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Authorized Distributor:
ZEN Programmable Relay
Operation Manual
Printed in August 2005
This operation manual is for ZEN-10C3@R-@-V2 (version-2) ZEN
Programmable Relays only. For version-1 or pre-version-1 ZEN Programmable Relays, refer to operation manual with Cat. No. Z183.
Preface
OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual.
The ZEN is a compact and highly functional controller that can be used to easily automate small-scale applications. Its development has drawn on OMRON's advanced control technology and expertise in manufacturing various types of controllers.
New Economy-type CPU Units (ZEN-10C3@R-@-V2) with the following changes have been added to the series. Twin timer operation has been added. Pulse output operation, multiple-day operation for weekly timers, and 8-digit counters with high- speed counting have also been added. These models cannot be connected to Expansion I/O Units.
This manual describes how to use the ZEN-10C3@R-@-V2 (version 2). Before using the ZEN, read this manual carefully so that you can use the ZEN correctly. Keep the manual close at hand so that you can refer to it whenever necessary.
Intended Audience
This manual is intended for the following readers.
• Persons in charge of introducing FA devices
• Persons who design FA systems
• Persons who install or connect FA devices
• Persons who manage working FA installations
Persons who use this product must have sufficient knowledge of electrical systems (i.e., an electrical engineer or the equivalent).
Warranty and Application Considerations
Warranty and Limitations of Liability
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 Consideration
Application Consideration
SUITABILITY FOR USE
THE PRODUCTS CONTAINED IN THIS DOCUMENT ARE NOT SAFETY RATED.
THEY ARE NOT DESIGNED OR RATED FOR ENSURING SAFETY OF PERSONS, AND SHOULD NOT BE RELIED UPON AS A SAFETY COMPONENT OR
PROTECTIVE DEVICE FOR SUCH PURPOSES. Please refer to separate catalogs for OMRON's safety rated products.
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 product.
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 document.
• 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 PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
Disclaimers
Copyright and Copy Permission
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.
Copyright and Copy Permission COPYRIGHT AND COPY PERMISSION
This document shall not be copied for sales or promotions without permission.
This document is protected by copyright and is intended solely for use in conjunction with the product. Please notify us before copying or reproducing this document in any manner, for any other purpose. If copying or transmitting this document to another, please copy or transmit it in its entirety.
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it refers to an OMRON product, regardless of whether or not it appears in the proper name of the product.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of information.
Note Indicates information of particular interest for efficient and convenient operation of the product.
1,2,3... 1. Indicates lists of one sort or anther, such as procedures, checklists, etc.
Precautions for Correct Use Precautions for Safe Use
Indicates precautionary information that should be heeded in using the ZEN.
About this Manual
This operation manual is for ZEN-10C3@R-@-V2 models of version-2 (-V2) ZEN Programmable Relays only. For version-1 or pre-version-1 ZEN Programmable Relays, refer to operation manual with Cat. No. Z183.
Manual Contents
Section 1 gives an outline of the ZEN, including descriptions of ZEN features and functions.
Section 2 explains how to mount and wire the ZEN and how to connect sensors.
Section 3 explains basic settings required to operate the ZEN and setting methods for internal bits.
Section 4 describes the many convenient functions provided by the ZEN.
Section 5 describes how to use optional products, such as Battery Units and Memory Cassettes.
Section 6 lists the error messages and provides probable causes and countermeasures for troubleshooting.
The Appendices provide specifications, technical references, version update information, allocations and setting sheets, and other information related to ZEN operation.
Related Manual
Manual Contents Cat. No.
ZEN Support Software Operation Manual
Describes installation and operating procedures for the ZEN Support Software.
Z184-E1-02
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of information.
Note Indicates information of particular interest for efficient and convenient operation of the product.
1,2,3... 1. Indicates lists of one sort or another, such as procedures, checklists, etc.
Precautions for Correct Use
Indicates precautionary information that should be heeded to ensure correct use of the ZEN.
Precautions for Safe Use
Indicates precautionary information that should be heeded to ensure safe use of the ZEN.
Indicate the buttons that needs to be pressed in operating procedures. Press each button once.
Indicate buttons that needs to be pressed in operating procedures.
Press one of the buttons once or more.
▲ ▼
Indicates that the display (the word “LANGUAGE” in this case) is flashing. In this manual, this state is described by saying that the
“flashing cursor” is at the word “LANGUAGE”. In this state it is possible to change settings and the position of the cursor.
LANGUAGE Indicates that the display (the letter “H” in this case) is flashing in reverse video. In this manual, this state is described by saying that the “highlighted cursor” is at the word “H”. In this state it is not possible to change settings but the cursor can be changed to the flashing cursor by pressing the OK button.
RUNPARAMETER SET CLOCK LANGUAGE
ENGLISH
OMRON, 2005
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein.
