Emko Elektronik A.S.. ESM-4435 Instruction Manual
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Emko Elektronik A.S.. ESM-4435 Instruction Manual

48 x 48 1/16 din universal input pid process controller
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ESM-4435 48 x 48 1/16 DIN
Universal Input PID Process Controller
- 4
digits process (PV) and
- Universal process input
- Dual or multi point calibration for
- Configurable ON/OFF, P, PI, PD and PID control forms
- Adaptation of PID coefficients to the system with Auto-tune and
Self-tune
- Manual/Automatic mode selection for control outputs
- Bumpless transfer
- Programmable heating, cooling and alarm functions for control
outputs
4 digits process set (SV) display
(TC, RTD, mV
, V
Voltage / Current input
Instruction Manual. ENG ESM-4435 02 V03 07/13
, mA
)

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Summary of Contents for Emko Elektronik A.S.. ESM-4435

  • Page 1 - Configurable ON/OFF, P, PI, PD and PID control forms - Adaptation of PID coefficients to the system with Auto-tune and Self-tune - Manual/Automatic mode selection for control outputs - Bumpless transfer - Programmable heating, cooling and alarm functions for control outputs Instruction Manual. ENG ESM-4435 02 V03 07/13...
  • Page 2 ABOUT INSTRUCTION MANUAL Instruction manual of ESM-4435 Process Controller consists of two main sections. Explanation of these sections are below. Also, there are other sections which include order information and technical specifications of the device. All titles and page numbers in instruction manual are in “CONTENTS”...

  • Page 3: Table Of Contents

    3.5.4 PROCESS INPUT CONNECTION OF 3-WIRE TRANSMITTERS WITH CURRENT OUTPUT 3.5.5 CONNECTION OF TRANSMITTERS WITH VOLTAGE OUTPUT TO PROCESS INPUT 3.6 GALVANIC ISOLATION TEST VALUES OF ESM-4435 PROCESS CONTROLLER 4.OUTPUT CONNECTION FORMS IN ESM-4435 PROCESS CONTROLLER........Page 4.1 PROCESS OUTPUT CONNECTION 4.2 ALARM OUTPUT -1 RELAY CONNECTION...
  • Page 4 16369 Bursa, TURKEY The manufacturer hereby declares that the product: Product Name : Process Controller Unit Type Number : ESM-4435 Product Category : Electrical equipment for measurement, control and laboratory use Conforms to the following directives : 2006 / 95 / EC The Low Voltage Directive...

  • Page 5: General Specifications

    Some application fields and applications which they are used are below: Application Fields Applications Glass PID Process Control Plastic Petro-Chemistry Textile Automative Machine production industries 1.1 General Specifications ESM-4435 Standard Universal Supply Input 100-240 V , 50/60Hz Power Supply Input Low Voltage (optional) Low Voltage (optional) Supply Input Supply Input...

  • Page 6: Ordering Information

    1.2 Ordering Information All order information of ESM-4435 are BC D FG HI ESM-4435 given on the table at left. User may form (48x48 DIN 1/16) appropriate device configuration from information and codes that at the table and Supply Voltage convert it to the ordering codes.

  • Page 7: Warranty

    1.3 Warranty EMKO Elektronik warrants that the equipment delivered is free from defects in material and workmanship. This warranty is provided for a period of two years. The warranty period starts from the delivery date. This warranty is in force if duty and responsibilities which are determined in warranty document and instruction manual performs by the customer completely.

  • Page 8: Installation

    2.Installation Before beginning installation of this product, please read the instruction manual and warnings below carefully. In package , - One piece unit - Two pieces mounting clamps - One piece instruction manual A visual inspection of this product for possible damage occured during shipment is recommended before installation.

  • Page 9: General Description

    Product Label Front Panel Panel surface IP65 protection (maximum thickness 5mm / 0.2 inch) NEMA 4X 2.2 Dimensions Maximum 5 mm / 0.2 inch ESM-4435 °C °F PSET ASET1 ASET2 Process Controller 48mm/ 1.89 inch 11.5 ± 1 mm /0.45 inch...

  • Page 10: Panel Cut-Out

    2.3 Panel Cut-Out 65 mm/2.56 inch (min) 46 mm/1.81 inch (min)

  • Page 11: Environmental Ratings

    2.4 Environmental Ratings Operating Conditions Operating Temperature : 0 to 50 °C Max. Operating Humidity : 90% Rh (non-condensing) Altitude : Up to 2000m. Forbidden Conditions: Corrosive atmosphere Explosive atmosphere Home applications (The unit is only for industrial applications) 2.5 Panel Mounting 1-Before mounting the device in your panel, make sure that the cut-out is of the right size.

