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Heater Burnout Detection

Section 5-9

Содержание G3PW

Страница 1: ...Cat No Z280 E1 01 User s Manual G3PW Power Controllers...

Страница 2: ...G3PW Power Controllers User s Manual Produced November 2008...

Страница 3: ...iv...

Страница 4: ...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...

Страница 5: ...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 wi...

Страница 6: ...nfirm 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...

Страница 7: ...le 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 speci...

Страница 8: ...or solid copper wire Use crimp terminals with insulative sleeves If the crimp terminals do not come with insulative sleeves attach insulative sleeves Use the size of crimp terminals specified in this...

Страница 9: ...ll 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...

Страница 10: ...wire in the sizes specified in this Instruction Sheet Use insulated crimp terminals with insulation sleeves If using crimp terminals that are not insulated cover them with insulation sleeves Also use...

Страница 11: ...welders high frequency sewing machines etc or surge 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...

Страница 12: ...rol Methods and I O Configuration 35 4 1 Control Methods 36 4 2 Output Modes 37 4 3 Monitored Items 38 4 4 Input System 39 4 5 Procedures for Operation and Setting Parameters 40 4 6 Setting Parameters...

Страница 13: ...able Area Read 81 6 7 Operation Command 82 6 8 Controller Attribute Read 83 6 9 Controller Status Read 84 6 10 Echo back Test 85 6 11 ASCII Table 86 SECTION 7 Error Processing 87 7 1 Checking Possible...

Страница 14: ...hat you can use the I O configuration and how to set parameters for the G3PW Power Controllers Section 5 describes the functions you can use when operating the G3PW Power Controllers Section 6 provide...

Страница 15: ...xvi...

Страница 16: ...w of the G3PW Power Controllers 1 1 Overview of G3PW Power Controller 2 1 2 G3PW Features 3 1 2 1 Features of Constant current and Standard Models 3 1 2 2 Features of Constant current Models Only 3 1...

Страница 17: ...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 Co...

Страница 18: ...put 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 hea...

Страница 19: ...ore 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...

Страница 20: ...ion External contacts alarm reset EJ1 Modular Temperature Controller or CompoWay F Master Proportional to phase angle same as G3PX Proportional to square voltage Proportional to voltage Constant curre...

Страница 21: ...otted screws C Screwless clamp terminal block 8 RS 485 com munications Blank Communications not supported FLK Communications supported 1 2 3 4 5 6 7 8 G3PW A2 E Number of phases Control termi nal bloc...

Страница 22: ...ON 2 Specifications and Nomenclature This section provides the specifications of the G3PW Power Controllers and describes the part names and functions 2 1 Specifications 8 2 2 Nomenclature and Operati...

Страница 23: ...pply frequency fluctuation 3 Hz Load current A220E 1 to 20 A A245E 1 to 45 A A260E 1 to 60 A Inrush current resistance A220E 220 A 60 Hz 1 cycle A245E 440 A 60 Hz 1 cycle A260E 440 A 60 Hz 1 cycle Out...

Страница 24: ...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...

Страница 25: ...7 to 63 Hz Leakage current 10 mA max 100 110 VAC 20 mA max 200 220 VAC Insulation resistance 100 M min at 500 VDC Dielectric strength 2 500 VAC at 50 60 Hz for 1 min between charged parts and non char...

Страница 26: ...ll parameters Transmission path connections Multipoint Communications method RS 485 Maximum transmission distance 500 m Number of nodes 31 Multi drop connections Sync method Start stop synchronization...

Страница 27: ...Supported 5 V 0 V input External main setting using external vari able resistor Supported Supported Supported Serial communica tions RS 485 Supported Selecting automatic or manual for the main setting...

Страница 28: ...d 1 element out of 5 Sup ported 1 element out of 10 SSR short circuit ele ment ON failure detec tion Supported Supported Supported Supported Supported SSR open failure Supported Supported CT Failure S...