Moreover, because OMRON is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting
TABLE OF CONTENTS
Preface . . . iv
Warranty and Application Considerations . . . v
OMRON Product References . . . viii
Visual Aids . . . viii
About this Manual . . . ix
Visual Aids . . . x
Precautions . . . xiii
Safety Precautions . . . xiv
Precautions for Safe Use . . . xvi
Precautions for Correct Use . . . xviii
Conformance to EC Directives . . . xx
SECTION 1 Outline . . . 1
1-1 Outline . . . 2
1-2 Features and Models . . . 8
1-3 Nomenclature and Basic Operation . . . 11
1-4 Memory Areas . . . 21
1-5 Allocating I/O Bit Numbers. . . 24
1-6 Preparations for Operation . . . 25
SECTION 2 Installation and Wiring . . . 27
2-1 Mounting . . . 28
2-2 Wiring . . . 29
SECTION 3 Programming and Operating Methods . . . 41
3-1 Selecting Display Language . . . 43
3-2 Setting the Date and Time . . . 44
3-3 Creating Ladder Programs . . . 46
3-4 Confirming Ladder Program Operation . . . 55
3-5 Correcting Ladder Programs . . . 57
3-6 Using Timers (T) and Holding Timers (#) . . . 60
3-7 Using Counters (C) and the 8-Digit Counter (F) . . . 64
TABLE OF CONTENTS
3-12 Comparing the 8-Digit Counter (F) Present Value Using 8-Digit
Comparators (G). . . 80
3-13 Displaying Messages (Display Bits (D)) . . . 82
3-14 Using Button Input Bits (B) . . . 85
SECTION 4 Special Functions. . . . 87
4-1 Protecting Programs . . . 88
4-2 Stabilizing Input Operations. . . 90
4-3 Changing Backlight Automatic Cutout Time. . . 92
4-4 Setting Daylight Saving Time (DST) . . . 93
4-5 Reading System Information . . . 94
SECTION 5 Optional Products . . . . 95
5-1 Mounting Battery Units . . . 96
5-2 Using Memory Cassettes . . . 97
5-3 Connecting the ZEN Support Software . . . 99
SECTION 6 Troubleshooting. . . 101
6-1 Troubleshooting . . . 102
6-2 Error Messages. . . 102
6-3 Deleting Error Messages . . . 104
Appendices
A Specifications . . . 105B Ladder Program Execution . . . 113
C Operating Mode at Startup . . . 117
D Version Upgrades . . . 119
E Application Examples . . . 125
F Allocations and Setting Table . . . 139
Index . . . 145
Revision History . . . 149
Precautions
This section provides precautions for using the ZEN Programmable Relays.
This information contained in this section is important for the safe and reliable application of the ZEN. You must read this section and understand the information before attempting to set up for a ZEN.
Safety Precautions. . . xiv
Precautions for Safe Use . . . xvi
Precautions for Correct Use . . . xviii
Conformance to EC Directives . . . xx
Precautions
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, will result in minor or moderate injury, or may result in serious injury or death. Additionally, there may be significant property damage.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or in property damage.
Symbol Meaning
Caution
General Caution
Indicates non-specific general cautions, warnings, and dangers.
Electrical Shock Caution
Indicates possibility of electric shock under specific conditions.
Explosion Caution
Indicates possibility of explosion under specific conditions.
Prohibition
Disassembly Prohibition
Indicates prohibitions when there is a possibility of injury, such as from electric shock, as the result of
disassembly.
Mandatory Caution
General Caution
Indicates non-specific general cautions, warnings, and dangers.
Precautions
Precautions
WARNING
Serious human hazard may occasionally occur due to ignition or rupture of the lithium battery used in the Battery Unit. Do not short the battery terminals or charge, disassemble, deform under pressure, or incinerate the battery.
Never use any battery that has been dropped on the floor or otherwise subjected to excessive shock.
CAUTION
Electric shock, fire, or malfunction may occur. Do not disassemble, modify, or repair the ZEN or touch any of the internal parts.
Electrical shock may occur. Never touch the I/O terminals, computer connector, or Battery Unit connector while power is being supplied.
Electrical shock may occur. Do not remove the Expansion Unit connector cover.
Fires may occasionally occur. Tighten the terminal block screws to the specified torque (0.5 to 0.6 N·m) so that they do not become loose.
Precautions
Please observe the following precautions for safe use of this products.
Circuit Design
1. All interface connectors and battery connector are live parts, they may not be directly connected to Softy Extra Low Voltage (SELV) circuit or to accessible conductive parts.
For the programming units and Personal Computers use only the connecting cable ZEN-CIF01 (optional accessory) manufactured by OMRON.
ZEN-CIF01 provides safe (reinforced) insulation between Personal Computers and ZEN.
2. Provide emergency stop circuits, external interlock circuits, limit circuits, and other safety circuits in addition to any provided within the ZEN control circuits to ensure safety of the overall system in the event of ZEN failure or external factors.
3. If the ZEN discovers an error during self-diagnosis, operation will be stopped and all outputs will be turned OFF. As a countermeasure for such problems, external safety measures must be provided to ensure safety in the overall system.
4. Outputs from the ZEN may remain ON or OFF due to faults in internal circuits such as output relay fusing or burning, or output transistor destruction. As a countermeasure for such problems, external safety measures must be provided to ensure safety in the overall system.
5. Fail-safe measures must be taken by the user to ensure overall system safety in the event of broken signal lines or momentary power interruptions.
6. The durability of the output relays is largely affected by the switching conditions.
Confirm the operation of the system under actual operating conditions and set the switching frequency to ensure that adequate performance will be provided.
Insulation faults and burning in the ZEN may result if relays are used after their performance has deteriorated.
