56 99 20 e 001 800 556 6766 e mela omron com 54 11 4783 5300 OMRON ELETR NICA DO BRASIL LTDA HEAD OFFICE Sao Paulo SP Brasil e 55 11 2101 6300 e www omron com br OMRON EUROPE B V Wegalaan 67 69 NL 2132 JD Hoofddorp The Netherlands e Tel 31 0 23 568 13 OO Fax 31 0 23 568 13 88 e www industrial omron eu Cat No Note Specifications are subject to change O 2013 Omron Electronics LLC Printed in U S A
78. larm output 1 ALARM1 caution Alarm output 2 ALARM2 warning Open collector outputs Maximum operating 30 VDC voltage Maximum load current Maximum residual 1 5 V voltage Maximum leakage 0 4 mA current Specifications Section 2 1 ltem Standard Models Constant current Models Model PARE G3PW A2 T EC FLK One RS 485 port CompoWay F slave function See note Serial communications Note Connection is possible to a Basic Unit in an EJ1 Modular Temperature Controller Parameters can be set and monitored from the CX Thermo Support Software running on a computer that is connected to the EJ1 End Unit Overcurrent detection Rated current x 120 min within 250 cycles SSR failure detection An error is detected within 3 seconds after an SSR failure e Phase angle range for SSR short circuit failure detection 0 to 72 e Phase angle range for SSR open failure detection 28 to 100 Power supply frequency error Not within 47 to 63 Hz Leakage current 10 mA max 100 110 VAC 20 mA max 200 220 VAC Insulation resistance 100 MQ min at 500 VDC Dielectric strength 2 500 VAC at 50 60 Hz for 1 min between charged parts and non charged parts Vibration resistance 10 to 55 to 10 Hz 100 m s Shock resistance 300 m s2 Ambient operating temperature 15 C to 55 C with no icing or condensation Ambient operating humidity 5 to 95 Storage temperature 25 C to 65 C with no icing or condensation
79. le indicates a precaution for electric shock The triangle symbol indicates precautions including warnings The specific operation is shown in the triangle and explained in text This example indicates a precaution for hot surfaces The triangle symbol indicates precautions including warnings The specific operation is shown in the triangle and explained in text This example indicates a general precaution The filled circle symbol indicates operations that you must do The specific operation is shown in the circle and explained in text This example shows a general precaution for something that you must do Vill E Safety Precautions Al WARNING Do not attempt to disassemble the Power Controller while the power is being supplied Doing so may occasionally result in strong electric shock Do not touch any of the terminals while the power is being supplied Also always attach the terminal block cover after completing wiring Touching live terminals may occasionally result in serious injury due to electric shock Fail safe measures must be taken by the customer to ensure safety in the event of incorrect missing or abnormal signals caused by broken signal lines momentary power interruptions or other causes Abnormal operation may result in serious accidents Do not use the Power Controller where subject to flammable or explosive gas Otherwise explosion may occur Use the wire sizes given in this document and use
80. lling heaters with large inrush currents Optimum Cycle With optimum cycle control the output is turned ON and OFF with each AC Control half cycle The output is switched at the voltage zero cross point enabling high precision temperature control while suppressing noise ON OFF Control With ON OFF control the control output is switched ON and OFF based on the ON OFF voltage signal from the temperature controller The output phase angle is set using operation keys or an external variable resistor SOA AAA Output OFF gt Output ON gt OutputOFF gt Output ON gt 36 Output Modes 4 2 Output Modes Section 4 2 When phase control is used as the control method any of the following four modes can be selected for the relationship of the control value to the output value Control pro portional to phase angle Same as G3PX Control pro portional to square volt age Control pro portional to voltage Constant cur rent control Constant current Mod els only In this mode the relation ship of the output phase angle to the output value has the same characteristics as for the G3PX Power Con troller Control Proportional to Phase Angle Same as G3PX 00 SS Sa aS a a ie a SS SS In this mode the square of the output voltage is propor tional to the output value When the load resistance is constant the output power value is proportional to the output value 80 100
81. matically return to the Initialize Set Values parameter P28 5 Turn the Power Controller power OFF and then back ON In the initial setting level press the LVL Key for at least 2 s The Power Con troller will be reset and restarted E04 EEPROM Checksum Error Total Run Time Error Recovery Procedure l2 oes An error occurred in the total run time area in EEPROM A total run time checksum error occurred when reading EEPROM at startup Reset the total run time to 0 and then turn the power OFF and back ON The total run time prior to the initialization will be lost 1 Move to the initial setting level Press the LVL Key for at least 2 s The Reset Total Run Time parameter P27 in the initial setting level will be displayed 2 Enter the Reset Total Run Time Menu Press the ENT RST Key 3 Select the Initialization Menu Press the UP Key once to display C oc INI on the display 4 Reset the total run time Press the ENT RST Key to initialize the total run time After 0 5 s the dis play will automatically return to the Reset Total Run Time Menu P27 5 Turn the Power Controller power OFF and then back ON In the initial setting level press the LVL Key for at least 2 s The Power Con troller will be reset and restarted 91 Detailed Descriptions of Errors Section 7 3 E10 SSR Short Circuit e An SSR short circuit error occurs when either an SSR short circuit failure occurs or when 0 None is set for the Heater Bur
82. me from 0 to 100 for increasing the output value gradually even SUP when the ma value increases E 0 0 to 99 9 s or 0 5 23 om Sig 2 m U pak Ur uo D E Y Sets the ae upper e 0 0 to 100 Default 100 0 If the output upper limit is oe lower than the output lower limit then the output upper limit will be treated as the output lower limit Output Lower Limit Sets the output lower limit 0 0 to 100 Default 0 0 If the output lower limit is set higher than the output upper limit then the output lower limit will be treated as the output upper limit Har Heater Burnout Sets the criteria for the heater burnout alarm output HBR Threshold 1 to 100 Default 100 Control Method Sets the control method 0 Phase control Default 1 Optimum cycle control H A Main Setting Auto Sets automatic or manual operation for the main setting A m matic Manual 0 Automatic Default 1 Manual Teach Heater Char This parameter is displayed only when the control method is set to phase control acteristics for Phase It is used to record heater characteristics resistance output value output phase Control angle for phase control Heater Characteristic This parameter is displayed only when the control method is set to phase control Resistance for Phase It is used to check and correct the heater characteristic resistance set by teaching Control 0 0 to 99 9 Q Default 0 0 Teach Heater
