Omron E5ZE Operation Manual
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Omron E5ZE Operation Manual

Omron E5ZE Operation Manual

Multipoint temperature controller
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E5ZE
Multipoint Temperature Controller
Operation Manual
Catalog No. H076-E3-1

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  • Page 1 E5ZE Multipoint Temperature Controller Operation Manual Catalog No. H076-E3-1...
  • Page 2 1. Indicates lists of one sort or another, such as procedures, checklists, etc.  OMRON, 1997 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 permis- sion of OMRON.

  • Page 3: Table Of Contents

    ..........Wiring CT Inputs and Control/Alarm Outputs .

  • Page 4: About This Manual

    This manual describes the installation and operation of E5ZE Multipoint Temperature Controllers and includes the sections described below. Refer to the following manuals according to the model being used before operating the E5ZE. Refer to the following manual when using the E5ZE Serial Communications Models: E5ZE Multipoint Temperature Controller Communications Manual (Cat.

  • Page 5: Precautions

    This section provides general precautions for using the E5ZE Multipoint Temperature Controller and related devices. The information contained in this section is important for the safe and reliable application of the E5ZE Multipoint Temperature Controller. You must read this section and understand the information contained before attempting to set up or operate an E5ZE Multipoint Temperature Controller.

  • Page 6: General Safety Precautions

    Do not attempt to disassemble, apply pressure, distort, subject to temperatures of 100°C or more, or throw the E5ZE into fire. A lithium battery is built into the E5ZE and any attempt to any of the above may result in fire, explosion, or combustion.
  • Page 7 Application Precautions Caution Tighten the screws on the terminal block to the torque specified in the manual. Loose screws may result in burning or malfunction. Caution Do not connect loads to the E5ZE that exceed the specified ratings. Excessively large loads may result in malfunction or burning.

  • Page 8: Introduction

    SECTION 1 Introduction This section describes the components, a standard system configuration, and the functions of the E5ZE. Refer to Section 2 Preparations and later sections for details on functions and their applications. Component Names and Functions ..........

  • Page 9: Component Names And Functions

    Lit when the E5ZE is receiving command data. Lit when the E5ZE is sending response data. CH0 to CH7: Lit for the control points for which the corresponding control outputs are ON. (Not lit for Current Output Models.) H0 to H7: Lit for the control points for which the corresponding heating outputs are ON.
  • Page 10 The setting selectors and switch are used to select the temperature sensor type, Switch the unit number, and the functions to be used with the E5ZE. Refer to 2-3 Setting Selectors and Switch for details on setting methods. Input Terminal Block The input terminal block is connected to a DC power supply, temperature sen- sor, and ground wire.

  • Page 11: System Configuration

    E5ZE-8 Multipoint Temperature Controller DeviceNet Communications Manu- al (H104) for details. • There are restrictions on the items that can be set or displayed from the E5ZD- SDL Setting Display Unit. Refer to the E5ZD-SDL Setting Display Unit Data- sheet (H61) for details.

  • Page 12: Main Functions

    • Output limiter • Output change rate limiter If an output value is outside the upper or lower limit for the output, the output will be limited to the preset upper or lower limit. The output change rate limiter limits the rate at which output values change per unit time.
  • Page 13 8 memory banks for each control point. Memory banks allow the set values for a control point to be changed as a group rather than resetting them individu- ally. Use the external contact inputs or communications to designate the re-...

  • Page 14: Preparations

    SECTION 2 Preparations This section provides details on operations that must be performed before starting the E5ZE, such as installation and wiring. List of Models ............

  • Page 15: List Of Models

    Current Output Unit are sold separately. 2. The heater burnout and SSR failure detection Control Output function of the E5ZE will be invalid if the heating side Option (see note 1) control output of the E5ZE is current output. Heater Burnout and SSR Failure Detection (see note 2) 3.

  • Page 16: Devicenet Communications Models

    E5ZE-8VCA Cooling resistance D1PB 24VDC thermometer Model Number Legend: E5ZE-8jjjjjj Control Point Heater Burnout and SSR Failure Detection Function (Not available with Current Output Models.) Control Method Communications Function Standard control D1: DeviceNet Heating and cooling control Input Type TC: Thermocouple...