System Startup and Program Changes
1. Check the user program for proper execution before actually running it on the Unit.
2. Disconnect the output lines from the system before testing operation in any system in which incorrect operation can result in injury or equipment damage.
3. Confirm safety before attempting any of the following operations.
• Changing the operating mode (RUN/STOP).
• Using the button switches.
• Changing bit status or parameter settings.
4. Double-check all wiring before turning ON the power supply.
Precautions for Safe Use
Precautions Installation and Wiring
1. Do not allow the ZEN to fall during installation.
2. Be sure that the DIN Track mounting levers, Memory Cassettes, Battery Units, cable connectors, and other items with locking devices are properly locked into place. Improper locking may result in malfunction.
3. Tighten mounting screws to the following torques.
CPU Units: 1.03 N⋅m max.
4. Use wires with cross-sectional areas of 0.2 to 2.5 mm2 (equivalent to AWG24 to AWG14) for wiring and strip them for 6.5 mm. If using stranded wires, always connect straight crimp terminals (0.25 to 2.5 mm2).
Handling
1. The environment of use of ZEN is "Pollution degree 2" and "Overvoltage category II" specified in IEC60664-1.
2. Always use the ZEN within the rated ambient operating temperature and humidity. The rated ambient operating temperature is 0 to 55°C. If the ZEN is used near sources of heat, such as a power supply, the internal temperature of the ZEN may increase, lowering the durability of the ZEN.
3. Discharge static electricity from your body, e.g., by touching a grounded metal plate, before touching any Unit.
4. The exterior of the Units will be damaged if it comes into contact with organic solvents (e.g., benzene or paint thinner), strong alkalies, or strong acids. Never allow such substances to come into contact with the Units.
5. Do not apply voltages exceeding the rated voltages. Internal elements may be destroyed.
6. Short failures or open failures may result from the destruction of output elements.
Do not use loads that exceed the rated output current.
Maintenance
When replacing a CPU Unit, transfer to the new Unit and confirm all settings for clock data, internal holding bits, holding timers, and counters before starting operation again.
Transportation and Storage
1. Use special packaging boxes when transporting the ZEN and do not subject it to excessive shock or vibration or drop it during shipment.
2. Store the ZEN in within the rated ranges. If the ZEN has been stored at −10°C or lower, allow it to stand at room temperature for 3 hours or longer before turning ON the power supply.
Precautions
Installation Environment
1. Do not install the ZEN in the following locations.
• Locations subject to radical changes in temperature
• Location with high humidity subject to condensation
• Locations subject to excessive dust or dirt
• Locations subject to corrosive gas
• Locations subject to direct sunlight
2. Do not install the ZEN in locations subject to shock or vibration. Extended use in such location may cause damage from stress.
3. In environments subject to static electricity (e.g., close to pipes conveying forming materials, powders, or fluid materials), separate the ZEN as far as possible from the source of static electricity.
4. The ZEN is neither waterproof nor oil-proof. Do not use it in locations subject to water or oil.
5. Use the ZEN within the allowable power supply voltage range. Be particularly careful in locations with bad power supply conditions, e.g., large fluctuations in the power supply voltage.
6. Do not install the ZEN in locations subject to excessive noise, which may cause the ZEN to fail.
7. Take appropriate and sufficient countermeasures when installing systems in the following locations:
• Locations subject to strong electromagnetic fields
• Locations subject to possible exposure to radioactivity Power Supply
1. Always turn OFF the power supply to the ZEN before attempting any of the following.
• Assembling the ZEN
• Connecting or disconnecting any cables or wiring
• Attaching or removing the Memory Cassette
• Attaching or removing the Battery Unit
2. If the power supply is interrupted for 2 days or more (at 25°C), the internal capacitor will discharge and internal bit status and the contents of PV areas will be lost or corrupted and dates and times will be reset. When restarting operation after the power supply has been interrupted for an extended period of time, check the system in advance to confirm that no errors will occur.
Handling
1. Connect connectors only after confirming that the direction or polarity is correct.
2. Failures could result if dust or dirt enters the ZEN. Always connect the connector cover to the computer connector whenever it is not being used.
Precautions for Correct Use
Precautions 3. Do not remove the label from the left side of the CPU Unit if a Battery Unit is not
mounted.
Other
1. The execution of the ladder program in the ZEN is different from that for other PLCs. Refer to Appendix B Ladder Program Execution when writing the ladder program.
2. Abide by all local ordinances and regulations when disposing of the ZEN.
Precautions
Conformance to EC Directives
Applicable Directives
• EMC Directives
• Low Voltage Directive
Concepts
EMC Directives
OMRON devices that comply with EC Directives also conform to the related EMC standards so that they can be more easily built into other devices or the overall machine.
The actual products have been checked for conformity to EMC standards. The ZEN complies with IEC/EN61131-2 clause 8. Whether the products conform to the standards in the system used by the customer, however, must be checked by the customer.
EMC-related performance of the OMRON devices that comply with EC Directives will vary depending on the configuration, wiring, and other conditions of the equipment or control panel on which the OMRON devices are installed. The customer must, therefore, perform the final check to confirm that devices and the overall machine conform to EMC standards.
Low Voltage Directive
Always ensure that devices operating at voltages of 50 to 1,000 VAC and 75 to 1,500 VDC meet the required safety standards. The ZEN complies with IEC/EN61131-2 clause 11.