83. mit is used to set upper and lower limits for the output value Instead of adjusting the rate of change of the output value in relation to the input value it enables upper and lower limits to be set on the current flowing to the heater Total Run Time The total run time exceeded detection function outputs an alarm when the Exceeded Detection total run time exceeds the preset Total Run Time Monitor value kh The total run time can be monitored for notification of the need for replacement or pre ventive maintenance of the Power Controller or heater 1 2 2 Features of Constant current Models Only Constant current Control for Controlling a Pure Metal or Nonmetal Heater Constant current control measures the load current with a built in CT and controls the load current so that it is proportional to the input This stabilizes the heating values of heaters pure metal or nonmetal for which the resis tance changes due to temperature changes or deterioration over time Current Limit for the The current limit function measures the load current with a built in CT and pro Load Current tects the heater by adjusting the phase angle to limit the load current so that a preset load current limit is not exceeded It is also used together with the soft start functions to limit the inrush current for pure metal heaters and nonmetal heaters G3PW Features Section 1 2 Heater Burnout Detection and Alarm Based on Heater Resistance This function detects ch
84. n be set as desired to write the MV from channel 1 to the G3PW with any communications unit number from 2 to 4 Connecting to an EJ1 Modular Temperature Controller Set the Communications Main Setting Number P25 to 0 automatic assignment L d Communications frames for the MV for all channels are EJ1 automatically sent from the EJ1 to the G3PW according to the TC4 communications unit numbers User programming is not required Chi 19 Ch2 M Ch3 MVI Ch4 MV Communications frame for Unit 1 IS Chip Ch2 MN Ch3 N l Ch4 M Communications frame for Unit 2 F 7 Ch2 V U Ch4 M Communications frame for Unit 3 CompoWay F Co RN eA A A Com RS 485 Ey 7 A a gary CREM Cha MY Communications frame for Unit 4 ara G The MVs from the EJ1 are received according to the Communications Main Setting Number When automatic assignment is used the number of the EJ1 channel will be the same as the communications unit number of the G3PW de te ate a G3PW G3PW G3PW G3PW Communica Communica Communica Communica tions Main Set tions Main Set tions Main Set tions Main Set ting Number 1 ting Number 2 ting Number 3 ting Number 4 Note When connecting to a PLC set the Communications Main Setting Number for all G3PW Power Controllers to 1 The send wait time is used to adjust the time required for the host to switch from sending to receiving status For the G3PW this adjusts the time between creating a response after receiving a
85. nal to Phase Angle Same as G3PX Control Proportional to Phase Angle Duty setting Q T OO iesen OE a e 100 eae OE aa 80 0 2 OO eas 60 A 40 i O 90 20 0 20 40 60 80 100 Input value 51 52 Duty Setting Section 5 3 2 Control Proportional to Square Voltage Duty setting Control Proportional to Square Voltage 100 fe aes do le a a n 100 H T e yi 80 o 3 3 od eee noe 60 2 40 L ha A 40 3 G 20 A a pa Se eer 20 0 20 40 60 80 100 Input value 3 Control Proportional to Square Voltage Control Proportional to Voltage Duty setting 100 poes E i ten aaa 100 D E E E a 80 q PE E anaie id O CE 60 Z BO A a o A gee ne ii da 40 A EEE a E ee 20 0 20 40 60 80 100 Input value 4 Constant current Control Duty setting Constant current Control 100 poo o eb 100 ar L a 80 z S 60 60 9 AO L 40 Oo 3 ee A AA eee eee ee 20 0 20 40 60 80 100 Input value Base up Function Section 5 4 5 4 Base up Function The base up function increases the output value so that it does not become 0 even when the input value is 0 Because the output value is held even when the input value is 0 the heater can be preheated This is effective for shortening the heating time when using a load for which the temperature increases slowly The base up value is set in the Base up Value BUP parameter in the adjust ment lev
86. nels User programming is not required The following settings are necessary to connect a PLC and G3PW Power Controllers with serial communications RS 485 is used for communications so up to 31 G3PW Power Controllers can be connected 1 Setall of the Communications Main Setting Number parameters P25 to 1 2 Setthe communications unit numbers to any values between 0 and 99 A maximum of 31 nodes can be connected Use the CMND instruction in the ladder program to send input variables to the G3PW Power Controllers Use a variable type of C1 81 and an address of 0000 for the communications main setting MV for each G3PW communica tions unit number Communications Settings Section 6 1 Communications frame for Unit 1 E Eas frame for Unit 2 E o frame for Unit 3 L SF frame for Unit 31 16 485 CompoWay F Fone Conlon to 31 G3PW Power Controllers RS can Fone Conlon connected G3PW G3PW G3PW U Unit 1 Unit 3 Unit 5 Unit 31 SYSMAC CS CJ series PLC MEE cru SCU Tem Unit pera ture input Heater Heater Heater Heater cT TT Ans ITI AA AS ommunica Communica Communica Communica 1 Hons Main Set tions Main Set tions Main Set tions Main Set i fing Number 1 ting Number 1 ting Number 1 ting Number 1 I Set all to 1 1 mei a m me me me me me me me me me me ee eS ee M Note Refer to the note on page 72 for information on the Communica tions Main Setting Numbers Example The communicat
87. nout Alarm Operation parameter P14 and all the heaters have burned out e With a standard model of the G3PW Power Controller this error will occur if a heater burnout occurs when only one heater is being used e An SSR short circuit error will occur if the power is turned ON with no load connected Parameter settings will still be enabled e Turn OFF the power to the Power Controller and to the heater and check for heater burnout If the heater is burned out replace it If heater burnout cannot be easily confirmed the following procedure can be used to isolate SSR short circuiting and heater burnout Isolating SSR Short circuiting and Heater Burnout N Caution 1 2 3 Using a Constant current Model E11 SSR Open Failure E12 CT Failure With a Constant current Model it is possible to distinguish between SSR short circuit and heater burnout alarms by using the following procedure 1 Set the reference value to 0 2 Restart the G3PW by turning the power OFF and back ON or by using the reset operation 3 Monitor the load current in the monitor level once the G3PW restarts oper ation If a large load current is flowing there is an SSR short circuit If a large load current is not flowing there is a heater burnout If there is an SSR short circuit a load current equivalent to a 100 output will flow Before turning ON the power again confirm that your equipment will not be affected With a Constant current Mod
88. o 240 VAC OY 50 60 Hz Fast acting fuse 31 Wiring for Specific Applications Section 3 4 3 4 Wiring for Specific Applications Automatic Operation Wiring Example for Automatic Operation Using Current Signal Input of 4 to 20 mA 1 2 3 4 5 ADA DOA D VAALAN ee ee n b bong Temperature controller or other controller 4 to 20 mA output Wiring Example for Automatic Operation Using Voltage Signal Input of 1 to 5 V i 2 o 4 5 ms Siz O ADIA DI ele sls H WII paye NU LOL pyre NU Temperature controller or other controller 1 to 5 V output Wiring Example for Automatic Operation Based on RS 485 Communications Multi drop See note Max of 31 nodes RS 485 RS 485 Main setting Main setting COM Duty setting Duty setting COM EJ1 Modular Temperature Controller CJ series Serial Communications Unit etc Alarm output 1 o N o or e w N z Alarm output 1 Alarm output 2 10 Alarm output 2 11 Event input 12 Event input 13 Reset input 14 Reset input For standard models 1 and 2 are not used Note A terminator must be connected at each end of the RS 485 trans mission path The terminators must be at least 54 Q combined 32 Wiring for Specific Applications Section 3 4 Manual Operation Wiring Example for Using an External Variable Resistor for the Main Setting Use a G32X V2