Страница 29: ...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 100 to 240 VAC Indicator Description ADJ Lit when in the adjustment level SET...

Страница 30: ...adjust ment level or from monitor level to ini tial setting level is possible even when an error occurs ENT RST Enter Reset Key Set value display Set value change and entry Error reset In the monitor...

Страница 31: ...rd models 1 and 2 are not used Pin No Name Description of function 1 RS 485 RS 485 communications 2 RS 485 3 Main setting Terminals for connecting external variable resistor for main setting 4 Main se...

Страница 32: ...Installation Environment 18 3 2 Installation 21 3 3 Wiring 26 3 3 1 Wiring the Power Supply and Load Circuits 26 3 3 2 Command Input and Power Supply Terminal Wiring 27 3 3 3 Wiring the Control Termi...

Страница 33: ...ccur Locations subject to excessive shocks or vibration Locations subject to direct heat radiated from heating devices Take appropriate and sufficient countermeasures when installing systems in the fo...

Страница 34: ...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...

Страница 35: ...resistance to inrush current For repetitive inrush current keep the inrush current below the values shown by the dotted lines G3PW A220E G3PW A245E A260E 200 150 100 50 0 50 30 10 Inrush current A pea...

Страница 36: ...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...

Страница 37: ...20E S 20 A Models with Terminal Block with Small Slotted Screws G3PW A220E C 20 A Models with Screwless Clamp Terminal Block G3PW A245E S A260E S 45 60 A Models with Terminal Block with Small Slotted...

Страница 38: ...3 2 G3PW A245E C A260E C 45 60 A Models with Screwless Clamp Terminal Block Mounting Hole Dimensions 188 171 5 70 155 138 104 G3PW A220 G3PW A245 100 min 158 0 2 Two M5 38 0 2 51 min 100 min 176 0 2...

Страница 39: ...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...

Страница 40: ...ger for cooling inside the panel it is most effective to mount it on the front of the Power Controller 155 mm min Airflow Airflow Airflow Wiring duct Wiring duct Mounting base If a device with a depth...

Страница 41: ...be damaged Caution 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...

Страница 42: ...the positive and negative signal wires to terminals 1 and 3 respectively Current Input 4 to 20 mA DC When using current input connect the positive and negative signal wires to terminals 2 and 3 respec...

Страница 43: ...with Small Slotted or Screwless Clamp Terminals Note Only models with terminal blocks with small slotted screws have terminal screws Use copper AWG26 to AWG16 twisted pair cable when connecting the wi...

Страница 44: ...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 Load Load EJ1 Modular Temperature Controller CJ series Serial Communica...

Страница 45: ...put Reset Input Number of event inputs 2 event inputs Contact input conditions ON 1 k max OFF 100 k min Non contact input conditions ON residual voltage 1 0 V min OFF leakage current 0 1 mA max Curren...

Страница 46: ...here 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 G3PW...

Страница 47: ...ans mission path The terminators must be at least 54 combined 1 2 3 4 5 Temperature controller or other controller 4 to 20 mA output 1 2 3 4 5 Temperature controller or other controller 1 to 5 V outpu...

Страница 48: ...le Resistor for the Main Setting Wiring Example for Using an External Variable Resistor for the Duty Setting 3 Main setting 4 Main setting COM Use a G32X V2K Variable Resistor to adjust the main setti...

Страница 49: ...34 Wiring for Specific Applications Section 3 4...

Страница 50: ...that you can use the I O configuration and how to set parameters for the G3PW Power Controllers 4 1 Control Methods 36 4 2 Output Modes 37 4 3 Monitored Items 38 4 4 Input System 39 4 5 Procedures fo...

Страница 51: ...the power supplied to the load Phase control is suitable for precise temperature control or for controlling heaters with large inrush currents Optimum Cycle Control With optimum cycle control the out...

Страница 52: ...alue is proportional to the output value Control pro portional to voltage In this mode the output volt age is proportional to the output value Constant cur rent control Constant current Mod els only I...