Conformance to EC Directives
The ZEN complies with EC Directives. To ensure that the machine or device in which the ZEN is used complies with EC Directives, the ZEN must be installed as follows:
1. The ZEN is an open-structure device and it must be installed within a control panel.
2. You must use reinforced insulation or double insulation for the DC power supplies used for the communications power supply and I/O power supplies.
3. ZEN models complying with EC Directives also conform to the Common Emission Standard (IEC/EN61131-2 clause 8). Radiated emission characteristics (10-m regulations) may vary depending on the configuration of the control panel used, other devices connected to the control panel, wiring, and other conditions. You must therefore confirm that the overall machine or equipment complies with EC Directives.
Precautions
Relay Output Noise Reduction Methods
The ZEN conforms to EN 61131-2 of the EMC Directives. However, noise generated by relay output switching may not satisfy these Standards. In such a case, a noise filter must be connected to the load side or other appropriate countermeasures must be provided external to the ZEN.
Countermeasures taken to satisfy the standards vary depending on the devices on the load side, wiring, configuration of machines, etc. Following are examples of
countermeasures for reducing the generated noise.
Countermeasures
(Refer to EN61131-2 for more details.)
• Countermeasures are not required if the frequency of load switching for the whole system with the ZEN included is less than 5 times per minute.
• Countermeasures are required if the frequency of load switching for the whole system with the ZEN included is 5 times per minute or higher.
Countermeasure Examples
When switching an inductive load, connect an surge protector, diodes, etc., in parallel with the load or contact as shown below.
Circuit Current Characteristic Required element
AC DC
CR method Yes Yes If the load is a relay or solenoid, there is a time lag between the moment the circuit is opened and the moment the load is reset.
If the supply voltage is 12 to 48 V, insert the surge protector in parallel with the load. If the supply voltage is 100 to 200 V, insert the surge protector between the contacts.
The capacitance of the capacitor must be 1 to 0.5 µF per contact current of 1 A and resistance of the resistor must be 0.5 to 1 Ω per contact voltage of 1 V. These values, however, vary with the load and the characteristics of the relay. Decide these values from experiments, and take into consideration that the capacitance suppresses spark discharge when the contacts are separated and the resistance limits the current that flows into the load when the circuit is closed again.
The dielectric strength of the capacitor must be 200 to 300 V. If the circuit is an AC circuit, use a capacitor with no polarity.
Power supply Inductive load
C R
Precautions
Diode method No Yes The diode connected in parallel with the load changes energy accumulated by the coil into a current, which then flows into the coil so that the current will be converted into Joule heat by the resistance of the inductive load.
This time lag, between the moment the circuit is opened and the moment the load is reset, caused by this method is longer than that caused by the CR method.
The reversed dielectric strength value of the diode must be at least 10 times as large as the circuit voltage value. The forward current of the diode must be the same as or larger than the load current.
The reversed dielectric strength value of the diode may be two to three times larger than the supply voltage if the surge protector is applied to electronic circuits with low circuit voltages.
Varistor method Yes Yes The varistor method prevents the imposition of high voltage between the contacts by using the constant voltage characteristic of the varistor. There is time lag between the moment the circuit is opened and the moment the load is reset.
If the supply voltage is 12 to 48 V, insert the varistor in parallel with the load. If the supply voltage is 100 to 200 V, insert the varistor between the contacts.
---
Circuit Current Characteristic Required element
AC DC
Power supply Inductive load
Power supply Inductive load
SECTION 1 Outline
This section gives an outline of the ZEN, including example applications, the system configurations and basic operations.
1-1 Outline . . . 2 1-2 Features and Models . . . 8 1-2-1 Features and System Configuration . . . 8 1-2-2 List of Models . . . 9 1-3 Nomenclature and Basic Operation . . . 11 1-3-1 Nomenclature. . . 11 1-3-2 Screen Transitions . . . 13 1-3-3 Basic Operation . . . 16 1-4 Memory Areas . . . 21 1-5 Allocating I/O Bit Numbers. . . 24 1-6 Preparations for Operation . . . 25
Outline Section 1-1
1-1 Outline
Economical, Small-scale Automatic Control
One CPU Unit provides 6 inputs and 4 outputs.
Easy Operation with an Inexpensive Controller
Ladder programming is possible directly from the CPU Unit. With Memory Cassettes (optional), ladder programs can be easily copied.
Smaller Control Panels
The ZEN is very small at 90 x 70 x 56 mm (H x W x D) and mounts essentially anywhere.
Less Assembly and Wiring Time Required for Control Panels
Simple one-touch DIN Track mounting. Built-in timers and counters so only power supply and I/O circuit wiring required.
Solid wires can be easily connected using only a screwdriver.
Refer to page 29.
3
Water-supply facilities in apartments, lighting control in offices.
3
3
70 mm
90 mm
3
Outline Section 1-1
Power Failure Countermeasures
EEPROM backs up the program and system settings data when no power is supplied to the ZEN.
Use a Battery Unit (optional) to back up work bits, holding timers, counters, and date/time data.
Refer to page 96.
Easy Saving and Copying of Programs
Use an optional Memory Cassette to easily save and copy programs.
Refer to page 97.