  • Page 12: Installation Mounting Clamp

    2.6 Installation Mounting Clamp The unit is designed for panel mounting. 1-Insert the unit in the panel cut-out from the front side. 2- Insert the mounting clamps to the holes that located top and bottom sides of device and screw up the fixing screws until the unit completely immobile within the panel Montage of the unit to a system must be done with it’s own fixing clamps.

  • Page 13: Electrical Wirings

    3.Electrical Wirings You must ensure that the device is correctly configured for your application. Incorrect configuration could result in damage to the process being controlled, and/or personal injury. It is your responsibility, as the installer, to ensure that the configuration is correct. Parameters of the device has factory default values.

  • Page 14: Electrical Wiring Diagram

    (TC, RTD, Voltage / Current) 0 to 50mV Alarm Output-2 0 to 10V Relay 0 to 20mA Pt-100 Alarm Out-2 5A@250V P/N : ESM-4435 CAT II Process Out 5A@250V Alarm Out-1 5A@250V Supply Voltage Input Process Output 100-240V 15%;+10% ) 50/60Hz...

  • Page 15: View Of The Labels

    3.3 View of the Labels 5A@250V 5A@250V 100-240V PROCESS OUT ALARM OUT-1 50/60Hz-6VA P/N : ESM-4435 CAT II 0 to 50mV 0 to 10V 0 to 20mA ALARM OUT-2 Pt-100 5A@250V...

  • Page 16: Connection Of Device Supply Voltage Input

    3.4 Connection of Device Supply Voltage Input Universal Supply Low Voltage 24 V Low Voltage 48 V Voltage Connection Supply Voltage Input Supply Voltage Input Note-2 Note-2 External External External Fuse Fuse Fuse (24V : 1 A (48V : 1 A (1 A (24V : 1 A...

  • Page 17: Process Input Connection

    3.5 Process Input Connection 3.5.1 TC (Thermocouple) Connection Connect the wires with the polarity as shown in the figure at left. Always use compensation wire corresponding to the thermocouple used. If present, the shield must be connected to a proper ground. Input resistance is greater than 10M 3.5.2 RTD Connection Pt-100...

  • Page 18: Process Input Connection Of Serial Transmitters With Current Output (Loop Powered)

    3.5.3 Process Input Connection of Serial Transmitters with Current Output (Loop Powered) Transmitter connection by using supply Transmitter connection by using external supply voltage on the device voltage source. Transmitter Transmitter External Power Supply Note-1 24 V ±10% 24 V ±10% Max.

  • Page 19: Connection Of Transmitters With Voltage Output To Process Input

    3.5.5 Connection of Transmitters with Voltage Output to Process Input Transmitter connection by using supply Transmitter connection by using external supply voltage on the device voltage source. mV, V mV, V External Power Supply Note-1 24 V ±10% 24 V ±10% Transmitter Transmitter...

  • Page 20: Galvanic Isolation Test Values Of Esm-4435 Process Controller

    3.6 Galvanic Isolation Test Values of ESM- 4435 Process Controller 2000V ( For ESM-4435.1..) 500V ( For ESM-4435.2..) 500V ( For ESM-4435.9..) Ground Supply Input 2000V 2000V Alarm Output-2 Relay 2000V 2000V Process Output Relay 2000V 2000V...

  • Page 21: Output Connection Forms In Esm-4435 Process Controller

    4. Output Connection Forms in ESM-4435 Process Controller 4.1 Process Output Connection Device T Fuse Last Control Element (Contactor) Fuse Load Fuses must be selected according to the applications. If the device Process Output is selected Current Output in order form , then Process Output connection is showen below.

  • Page 22: Alarm Output-1 Relay Connection

    4.2 Alarm Output-1 Relay Connection Device T Fuse Last Control Element (Contactor) Fuse Load Fuses must be selected according to the applications. 4.3 Alarm Output-2 Relay Connection Device T Fuse Last Control Element (Contactor) Fuse Load Fuses must be selected according to the applications.

  • Page 23: Definition Of Front Panel And Accessing To The Parameters

    (for Process Output) LED Led indication of Manual Operation LED indication of °F (for Process Output) LED Fahrenheit Unit LED indication of units other than °C and °F ESM-4435 LED indication of Process status °C Displays Process Value (PV) °F LED indication of...

  • Page 24: Observation Of Software Revision On The Bottom Display When Power Is On

    5.2 Observation of Software Revision on the Bottom Display When Power Is On When the power is applied to the device all led indicators and display segments are momentarily illuminated for testing. Software revision number of the controller is momentarily illuminated on the bottom display. ESM-4435 °C °F PSET...

