OMRON G3PA-240B-VD Solid State Relay

ال اومرون G3PA series single-phase solid state relay (SSR) with integrated heat sink, zero-crossing turn-on, تركيب السكك الحديدية DIN, directly driven by بلك DC signals. Widely used for non-contact switching control of heating elements, fans and lamp loads.

ملاحظة هامة: تم إيقاف هذا النموذج. Only stock units are available or alternative models should be selected.

1. تعريف رمز النموذج

G3PA: اسم السلسلة, solid state relay with integrated heat sink

2: مرحلة واحدة, AC24~240V output specification

40: Rated load current 40A

ب: Built-in heat sink

VD: DC5~24V DC input control, opto-triac isolation, zero-crossing turn-on

2. المواصفات الكهربائية الأساسية

✅ Input Side (Control Terminals +A1, -A2)

السيطرة على الجهد: DC5~24V, operating range DC4~30V

Maximum input current: 7أماه (directly drivable by PLC output point)

Operating voltage ≤DC4V; Reset voltage ≥DC1V

عزل: Opto-triac isolation

✅ Output Side (Load Terminals 1, 2)

Rated load voltage: AC24~240V, operating range AC19~264V (50/60هرتز)

Rated load current: 40A @40℃; derate to 36A for dense side-by-side mounting

Surge withstand current: 440أ (60هرتز, 1 دورة)

I²t: 1260 A²s

On-state voltage drop: ≤1.6V RMS

Switching characteristic: Zero-cross turn-on, reduces switching surge

تشغيل / release time: Within half cycle of load power supply +1ms

✅ Environmental & ميكانيكية

درجة حرارة التشغيل: -30℃ ~ +80℃ (لا التكثيف)

تصاعد: DIN rail or screw mounting; screw type terminals

أبعاد: W47 × H100 × D100 mm

Dielectric strength between input and output: AC4000V

3. سيناريوهات التطبيق النموذجية

Temperature control: Heating tubes, ceramic heaters, infrared heating (الأكثر شيوعا)

إضاءة: High power lamp banks, halogen lamps

المحركات: Small single-phase fans (resistive / weakly inductive load preferred)

ملحوظة: Inductive loads and loads with large starting inrush current require additional varistor and RC snubber protection.

4. إرشادات الأسلاك
5. +أ1, -A2: DC control signal, good polarity tolerance. It is recommended to connect PLC positive output to A1.
6. المحطات 1, 2: Connected in series to AC load circuit, L/N non-polarity.
7. RC snubber circuit + varistor connected in parallel at output terminals for inductive loads.
8. Derate current and reserve heat dissipation clearance when multiple SSRs are installed side by side on DIN rail.
9. Replacement Models for Discontinued Product
10. Upward replacement within same series: G3PA-260B-VD (60أ, DC5~24V input). Same pin layout with higher capacity.
11. New generation alternative: G3PE series G3PE-245B, 45A DC control, جبل السكك الحديدية DIN, الاستبدال المباشر.
12. Domestic compatible SSR: 40A solid state relay, DC5-24V input, AC240V, zero-cross type with integrated heat sink.
13. استكشاف الأخطاء وإصلاحها الشائعة
14. Input LED does not light: Check PLC output voltage and broken wiring; insufficient input current to drive SSR.
15. LED lights but load does not turn on: محطات الإخراج فضفاضة, broken load; internal triac damage.
16. Load remains energized after control signal removed: SSR short-circuit failure (common for heating loads), usually caused by overheating or surge breakdown.
17. Frequent false triggering: Control cable runs in parallel with power cable causing interference; connect 1000pF anti-interference capacitor at input side.
18. ملاحظات الاختيار
19. الأحمال المقاومة: Derate to 0.7 times rated current for selection.
20. Heating loads have low cold resistance with large starting inrush current, sufficient current margin is required.
21. Further derate when ambient temperature >40℃ or densely mounted.
22. Solid state relay has no mechanical contacts, cannot serve as safety disconnect switch. Circuit breaker must be fitted on main circuit.

