Omron E5AJ-A2HB Operation Manual
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Omron E5AJ-A2HB Operation Manual

E5*j series
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E5jJ Temperature Controller
Operation Manual
Cat. No. Z103-E3-1

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Summary of Contents for Omron E5AJ-A2HB

  • Page 1 E5jJ Temperature Controller Operation Manual Cat. No. Z103-E3-1...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 Introduction ........Features .
  • Page 4 TABLE OF CONTENTS SECTION 10 Auto-tuning ........10-1 Starting Auto-tuning .

  • Page 5: About This Manual

    About this Manual: This manual describes the installation and operation of the Thermac E5jJ Temperature Controller and includes the sections described below. Please read this manual carefully and be sure you understand the information provided before attempting to install and operate the Thermac E5jJ Temperature Controller. Section 1 describes the specifications and basic features of the Thermac E5jJ Temperature Controller.

  • Page 6: Introduction

    SECTION 1 Introduction This section describes the specifications and basic features of the Thermac E5jJ Temperature Controller. Features ..............Models .

  • Page 7: Features

    Models Section 1-2 Features The basic features of the Thermac E5jJ Temperature Controller are outlined below. Fuzzy Self-tuning When using a conventional temperature controller for ideal temperature control, it is necessary to adjust the PID constants of the temperature controller accord- ing to the controlled device.
  • Page 8 2 relay output points with heater burnout alarm (see note 1) Event input 2 points (set point selection, RUN/STOP) (see note 2) Control output Replaceable Output Unit (sold separately) Model Communications function E5AJ-A2HB RS-232C E5AJ-A2H01 RS-422 E5AJ-A2H02 RS-485 E5AJ-A2H03 Communications Board add-on model...

  • Page 9: Specifications

    Specifications Section 1-3 E5CJ (Simple and Standard Models) 48 X 48mm Type Simple model type Standard model type Alarm 2 replay output points with the same common. (see note 1) Heater burnout alarm Yes (see note) Event input 1 point (set point selection) Model Control output...
  • Page 10 Specifications Section 1-3 Item Specification Indication method E5AJ All digital indication (PV: Red, 15 mm; SV: Green, 10.5 mm) E5EJ All digital indication (PV: Red, 14 mm; SV: Green, 9.5 mm) E5CJ All digital indication (PV: Red, 12 mm, SV: Green 8.0 Event input Contact input: ON: 1 kΩ...

  • Page 11: Characteristics

    Specifications Section 1-3 1-3-2 Characteristics E5jJ Item Specification Indication accuracy 0.5% or 1 C whichever is larger 1 digit max. Thermocouple K, T, or N at a temperature of –100 C; thermocouple U at digit max. Hysteresis (for ON/OFF control) 0.1 to 999.9 C/ F (in units of 0.1 C/ F) Proportional band 0.1 to 999.9 C/ F (in units of 0.1 C/ F)
  • Page 12 Specifications Section 1-3 Output Unit Model Life expectancy E53-R Relay Output Unit Mechanical 10,000,000 times min. Electrical 100,000 times min. Heater Burnout Alarm Item Specification Max. heater current Single-phase 50 A VAC (see note 1) Heater current value display accuracy 5% FS 1 digit max.

  • Page 13: Sensor And Mode Settings

    SECTION 2 Sensor and Mode Settings This section describes the sensor and mode settings of the Thermac E5jJ Temperature Controller that are necessary before turning on the Thermac E5jJ Temperature Controller. Disassembly ............. Output Units .

  • Page 14: Disassembly

    Output Units Section 2-2 Disassembly Before turning on the E5jJ, set its sensor type and control mode with the inter- nal selectors. Refer to the following illustrations for disassembling the E5jJ to access the internal switch settings. Hook Press the hook and pull the front panel.

  • Page 15: Internal Switch Settings

    Internal Switch Settings Section 2-3 NPN Model: E53-Q (40 mA at 12 VDC) and E53-Q3 (20 mA at 24 VDC) LOAD INPUT – – PNP Model: E53-Q4 (20 mA at 24 VDC) LOAD INPUT – – Internal Switch Settings 2-3-1 Internal Switch Positions E5AJ ALM2 Bottom view...
  • Page 16 Internal Switch Settings Section 2-3 E5CJ ALM2 Top view Bottom view Alarm mode selector 2 PROTECT ALM1 Key protection Alarm mode selector 1 switch INPUT Input type selector FUNCTION Function selector Note The E5CJ with no alarm does not incorporate ALM1 or ALM2. 2-3-2 Input Type Selector Setting The input type selector is factory-set to 2 (K).