  • Page 25: Adjustment Of Process And Alarm Set Values

    5.3 Adjustment of Process and Alarm Set Values Process °C °C °C Operation °F °F °F Set Screen Screen PSET ASET1 ASET2 PSET ASET1 ASET2 PSET ASET1 ASET2 For saving Set When SET button is pressed, PSET Set value can be changed v a l u e a n d LED flashes.

  • Page 26: Easy Access Diagram For Program Parameters

    5.4 Easy Access Diagram For Program Parameters Password Main Password °C °C °C °C °F °F °F °F Entering Operation Entering Screen Screen Screen PSET ASET1 ASET2 PSET ASET1 ASET2 PSET ASET1 ASET2 PSET ASET1 ASET2 Confirm the Press “P” button for Press SET/OK button for Enter the password with password with...
  • Page 27 5.4 Easy Access Diagram For Program Parameters PCnF ALn1 ALn2 Genn Password °C °C °C °C °C °F °F °F °F °F Menu Menu Menu Menu Menu PSET ASET1 ASET2 PSET ASET1 ASET2 PSET ASET1 ASET2 PSET ASET1 ASET2 PSET ASET1 ASET2 °C...

  • Page 28: Accessing To The Technician Menu

    5.5 Accessing to the Technician Menu The parameters have been divided into groups according to their functions. Every group has a title and firstly user must determine the title (menu) for accessing to the parameters. Refer to the parameters section for detailed information about parameters. °C °C °C...
  • Page 29 °C PINP CONF Menu °F Configuration parameters of process input PSET ASET1 ASET2 Technician can access to the Technician can access to the former menu by pressing menu following menu by pressing menu changing back button. changing next button °C PID CONF Menu °F PID algorithm parameters...
  • Page 30 °C GENN CONF Menu °F General parameters PSET ASET1 ASET2 Technician can access to the Technician can access to the former menu by pressing menu following menu by pressing menu changing back button. changing next button This menu is not accessible if °C PASS CONF Menu °F...

  • Page 31: Changing And Saving Parameters

    5.6 Changing and Saving Parameters Example-1 : To change Process Input Type parameter Process Input Type parameter is in “PýnP Conf” menu, so PýnP ConF menu must be accessed firstly in order to reach parameter. °C °C °C Technician Operation °F °F °F...
  • Page 32 Process Input Type Selection °C °F means, input type is RTD. PSET ASET1 ASET2 Parameter can be changed with increment and decrement buttons °C Process Input Type °F Selection TC input type is selected PSET ASET1 ASET2 Press Set button to confirm the value and access to the next parameter.
  • Page 33 Example-2 : Changing operation form from “Auto” to “Manual” and adjustment of % output. If operation form is Auto (Close-Loop Control) and there is an output with PID or ON/OFF control form, device controls the process outputs by calculating the % output values automaticaly.
  • Page 34 °C Alarm-1 Set Screen °F ASET1 Led flashes PSET ASET1 ASET2 Press SET button Alarm-2 Set Screen °C ASET2 Led flashes °F PSET ASET1 ASET2 Press SET button Manual Led flashes °C Operation Screen °F %Output value can be changed with increment and decrement buttons.
  • Page 35 Example-3 : To change proportional band parameter Proportional band parameter is in “Pýd Conf” menu, so “Pýd Conf” menu must be accessed firstly. Operation Screen Technician °C °C °C °F °F °F Menu Entering Screen PSET PSET PSET ASET1 ASET2 ASET1 ASET2 ASET1...
  • Page 36 °C PINP CONF Menu °F Configuration parameters of process input PSET ASET1 ASET2 Technician can access to the Technician can access to the former menu by pressing following menu by pressing menu menu changing back button. changing next button PID CONF Menu °C °F PID algorithm parameters...
  • Page 37 Integral Time °C °F Pid CONF Menu PSET ASET1 ASET2 When Menu button is pressed, technician can access to the Press Set button to access to the menu pages. next parameter °C °C °F °F PSET PSET ASET1 ASET2 ASET1 ASET2 For accessing to the other menus, press menu changing...
  • Page 38 Example-4 : To change Voltage / Current Input Calibration Type Selection parameter in “PýnP Conf” menu Parameter is in “PýnP ConF” menu. For accessing to this parameter, technician must access to “PýnP ConF” menu firstly. In this example, changing input type of a device from thermocouple to Voltage / Current and dual point calibration selection is shown.
  • Page 39 °C PINP CONF Menu °F Configuration parameters of process input PSET ASET1 ASET2 Technician can access to the Enter PýnP ConF menu by former menu by pressing pressing Set button menu changing back button. Process Input Type Selection °C °F For accessing to parameter, parameter must be...
  • Page 40 °C Voltage / Current Input °F Calibration Type Selection PSET ASET1 ASET2 Press Set button to confirm the value and access to the next parameter °C Minimum value for °F selectable dual point calibration PINP CONF Menu PSET ASET1 ASET2 When Menu button is pressed, Press Set button to access to the technician can access to the...
  • Page 41 6. Parameters Parameters are divided into two groups. They are Process / Alarm Set parameters and Technician parameters. Technician parameters are grouped into subgroups according to their functions. The subgroups are named as menu pages. 6.1 Process / Alarm SET Parameters Process set value Process set value can be adjusted from minimum value of set scale...