OMRON G3PA-240B-VD (40A DC to AC Zero-cross SSR) حالات التطبيق النموذجية

Product Recap: Integrated heat sink, تركيب السكك الحديدية DIN, DC5~24V input, AC24~240V 40A, zero-cross turn-on. Directly driven by PLC, mainly suitable for resistive loads. RC+MOV snubber required for inductive loads.

قضية 1: Temperature Control System – Industrial Heating Tube Control (Most Popular)

طلب

أفران, hot presses, plastic dryers, mold temperature machines, food baking lines, single-phase 220V heating tubes, max power ~8kW (220V×40A), PID power regulation by PLC + تحكم في درجة الحرارة.

تكوين النظام

1. يتحكم: Transistor output DC24V from temperature controller / PLC connected to A1/A2 of G3PA; zero-cross switching reduces grid harmonic distortion.
2. الدائرة الرئيسية: AC220L → SSR terminal 1; صالة 2 → heating tube → N.
3. حماية: 3P circuit breaker + fast fuse at upstream; thermocouple over-temperature protection is recommended for heating tubes.
4. Snubber: RC optional for resistive loads; 470V varistor is recommended for high power applications to absorb grid surge.

Derating Recommendation

Continuous long-term operation: Load current controlled within 28A (0.7×rating); reduce to 24A for side-by-side multi-unit installation.

المزايا

Contactless operation, no contact erosion even under frequent switching (several times per second), higher PID temperature control accuracy.

Common Pitfall

Heating tubes have large cold-state inrush current. Continuous full-current operation tends to break down SSR; do not treat rated 40A as continuous operating current.

قضية 2: High Power Halogen / Infrared Lamp Bank Control

طلب

UV curing lamps, infrared heating lamps, industrial inspection light sources, infrared radiation panels for drying lines, 220V AC lamp banks.

تكوين النظام

PLC DC24V output drives SSR; lamp load connected in parallel to SSR output terminals.

Halogen lamp has extremely low cold resistance, inrush current at switch-on can reach 8~10 times rated current.

احتياطات

1. Zero-cross G3PA is well suited for lamp loads, turn-on at voltage zero point to reduce inrush.
2. Heavy derating is mandatory: lamp load at 0.4~0.5 times SSR rating; load ≤20A for this 40A SSR.
3. NTC surge limiting thermistor in series is recommended.

المزايا

Silent switching, no electric arc under frequent on/off, suitable for automated production line light sources.

قضية 3: المشجعين / Small Single-phase Motors (Inductive Load)

طلب

Air duct heating matched fans, cabinet high-power cooling fans, small conveying single-phase fans for continuous start-stop control.

This is inductive load, RC snubber + MOV varistor must be installed (100Ω/2W +0.1μF/400VAC +470V varistor).

نظام

PLC controls SSR to start/stop fan; circuit breaker fitted upstream of SSR.

القيد

Not suitable for frequent forward/reverse rotation of motor; not applicable for high-power motors with huge starting surge.

Back EMF generated at motor power-off can easily damage SSR, RC snubber is essential.

قضية 4: Solenoid Valve Bank, AC Contactor Coil Drive (Small Inductive Load)

طلب

Packaging equipment, pneumatic production lines, multiple parallel AC220V solenoid coils controlled centrally by PLC.

تكوين النظام

SSR output drives multiple parallel AC220V solenoid coils; RC+MOV connected in parallel to SSR terminals.

ملحوظات

Solenoid coil is inductance, generates high voltage spike at turn-off; total load current cannot exceed 40A.

Minor chattering of solenoid after SSR turn-off may occur due to RC leakage current. حل: connect 10kΩ/5W bleeder resistor across load terminals.

قضية 5: 220V AC Motorized Rollers for Conveyor Lines / Small Conveying Equipment

طلب

Logistics sorting lines, packaging conveyor lines, start-stop control of single-phase 220V motorized rollers.