Programming and Monitoring from a Personal Computer
Windows-based ZEN Support Software is available and provides a complete simulation function.
Refer to page 99.
3
Battery Unit
3
Ladder program data/settings.
Memory Cassette
3
ZEN Support Software (CD-ROM)
Outline Section 1-1
Greater Switching Capacity
The output contacts have 8-A switching capacity (250 VAC). All contacts are independent.
Refer to page 38.
AC Inputs
For CPU Units with AC power supply inputs, 100 to 240 VAC can be directly connected.
Refer to page 32.
Easy Program Design
There are 3 different operations that can be set for bit outputs. Self- holding bits also can be easily programmed.
Refer to page 50.
Complicated Timers without Additional Programming
Any of the 16 timers support 5 types of operation and 3 timing ranges.
There are also 8 built-in holding timers that hold data during power interruptions.
8 A max.
MC 250 V
L N NCI0 I1 I2 I3 I4 I5
Circuit protector 100 to 240 VAC
L N
Ry
Normal operation Set/reset operation Alternate operation
Outline Section 1-1 Refer to page 60.
Incremental and Decremental Counters
There are 16 built-in counters that can be switched between incrementing and decrementing.
Use Comparators to enable programming multiple outputs from a counter.
Counters: Refer to page 64.
Comparators: Refer to page 77.
Season- or Day-dependent Operating Times
CPU Units with built-in calendar and clock functions have 16 weekly timers and 16 calendar timers. Seasonal control is possible using calendar timers and day/time control is possible with weekly timers.
Weekly timers: Refer to page 67.
Calendar timers: Refer to page 72.
Direct Analog Inputs
TIM
ON delay OFF delay One-shot pulse Flashing pulse Twin timer
0.01 to 99.99 s 1 s to 99 min 59 s 1 min to 99 h 59 min
C D R
CNT
Control number of cars entering and leaving a car park.
MO−FR
SA−SU
For gardens, parks, and recreational ponds.
Outline Section 1-1 Refer to page 74.
Easier Maintenance
Use the display function in CPU Units to display user-specified messages, the date, time, or other data. Button switches can also be used as input contacts. Applications include usage as a simple display operation panel.
Refer to page 82.
Longer Backlight for Dark Situations
The automatic cutout time for the backlight for CPU Units can be set to 2, 10, or 30 minutes, or set to operate continuously. With the display function, the backlight can also be set to turn ON when a message is displayed.
Refer to page 92.
Temperature control for hot houses and tanks. Prevent freezing of swimming pools.
3
Outline Section 1-1
Prevent Chattering and Noise-related Malfunctions
Set the input filters to extend the filter timer and prevent malfunctions.
Refer to page 90.
Exporting Systems Overseas
Display for CPU Units is available in 6 languages. A Daylight Saving Time (DST) function also supported.
Changing display language: Refer to page 43.
Daylight Saving Time (DST) settings: Refer to page 93.
Programming Security
Programs can be protected by setting a password.
Refer to page 88.
Filter timer ON
3
ENGLISH JAPANESE GERMAN FRENCH ITALIAN SPANISH
3 9 5 4
PASSWORD 0000
RUN
Features and Models Section 1-2
1-2 Features and Models
1-2-1 Features and System Configuration
The ZEN is small but has a wide range of functions and is easy to use. The ZEN facilitates small-scale automatic control.
• Simple button-operated programming.
• Highly visible, backlit LCD.
• Adjustable automatic cutout time for the backlight.
• Six-language display.
• Display function for user-specified messages (4 lines x 12 characters), time, or timer, counter, or analog-converted value displays.
• Button switches allowing operation buttons to be used as input contacts.
• Built-in weekly and calendar timers to allow simple seasonal, daily, or time-based operation.
• Both 100 to 240-VAC and 12 to 24-VDC power supply models available.
• Built-in analog comparator for temperature control and other analog applications (provided on CPU Units with DC power supply inputs, two analog inputs 0 to 10 V).
• Input filter settings to prevent noise-related malfunctions for CPU Units.
• Program and settings data backed up on built-in EEPROM.
• Programming using ladder diagrams.
• Password function to protect programs.
Features and Models Section 1-2
1-2-2 List of Models
CPU Units with 10 I/O Points
Shape Power
supply/
input voltage
Inputs Outputs Analog inputs
Model number
With display and operation buttons
Economy type (Expansion I/O Units cannot be connected)
100 to 240 VAC, 50/60 Hz
6 inputs Relays 4 outputs No ZEN-10C3AR-A-V2
12 to 24 VDC Yes ZEN-10C3DR-D-V2
3
CPU Unit
ZEN-BAT01 Battery Unit
Programs can be saved and copied by using a Memory Cassette (optional).
Personal computer connecting cable
ZEN-SOFT01-V4 ZEN Support Software
Programs can be created, edited, saved, and printed, and operation can be simulated using the ZEN Support Software (optional).
ZEN-ME01 Memory Cassette Work bits, holding timer data, counter data, and date/time data will be backed up during long-term power supply interruptions if a Battery Unit (optional) is mounted.
