Omron G3PW User manual

Cat. No. Z280-E1-01
User's Manual
G3PW
Power Controllers

G3PW
Power Controllers
User’s Manual
Produced November 2008

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v
Preface
This manual describes the G3PW Power Controllers, including information on functions, performance,
and application methods. Observe the following precautions in using the G3PW.
• Allow only a specialists with sufficient knowledge of electrical systems to
handle the G3PW.
• Read this manual thoroughly, be sure you understand the contents, and
use the G3PW correctly.
• 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, o
r
by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission o
f
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 precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility
for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in
this publication.

vi
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.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, 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:
•Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or
uses not described in this manual.
•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 regulations.
•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.

vii
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 suitability 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.

viii
■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.
■Symbols
Safety Precautions
WARNING Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Additionally, there may be severe property damage.
CAUTION Indicates a potentially hazardous situation which, if not
avoided, is likely to result in minor or moderate injury or in
property damage.
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 example 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.

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■Safety Precautions
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 twisted copper
wires 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
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.

x
CAUTION
The Power Controller and the heat sink become very hot. Do not touch
anything but the setting keyswhile 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 occasionally 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 anddevices. To maintain safety inthe 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 cause a fire.

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●Installation Environment
• 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.
• Locations subject to water, oil, or chemicals
• Locations subject to direct sunlight
• Locations where dust or corrosive gases (in particular, sulfuric or ammonia gas) are present
• Locations subject to extreme temperature changes
• Locations where icing or condensation may occur
• Locations subject to excessive shocks or vibration
• Locations subject to direct heat radiated from heating devices
●Installation and Wiring
• 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.
• Take safety measures, such as wearing safety shoes, in case the Power Controller falls.
• Touch the Power Controller only after first touching a grounded metal object to discharge any static elec-
tricity from your body.
• Always ground the Power Controller to 100 Ωor less. There are no ground terminals provided, so use the
heat sink mounting screws as ground terminals.
• Check the terminal number and polarity for each input before connecting it.
• Use copper twisted 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 terminals of the sizes specified in this Instruction Sheet.
• Insert connectors all the way.
• Do not connect anything to unused terminals.
●Safety Measures and Checking
• Install a switch or circuit breaker so that the operator can immediately turn OFF the power, and provide a
suitable display.
• 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.
• 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.
• To prevent electric shock, damage, or malfunction, complete all the wiring before turning ON the power.
• 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.
●Preventing Inductive Noise
• Install a switch or circuit breaker so that the operator can immediately turn OFF the power, and provide a
suitable display.
• 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.
Precautions for Safe Use

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• 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.
• 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.
●Preventing Inductive Noise
• 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.
• 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 wire power lines together with or parallel to Power Control-
ler wiring. Using shielded cables and using separate conduits or ducts is recommended.
• 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).
• 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.
●Cleaning
• Do not use paint thinner or similar chemical to clean with. Use commercially available standard grade alco-
hol.
●Storage
• Store the Power Controller within the rated ambient temperature.

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TABLE OF CONTENTS
SECTION 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1 Overview of G3PW Power Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 G3PW Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-3 I/O Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-4 Models and Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SECTION 2
Specifications and Nomenclature . . . . . . . . . . . . . . . . . . . . . 7
2-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2 Nomenclature and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 3
Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-1 Installation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-4 Wiring for Specific Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 4
Control 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 in the Initial Setting Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SECTION 5
Descriptions of Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5-1 External 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 Down Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5-7 Load Current Limit (Constant-current Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5-8 Monitoring Total Run Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5-9 Heater Burnout Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

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TABLE OF CONTENTS
SECTION 6
CompoWay/F Communications . . . . . . . . . . . . . . . . . . . . . . 63
6-1 Communications Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
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 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 Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7-2 Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7-3 Detailed Descriptions of Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Appendices
A Parameters Set in Initial Setting Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
B Parameter Settings in the Adjustment Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

xv
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 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.
!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.

xvi

1
SECTION 1
Overview
This section provides an overview 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
1-3 I/O Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-4 Models and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2
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.
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.
Temperature
controller
Measured
temperature
Temperature sensor
Heater
Input value (4 to 20 mA or 1 to 5V)
Continuous proportional
current output (phase control
or optimum cycle control)
G3PW Power Controller

3
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. Inrush 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 limit 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
Exceeded Detection The total run time exceeded detection function outputs an alarm when the
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
Load Current The current limit function measures the load current with a built-in CT and pro-
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.

4
G3PW Features Section 1-2
Heater Burnout Detection and Alarm Based on Heater Resistance
This function detects changes 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.
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 connected to the EJ1 End
Unit. For details, refer to the EJ1 Modular Temperature Controller User’s Man-
ual (Cat. No. H142).
Measured
temperature
G3PW Power Controllers
8 max.
Heater
Temperature sensors
Input value
(Connected to Basic Unit.)
(Connected to End Unit.)
RS-485
EJ1 Modular
Temperature
Controller
CX-Thermo
(Enables setting and
monitoring Power
Controller parameters.)

5
I/O Block Diagram Section 1-3
1-3 I/O Block Diagram
Phase control
or ON/OFF
Control
Input signal (4 to 20 mA, 1
to 5 V, or voltage ON/OFF
input (5 VDC/0 VDC))
External main
setting (2 kΩ)
External duty
setting (2 kΩ)
Event input
(automatic/manual
setting or control method
selection)
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-current
control (See note.)
• Current limit (See note.)
• Heater burnout alarm
(See note.)
Built-in
CT
Alarm output 1
(contacts)
Alarm output 2
(contacts)
RS-485
(See note.)
or
Control method
G3PW Power Controller
Automatic
Manual
Note: Constant-current
Models only.
Heater
Optimum cycle
control