  • Page 17: Alarm Mode Setting

    Internal Switch Settings Section 2-3 2-3-3 Alarm Mode Setting ALM1 and ALM2 are both factory-set to 2 (upper limit alarm). Refer to the follow- ing table for the selection of the desired alarm mode. ALM2 ALM1 Selector Alarm mode Alarm output Setting range Positive alarm set Negative alarm set...

  • Page 18: Standby Sequence

    Internal Switch Settings Section 2-3 2-3-4 Standby Sequence The alarm output is ON the moment the E5jJ is turned on because the process value is within the alarm range. To prevent this, select a mode with a standby sequence. If a mode with a await sequence is selected, the alarm output will not be ON even if the process value is within the alarm range unless the process value once goes out of the alarm range.

  • Page 19: Key Protection Switch Settings

    Internal Switch Settings Section 2-3 2-3-6 Key Protection Switch Settings The key protection switch is used to prohibit parameter changes as shown in the following table. The key protection switch is factory-set to OFF. PROTECT Mode Protection Prohibits all set value changes except the set point. The Level Key is not available.

  • Page 20: Settings Before Operation

    SECTION 3 Settings Before Operation This section describes the settings of the Thermac E5jJ Temperature Controller that are necessary before operating the Thermac E5jJ Temperature Controller. Nomenclature ............Setting Flowchart .

  • Page 21: Nomenclature

    Section 3-1 Nomenclature Nomenclature The following is the front panel of the E5AJ-A2HB. The front panels of the E5EJ and E5CJ are similar to the front panel of the E5AJ-A2HB. Process Value (PV) display Displays not only the process value but also indicates the pa-...

  • Page 22: Setting Flowchart

    Setting Flowchart Section 3-2 Setting Flowchart The Thermac E5jJ Temperature Controller starts control at the set point and continues controlling even while set values are being input for each display level. Therefore, when operating the E5jJ after inputting all the set values, turn the power supply to the Temperature Controller off and then on again.

  • Page 23: List Of Parameters

    List of Parameters Section 3-3 List of Parameters Display Level 0 Display Name Setting range Setting Remarks before shipping Process value Set point lower limit The present set point is display and set to set point upper displayed and can be point setting limit ( C/ F) changed if the E5jJ...
  • Page 24 List of Parameters Section 3-3 Display Name Setting/Display Setting Remarks Range before shipping Heater current 0.0 to 55.0 A For models incorporating a value display heater burnout alarm. If the current exceeds 55.0 A, ffff will be Nothing is displayed if the displayed on the set E5jJ has current control value display.

  • Page 25: Parameters On Display Level 0

    Parameters on Display Level 0 Section 3-4 Parameters on Display Level 0 The value set before shipping appears (Set point setting) Displays when the E5jJ incorporates an alarm function (see note). (Alarm 1 setting) Displays when the E5jJ incorporates an alarm function (see note). (Alarm 2 setting) Note: The process value will not be displayed if the alarm mode switch is set to 0 or if the E5jJ does...

  • Page 26: Parameters On Display Level 0

    Parameters on Display Level 1 Section 3-5 Parameters on Display Level 1 The value set before shipping appears (Output value display) Displays when the E5jJ in PID control operation has a relay or voltage output. (Control period setting) Displays when the E5jJ is in ON/ OFF control operation.

  • Page 27: Section 4 Fuzzy Self-Tuning

    Parameters on Display Level 1 Section 3-5 o Output Value Display The output value is displayed within a range of 0.0% to 100.0%. cp Control Period Setting It is possible to set the control period within a range of 1 to 99 s. The control peri- od is the period required by the E5jJ to turn ON and OFF its relay output or volt- age output.
  • Page 28 Parameters on Display Level 1 Section 3-5 p Proportional Band Setting It is possible to set the proportional band within a range of 0.1 to 999.9 C/ F. i Integral Time Setting It is possible to set the integral time within a range of 0 to 3999 s. d Derivative Time Setting It is possible to set the derivative time within a range of 0 to 3999 s.