3
Features and Models Section 1-2
Power Supply Unit
Programming Device
Optional Products
Name and appearance Specifications Model number
Switching Power supply Unit
Input voltage: 100 to 240 VAC Output voltage: 24 VDC Output capacity: 1.3 A Capacity: 30 W
ZEN-PA03024
Name and appearance Functions Model number
ZEN Support Software Runs on Windows 95, 98, ME, 2000, XP, or NT4.0 Service Pack 3 (CD-ROM)
Used for offline programming, all parameter settings, program transfers, and printing.
ZEN-SOFT01-V4
Personal Computer Connecting Cable
Connects the computer and ZEN when the ZEN Support Software is used.
(Cable length: 2 m)
ZEN-CIF01
Name and appearance
Functions Model number
Memory Cassette EEP-ROM
Used to save and copy programs.
ZEN-ME01
Battery Unit Uses a battery to back up programs and data.
Mount a Battery Unit if the loss of calendar, clock, holding bit, holding timer, and counter present values will cause problems in systems with long power interruptions. (Battery life: 10 years minimum)
ZEN-BAT01
Nomenclature and Basic Operation Section 1-3
1-3 Nomenclature and Basic Operation 1-3-1 Nomenclature
Note Economy-type CPU Units do not have an Expansion Unit connector. Do not remove the Expansion Unit connector cover on these CPU Units.
Display Screen and Operation Buttons
Icon Meanings
3
Left Side
Battery Unit connector (Remove the seal to connect the Battery Unit.)
Front Power supply
terminals Input terminals
LCD Operation buttons
Output terminals ZEN Support Software connector (also used for Memory Cassette.)
Right Side
Expansion Unit connector cover.
(See note.) ZEN Support Software connector
(also used for Memory Cassette.)
3
LCD DEL Button ALT Button
Cursor Buttons
ESC Button OK Button
Nomenclature and Basic Operation Section 1-3
Operation Button Names and Operations
▲ Displayed when there is a higher-level menu or ladder program line than the one currently displayed.
▼ Displayed when there is a lower-level menu or ladder program line than the one currently displayed.
Displayed when a password has been set.
Button Function
Menus Writing ladder program Setting parameters Button switch (See page 85.)
DEL
--- Deletes inputs, outputs, connection lines, and blank lines.
--- B6 ON
ALT
--- Switches between normally open and normally closed conditions.
Changes to connection line write mode.
Inserts a line.
--- B7 ON
Up
Moves the cursor up and down.
Moves the cursor up and down.
Selects bit types and functions.
Moves the cursor up and down.
Changes numerals and parameters.
B5 ON
Down
B2 ON
Left
--- Moves the cursor right and left.
Moves the cursor right and left.
B3 ON
Right
B4 ON
ESC
Returns to the previous screen.
Cancels the setting and returns to the previous operation.
Cancels the setting and returns to the previous operation.
B0 ON
OK
Selects the menu item at the cursor position.
Confirms the setting. Confirms the setting. B1 ON
Icon Meaning
Nomenclature and Basic Operation Section 1-3
1-3-2 Screen Transitions
Display Screens
Main Screen STOP Mode
When power is turned ON
Display Function Screen
Note: The display will be blank if the display function is not being used.
(User- specified message)
RUN Mode
When power is turned ON
Display Function Screen
Note: The display will be blank if the display function is not being used.
(User- specified message)
STOP Mode
PROGRAM RUN PARAMETER SET CLOCK
PARAMETER SET CLOCK LANGUAGE OTHER
RUN Mode
MONITOR STOP PARAMETER SET CLOCK
RUN
PARAMETER SET CLOCK LANGUAGE OTHER
RUN RUN
RUN
I0 I1 I2 I3 I4 I5
( : OFF/●: ON)
Q0 Q1 Q2 Q3
@ @ @ @ Day
Time (min:s)Operating mode CPU input bit (I) status
CPU output bit (Q) status (@: OFF/■: ON) Day display
SU: Sunday MO: Monday TU: Tuesday WE: Wednesday TH: Thursday FR: Friday
Nomenclature and Basic Operation Section 1-3
Menu Screen Configuration
MONITOR STOPPARAMETER SET CLOCK
▼
RUN Mode Ladder Monitor Screen
The ON/OFF status of input bits can be checked by monitoring the ladder program.
Switches to STOP mode.
The operation status of the timers, counters, and analog comparators can be monitored and the settings changed during operation. Refer to page 19.
STOP Mode Ladder Program Edit Screen
(Refer to page 17.)
PROGRAM RUNPARAMETER SET CLOCK
▼
EDIT PROG DELETE PROG CASSETTE
Creates and edits ladder program.
Deletes ladder program and parameters.
Memory Cassette Operation (Refer to page 97.)
SAVE(CPU-MC) LOAD(MC-CPU) ERASE
Transfers programs between ZEN and the Memory Cassette and initializes the Memory Cassette.
Switches to RUN mode.
Note: Displayed only when a Memory Cassette is mounted.
Changes the settings for timers, counters, and analog comparators.
(Refer to page 22.) Date and Time Settings (Refer to page 44.)
PROGRAM RUNPARAMETER SET CLOCK
▼
SET CLOCK
SUMMER TIME SET CLOCK
yy/mm/dd 00/01/01 00:03(SA)
Sets the date and time.
Set when shipping to countries that use summer time. (Refer to page 93.) Display Language Settings (Refer to page 43.)
SET CLOCK
LANGUAGE LANGUAGE
ENGLISH
▲ ▼
The display language can be changed.