  • Page 17: Mounting The Serial Communications Models

    Mounting the Serial Communications Models I/O Units I/O Units are not mounted on the E5ZE. Mount the appropriate I/O Units according to the specification of the E5ZE. The diagram below is the view from the back of component side. Type of I/O Units...
  • Page 18 3. Remove the casing. 4. Mount the Units in the same manner as the model without casing. 5. Fix the connector to the case using the connector fixing screws with a torque of 0.34 to 0.39 NSm. 6. Replace the casing in its original position using six casing fixing screws.

  • Page 19: Setting Selectors And Switch

    When more than one E5ZE Multipoint Temperature Controller is being used with RS-422 or RS-485 communications, set a different unit number for each E5ZE. • The selector settings 0 to F correspond to unit numbers 00 to 0F. The factory setting of 0 corresponds to unit number 00.

  • Page 20: Function Switch

    E5ZD-SDL Setting Display Unit connection Memory bank designation method Baud rate (serial communications) Baud Rate (Serial Set the baud rate using pins 1 and 2 to the baud rate of the host device con- Communications) nected to the EZ5E. Baud rate...
  • Page 21 Pin 5 The factory setting is for stop operation control (pin 5 OFF). If the power is turned OFF during manual operation and pin 5 is set to ON (con- tinuous operation), manual operation will automatically begin when the power is turned ON again.

  • Page 22: Installation

    Installation Section Installation 2-4-1 External and Panel Dimensions Unit: mm Mounting Hole Dimensions Serial Communications Model Four, M4 E5ZE-8jjjD1jB Four, M4 (DeviceNet Interface)

  • Page 23: Mounting

    E5ZE-8jjjjjB: 4 x M4 screws • Use spring and flat washers and tighten to a torque of 0.43 to 0.58 N S m {4.4 to 5.9 kgf S cm}. • Do not mount the terminal block with the connectors facing upwards. Doing so may cause measurement errors.

  • Page 24: Power Supply And Input Wiring

    Model, when reconnecting make sure that the E5ZE’s lot number and serial number are the same as those of the terminal block. Accuracy cannot be guar- anteed for a Unit that has been connected to a terminal block with a different lot number and serial number.

  • Page 25: Terminal Arrangement

    2-5-4 Power Supply The power supply specifications are as follows: 24 VDC (20.4 to 26.4 VDC) 15 W + 20% max. Use a power supply with a minimum capacity of 2 A. Be sure to consider the in- rush current. 2-5-5 Ground...

  • Page 26: Wiring Ct Inputs And Control/Alarm Outputs

    • Do not touch the cold junction compensators. • Short-circuit the positive and negative terminals of each control point that is not used. The process value for each control point that is not being used will be the ambient temperature of the terminal block.

  • Page 27: Ct Inputs

    The following diagram shows the terminal arrangement for CT inputs when a XW2B-20G5/4 Connector Terminal Conversion Unit is connected. Connect CT0 to CT7 to the CT inputs for control points 0 to 7. For example, CT0 will detect heater burnout or SSR failure for the output of control point 0.

  • Page 28: Outputs

    • The terminal arrangement for outputs when an XW2B-20G5/4 Connector Ter- minal Conversion Unit is connected is shown in the following diagram. CONTROL Connector Terminal Block • The output specifications are shown in the following table. Connect a load that is compatible with the output type and output rating. Output Specification 12 ±...
  • Page 29 Alarm 1 Temperature controller error • The following table shows the specifications for alarm output and cooling con- trol output. The E5ZE does not have an overcurrent protection function for alarm output and cooling control output. Connect a load to each alarm output and cooling control output that corresponds to the output ratings.
  • Page 30 Cooling control output (Do not use with E5ZE-8Ajjjj Standard Models.) • Do not use terminals marked “Don’t use.” Doing so may cause the E5ZE or G7TC to malfunction. • G7TC-OC08 I/O Blocks cannot be used with E5ZE-8Vjjjj Heating and Cooling Control Models.

  • Page 31: Connecting Communications

    • The E5ZE’s RS-232C communications do not support a CD (carrier detect) signal from the host device. If the CD signal is required, provide support at the host device. When using the RS-232C auxiliary setting jack on the E5ZE-8jjjD1jB (DeviceNet Model with casing), use the following Connecting Cables.

  • Page 32: Rs-422 And Rs-485

    • Use crimp terminals or solder the wire ends when wiring the terminals. • Tighten the terminal screws to a torque of 0.59 N S m, or 6 kgf S cm. • Do not apply a force of more than 100 N or 10.2 kgf to the terminal screws.
  • Page 33 Connecting Communications Section • The following crimp terminals can be used. Crimp Terminal Terminal Block Screw Dimensions 10.4 mm 6 mm max. M3 x 7.2 screws with 6.25 mm square washers 6 mm max. End Soldering Length of exposed wire: 6 to 7 mm...