Key Points

RC+MOV snubber mandatory for motor inductive load; not suitable for frequent jogging with heavy impact, applicable for long run operation with long interval start-stop.

قضية 6: Environmental Test Chamber Heating Circuit

طلب

درجة حرارة ثابتة & humidity chamber, aging test chamber, resistive heating circuit with continuous PID power regulation.

تكوين النظام

PID DC24V output from temperature controller drives G3PA; multi-section heating zone control with multiple G3PA mounted side by side on DIN rail.

الملاحظات الرئيسية

Derate current and reserve heat dissipation clearance for side-by-side installation; ambient temperature around SSR must not exceed 60℃.

Load Selection Summary Table

General Usage Prohibitions for G3PA-240B-VD

1. ❌ Not for large air compressors, high-power single-phase motors (excessive starting surge)
2. ❌ Cannot act as safety disconnect switch, independent circuit breaker required for main circuit
3. ❌ Not suitable for high-frequency high-voltage inductive loads; triac short-circuit failure risk (SSR stuck ON, load continuously powered, risk of over-temperature fire in temperature control systems)
4. ❌ Further current derating required when ambient temperature＞60℃

G3PA-240B-VD Fault List by Application Scenario

نموذج: Omron G3PA-240B-VD, 40A DC input zero-cross SSR; main failure modes: permanent short-circuit at output (most hazardous), failure to turn on, intermittent false triggering.

Precaution: If SSR fails shorted, load stays energized continuously. Over-temperature fire risk is high for heating systems. Independent over-temperature protection must be fitted on main circuit.

قضية 1: Heating Tube / Oven, Mold Temperature Machine (تحميل مقاوم, الأكثر شيوعًا)

Fault1: SSR short-circuits after operating for a period, heating never stops

أعراض: PLC control signal removed, no input at A1/A2, heating tube remains heated; SSR housing very hot.

السبب الجذري:

1) Long-time full current operation without 0.7 derating; insufficient heat dissipation with side-by-side mounting.

2) Aging heating tube with partial short circuit, surge current breaks triac.

3) Grid voltage spike without varistor protection.

علاج: Control load current ≤28A; install 470V varistor; periodically test insulation of heating tube; add independent over-temperature thermostat for hard cut-off.

Fault2: Large temperature fluctuation under PID control, intermittent heating

أعراض: Temperature controller output normal, heating cuts in and out randomly.

السبب الجذري:

1) Insufficient output current from PLC, voltage drop on cable.

2) Loose SSR terminals, contact resistance generates heat.

3) Oxidized wiring of heating tube, اتصال ضعيف.

علاج: تشديد المحطات (torque 0.8~1.0N·m); check driving capacity of PLC transistor output; replace aged heating tube.

Fault3: SSR indicator LED on, but no heating

السبب الجذري: Broken output circuit, burnt heating tube; open-circuit damage of internal triac.

علاج: Measure resistance of heating tube after power-off; measure AC voltage across SSR output terminals.

قضية 2: Halogen / Infrared Lamp Bank

Fault1: SSR damaged immediately upon lamp switch-on

أعراض: SSR burns out right after lamp activation even if average current is low.

السبب الجذري: Extremely low cold resistance of halogen lamp, inrush current reaches 8~10 times rated; zero-cross turn-on still cannot eliminate huge surge without derating.

علاج: Limit load current to 0.4~0.5×SSR rating; fit NTC surge suppression thermistor in lamp circuit; prefer lamp-specific SSR.

Fault2: Lamp flickering

السبب الجذري: Fluctuating supply voltage; lamp aging; internal component aging of SSR.

علاج: Replace aged lamps; verify power supply stability.

قضية 3: Single-phase Fan, Small Motor (Inductive Load)

Fault1: SSR breaks down every time fan stops

أعراض: Fan runs normally, SSR fails when control signal turns off.

السبب الجذري: Inductance of motor winding generates high back EMF at power-off; RC+MOV not fitted.