English, Japanese, German, French, Italian, and Spanish
EDIT PROGRAM NO YES
▲ ▼
Other Settings
PARAMETER SET CLOCK LANGUAGE OTHER
▲
PASSWORD BACKLIGHT INPUT FILTER SYSTEM INF
▼
Other settings can be made. Refer to the following page for details.
Select YES with
RUN RUN
Nomenclature and Basic Operation Section 1-3
Other Submenus
PASSWORD BACKLIGHT INPUT FILTER SYSTEM INF
▼
PASSWORD 0000
Setting Passwords (Refer to page 88.)
Set a password when you want to protect programs from being read. The password setting range is 0000 to 9999.
BACKLIGHT INPUT FILTER SYSTEM INF MODEM INI
▲ BACKLIGHT
2min
Changing Cutout Time for Backlight (Refer to page 92.) Set the automatic cutout time for the backlight in the LCD screen.
2 min, 10 min, 30 min, Always ON
INNER EXP1EXP2 EXP3
Setting Input Filters (Refer to page 90.)
Set the input filters to ON or OFF for the CPU Unit or Expansion I/O Units. Set to ON when noise or chattering may affect operation.
U03.00 050701 INT:I06O04 EX1:I00O00
Reading System Information (Refer to page 94.)
Read system information, such as the CPU Unit software version or the date it was created, the number of I/O points on the CPU Unit, and whether or not LCD, RTC, or analog input functions are supported.
▼ EX2:I00O00 EX3:I00O00 RMT:I00000 LCD:YES
▲ ▼ RMT:I00000 LCD:YES RTC:YES ADC:YES
▲
For future expansion. Do not set.
Nomenclature and Basic Operation Section 1-3
1-3-3 Basic Operation Menu Selection Example
Use the Up/Down Buttons to move the cursor.
Press the OK Button to select the flashing menu. The settings will flash on a reversed display.
Settings cannot be changed during reversed display.
Press the OK Button to change from a highlighted cursor to a flashing cursor.
Settings can now be changed.
Use the Up/Down Buttons to change the setting.
Use the Up Button to select GERMAN.
RUNPARAMETER SET CLOCK LANGUAGE
▲ ▼
Main menu display
Flashing cursor
LANGUAGE
Highlighted cursor
ENGLISH
LANGUAGE
ENGLISH
Flashing cursor
LANGUAGE GERMAN
LANGUAGE SET?
OK/ESC GERMAN
A confirmation message will be displayed asking if you want to change to German display.
RUNPARAMETER KALENDER SPRACHE
▲ ▼
Press the OK Button to change from English to German.
RUNPARAMETER SET CLOCK LANGUAGE
▲ ▼
Press the ESC Button to cancel the change and return to the previous screen.
Nomenclature and Basic Operation Section 1-3
Example Operation in the Ladder Program Edit Screen
The highlighted cursor will appear in the initial write position. During highlighted cursor display, the cursor can be moved to the input or output write positions.
Up/Down Buttons: Move the highlighted cursor up and down.
Left/Right Buttons: Move the highlighted cursor Left/Right.
Press the OK Button at the input write position to display the input default setting IO and the normally open condition symbol. “I”
will flash.
• Flashing Cursor at the I Position Up/Down Buttons: Change the bit type.
Right Button: Moves the flashing cursor to the right.
OK Button: Sets the bit type and moves the flashing cursor to the bit address position.
• Flashing Cursor at the 0 Position Up/Down Buttons: Change the bit address.
OK Button: Completes the writing of the bit.
• Switching between Normally Open and Normally Closed Conditions
You can use the ALT Button to switch between the N.O. and N.C. conditions, regardless of the position of the flashing cursor.
When the first input has been written, the highlighted cursor moves to the next input position.
Use the above procedure to enter program input conditions in series.
When writing serial inputs, the connecting line between inputs is drawn automatically.
Select Program/
Edit.
Line No.
at cursor Highlighted cursor
Nomenclature and Basic Operation Section 1-3 Press the ALT Button with the highlighted cursor in the input writing position to change the cursor to a flashing left arrow to enable connecting lines to be drawn.
Up/Down Buttons: Draw vertical connecting lines.
Left/Right Buttons: Draw horizontal connecting lines.
Press the Right Button twice to draw a line to the output bit. The cursor will change to a highlighted cursor at the output bit write position.
Press the OK Button at the output bit write position to display the default output Q0. Q will flash.
• Flashing Cursor at the Q (Bit Type) Position
Up/Down Buttons: Change the type of output
Right/Left Buttons: Move the flashing cursor.
OK Button: Sets the bit type and moves the flashing cursor to the bit address position.
• Flashing Cursor at the (Additional Output Function) Position
Up/Down Buttons: Selects the additional output function
OK Button: Sets the additional output function and moves the flashing cursor to the bit address position.
• Flashing Cursor at the 0 (Bit Address) Position
Up/Down Buttons: Select the bit address OK Button: Completes the output write.
Press the OK Button to complete the bit write and to move the highlighted cursor to the first input position ON the next line.
Press the ESC Button to complete the writing of the ladder program and to return to the menu screen.
▼
▼
▼
▼
▼
01
▼
Nomenclature and Basic Operation Section 1-3
Example Parameter Settings Screen Operation
When PARAMETER is selected, the settings for bits that are being used by the ladder program are displayed.