  • Page 29: Fuzzy Self-Tuning

    SECTION 4 Fuzzy Self-tuning This section provides the procedures required to adjust all PID constants using fuzzy self-tuning according to the characteris- tics of the device for ideal temperature control. Fuzzy Self-tuning Operation ..........4-1-1 Step Response Tuning (SRT) .

  • Page 30: Fuzzy Self-Tuning Operation

    Note Be sure to turn on the power supply to the load either before or simultaneously with the start of Temperature Controller operation. When using the E5AJ-A2HB or E5EJ-A2HB, you can change the RUN/STOP setting to RUN via event input 2 after supplying power to the load.

  • Page 31: Disturbance Tuning (Dt)

    Section 4-1 Fuzzy Self-tuning Operation SRT Startup Condition SRT will be ON if the following conditions are satisfied simultaneously when the Temperature Controller is turned on or the set point is changed. At the time the Temperature Controller At the time set point is changed starts operating 1) The set point at the time the 1) The new set point is different from...

  • Page 32: Hunting Tuning (Ht)

    Section 4-1 Fuzzy Self-tuning Operation DT at the Time of External After the process value reaches the set point and becomes stable, if the process Disturbance Response value is disturbed and the disturbance exceeds the stable range, the distur- bance is regarded as external disturbance At the time of disturbance, DT mea- sures the external disturbance waveform and adjusts the PID constants so that the external disturbance waveform will be as close as possible to the most ideal external disturbance response waveform.

  • Page 33: Troubleshooting

    Troubleshooting Section 4-2 HT may change the PID constants even though the PID constants are ideal for the control system. Refer to 9-1 Engineering Level for details. External disturbance Figure A: Waveform with HT turned ON External disturbance T1<T2 Figure B: Waveform with HT turned OFF Note The stable range is set to 27 F with the E5jJ-jjjj-F.

  • Page 34: Terminology

    Terminology Section 4-3 Phenomenon Probable cause Countermeasure Hunting does not stop. The control period is too long for the Shorten the control period. characteristics of the controlled device, which causes hunting in synchronization with the control period. The temperature is influenced by In this case, however, 100% continuous external disturbance (i.e., improvement will not be possible...

  • Page 35: Hunting

    Terminology Section 4-3 self-tuning will not be activated if the temperature is stable because the Temper- ature Controller deems that temperature control is smooth. Shorter than the stability judgement time. Stable range Set point Stable range (Set to 15.0 C before shipping) Stability judgement time Stable Stable...

  • Page 36: Startup

    Terminology Section 4-3 4-3-6 Startup Startup means that the Temperature Controller starts operating. The following conditions are required to operate the Temperature Controller. The Temperature Controller must be turned ON. No sensor error has occurred. If a model with event input 2 is used, event input 2 must be set to RUN. Event input 2 is set to RUN before shipping.

  • Page 37: Installation And Wiring

    SECTION 5 Installation and Wiring This section describes the installation and wiring of the Thermac E5jJ Temperature Controller. Installation ............. . 5-1-1 Dimensions and Mounting Holes .

  • Page 38: Installation

    Section 5-1 Installation Installation Install the E5jJ in the following places. 1, 2, 3... 1. Where there is little mechanical vibration or shock. 2. Where there is no corrosive gas such as sulfide gas. 3. Where the ambient temperature is within –10 to 55 C. 4.

  • Page 39: Wiring

    Wiring Section 5-2 Wiring Refer to the terminal arrangements to wire the E5jJ. Before wiring, observe the following. 1, 2, 3... 1. When connecting extension wires to the thermocouple, use proper compen- sating lead wires. 2. When connecting extension wires to the platinum resistance thermometer, use three low-resistance wires of equal resistance.

  • Page 40: Terminal Arrangement

    Terminal Arrangement Section 5-3 Terminal Arrangement E5AJ/E5EJ Standard Model Write the name See note 2. of the Output Event input 1 (EV1) Unit to be used Externally selects the set point. on the name- Relay Output Unit plate on the Open : Set point 0 E53-R...
  • Page 41 Terminal Arrangement Section 5-3 2. Only the heater burnout alarm will be output from the alarm output 1 termi- nals if alarm mode switch 1 is set to 0. Only the temperature alarm will be output if the heater burnout alarm value is set to 0.0 A. E5CJ Standard Model Control output (OUT) Voltage Output Unit...