علاج: Install RC snubber (100Ω/2W +0.1μF/400VAC in series) +470V varistor, wire directly close to SSR terminals.

Fault2: Fan slowly rotates after SSR turned off

أعراض: Fan does not fully stop after PLC signal removed, low speed rotation.

السبب الجذري: Leakage current introduced by RC snubber, weak voltage induced on motor winding.

علاج: Fit 10kΩ/5W bleeder resistor across motor terminals; or use mechanical contactor for complete cut-off.

قضية 4: AC220V Solenoid Coil Bank (Inductive Load)

Fault1: Solenoid randomly pulls in (false triggering)

أعراض: Solenoid occasionally chattering or actuating without PLC output signal.

السبب الجذري: RC leakage current; electromagnetic interference when control cable runs parallel with power cable; excessively long control wire.

علاج: Fit 10kΩ/5W bleeder resistor across load terminals; separate routing for control and power cables; fit 1000pF anti-interference capacitor at input side.

Fault2: SSR damaged after multiple switching cycles

السبب الجذري: High voltage spike from coil turn-off without RC+MOV protection.

علاج: Install RC+MOV; do not connect excessive solenoids in parallel, derate total current to 0.6×rating.

قضية 5: Conveyor Motorized Roller

Fault1: Unstable start-stop of roller, occasional start failure

أعراض: Roller sometimes fails to start even when control signal is sent to SSR.

السبب الجذري: Large motor starting surge; insufficient SSR margin; voltage drop on cable.

علاج: Reduce load capacity; verify power cable gauge; RC+MOV mandatory for inductive load.

Fault2: Severe overheating of SSR

السبب الجذري: Long-time heavy current operation; poor heat dissipation for multiple SSR mounted side by side on DIN rail.

علاج: Increase mounting gap between SSR units; reduce load current; add auxiliary cooling fan if necessary.

General Common Faults (ينطبق على كافة السيناريوهات)

1. Input indicator LED at A1/A2 does not light

Troubleshooting sequence:

1) Check PLC output, confirm DC24V present.

2) Broken control wire, قطبية معكوسة (tolerated to some extent, long-term reverse polarity damages input LED).

3) Burnt input circuit of SSR.

2. Input LED normal, no output action

استكشاف الأخطاء وإصلاحها: Main power supply available; loose output terminals; open-circuit damage of internal triac.

3. Random SSR failure under high ambient temperature

السبب الجذري: Ambient temperature＞60℃, heat dissipation deteriorates, device characteristic drift.

علاج: تحسين تهوية الخزانة; further derate current; mount SSR away from heat-generating components.

4. Random SSR false actuation caused by interference

أعراض: SSR turns on/off irregularly during equipment operation.

التدابير المضادة:

1) Separate cable trunking for control signal and power cable, avoid long parallel routing.

2) Fit isolation relay at PLC output side.

3) Connect 1000pF high voltage ceramic capacitor at input side.

Rapid Fault Diagnosis Procedure (For On-site Commissioning)

1. Disconnect AC main power, keep DC24V control power on, check whether SSR input LED follows PLC signal.
2. خارج السلطة, measure resistance across SSR output terminals:

الحالة الطبيعية (no input signal): High resistance, Mega-ohm level.

Resistance close to conducting state without input: SSR short-circuited, DO NOT energize!

3. Power on with load, measure AC voltage across SSR output terminals:

With ON signal: Voltage drop across SSR ≤1.6V.

With OFF signal: Voltage across SSR close to AC220V.

4. Check SSR housing temperature; improve derating or heat dissipation if temperature exceeds 70℃.

قواعد السلامة

1. Short-circuit failure is the typical failure mode of this SSR. Independent mechanical over-temperature protection must be fitted for heating applications; do not rely only on PLC and SSR.
2. Do not run long-term test without RC+MOV for any inductive load.
3. SSR shall not be used as safety isolation switch; main circuit breaker must be opened for equipment maintenance.