  • Page 42: Parameters

    6.2 Technician Parameters 6.2.1 Selection of PID Tune and Operation Form TUNE SELECTION By selecting one of the methods below, device can determine the PID parameters. Device operates according to the defined PID parameters Auto tune (Limit Cycle Tuning) operation Self tune (Step Response Tuning) operation Auto-Self Tune Self Tune operation is performed, if the conditions are...
  • Page 43 TUNE METHODS There are 2 different methods for determining PID parameters by the device. These are Auto tune ( Limit Cycle Tuning) and Self Tune (Step Response Tuning) methods. Determining of PID parameters with Auto Tune is started in these conditions : 1- By the user in any time, 2- By the device when system gets unstable and starts oscillation If process value is out of Set ±...
  • Page 44 Auto Tune (Limit Cycle Tuning) operation ; if heating or heating-cooling function and PID control form is selected, process control output runs according to heating if cooling function and PID control form is selected, process control output runs according to cooling . Control is unstable While Atun Process...

  • Page 45: Process Output

    PID coefficients are determined Process and system becomes stable. Value Process Set Value ( Start Value + [ ( Set - Start Value) ] Stun Start Value Time Process Output 100% If cooling function and PID control form is selected for the system; If set value is less than process value, process output becomes active till to the Temperature - [(Temperature-Set) / 2] value.
  • Page 46 If Self Tune operation is finished without any problem, device saves new PID parameters to memory and runs. It changes parameter. parameter is it is changed to , if it is , it is changed Self Tune operation is interrupted at half, PID parameters and parameter are not changed, device continues to run with former PID parameters.

  • Page 47: Function Selection For Top And Bottom Display

    BUMPLESS TRANSFER Process output value in manual control is not taken into consideration while passing from manual control to automatic control. New control output that is measured in automatic control is applied to process output. Last %output value is taken output value of manual control and manual control continues while passing from automatic control to manual control.

  • Page 48: Process Input Type And Relevant Parameters With Process Input

    6.2.3 Process Input Type and Relevant Parameters with Process Input Defines the process input type. TC input type selection RTD input type selection Voltage / Current input type selection. Defines type and scale of the thermocouple for TC input. It is active if TC input type is selected.
  • Page 49 Defines type and scale of sensor for RTD input. It is active if RTD input is selected. PT-100 ( -200°C ; 650°C ) or ( -328°F ; 1202°F) PT-100 ( -199.9°C ; 650.0°C ) or ( -199.9°F ;999.9°F) Defines input range and scale of Voltage / Current input.It is active if Voltage / Current is selected.
  • Page 50 Process Set value Po10 Po11 Po09 Po12 Po08 Po13 Po07 Po14 Po15 Po06 Po16 Po05 Po04 Po03 Po02 Po01 Po00 = 0 3.125 6.25 9.375 12.5 15.625 18.75 21.825 28.125 31.25 34.375 37.5 40.625 43.75 46.875 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 0-50 mV range are divided into 16 egual parts.

  • Page 51: Pid Configuration Parameters

    6.2.4 PID Configuration Parameters If any output is configured as heating PID ; parameters are accessible If no output is configured as PID , Only parameters are accessible in PID CONF menu. PROPORTIONAL BAND ( 0.0% , 999.9% ) Full Scale ( ) %.
  • Page 52 MÝNÝMUM CONTROL OUTPUT ( 0.0% , It is % of minimum output. Even as a result of the PID calculation device calculates the %output value less than this parameter, heating or cooling output is active minimum for OLL parameter. CALCULATED OUTPUT GIVEN OUTPUT...