  • Page 34: Devicenet Interface

    Node address Always set to OFF Baud rate DeviceNet connector • Pins 1 to 6 are used to set the node address. The factory setting is 00 (pins 1 to 6 all OFF). Pin 1 Pin 2 Pin 3 Pin 4...
  • Page 35 Connecting Communications Section • Pins 7 and 8 are used to set the baud rate. Be sure to set the baud rate to match that of the DeviceNet Master Unit. The factory setting is 125 kbps (pins 7 and 8 OFF).

  • Page 36: Functions

    SECTION 3 Functions This section provides details on the functions of the E5ZE and their applications. For details on the settings and measurement values for the functions, refer to the E5ZE Multipoint Temperature Controller Communications Manual (H77) and the E5ZE-8 Multipoint Temperature Controller DeviceNet Communications Manual (H104).

  • Page 37: Data Configuration

    E5ZE-8Vjjjjj Heating and Cooling Control Models. Memory Banks The E5ZE has 8 memory banks, 0 to 7, for each control point. The memory banks store specific groups of setting data. The E5ZE controls each control point according to the contents of the current memory bank.

  • Page 38: I/O Settings

    The E5ZE is available in models that can be used for thermocouple inputs or platinum resistance thermometer inputs. The input type is set using the INPUT selector on the front panel of the Unit. Re- fer to 2-3 Setting Selectors and Switch for details on settings.

  • Page 39: Set Point And Process Value

    • If the setting unit is set to 0.1, and data is read after changing the setting unit to 0, any value after the decimal point will be rounded off to a whole integer. For example, 1234.5 will be read as 1235.

  • Page 40: Alarm Output Settings

    Section 3-4 Alarm Output Settings • The alarm outputs can be set for alarms 1 and 2 for each control point. Each alarm output will be output from the alarm 1 and alarm 2 terminals. The alarm 1 and 2 terminals are used for all control points.

  • Page 41: Alarm Temperatures

    • Set the alarm temperature in each memory bank. The alarm temperature set- ting is not required, however, if the alarm mode is set to 00 (no alarm function) or 0C (HB and HS alarm).

  • Page 42: Output Limitations

    • If the lower limit is 100.0, the output value will be 100.0%. • If the upper limit is 0.0, the output value will be 0.0%. • If the upper limit is equal to the lower limit, the output value will be equal to the output limits.

  • Page 43: Ramp

    • Set the change rate of the ramp interval in each memory bank. The ramp value and the ramp time unit (hour, minute, or second) must also be set. • The setting range is 0.1 to 99.9 (°C or °F divided by the ramp time unit).The default is 0.0, i.e., the ramp function is disabled.

  • Page 44: Control Adjustments

    (If the DeviceNet is being used, auto-tuning cannot be executed in sequence.) • If auto-tuning is cancelled, the auto-tuning will stop for all control points at the same time. (If the DeviceNet is being used, auto-tuning can be stopped for each control point separately.)
  • Page 45 • The auto-tuning execution time may be extended depending on the controlled object. In such a case, the time required for auto-tuning to be completed may be reduced if the proportional band (P constant) is set to 0.0. The E5ZE goes into ON/OFF operation with oscillations increasing.

  • Page 46: Control Method Selection

    Section 3-8 3-7-2 Manual Reset The manual reset function is used to correct a constant offset from the set point after a stable condition is obtained when using P or PD control. • When an offset occurs, change the manual reset value as shown in the follow- ing graph.

  • Page 47: On/Off Control

    Operating Conditions • The manual output value can be set only during manual operation. The manual output value cannot be set if there is a temperature sensor input error or a Tem- perature Controller error. • Manual operation cannot be started if auto-tuning is being executed or there is a Temperature Controller error.

  • Page 48: Heating And Cooling Control

    • Control output may occur within the dead band for other types of control apart from proportional control and ON/OFF control. • Set the dead band in each memory bank. • The setting range of the dead band is –999 to +999°C (or °F). The default is 0.

  • Page 49: Heater Burnout Detection

    • Set cooling coefficients in each memory bank. • The cooling coefficient setting range is 0.0 to 10.0. The default is 1.0. • If the cooling coefficient is set to 0.0, the cooling control output value will be 0%. 3-10 Heater Burnout Detection...
  • Page 50 • Set the heater burnout detection current value. The setting range is between 0.0 and 50.0 A. • If the HB alarm is set to 0.0, it will always be OFF, and if it is set to 50.0, it will always be ON. The default is 0.0 (always OFF).