Страница 53: ...de the output value and the output phase angle will be the same Load Current A The load current A detected by the built in CT is displayed This feature is supported for Constant current Models only Fi...

Страница 54: ...y for commands for switching outputs ON and OFF with 5 V or 0 V The input value is set manually Manual Input External Variable Resistor Main Setting Use an external G32X V2K Variable Resistor to set t...

Страница 55: ...the same mode as the G3PX Parameter Settings in the Initial Setting Level Press the LVL Key for at least 2 s to move to the initial setting level Then set the following parameters in order using the...

Страница 56: ...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 Press the LVL Key for at least 2 s to return to the monit...

Страница 57: ...arameter P28 1 0 p 0 1 0 2 1 p 0 2 t b a 8 2 p i n i Press the DOWN Key 11 times The set value will be displayed Press the DOWN Key 16 times ADJ SET EV ADJ SET EV ADJ SET EV ADJ SET EV ADJ SET EV ADJ...

Страница 58: ...ase angle same as G3PX Output mode Proportional to phase angle same as G3PX Proportional to square voltage Proportional to voltage Constant current control Optimum cycle control ON OFF control Paramet...

Страница 59: ...e Constant P03 Event Input Assignment P11 No Assignment P11 0 Phase Control and Optimum Cycle Control Selection P11 1 Main Setting Automatic Manual Selection P11 2 To settings related to protective fu...

Страница 60: ...ment 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 Output mode Proportional to phase angle same as G3PX Proporti...

Страница 61: ...46 Setting Parameters in the Initial Setting Level Section 4 6...

Страница 62: ...ernal Contact Input Functions 48 5 2 Inputting the Main Setting with an External Variable Resistor 50 5 3 Duty Setting 51 5 4 Base up Function 53 5 5 Output Limits 54 5 6 Soft start Up and Soft start...

Страница 63: ...the parameter to 1 control method selection The event input can be used to switch between the following control methods Phase control Optimum cycle control Note 1 When constant current control is set...

Страница 64: ...ternal duty input alarm E51 flashing Total run time alarm E60 flashing Automatic opera tion The input value is set by the linear input 4 to 20 mA or 1 to 5 V or by using communications Manual operatio...

Страница 65: ...method selection 2 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...

Страница 66: ...ternal duty setting is made using either key inputs or communica tions Constant current Models only The duty setting is held in the internal memory area even when the power is interrupted The duty is...

Страница 67: ...100 60 80 60 20 80 60 40 20 100 Output value Duty setting Input value 20 40 80 Control Proportional to Square Voltage 100 40 0 100 60 80 60 20 80 60 40 20 100 Voltage Duty setting Input value 20 40 80...

Страница 68: ...g communications Constant current Models only The output value is found with the following formula Output value Duty setting input value Base up value Example Setting the Base up Value to 30 1 2 3 1 W...

Страница 69: ...el 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...

Страница 70: ...t start down time to a value from 0 0 to 99 9 s Relationships between Input and Output Values and Soft start Up and Down Times Caution Specify the soft start up time so that the inrush current will no...

Страница 71: ...odels only 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 The following example shows the l...

Страница 72: ...n Time Exceeded Operation parameter P15 in the initial setting level The total run time exceeded alarm is set in the Total Run Time Alarm Set Value parameter P16 in the initial setting level The total...

Страница 73: ...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 Relationship betwee...

Страница 74: ...is executed the present resistance is automatically used as the heater characteristic resistance Teaching cannot be executed when the current flowing to the CT is less than 10 of the rated current Pe...

Страница 75: ...tected 2 If the Heater Burnout Threshold is too small the alarm output may be un stable Heater Burnout Detection Lower Limit The Heater Burnout Detection Lower Limit parameter is used to limit the ran...

Страница 76: ...at at least 10 of the rated current is flowing and that control is stable Set the Heater Burnout Alarm Operation parameter P14 to a value other than 0 Execute teaching TPC or TCC for the heater charac...