  • Page 53: Inputs

    ANTI-RESET WINDUP (0, SCALE HIGH POINT) While PID operation is running if <= process value <= condition is true, integral value is calculated. If the condition is not true, integral value is not calculated and last calculated integral value is used. Scale High Point : Maximum process input value in Pt-100 and Tc inputs 9999 for fixed dual point calibration used inputs,...
  • Page 54 PID OUTPUT OFFSET (FOR HEATING PID 0.0%, 100.0%) (FOR COOLING PID -100.0%, 0.0%) This parameter is added to “Output %” which is calculated at the end of the PID. Process Output 100% PoFS = 5.0% PoFS = -5.0% Process Value OUTPUT OFFSET RELATED TO PID SET (FOR HEATING PID 0.0%, 100.0%) (FOR COOLING PID -100.0%, 0.0%)
  • Page 55 PROCESS VALUE STABILIZATION ( 1, SCALE HIGH POINT) It is used for controlling if process value oscillates or not when Parameter is <= Process Value <= condition is not true and process value starts to oscillate (as shown in the diagram). If parameter is ,then parameter is selected...
  • Page 56 > 0 Process Output 100% Process Value Set Value Cooling Set Value < 0 Process Output 100% Process Value Cooling Set Value Set Value SENSOR BREAK OUTPUT VALUE (FOR HEATING PID 0.0%, 100.0%) (FOR COOLING PID -100.0%, 0.0%) When sensor breaks, controlling of the process can continue by entering % output value to parameter.

  • Page 57: Process Output Configuration Parameters

    6.2.5 Process Output Configuration Parameters It determines output functions of Process Outputs 0-20 mA output 4-20 mA output If Process Output is chosen Current Output, then parameter is shown Parameter can be adjust only PID mode. If Process Output is chosen Relay Output, then parameter is invisible.

  • Page 58: Alarm Output-1 Configuration Parameters

    6.2.6 ALARM Output-1 Configuration Parameters It determines logic output function for Alarm Output-1 Alarm output Manual / Automatic data output Sensor break alarm output Output is active when the process value is out of the band which is defined with minimum value of operating scale and maximum value of operating scale It determines alarm type for Output-1.
  • Page 59 Deviation Band Alarm Alarm Process Output Process Set - Alarm Set Process Set + Alarm Set Process Value Deviation Range Alarm Process Alarm Output Process Set + Alarm Set Process Set - Alarm Set Process Value Alarm- 1 hysteresis value. it can be adjusted from 0% to 50% of process input scale It is active if logic output function of Alarm Output-1 is alarm output.

  • Page 60: Alarm Output-2 Configuration Parameters

    6.2.7 ALARM Output-2 Configuration Parameters It determines logic output function for Alarm Output-2 Alarm output Manual / Automatic data output Sensor break alarm output Output is active when the process value is out of the band which is defined with minimum value of operating scale and maximum value of operating scale It determines alarm type for Output-2.
  • Page 61 Deviation band alarm Alarm Output Process Process Set + Alarm Set Process Set - Alarm Set Process Value Deviation range alarm Alarm Output Process Process Set + Alarm Set Process Set - Alarm Set Process Value Alarm- 2 hysteresis value. it can be adjusted from 0% to 50% of process input scale It is active if logic output function of Alarm Output-2 is alarm output.

  • Page 62: General Parameters

    6.2.8 General Parameters Minimum value for process set and alarm set values. It is named as low limit of set scale. It can be adjusted from low limit of input selected with parameter parameter. Please refer to Section 6 .2.3 Process Input Type and Relevant Parameters with Process Input for parameter Maximum value for process set and alarm set values.

  • Page 63: Technician Password

    6.2.9 Technician Password It is used for accessing to the technician parameters. It can be adjusted from 0 to 9999. If it is ; there is no password protection while entering to the technician parameters. If it is different from “ 0” and user wants to access to the technician parameters;...

  • Page 64: Failure Messages In Esm-4435 Process Controllers

    7. Failure Messages in ESM-4435 Process Controllers 1 - Sensor failure in analogue inputs. Sensor connection is wrong or °C °F there is no sensor connection. PSET ASET1 ASET2 2 - If value on top display blinks : If analogue input value is less than °C...

  • Page 65: Specifications

    5 - If tuning operation can not be completed in 8 hours, AT led starts to °C °F blink.Blinking can be canceled by pressing Enter button. For details on parameters, refer to Section 6.2.1 PSET ASET1 ASET2 6 - If user does not do anything for 120 seconds °C °C °F...

  • Page 66: Other Information

    Current Input Types : Selectable by parameters 0...20mA , 4...20mA Accuracy : ± 0,25% of full scale for thermocouple, thermoresistance voltage, ± 0,70% of full scale for current. Cold Junction Compensation : Automatically ± 0.1°C/1°C. Line Compensation : Maximum 10 Sensor Break Protection : Upscale Sampling Cycle...

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