  • Page 42: Troubleshooting

    SECTION 6 Troubleshooting This section describes the troubleshooting of the Thermac E5jJ Temperature Controller. Error Display and Output ........... Troubleshooting .
  • Page 43 Abnormal Normal operation (accuracy The E5jJ needs calibration. Contact your calibration data. not guaranteed) OMRON representative. Displayed for 2 s when the E5jJ is turned on. Note If the input is within the possible controlling range but exceeding the possible display range (–1999 to 9999),...
  • Page 44 Troubleshooting Section 6-2 Phenomenon Probable cause Countermeasure The process value is abnormal or not The input polarity is wrong or the Properly wire the terminals. obtained. connection is wrong. The input-type setting is incorrect. Properly set the input with the input-type selector.

  • Page 45: Section 7 Event Input Function

    SECTION 7 Event Input Function This section describes how the event input function of the Thermac E5jJ Temperature Controller works. Event Input Function ............7-1-1 Set Point Selection .

  • Page 46: Event Input Function

    Section 7-1 Event Input Function Event Input Function The E5jJ-jB with an event input function is operated with ease with external relay signal selection. Set Point Selection It is possible to select one of the set points previously set for control operation. RUN/STOP Selection It is possible to enable the E5AJ-jB and E5EJ-jB to RUN or STOP.
  • Page 47 Section 7-1 Event Input Function 7-1-3 Signal Input Method The event input terminals can be short-circuited using a relay or transistor as shown in the following diagram. +24 V 470 Ω 3 kΩ Flow current: 7 mA approx. VF = 1.2 VF = 0.6 Signal Input Types Contact Input...

  • Page 48: Section 8 Heater Burnout Detection

    SECTION 8 Heater Burnout Detection This section describes the basic features of heater burnout detection and necessary steps that should be taken at the time of heater burnout, as well as the method of obtaining heater burnout alarm values. Heater Burnout Detection .

  • Page 49: Heater Burnout Procedures

    Heater Burnout Procedures Section 8-2 Heater Burnout Detection To detect heater burnout, wire one of the lead wires for each heater through the hole of the Current Transformer (CT). The CT generates an AC current accord- ing to the current flow of the lead wire. The Thermac E5jJ Temperature Control- ler measures the AC current to check the current flowing to the heater.

  • Page 50: Wiring The Current Transformer

    Heater Burnout Alarm Value Section 8-4 Wiring the Current Transformer Refer to the following diagram for the wiring the CT. To the CT input terminals of the E5jJ. The CT input terminals have no polarity. Relay driven with control output Heater To heater AC power supply...

  • Page 51: Setting Examples

    Heater Burnout Alarm Value Section 8-4 The normal heater current value should be 50.0 A max. The heater current value can, however, display up to 55.0 A. If the current value exceeds 55.0 A, CT input overflow will result and ffff will be displayed. CT input overflow 8-4-1 Setting Examples...
  • Page 52 Heater Burnout Alarm Value Section 8-4 creases. The displayed heater current value increases in proportion to the number of turns of the wire passing through the CT. Heater wire The wire passes through the CT twice. 3. Obtain the heater burnout alarm value using the method in example 1. Apparent normal current = (400 + 1700 + 2000) B 200 x 2 = 41.0 A Normal heater current value...

  • Page 53: Engineering Level Settings

    SECTION 9 Engineering Level Settings This section describes the parameters that can be changed on the engineering level. These parameters should be changed only when the values set before shipping do not suit the application. After these parameters are changed on the engineering level, record the contents of the changes for your future reference.

  • Page 54: Engineering Level

    Engineering Level Parameter List Section 9-2 Engineering Level To go to engineering level, set pin 4 of the internal function switch of the E5jJ to ON before turning the E5jJ on. After this setting, set pin 4 of the internal func- tion switch to OFF.
  • Page 55 Engineering Level Parameter List Section 9-2 Display Name Setting range Setting before User’s remarks shipping SL-H Set point upper limit Set range lower limit 1300 (2300) value value to set range upper limit value (see note 1). ( C/ F) EV-2 Event input 2 type 0: Set point selection...