Страница 77: ...62 Heater Burnout Detection Section 5 9...

Страница 78: ...1 Introduction 64 6 1 2 Communications Settings 64 6 1 3 Connection Example 68 6 2 Frame Configuration 73 6 3 FINS mini Text 75 6 4 Services and Addresses 76 6 5 Variable Area Write 79 6 6 Variable A...

Страница 79: ...well established FINS used exten sively with OMRON Programmable Controllers together with a consistent frame format to facilitate communications between more than one compo nent and between personal...

Страница 80: ...2 bit p23 Communications Parity non None evn Even odd Odd EVN EVEN p24 Send Wait Time 0 to 99 ms 1 ms p25 Communications Main Set ting Number Connection to an OMRON EJ1 Modular Temperature Controller...

Страница 81: ...re 1 2 3 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 displ...

Страница 82: ...ntil the desired communications parameter is displayed Power ON RUN Mode Screen Display Initial Settings Mode Screen Display Communications unit number Communications baud rate Communications data len...

Страница 83: ...19 can be set to the same numbers as the EJ1 channel numbers as shown below Display the initial settings mode screen and then use the Up and Down Keys to display p19 the parameter for which the settin...

Страница 84: ...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 1...

Страница 85: ...s 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 ea...

Страница 86: ...unica tions Main Set ting Number 1 Up to 31 G3PW Power Controllers can be connected Unit 1 Unit 3 Unit 5 Unit 31 G3PW G3PW G3PW G3PW Heater CPU Unit SCU SYSMAC CS CJ series PLC Tem pera ture input Com...

Страница 87: ...ving status For the G3PW this adjusts the time between creating a response after receiving a transmission and switching to send sta tus If switching time will not cause problems the send wait time can...

Страница 88: ...frame Always set 02H Unit No Set the unit number that is set on SW1 on the front of the G3PW No response will be received if another unit number is set Sub address and SID Not used by the G3PW Always...

Страница 89: ...ta was received when the reception data buffer was full 13 BCC error The calculated BCC value is different from the received BCC value 14 Format error The FINS mini command text contains characters ot...

Страница 90: ...se code are trans ferred in the response frame following the above MRC SRC Data is then transferred following the MRES and SRES Note FINS Factory Interface Network Service The FINS protocol provides m...

Страница 91: ...fer size of the Controller 06 01 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...

Страница 92: ...H 000003E8 000D Output Lower Limit H 00000000 to H 000003E8 000E Heater Burnout Threshold H 00000001 to H 00000064 000F Heater Characteristic Resistance for Phase Control H 00000000 to H 000003E7 The...

Страница 93: ...trol Method Default H 00000000 to H 00000001 0 Phase control 1 Optimum cycle control 000F Main Setting Automatic Manual Default H 00000000 to H 00000001 0 Automatic 1 Manual 0010 Number of Alarms for...

Страница 94: ...manipulated variable for channel 1 to 50 set value 4 digits Command STX 01000010281000000000101F4 ETX BCC Response STX 01000001020000 ETX BCC 01 MRC 2 SRC 2 Variable type 4 4 02 2 2 00 Write start ad...

Страница 95: ...otection Error Operation No error No error No error No error No error No error No error No error No error No error No error Error Error Error Error Error Error Error Error Error Error Error Not used O...

Страница 96: ...mand reads current set value 4 digits Command STX 0100001018E0004000001 ETX BCC Response STX 010000010100000000 ETX BCC 01 2 MRC 2 SRC 2 4 4 01 2 00 Read start address Variable type Bit position No of...

Страница 97: ...xecute an error reset to release the pause Response Codes Example The following command executes a software reset Command STX 0100030050600 ETX BCC Response None 05 Related information MRC 2 SRC 2 30...