  • Page 51: Ssr Failure Detection

    Operating Conditions • Set the control point for which the HS alarm is to be used. The factory setting is for the HS alarm to be disabled for all control points. The HS alarm is set by executing the HB Alarm/HS Alarm Effective Control Point Setting (WU) com- mand.
  • Page 52 SSR failure detection current = Normal SSR leakage current • For example, if the normal SSR leakage current value is 1.0 A, the SSR failure detection current is as follows: SSR failure detection current = 1.0 2 = 2.0 A...

  • Page 53: Troubleshooting

    SECTION 4 Troubleshooting This section describes the troubleshooting procedure and possible errors and remedies when the E5ZE is not operating prop- erly. When performing troubleshooting follow the order in which information is provided in this section. Troubleshooting Procedure ..........

  • Page 54: Section 4 Troubleshooting

    Section 4-1 Troubleshooting Procedure Troubleshooting Procedure If the E5ZE has an error, refer to the following items to find the possible cause of the error and take corrective measures. 1, 2, 3... 1. Indicators Check the operating status of the E5ZE using the indicators.

  • Page 55: Communications Errors

    Section 4-2 4. Troubleshooting Based on Error Symptoms If the cause of the error is still unknown after checking all the previously men- tioned items, find the cause by isolating the symptoms of the error while re- ferring to the tables in this section, and remedy accordingly.

  • Page 56: Communications Errors

    E5ZE Units are turned ON. Unstable signal of the E5ZE, which is generated Initialize the reception buffer of the host device when the E5ZE is turned ON or OFF, is read as at the following stages. data by the host device.

  • Page 57: Temperature Sensing Errors

    Radio transmitter is being used near the E5ZE. Shield the E5ZE. E5ZE is affected by heat radiation from Peripheral Install the E5ZE in a location where it will not be Devices and the temperature of the terminal block affected by heat radiation.

  • Page 58: Temperature Sensing Errors

    1, 2, 3... 1. Connect a 100-Ω resistor between the A and B temperature sensor input terminals and short-circuit the B terminals. 2. If the temperature sensed by the E5ZE is 0.0°C or 32.0°F, the E5ZE is oper- ating normally. Thermocouple 1, 2, 3...

  • Page 59: Temperature Control Errors

    • Replace the heater with one having a larger Heat capacity of the heater is too small. heat capacity. • If more than one heater is used and some are burnt out, replace the heaters. Overheating prevention device for the E5ZE is The set value of the overheating prevention operating.

  • Page 60: Temperature Control Errors

    • Execute auto-tuning. PID constants of the E5ZE are incorrect. • Set the PID constants of the E5ZE to the values suitable to the system. • Set the output limit value of the E5ZE to an...

  • Page 61: Output Errors

    Output Errors Section 4-5 Hunting For troubleshooting problems with connections and settings, refer to the same probable causes and remedies as provided for overshooting and undershoot- ing. Probable cause Remedy Operation Heat capacity of a heater controlling the Use a heater with a heat capacity suited to the temperature of an object is too large for the object.

  • Page 62: Output Errors

    When designating a memory bank with contact Set the E5ZE so that the ON or OFF status of the input, the ON or OFF status of the contact is not contact is kept on hold while designating the kept on hold.

  • Page 63: Hb Alarm And Hs Alarm Errors

    HB Alarm and HS Alarm Errors Section 4-6 HB Alarm and HS Alarm Errors HB Alarm and HS Alarm Errors: Heater Burnout Detection or SSR Failure Detection Function Not Possible Probable cause Remedy Connections Current Transformer is not connected. Connect a Current Transformer to the E5ZE.