89. on and defend or set tle 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 Property Confidentiality Any intellectual property in the Products is the exclu 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 Export Controls Buyer shall comply with all applicable laws regulations and 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 Miscellaneous a Waiver No failure or delay by Omron in exercising any right and no course of dealing between Buyer and Omron shall operate as a waiver of rights by Omron b Assignment Buyer may not assign its rights hereunder without Omron s written consent c Law These Terms are governed by the law of the jurisdiction of the home office of the Omron company from which Buyer is purchasing th
90. onstant current 8 constant current control 37 Constant current Models 3 8 continuous proportional output 2 control method 8 control methods 36 control proportional to phase angle 37 control proportional to square voltage 37 control proportional to voltage 37 control terminal block 14 28 CT 9 CT failure 92 current detection 9 current input terminals 27 32 current limit 3 current transformer 9 current temperature characteristic 19 CX Thermo Support Software 4 D dielectric strength 10 dimensions 22 duty setting 2 51 external variable resistor 51 internal 51 E EEPROM checksum error 91 EJ1 2 4 10 end nodes 31 error displays 89 errors recovery 91 errors for which the output continues 90 errors that stop the output 89 event inputs 3 9 48 external contact input 5 external contact inputs 48 external duty input alarm 94 external duty setting 5 29 external input range alarm 94 external main setting 5 29 external setting Variable Resistor 6 external setting inputs 29 F FINS 64 FINS mini 75 command services 76 frequency error 93 Fuse Holder 10 27 fuses 10 fast acting 26 27 time delay 26 27 99 G grounding 31 H heater burnout alarm 9 93 heater burnout detection 4 58 multiple detections 9 number of alarms for detection 9 setting range 9 heater burnout detection accuracy 9 heater resistance 4 inductive noise
91. ooo 31 3 4 Wiring for Specific Applications oo 32 17 Installation Environment Section 3 1 3 1 Installation Environment Installation Environment Installation Location N WARNING Ambient Temperature Use and store the Power Controller within the rated ambient temperature and humidity ranges If more them one Power Controller is installed side by side or vertically the heat that is generated will cause the internal temperatures of the Power Controllers to rise and will shorten their service life In these kinds of installations take suitable measures such as installing fans for forced cool ing The Power Controller is designed for indoor use only Also do not use the Power Controller in the following environments e Locations subject to water or oil e Locations subject to direct sunlight e Locations where dust or corrosive gases in particular sulfuric or ammo nia gas are present e Locations where flammable or explosive gases are present e Locations subject to extreme temperature changes e Locations where icing or condensation may occur e Locations subject to excessive shocks or vibration e Locations subject to direct heat radiated from heating devices Take appropriate and sufficient countermeasures when installing systems in the following locations e Locations subject to static electricity or other forms of noise e Locations subject to strong electromagnetic fields e Locations subject to possibl
92. or External Settings g m Wiring to Adjust the Main m Wiring to Adjust the Duty Setting Setting Use a G32X V2K Variable Resistor to adjust the main setting Use a G32X V2K Variable Resistor to adjust the duty setting 3 Main setting 4 Main setting COM 5 Duty setting o ee ee ee ee KO 6 Duty setting COM rea oea o I Alarm Outputs i Output status Open collector o Number of out 2 3 puts 4 Maximum oper 30 VDC 5 ating voltage 6 7 Alarm output 1 8 Alarm output 1 9 Alarm output 2 10 Alarm output 2 11 12 13 14 29 Wiring Section 3 3 1 2 3 1 When alarm output 1 or alarm output 2 is reset i e the power turns ON or the initial setting level is exited the alarm output will be inactive for 1 sec ond Allow for this in the system design when using an alarm output G3PW Power Controller AC power supply ALARM 1 2 Operation for NO Contacts i Alarm output Inactive period i ALARM 1 2 Operation for NC contacts 1 s max i A i l Power ON Alarm 2 If you connect a contact relay or any device containing a coil to the alarm output wire a diode in parallel with the relay coil as shown in the figure Alarm output 1 Alarm output 1 Alarm output 2 2 0 Alarm output Operation Selection Input m Reset Input CON O Qn E GO M 0 JO GQ E ON CLO 10 11 Event input 1
93. ration Set the parameter to 0 No assignment The event input will not function regardless of its open closed status If a setting other than 0 No assignment is selected the control method and automatic manual operation will be switched according to the status of the event input If you are not using the event input always set the parameter to 0 No assignment Set the parameter to 1 control method selection The event input can be used to switch between the following control methods e Phase control e Optimum cycle control a Eventinputstatus Meaning RI ns 485 L Event input status 4 Main setting COM Closed Optimum cycle control 5 Duty setting 6 Duty setting COM 7 Alarm output 1 8 Alarm output 1 Phase control J 9 Alarm output 2 10 Alarm output 2 11 Event input 12 Event input Optimum pale cycle control 13 Reset input 14 Reset input For standard models 1 and 2 are not used 1 When constant current control is set as the output mode for phase con trol constant current control is always used and the control method can not be switched by using the event input 2 When 1 control method selection is set for the Event Input Assignment parameter P11 the Control Method Selection TYP will not be dis played In addition if the Control Method Selection parameter is changed by using communications an operation error response will be returned
94. represent the result of Omron s test conditions and the user must correlate it to actual application require ments Actual performance is subject to the Omron s Warranty and Limitations of Liability Change in Specifications Product specifications and accessories may be changed at any time based on improvements and other reasons It is our prac tice to change part numbers when published ratings or features are changed or when significant construction changes are made However some specifica tions of the Product may be changed without any notice When in doubt spe cial 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 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 AUTOMATION amp SAFETY OMRON INDUSTRIAL AUTOMATION THE AMERICAS HEADQUARTERS Schaumburg IL USA e 847 843 7900 800 556 6766 e www omron247 com OMRON CANADA INC HEAD OFFICE OMRON ARGENTINA SALES OFFICE Toronto ON Canada s 416 286 6465 866 986 6766 e www omron247 com Cono Sur e 54 11 4783 5300 OMRON ELECTRONICS DE MEXICO HEAD OFFICE OMRON CHILE SALES OFFICE M xico DF e 52 55 59 01 43 00 s 001 800 556 6766 s me