(1) Selecting Parameters to Display
Press the OK Button to change the highlighted cursor to a flashing cursor.
Use the Up/Down Buttons to select another timer.
When multiple parameters of the same type have been selected, use the Up/Down Buttons to scroll through the numbers.
Press the Left Button to switch to another type, move the flashing cursor to the bit type position and use the Up/Down Buttons to select the bit type.
Move the flashing cursor to the bit type position and use the Up/Down Buttons to select another bit type.
(2) Setting and Changing Parameters
Use the Left/Right Buttons to move the highlighted cursor to the parameter to be set.
Press the OK Button to confirm the set position. The cursor will change to a flashing cursor.
Use the Up/Down Buttons to set the parameter.
Select Parameters on menu screen.
/
/
/
Nomenclature and Basic Operation Section 1-3 Use the Left/Right or Up/Down Buttons to move the highlighted cursor to the parameter to be set.
Press the OK Button to confirm the set position. The cursor will change to a flashing cursor.
Use the Left/Right Buttons to select the digit to be set.
Use the Up/Down Buttons to change the value of each digit.
Press the OK Button to confirm the setting.
Press the ESC Button to complete the settings.
Note If the ESC Button is pressed while ladder program or parameter settings are being input, the input to that point will be canceled and the settings will return to the original settings.
Memory Areas Section 1-4
1-4 Memory Areas
I/O, Work, and Internal Holding Bits
Note The following additional functions can be selected for bit outputs.
Name Type Bit addresses
No.
of bits
Function Ladder
programs Page
CPU Unit input bits
I 0 to 5 6 CPU Units
with 10 I/O pts
Reflect the ON/OFF status of the input devices connected to the CPU Unit input terminals.
N.O./N.C.
inputs 24
0 to b 12 CPU Units with 20 I/O pts Button
input bits
B 0 to 7 8 Turn ON when the operation buttons are pressed in RUN mode. Cannot be used for LED-type CPU Units.
85
Analog comparator bits
A 0 to 3 4 Output the comparison result for analog inputs. Can only be used for models with a 24-VDC power supply.
74
Compara- tor bits
P 0 to f 16 Compare the present value of timers (T), holding timers (#), and counters (C), and outputs the comparison result.
77
8-Digit comparator bits
G 0 to 3 4 Compare the present value of 8-digit counters (F) with a constant and outputs the comparison result
80
CPU Unit output bits
Q 0 to 3 4 CPU Units
with 10 I/O pts
Output the ON/OFF status of the output bits to the outputs devices connected to the CPU Unit.
N.O./N.C.
inputs Outputs (See note.)
24
0 to 7 8 CPU Units with 20 I/O pts 0 to 2 3 CPU Units
with Commu- nications
Work bits M 0 to f 16 Can only be used within the program.
Cannot output to an external device.
-
Holding bits
H 0 to f 16 Same as for work bits however the holding bits maintain ON/OFF status when power is turned OFF.
-
Execution condition
Bit address Bit type
Additional function ([, S, R, A)
Memory Areas Section 1-4
Timers and Counters
Timer Types
Normal output [ Turns ON or OFF according to the ON/OFF status of the execution condition.
Set/Reset S (set) Holds ON status after the execution condition turns ON once.
R (reset) Holds OFF status after the execution condition turns ON once.
Alternate A Alternates between ON and OFF whenever the execution condition turns ON (input latch operation).
Name Type Bit ad- dresses
No. of timers/
counters
Function Use in
ladder programs
Page
Timer T 0 to f 16 Can be switched between ON delay, OFF delay, one-shot, flashing pulse, and twin timer
operation.(See note.)
N.O./N.C.
condition 60
Holding timer
# 0 to 7 8 Hold the present value during counting even if the trigger input or power supply is turned OFF.
Continues the timing when the trigger input or power supply is turned ON again.
60
Counter C 0 to f 16 Four-digit reversible counters that can be incremented and decremented.
64
8-Digit counter
F 0 1 An eight-digit reversible counter that can be incremented and decremented. CPU Units with DC power supplies support a high- speed counter up to 150 Hz.
64
Weekly timer
@ 0 to f 16 Can be switched between normal operation, operation between days, and pulse output operation.
67
Calendar timer
0 to f 16 Can turn ON or OFF during a specified date period.
72
X ON delay Times down while the trigger input is ON and turns ON the timer bit when the set time is reached.
■ OFF delay
Turns ON the timer bit while the trigger input is ON, starts timing down when the trigger input turns OFF, and turns OFF the timer bit when the set time is reached.
O One-shot Turns ON the timer bit for the set period when the trigger input changes from OFF to ON only.
F Flashing pulse
Timer bit repeatedly turns ON/OFF at set intervals while the trigger input is ON.
W Twin Timer bit repeatedly turns ON/OFF at set intervals while the trigger input is ON. The ON time and OFF time can be set separately.
Memory Areas Section 1-4
Display Bits
Function switching
Name Type Bit
addresses No.
of bits
Function Use in
ladder programs
Page
Display D 0 to f 16 Display user-specified character strings, times, timer present values, counter present values, or analog-converted values.
Output 82
D Display C Clear display D Display No.
Function switching