Страница 98: ...would be returned for a model with a 45 A rating Command STX 010000503 ETX BCC Response STX 01000005030000G3PW A12030071 ETX BCC 03 MRC 2 SRC 2 05 05 Model number MRC 2 SRC 2 4 10 03 4 G3PW Buffer si...

Страница 99: ...4 2 2 Response code Operating status Related information Operating status Meaning 00 Operating when operating status is read in Monitor Level or Adjustment Level and an error has not occurred 01 Stopp...

Страница 100: ...unications data length setting 2 Response Codes Example Command STX 010000801123 ETX BCC Response STX 01000008010000123 ETX BCC 08 Test Data MRC 2 SRC 2 0 to 200 01 08 MRC 2 SRC 2 Response code 4 0 to...

Страница 101: ...6 7 0 NUL DLE SPACE 0 P p 1 SOH DC1 1 A Q a q 2 STX DC2 2 B R b r 3 ETX DC3 3 C S c s 4 EOT DC4 4 D T d t 5 ENQ NAK 5 E U e u 6 ACK SYN 6 F V f v 7 BEL ETB 7 G W g w 8 BS CAN 8 H X h x 9 HT EM 9 I Y...

Страница 102: ...87 SECTION 7 Error Processing This section provides troubleshooting information 7 1 Checking Possible Errors 88 7 2 Error Displays 89 7 3 Detailed Descriptions of Errors 91...

Страница 103: ...g is not 0 0 Check whether the output upper limit OLU is 0 0 The setting is not 0 0 The setting is 0 0 Increase the output upper limit Check whether the Input Signal Type P04 setting is correct The se...

Страница 104: ...r elements are all burned out Check that the heater is not burned out Turn ON the power again If this does not remove the error the operation of the Power Controller must be checked by OMRON e20 Heate...

Страница 105: ...cause Countermeasures e40 Heater Burnout Alarm when assigned to alarm level 2 The heater resistance rate of change exceeded value set for the Heater Burnout Threshold HBR parameter for more cycles th...

Страница 106: ...Menu Press the UP Key once to display ini 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 automatically return to the Ini...

Страница 107: ...ent to a 100 output will flow Before turning ON the power again confirm that your equipment will not be affected Using a Constant current Model With a Constant current Model it is possible to distingu...

Страница 108: ...when the power supply frequency is outside of the range of 47 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...

Страница 109: ...ns E60 Total Run Time Alarm 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...

Страница 110: ...ethod selection the control method selected with the event inputs will be used regardless of the setting of this parameter p08 Main Setting Auto matic Manual Default Sets the main setting input mode t...

Страница 111: ...1 p20 Communications Baud Rate 1 Sets the baud rate for CompoWay F 9 6 9 6 k bit s 19 2 19 2 k bit s 38 4 38 4 k bit s 57 6 57 6 k bit s Default p21 Communications Data Length 1 Sets the data length f...

Страница 112: ...100 Default 100 typ TYP Control Method Sets the control method 0 Phase control Default 1 Optimum cycle control a m A m Main Setting Auto matic Manual Sets automatic or manual operation for the main s...

Страница 113: ...98 Parameter Settings in the Adjustment Level Appendix B...

Страница 114: ...nal 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 curr...

Страница 115: ...um 8 load current 38 load current limit 8 56 load terminal block 15 26 M main setting external variable resistor 50 main setting input 39 44 manual operation external variable resistor 33 input 39 inp...

Страница 116: ...s 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...

Страница 117: ...102 Index...

Страница 118: ...talog number on the front cover of the manual The following table outlines the changes made to the manual during each revision Page numbers refer to the previous version Revision code Date Revised con...

Страница 119: ......

Страница 120: ...rg IL 60173 5302 U S A Tel 1 847 843 7900 Fax 1 847 843 7787 OMRON ASIA PACIFIC PTE LTD No 438A Alexandra Road 05 05 08 Lobby 2 Alexandra Technopark Singapore 119967 Tel 65 6835 3011 Fax 65 6835 2711...

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