95. rom when power is turned ON until normal operation is possible Addresses Variable Type CE 8E Monitor Level Parameters Address Daa Dataran 7 The dala range is ten times the actual values 0007 Notus famy O 0008 Notused famas ooo 009 notus famas ooo 010 nouse fams ooo oon Notused amwys oo o2 nouse fams ooo foots haret famy Ooo x The data ranges apply to all models of the G3PW 76 Services and Addresses Section 6 4 Variable Type C1 81 Adjustment Level Parameters Address Baa Dataramge Notati n O Communications Main Setting H 00000000 to H 000003E8 The data range is ten times the actual values 000E Heater Burnout Threshold Ho0000001 to 00000064 000F Heater Characteristic Resistance for Phase H 00000000 to H 000003E7 The data range is ten times Control the actual values 0010 Heater Characteristic Resistance for Opti H 00000000 to H 000003E7 mum Cycle Control 0011 Heater Burnout Detection Lower Limit H 00000000 to H 000003E8 Note Use address 0000 to set the communications main setting input variable from the PLC Variable Type C3 83 address Bata Daarn T OO 0000 Communications Data H 00000000 or H 00000001 O 7 bits Length 1 8 bits 0001 Communications Stop Bits H 00000000 or H 00000001 O 1 bit 1 2 bits Communications Parity H 00000000 to H 00000002 0003 Send Wait Time H 00000000 to H 00000063 O to 99 ms 0004 Communications Timeou
96. rvices and Addresses for the notation used for set values in communications 2 The following MV will be sent from the EJ1 to the G3PW Unit regardless of whether the control method is set to standard or heating cooling con trol The MV manipulated variable sent from the EJ1 is used as the input variable by the G3PW TC4 G3PW CH1 Control Output aa Heating CH1 Control Output Heating CH2 Control Output Heating CH2 Control Output Heating CH3 Control Output Heating CH3 Control Output Heating CH4 Control Output Heating CH4 Control Output Heating CH1 Control Output Cooling CH1 Control Output Cooling CH2 Control Output Cooling CH2 Control Output Cooling CH3 Control Output Cooling CH3 Control Output Cooling no lr lo ll UM CH4 Control Output Cooling CH4 Control Output Cooling e When standard control is being used the Channel 1 to 4 control outputs for cooling are set to 0 0 e With a TC2 the Channel 3 and 4 control outputs for heating and cooling are set to 0 0 65 Communications Settings Other Settings Note Section 6 1 The following parameters must be set to write the MV manipulated variable to the G3PW via communications Display Parameter Setting range PON Input Signal Type 0 Linear input Main Setting Automatic Input 1 Communications Selection
97. s 0 0 Increase the duty setting The setting is not 0 0 The setting Check whether the output upper limit is 0 0 OLU is 0 0 Increase the output upper limit The setting is not 0 0 Check whether the Input Signal Type P04 setting is correct The setting is correct Check whether the Main Setting Automatic Manual Default P08 setting is correct The setting is correct Automatic input Manual input Check whether the Main Setting Automatic Input Selection P05 setting is correct Check whether the Main Setting Manual Input Selection P06 setting is correct The communications input is correctly set Check whether the Communications Main Setting Number P25 setting is correct 88 Error Displays Section 7 2 7 2 Error Displays Errors That Stop the Output Alarm Level 1 Display Errormame Probable cause ED RAM Error Error in the internal memory or Turn ON the power again If this does not remove EEPROM Checksum nonvolatile memory the error the operation of the Power Controller must Error Calibration Value be checked by OMRON Error lllegal Identifica tion Code EEPROM Checksum Error in the set values in the Move to the initial setting level and initialize the set Error Set Value nonvolatile memory values If this does not remove the error the opera tion of the Power Controller must be checked by OMRON EEPROM Checksum Error in the total run time in the Move to th
98. sistor input Selection 1 Key input 000E Control Method Default H 00000000 to H 00000001 0 Phase control 1 Optimum cycle control 000F Main Setting Automatic H 00000000 to H 00000001 0 Automatic Manual Default 1 Manual 0010 Number of Alarms for H 00000000 to H 000003E7 O to 999 alarms Heater Burnout Detection 0011 Load Current Upper Limit H 00000000 to H 00000294 0 0 to 66 0 A See note 2 0 Function disabled 0012 Event Input Assignment H 00000000 to H 00000002 0 No assignment 1 Control method selection 2 Main setting automatic manual selection 0013 Alarm Output Open in H 00000000 to H 00000001 0 Close in alarm NO contact operation Alarm 1 Open in alarm NC contact operation 0014 Heater Burnout Alarm H 00000000 to H 00000002 0 Disable Operation 1 Alarm level 1 fatal error 2 Alarm level 2 nonfatal error 0015 Total Run Time Exceeded H 00000000 to H 00000002 0 Disable Alarm Operation 1 Alarm level 1 fatal error 2 Alarm level 2 nonfatal error 0016 Total Run Time Alarm Set H 00000000 to H 000003E7 0 0 to 99 9 kh See note 2 Value 0 0 Function disabled 0017 External Inout Range H 00000000 to H 00000002 0 Disable Alarm Operation 1 Alarm level 1 fatal error 2 Alarm level 2 nonfatal error 0018 External Duty Input Alarm H 00000000 to H 00000002 0 Disable Operation 1 Alarm level 1 fatal error 2 Alarm level 2 nonfatal error Note 1 Specify 1 for a connection with
99. ssing was completed normally Example The following command reads current set value 8 digits Command STX J010000101CE0004000001 ETX BCC Response STX 0100000101000000000000 ET X BCC Example The following command reads current set value 4 digits Command STX J0100001018E0004000001 ETX BCC Response STX 010000010100000000 ET X BCC 81 Operation Command Section 6 7 6 7 Operation Command This command is used to start and stop operation save the manipulated vari able execute a software reset or initialize settings Command Operation Related MRC SRE code information se for 2 2 2 2 Response MRC SRC Response code ei i Operation Codes and code a Software Reset Always 00 Setting Level Change See note 1 00 Display level other than Initial Setting Level 01 Display Initial Setting Level Main Setting Automatic Manual Selec 00 Automatic tion See note 2 01 Manual Control Method Selection See note 3 00 Phase control 01 Optimum cycle control FOB Parameter Inialzation See note 4 Teas FoD Total Time Initialization See note 4 Always n Note 1 Execute a software reset to go from Initial Setting Level to Monitor Level 2 To use operation code 09 switching between automatic and manual for the main setting must not be assigned to an event input i e P11 must not be set to 2 Always set P11 to 0 before using this operation code An operation error
100. ssing was completed normally Example The following response would be returned for a model with a 45 A rating Command STX 010000503 ET X BCC Response STX 01000005030000G3PW A12030071 ETX BCC 83 Controller Status Read Section 6 9 6 9 Controller Status Read This service reads the operating status and error status Command MRC SRC os or 2 2 Response Operating Related Response code Status information MRC SRC L l 2 2 4 2 2 Operating Status Operating status Meaning Operating when operating status is read in Monitor Level or e Level and an error has not occurred K Stopped other conditions NES ON when operation is Error status rer stopped for an error ie used I E Notused L Notused Notused Notused Notused Related Information Response Code Response code Errormame Cause 1001 Command length too long The command is too long Normal end Processing was completed normally Example Command STX 010000601 ETX BCC Response STX 010000060100000000 ET X BCC 84 Echo back Test Section 6 10 6 10 Echo back Test This command performs an echo back test Command Test Data ern Response aaa code Test Data TT a 0 to 200 1 Test Data The test data can contain up to 200 00C8H bytes Set the test data within the following ranges according to the communications data length setting Data length Test data ASCII 2