  • Page 64: A Specifications

    Max. load resistance: 600 Ω Alarm outputs Cooling control output: 8 points Temperature alarm: Two points (one for alarm 1 and one for alarm 2) for total output of each control point HB alarm (heater burnout detection): One point for total output of each...
  • Page 65 Appendix A Specifications Item Specification –10 to 55 °C (0 to 55 °C for the E5ZE-8jjjD1jB) Ambient operating temperature (with no icing or condensation) Ambient operating humidity 35% to 85% RH –25 to 65 °C (with no icing or condensation)

  • Page 66: Specifications

    E5ZE Characteristics Item Specification Measurement –20°C (lower limit of the setting range) to 20°C (upper limit of the setting range) range –40°F (lower limit of the setting range) to 40°F (upper limit of the setting range) Setting Setting unit range...
  • Page 67 CT input measurement accu- racy HB and HS alarm setting range 0.0 to 50.0 A (in units of 0.1 A) HB and HS alarm setting accu- There is no difference between the CT input measurement accuracy and HB and HS racy alarm setting accuracy.
  • Page 68 Note 1. These alarm mode settings include the standby sequence. °C/°F 2. When DeviceNet is used to set the alarm settings, the upper limit is 3,000.0 (in units of 0.1) 3. The applicable standards for the temperature sensor input types are as follows:...

  • Page 69: B Current Transformer Specifications

    {10 G} max. Weight Approx. 11.5 g Approx. 50 g Accessories None Armatures: Plugs: Note The maximum continuous heater current of the E5ZE is 50 A. Dimensions E54-CT1 E54-CT3 2.36 dia. 12 dia. 5.8 dia. 40 × 40 Two, 3.5 dia.

  • Page 70: C Manually Setting Pid Constants

    Integral operation is used to gradually eliminate the offset of the temperature that is caused by proportional control. Do not set the value of the integral time to too small a value in attempt to quickly eliminate the offset of the tempera- ture.
  • Page 71 Adjustment Adjust the value of the derivative time from the larger value (longer time) to a smaller value (shorter time) to find the optimum derivative time. If there is hunting of the temperature with a short cycle, the derivative time may be set too long and the temperature control response may be too fast.
  • Page 72 Temperature Quick stabilization Slow stabilization Set point Set point Excessive undershooting Time Time The following table shows the tendency of external disturbance response when fuzzy constants are adjusted. Fuzzy constants External disturbance response Excessive Oscillation Stabilization value time Fuzzy strength...

  • Page 73: D Saving Data

    If the E5ZE is turned OFF before the E5ZE completes transmitting the response of the WE command, the temper- ature control data set with the E5ZE may not be saved and when the power is turned ON again a memory error may occur.

  • Page 74: E Hardware Test

    • Temperature sensor input test • Current Transformer (CT) input test Hardware Test Mode Set the FUNCTION switch pins according to the following diagram, so that the E5ZE will be in hardware test mode. Power is OFF. Turn pins 3 to 5 and 8 ON.
  • Page 75 If a contact connecting a memory bank designation input is ON, the MB designation input indicator (MB0 to MB2) corresponding to the contact will be lit. If the MB designation input indicator is not lit, check that the input is wired correctly.
  • Page 76 Procedure 1, 2, 3... 1. While in hardware test mode, set the UNIT or INPUT selector of the E5ZE so that the control output or alarm output will be ON. The relationship between the selectors and the outputs is shown in the following tables.
  • Page 77 The carry current and leakage current of a control point that is measured using CT input are displayed as bar graphs by using the E5ZE indicators. The carry current is the CT input measurement when the control output is turned ON. The leakage current is the CT input measurement when the control output is turned OFF.
  • Page 78 If MB0, MB1, or MB2 is lit, this does not indicate an error. Current Output The E5ZE Current Output Model can be connected to a Power Controller or a Cycle Control Unit to enable more accurate temperature control. Heater voltage Heater voltage 0.2 s (control period)
  • Page 79 Output value: 0% to 100% Current output value: to 20 –0.6 –0 Output with Control Interrupted Output value: Current output value: –0.6 Output with Control Interrupted by Error Output with Temperature Controller error Output value: –16% Current output value: 1±0.5 mA...

  • Page 80: F Available Models

    2. The heater burnout and SSR failure detection function Option (see note 1) of the E5ZE will be invalid if the heating side control out- put of the E5ZE is current output. Heater Burnout and SSR Failure Detection (see note 2) 3.
  • Page 81 E5ZE-8VCA Cooling resistance D1PB 24VDC thermometer Model Number Legend: E5ZE-8jjjjjj Control Point Heater Burnout and SSR Failure Detection Function (Not available with Current Output Models.) Control Method Communications Function Standard control D1: CompoBus/D Heating and cooling control Input Type TC: Thermocouple...

  • Page 82: Revision History

    Multipoint Temperature Controller Operation Manual Revision History A manual revision code appears as a suffix to the catalog number on the front cover of the manual. Cat. No. H076-E3-1 Revision code The following table outlines the changes made to the manual during each revision.

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