  • Page 56: Engineering Level Parameters

    Engineering Level Parameters Section 9-3 Engineering Level Parameters The value set before shipping appears. (see note 1) ( C/ F selection) Displayed if the E5jJ with a com- munications function is used. (Data bit length setting) (Parity check setting) (Stop bit length setting) Displayed if the E5jJ is in advanced PID operation with fuzzy self-tuning.
  • Page 57 Engineering Level Parameters Section 9-3 rd u C/ F Selection To change the temperature display unit from C to F, press the Up Key so that f will be displayed in the set value display. c: C f: F E5jJ with The communications specifications of the E5jJ are as follows: Communications Function Data bit length: ASCII 7- (set before shipping) or 8-bit code...
  • Page 58 Engineering Level Parameters Section 9-3 ret Automatic Return of By setting automatic return of display mode, the display will return to the normal Display Mode (Return Time) operation display (on level 0 displaying the process value or set point) if no key is operated for the time set with this parameter.
  • Page 59 Engineering Level Parameters Section 9-3 eu 2 Event Input 2 Type It is possible to select the function of event input 2. If 0 (set point value selection) Selection is selected, sp 2 and sp 3 will be displayed on display level 1 and if 1 is selected RUN/STOP will be selected.

  • Page 60: Auto-Tuning

    SECTION 10 Auto-tuning This section describes how to execute auto-tuning. 10-1 Starting Auto-tuning ............10-2 Conditions that Prevent Auto-tuning .

  • Page 61: Starting Auto-Tuning

    Changing Parameters during Auto-tuning Section 10-4 10-1 Starting Auto-tuning Auto-tuning can be started by using the following procedure. Use this procedure when appropriate results are not achieved via fuzzy self-tuning. 1, 2, 3... 1. Turn ON pin 3 of the function selector switch to select the advanced PID con- trol mode (refer to Section 2-3-5 ).

  • Page 62: Dimensions/Mounting Holes

    Appendix A Dimensions/Mounting Holes E5AJ Dimensions 96 x 96 91 x 91 Mounting Holes +0.8 (96 x units – 3.5) +0.8 +0.8 120 min. Note 1. All dimensions shown are in millimeters. 2. Side-by-side close mounting is not possible for E5AJs equipped with the Watertight Cover (sold sepa- rately).
  • Page 63 Appendix A Dimensions/Mounting Holes E5EJ Dimensions Mounting Holes +0.6 (48 x units – 2.5) +0.8 +0.8 120 min. Note 1. All dimensions shown are in millimeters. 2. Side-by-side close mounting is not possible for E5EJs equipped with the Watertight Cover sold sepa- rately).
  • Page 64 Appendix A Dimensions/Mounting Holes Mounting Holes +0.6 (48 x units – 2.5) +0.6 +0.6 60 min. Note 1. All dimensions shown are in millimeters. 2. Side-by-side close mounting is not possible for E5CJs equipped with the Watertight Cover (sold sepa- rately).
  • Page 65 Appendix A Dimensions/Mounting Holes E53-COV03 E5EJ with Terminal Cover...

  • Page 66: Index

    Index engineering level advanced PID alarm hysteresis, 60 function, 2 automatic return of display mode, 60 setting, 14 communications, 59 setting with fuzzy self-tuning, 14 data bit length, 59 input shift display, 60 alarm mode parameters, 19 changing, 22 parameters table, 56 setting.
  • Page 67 Index set point See also event input function adjusting changeable range, 60 installation setting type, 22 mounting, 36 precautions, 36 settings advanced PID control, 14 integral time range, 25 alarm mode selection, 13 interference, definition, 33 functions. See functions fuzzy self-tuning, 14 internal switches, sensor type and control mode, 10 internal switches, 11, 12 key protection switch, 15...

  • Page 68: Revision History

    Revision History E5jJ Temperature Controller Operation Manual A manual revision code appears as a suffix to the catalog number on the front cover of the manual. Cat. No. WZ103-E3-1 Revision code The following table outlines the changes made to the manual during each revision. Page numbers refer to the previous version for manuals designated as E1 revisions.
  • Page 69 Revision History Revision code Date Revised content Z103-E1-5 February 1998 Page 4: Supply voltage and power consumption specifications changed. Page 19: Thermac E5jJ information added to the beginning of 3-2 Setting Flowchart . Pages 38, 39: Terminal arrangement diagrams changed. Page 56: Information added to 9-1 Engineering Level .

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