101. t H 00000000 to H 000003E7 0 Communications timeout function disabled Time 0 to 999 s 0005 Communications Unit H 00000000 to H 00000063 0 to 99 Number 0006 Communications Baud H 00000000 to H 00000003 0 9 6 k bit s Rate 1 19 2 k bit s 2 38 4 k bit s 3 57 6 k bit s TI Services and Addresses Section 6 4 Address Daa Datarange Notation 0007 Communications Main Set H 00000000 to H 00000008 0 Automatic assignment ting Number See note 1 1 CH1 control output heating 2 CH2 control output heating 3 CH3 control output heating N ar 4 CH4 control output heating 5 CH1 control output cooling Nr 6 CH2 control output cooling 7 CH3 control output cooling 8 CH4 control output cooling 0008 External Duty Input H 00000000 to H 00000001 0 Disable Enable Disable 1 Enable 0009 Output Mode Selection H 00000000 to H 00000003 0 Proportional to phase angle same as G3PX 1 Proportional to square voltage A aaa a 2 Proportional to voltage 3 Constant current 000A Input Digital Filter Time H 00000000 to H 000003E8 0 0 to 100 ms See note 2 Constant 000B Input Signal Type H 00000000 to H 00000001 O Linear input 1 Voltage ON OFF input 000C Main Setting Automatic H 00000000 to H 00000001 0 4 to 20 mA or 1 to 5 VDC Input Selection 1 Communications 000D Main Setting Manual Input H 00000000 to H 00000001 0 External variable re
102. t Detection Section 5 9 e Heater Characteristic Resistance HPR or HCR in adjustment level Setting the Operation for When a Heater Burnout Alarm Occurs To use the heater burnout detection function set the Heater Burnout Alarm Operation parameter P14 to a value other than 0 in the initial setting level P14 setting Meaning Description O No operation Heater burnout detection does not operate Alarm level 1 Heater burnout detection functions at alarm level 1 Alarm level 2 Heater burnout detection functions at alarm level 2 Heater Characteristic The heater characteristic resistance is the value equivalent to the combined Resistance resistance of the connected heater loads Note The power supply voltage is assumed to be 100 V When the power supply voltage is 200 V the heater characteristic resistance will be one half of the actual combined resistance Heater characteristic resistance Combined resistance x 100 Power supply voltage The heater characteristic resistance can also be set directly but it is recom mended that it first be set using the teaching function Accurate heater characteristic resistance can be easily set by using the Teach Heater Characteristics for Phase Control TPC or Teach Heater Characteris tics for Optimum Cycle Control TCC parameters in the adjustment level Teaching Operations in When teaching is executed the present resistance is automatically used as the Adjustment Level the heat
103. t ETX BCC BCC Calculation Example 30H 30H 30H 30H oe 35H 30H 30H BCC 30H 930H09 30H930H930H0930H935H 30HH33HS 03H 35H XOR exclusive OR calculation Note No response will be returned unless the frame contains all elements up to the ETX and BCC e The following notation is used for hexadecimal and ASCII text The suffix H is added after the number e g 02H ASCII ASCII text is indicated inside quotation marks e g 00 73 Frame Configuration Section 6 2 End Codes CompoWay F Communications End code Description FINS command error The specified FINS command could not be executed 10 Parity error The OR of 1 bits in received data does not match the set ting for the communications parity Stop bitis 0 The next data was received when the reception data buffer was full 14 Format error The FINS mini command text contains characters other than 0 to 9 and A to E For details on the echoback test refer to 6 10 Echo back Test SID and the FINS mini command text are not included Sub address error The sub address is not included Frame length error The received frame exceeds the required number of bytes ETS Normal completion Command processing was completed normally boa BCC error The calculated BCC value is different from the received BCC value 74 FINS mini Text Section 6 3 6 3 FINS mini Text Command Text Response Text Note The structure of F
104. t generate significant amounts of heat such as heaters transformers and high capacity resis tors e If the ambient temperature reaches 55 C or higher install an air condi tioner to lower the temperature Note TY more than one Power Controller is installed side by side or vertically the heat that is generated will cause the internal temperatures of the Power Con trollers to rise and will shorten their service life Take suitable measures such as installing fans for forced air cooling e Do not install the Power Controller in a control panel together with high voltage devices e Install the Power Controller at least 200 mm away from power lines Recommended External Noise Filter We recommend installing a noise filter on the primary side to improve noise immunity Recommended filter RSMN series Filters from TDK Lambda Corporation RSMN 2030 For 20 A RSMN 2060 For 45 60 A Refer to 3 3 5 Wiring an External Noise Filter for wiring methods 19 Installation Environment Section 3 1 Resistance to Inrush Current The solid lines in the following graphs show the non repetitive resistance to inrush current For repetitive inrush current keep the inrush current below the values shown by the dotted lines m G3PW A220E_ 200 150 Inrush current A peak 100 90 10 30 50 100 200 500 1 000 5 000 Power ON time ms m G3PW A245El 1 A260E Inrush current A peak IN O O 200 100 10 30
105. t level press the LVL Key for at least 2 s to move to the initial setting level Then make the parameter set tings in the initial setting level In this level power to the load is turned OFF e Press the LVL Key for at least 2 s to return to the monitor level from the initial setting level It is not possible to directly return to the adjustment level from the initial setting level 41 Procedures for Operation and Setting Parameters Section 4 5 en gt Setting Parameters in the Initial Setting Level ADJ SETEV I The set value will be displayed The set value is changed by l Press the ENT RST Key to S Press the DOWN Key 11 times ES presang E T D y SR tnerne iy to return Keys The display will flash y Plier I l Press the ENT RST Key to The set value is incremented or decremented by Press the DOWN Key 16 times ES enter the set value and return to pressing the UP or DOWN Key Holding down d y the previous display the key changes the set value more quickly O R ADJ SET EV O R L ADJ SET EV O MO ADJ SET EV S Press the ENT RST Key to initialize Mente UF Kay iS pracsod the IN the setting and return to the initialization display will flash previous display 1 2 3 1 Press the UP and DOWN Keys to select the parameter that is to be set from External Duty Input Enable Disable parameter P01 to Initialize Set Values parameter P28 2 Press th
106. t up time so that the inrush current will not be too large If the soft start up time is set too low the inrush current cannot be suppressed and the load may be damaged 55 Load Current Limit Constant current Models Only Section 5 7 5 7 Load Current Limit Constant current Models Only 56 N Caution The load current limit function is used to measure the load current with the built in CT and to limit the load current by adjusting the output phase angle so that the load current does not exceed the value set in the Load Current Upper Limit parameter P10 Setting range 0 0 to 66 0 A e The load current upper limit is set in the Load Current Upper Limit param eter P10 in the initial setting level e This function can be used with Constant current Models only e When this function is being used the output value that is actually output will be smaller than the output value that is calculated based on the input value e The following example shows the load current limit function used when the maximum load current is 20 A Load current A D 0 O EH aE a SE i iie eS S Load current upper limit 16 a El 16A 0 80 100 Output value The load current limit function cannot be used to suppress the inrush current for loads with a large inrush current For loads with a large inrush current use the load current limit function together with the soft start up function to sup press the inrush current The response
107. ter Overcurrent Error E30 Zero Cross Error E31 Frequency Error E40 Heater Burnout Alarm Stop operation and check the power flow to all heaters Replace the heaters Is a value greater than 90 number of heater elements set for the Heater Burnout Threshold parameter HBR Is there burnout at some or all of the heaters Yes Section 7 3 2 Set the output mode to a mode other than constant current Press the LVL Key for at least 2 s to enter the initial setting mode Select 0 Proportional to phase angle in the Output Mode Selection parameter P02 3 Ifan E10 SSR short circuit error occurs after restarting there is a high probability of heater burnout 4 Return the output mode to constant current mode A heater overcurrent error occurs when the load current exceeds 120 of the rated current for 250 cycles approx 5 s Reduce the input value and then perform a reset operation using the ENT RST Key a reset input or a reset command via communications If the load current becomes too large consider using the duty setting or output limit function A zero cross error occurs when there is a failure to detect the power supply zero cross point Check whether the power supply waveforms are irregular and perform a reset operation using the ENT RST Key a reset input or a reset command via communications A frequency error occurs when the power supply frequency is outside of the range of 4
108. the PLC 2 Set ten times the actual value 78 Variable Area Write Section 6 5 6 5 Variable Area Write Command Note Response This command changes set values Write start MRC SRC Variable type address Bit position No of elements Set values KRI de C a 2 2 2 4 2 4 No of elements x 8 or 4 In the G3PW the bit position is not used Set it to 00 MRC SRC Response code EME 2 2 4 E Variable Type and Write Start Address Refer to the 6 4 Services and Addresses E Number of Elements Specify the number of elements for which the set value is to be changed Up to 8 elements can be specified E Response Code Response code Erormame Bang 1002 Command length too short The command is too short 4101 Area type error The specified variable type does not exist Number of elements Number The specified number of ele of data do not agree ments does not agree with the actual number of data ele ments Parameter error The bit position specification is not 00 A set value is outside of the setting range 2203 Operation error An error occurred in nonvola tile memory 0000 Normal end Processing was completed normally Example The following command changes the manipulated variable for channel 1 to 50 set value 8 digits Command STX 010000102C10000000001000001 F4 ETX BCC Response STX 01000001020000 ET X BCC Example The following command changes
109. time that is required before the load current can be suppressed is 500 ms max Monitoring Total Run Time Section 5 8 5 8 Monitoring Total Run Time The total run time monitor function is used to calculate the total time that power is ON to the G3PW Power Controller and to output an alarm when the time reaches the preset value in the Total Run Time Alarm Set Value parame ter P16 This function can be used for maintenance and managing equip ment by presetting replacement times for devices such as heaters in the Total Run Time Alarm Set Value parameter Operation during an alarm output is set in the Total Run Time Exceeded Operation parameter P15 in the initial setting level 0 Nooperation The alarm does not operate 1 Alarm level 1 An alarm is output to the ALARM1 contacts and operation is stopped 2 Alarm level 2 An alarm is output to the ALARM2 contacts and operation continues The total run time exceeded alarm is set in the Total Run Time Alarm Set Value parameter P16 in the initial setting level P16 setting range 0 0 to 99 9 kh 0 0 Operation stopped The total run time is cleared by the Initialize Set Values parameter P27 in the initial setting level pa soning Meaning 0 Do not initialize Initialize Use the Total Run Time Monitor parameter POT in the monitor level to mon itor the present total run time 57 Heater Burnout Detection Section 5 9 5 9 Heater Burnout Detection O
110. tions e 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 vi 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 s
111. to 20 1 to 45 or 1 to A 60 Optimum ayala comal sd dd __ Supported Supported Supported Output mode Proportional to phase Supported Supported Supported Supported Supported Supported Supported Supported angle control Proportional to volt Supported Supported age control Proportional to square voltage control Constant current con trol proportional to Supported Supported Supported current Input signals Analog input continu Supported Supported Supported from host ous proportional Voltage ON OFF input Supported Supported Supported time proportional 5 V O V 5 V O V input input External main setting Supported Supported Supported using external vari able resistor Serial communica S Supported tions RS 485 Selecting automatic or manual for the Switched by changing connections main setting Event Event input key input key Operation operation communi cations Supported Supported Supported Supported Supported Supported Supported Supported Supported Functions Displayed on 7 seg Supported Supported ment display Level indicators out Supported Supported Supported Supported Supported Supported Supported put display Long soft start up Supported Supported Supported Supported Supported Supported down Soft start down func Sup up Sup Sup Sup Sup Sup Supported Supported tion portedY ported port
112. to the load terminal block before using the Power Control ler Failure to do so may damage internal components due to mechanical stress O Preventing Inductive Noise e Install a switch or circuit breaker so that the operator can immediately turn OFF the power and provide a suitable display e Apply the power supply voltage through the contacts of a switch relay or similar device so it reaches the rated voltage within 2 s If the power supply voltage is increased gradually the power supply may not be reset or outputs may malfunction X e Use a power supply voltage input voltage input current and load within the specifications and rated ranges for the Power Controller Use a load that draws a current at the maximum output that is within the rated current range of the Power Controller If the current drawn by the load is not within the rated current range malfunction or fire may occur e Make sure that the protective cover is attached to the load terminal block before using the Power Control ler Failure to do so may damage internal components due to mechanical stress O Preventing Inductive Noise e Allow as much space as possible between the Power Controller and devices that generate powerful high frequencies high frequency welders high frequency sewing machines etc or surge e Keep the signal lines that connect to the Power Controller s terminal block away from power cables carry ing high voltages or large currents Also do not w
113. twisted copper wires or solid copper wire Use crimp terminals with insulative sleeves lf the crimp terminals do not come with insulative sleeves attach insulative sleeves Use the size of crimp terminals specified in this document Make sure that the phases match for load terminal T1 and power supply terminal 4 N and for load terminal L1 and power supply terminal 5 L Insert suitable fuses in the power supply line and load output line to protect the circuits The Power Controller will not operate normally if the wiring is not correct and the load may be damaged Leave at least 100 mm of space above and below the Power Controller when installing it to allow heat to dissipate Do not obstruct the area around the Power Controller and especially the area around the heat sink Install the Power Controller in the direction shown in this Instruction Sheet The Power Controller generates a lot of heat and it uses natural heat convection for cooling Installing the Power Controller in the wrong direction may cause in malfunctions or accidents DO gt PO 1X Al CAUTION The Power Controller and the heat sink become very hot Do not touch anything but the setting keys while power is being supplied or just after the power supply is turned OFF Doing so may cause burns Do not attempt to disassemble modify or repair the Power Controller or touch any of the internal parts Minor electric shock fire or malfunction may occasionall
114. uitability 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 vil Safety Precautions E 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 Indicates a potentially hazardous situation which if not AIN NTE avoided could result in death or serious injury Additionally there may be severe property damage Indicates a potentially hazardous situation which if not AMAN Ue LNY avoided is likely to result in minor or moderate injury or in property damage E Symbols The circle and slash symbol indicates operations that you must not do The specific operation is shown in the circle and explained in text The triangle symbol indicates precautions including warnings The specific operation is shown in the triangle and explained in text This examp
115. unctions 45 phase control 2 5 8 36 power supply frequency error 10 protective cover 14 pure metal heaters 3 R RAM error 91 rated voltage 8 reset input 30 reset event indicator 14 S safety measures Xi safety precautions vill 1x screwless clamp terminal block 6 send wait time 72 serial communications 10 11 Serial Communications Unit Board 70 serial connection 4 side by side mounting 19 soft start down function 3 8 55 soft start up function 3 8 55 solid state relay 2 SSR 2 10 92 Standard Models 3 8 storage xii Super rapid Fuse 10 27 T temperature controller 2 temperature sensor 2 terminal block with small slotted screws 6 terminating resistance 31 total run time 3 57 total run time alarm 94 V Variable Resistor 6 Index voltage input terminals 27 32 voltage ON OFF input 8 W weight 10 wiring X1 26 load 26 power supply 26 Z zero cross error 93 101 Index 102 Revision History A manual revision code appears as a Suffix to the catalog number on the front cover of the manual Cat No Z280 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 Date Revised content November 2008 Original production 103 Terms and Conditions of Sale OMRON 12 Offer Acceptance These terms and condit
116. unications Baud Rate Communications Data Length Communications Stop Bits Communications Par ity 1 Communications Main Setting Num ber Initialize Set Values 1 Constant current Models only Send Wait Time Appendix A Setting Sets the alarm level to use when the total run time exceeds the set value ti Disable Default i Alarm level 1 fatal error C Alarm level 2 nonfatal error An alarm is output when the total run time exceeds the set value 0 0 to 99 9 kh ni This function stops when the parameter is set to 0 0 Default Lot Sets the alarm level when an external variable resistor disconnection occurs or when the 4 to 20 mA or 1 to 5 V input range is exceeded U Disable Default Alarm level 1 fatal error Alarm level 2 nonfatal error Sets the alarm level when an external duty variable resistor disconnection occurs or when the 4 to 20 mA or 1 to 5 V input range is exceeded U Disable Default i Alarm level 1 fatal error C Alarm level 2 nonfatal error Communications Unit Sets the Communications unit number for CompoWay F Number O to 99 Default 1 Sets the baud rate for CompoWay F 5 9 6 k bit s 19 2 k bit s 38 4 k bit s 57 6 k bit s Default Sets the data length for communications i 7 bits Default A 8 bits Sets the number of stop bits for communications i 1 bit 2 bits Default Sets the parity for communicat
117. ush current can be suppressed by selecting phase control with the soft start up down functions at startup and high frequency noise can be suppressed by switching to optimum cycle con trol when in a steady state A Wide Selection of Output Modes Is Available for Phase Control With phase control any of the following modes can be selected for the input signal or external setting a mode with the output proportional to the phase angle a mode with the output proportional to the voltage a mode with the out put proportional to the square of the voltage i e the power or a mode with the output proportional to the current constant current mode see note Note Constant current Models only Soft start Up and Soft start Down Functions The soft start up and soft start down functions are used to change the output value gradually within a set rate of change even when the input value changes suddenly You can set the time for the output value to go from 0 to 100 or from 100 to 0 to 0 0 to 99 9 s Duty Setting The duty setting is used to set the rate of change from 0 to 100 of the out put value in relation to the input value Base up Function The base up function increases the output value so that the output value does not go to 0 even when the input value is 0 This enables preheating the heater even at an input value of 0 which is effective when using a load for which the heater temperature increases slowly Output Limit The output li
118. value will always be taken as the lower limit Setting range Ce Default Output Upper Limit A06 0 0 to 100 Output Lower Limit A07 0 0 to 100 Output value 1 00 diosa deb aieuce siew s T i mus Output upper limit 80 essesessscoscoessososoososoossosscsesosossossosoessossosesssossossossossossoseossossoss a Output lower limit 20 e 0 50 100 Input value Soft start Up and Soft start Down Functions Section 5 6 5 6 Soft start Up and Soft start Down Functions The soft start up and soft start down functions are used to change the output value gradually within a set rate of change even when the input value changes suddenly You can set the time for the output value to go from 0 to 100 i e the SUP soft start up time and the time for the output value to go from 100 to 0 i e the SDN soft start down time to a value from 0 0 to 99 9 s Setting range 5 Default s Meaning Soft start Up Time 0 0 to 99 9 0 5 The time for the output value SUP to go from 0 to 100 Soft start Down 0 0 to 99 9 The time for the output value Time SDN to go from 100 to 0 e Relationships between Input and Output Values and Soft start Up and Down Times Input value 100 1 1 1 1 1 1 1 1 1 0 1 ime Output value i 1 1 I 1 1 1 1 1 1 1 1 100 ye i 1 s vi v a 1 1 1 1 1 1 r 0 Time Soft start up time Soft start down time N Caution Specify the soft star
119. vent input the Power Controller reset is not required Duty Setting 5 3 Duty Setting Internal Duty Setting External Duty Setting Relation between Input Values and Outputs in Each Output Mode Section 5 3 The duty setting function is used to the set rate of change from 0 to 100 of the output value in relation to the input value analog input signal key input setting or external variable resistor setting Output value Duty setting aE A 00 80 O MO 80 60 P bsedsavedeseeesdicedesseseses EREE O A rss EE EE 60 ED T E A acai EE l 40 27 A A A AAA 20 0 50 100 Input value There are two duty settings internal and external The internal duty setting is held in the internal memory area and the external duty setting is set by using an external variable resistor The duty that is used is the product of the inter nal and external duty settings Duty value Internal duty setting x External duty setting e The internal duty setting is made using either key inputs or communica tions Constant current Models only e The duty setting is held in the internal memory area even when the power is interrupted e The duty is set in the adjustment level DTY e The external duty setting is made using an external variable resistor e To use the external duty setting function set the External Duty Input Enable Disable parameter P01 to 1 enable in the initial setting level 1 Control Proportio
120. verview The heater burnout detection function is used to compare a preset heater resistance value with the estimated resistance during operation to detect a burnout and output an alarm if the resistance during operation rises above the criteria The present resistance is estimated based on the present output value and the current detected by the built in CT Note The accuracy of heater burnout detection will be lower for heaters for which the resistance significantly changes depending on the temperature If the rate of change in the heater resistance exceeds the criteria for detecting a heater burnout a false heater burnout will be detected The criteria for detecting a heater burnout is set in the Heater Burnout Threshold parameter HBR Resistance increase Current Normal resistance Current is reduced of 1 5x is detected gt is stored Heater Heater Relationship between Parameters and Resistance The following diagram shows the relationship between the heater burnout detection parameters and the resistance Resistance Heater burnout determination area L Resistance after burnout Heater Burnout Threshold Heater Characteristic RGG ciane Resistance Output value Heater Burnout Detection Lower Limit Basic Parameters Before the heater burnout detection function can be used the following two parameters must be set e Heater Burnout Alarm Operation P14 in initial setting level 58 Heater Burnou
121. xternal resistor wir ing is disconnected Then perform a reset operation using the ENT RST Key a reset input or a reset command via communications An external duty input alarm occurs when an external variable duty setting input is outside of the input range Check whether the external resistor wiring is disconnected Then perform a reset operation using the ENT RST Key a reset input or a reset command via communications A total run time alarm occurs when the total run time exceeds the time set in the Total Run Time Threshold parameter P17 Either increase the setting for the Total Run Time Threshold parameter P17 in the initial setting level or reset the total run time by setting the Reset Total Run Time parameter P27 to 1 Then perform a reset operation using the ENT RST Key a reset input or a reset command via communications A communications timeout alarm occurs when communications with the host controller fail because the time set in the Communications Timeout Time parameter P26 is exceeded Check whether the host device is operating nor mally and whether there is a burnout in the communications lines The error status will be cleared by correctly writing the main setting from the host To not have communications timeouts detected set the Communications Tim eout Time parameter P26 to 0 Appendix A Parameters Set in Initial Setting Level Display Name ag O O External Duty Input Enables or disables setting th
122. y Omron before shipment Omron Compa nies 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 environ ments 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 www omron247 com or contact your Omron representative for pub lished information Limitation on Liability Etc OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY 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 Indemnities 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 inves tigation 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 Omr
123. y occur Do not allow chips or filings from installation work pieces of metal or wire clippings to enter the Power Controller Doing so may occasionally result in minor electric shock fire or malfunction Always connect the load to load terminal T1 Also always connect power supply terminal 4 N directly to the power supply Do not connect it through the load If the wiring is not correct the fault detection function of the Power Controller will stop the output operation When using the Power Controller to control the primary side of a transformer do not open the circuit on the secondary side of the transformer while the Power Controller is operating Do not touch the connecting cables while power is being supplied Static electricity from your body may cause malfunctioning If a malfunction in the Power Controller prevents control operations or if an alarm cannot be output it may occasionally cause damage to the connected equipment and devices To maintain safety in the event of a malfunction in the Power Controller always take appropriate safety measures such as installing a separate monitoring system Set the parameters of the Power Controller so that they are suitable for the system being controlled If they are not suitable unexpected operation may occasionally result in property damage or accidents Tighten the terminal screws to the torque specified in this Instruction Sheet If the screws are loose it may occasionally
124. yers 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 equip ment and installations subject to separate industry or government regulations iv Systems machines and equipment that could present a risk to life or prop erty Please know and observe all prohibitions of use applicable to this Prod uct 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 Programmable Products Omron Companies shall not be responsible for the user s programming of a programmable Product or any consequence thereof Performance Data Data presented in Omron Company websites catalogs and other materials is provided as a guide for the user in determining suitabil ity and does not constitute a warranty It may

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