E5J Temperature Controller
Operation Manual
Cat. No. Z103-E3-1
Notice:
OMRON products are manufactured for use according to proper procedures by a qualified operator
and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always heed
the information provided with them. Failure to heed precautions can result in injury to people or damage to the product.
!
DANGER
Indicates information that, if not heeded, is likely to result in loss of life or serious
injury.
! WARNING Indicates information that, if not heeded, could possibly result in loss of life or
serious injury.
! Caution
Indicates information that, if not heeded, could result in relatively serious or minor injury, damage to the product, or faulty operation.
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.
The abbreviation “Ch,” which appears in some displays and on some OMRON products, often means
“word” and is abbreviated “Wd” in documentation in this sense.
The abbreviation “PC” means Programmable Controller and is not used as an abbreviation for anything else.
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.
OMRON, 1998
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 from the use of the information contained in this publication.
v
TABLE OF CONTENTS
SECTION 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2
1-3
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2
Sensor and Mode Settings . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-2
2-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3
Settings Before Operation . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2
3-3
3-4
3-5
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameters on Display Level 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameters on Display Level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4
Fuzzy Self-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-2
4-3
Fuzzy Self-tuning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5
Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-2
5-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-2
Error Display and Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7
Event Input Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
Event Input Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8
Heater Burnout Detection . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-2
8-3
8-4
Heater Burnout Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Burnout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring the Current Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Burnout Alarm Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9
Engineering Level Settings . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-2
9-3
Engineering Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engineering Level Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engineering Level Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
2
4
9
10
10
11
17
18
19
20
22
23
27
28
31
32
35
36
37
38
41
42
42
45
46
49
50
50
51
51
55
56
56
58
vii
TABLE OF CONTENTS
SECTION 10
Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
10-2
10-3
10-4
Starting Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions that Prevent Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Force-ending Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Parameters during Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
64
64
64
64
Appendices
A
Dimensions/Mounting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii
65
69
71
About this Manual:
This manual describes the installation and operation of the Thermac E5J 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 E5J Temperature Controller.
Section 1 describes the specifications and basic features of the Thermac E5J Temperature Controller.
Section 2 describes the sensor and mode settings of the Thermac E5J Temperature Controller that are
necessary before turning on the Thermac E5J Temperature Controller.
Section 3 describes the settings of the Thermac E5J Temperature Controller that are necessary before
operating the Thermac E5J Temperature Controller.
Section 4 provides the procedures required to adjust all PID constants using fuzzy self-tuning according
to the characteristics of the device for ideal temperature control.
Section 5 describes the installation and wiring of the Thermac E5J Temperature Controller.
Section 6 describes the troubleshooting of the Thermac E5J Temperature Controller.
Section 7 describes how the event input function of the Thermac E5J Temperature Controller works.
Section 8 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.
Section 9 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.
Section 10 describes how to execute auto-tuning.
The Appendix provides the dimensions and mounting specifications for the various Thermac E5J Temperature Controller Units.
! WARNING Failure to read and understand the information provided in this manual may result in
personal injury or death, damage to the product, or product failure. Please read each
section in its entirety and be sure you understand the information provided in the section
and related sections before attempting any of the procedures or operations given.
ix
SECTION 1
Introduction
This section describes the specifications and basic features of the Thermac E5J Temperature Controller.
1-1
1-2
1-3
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3-1 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3-2 Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
4
4
6
1
Models
1-1
Section 1-2
Features
The basic features of the Thermac E5J 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 according to the controlled device. The Thermac E5J Temperature Controller incorporates a fuzzy self-tuning function, thus allowing ideal temperature control
without any adjustment of the PID constants. The user needs only to set the
E5J to the desired temperature for ideal temperature control.
Auto-tuning
Auto-tuning is also available. It is useful when appropriate results are not
obtained through fuzzy self-tuning. (Refer to Section 10 Auto-tuning.)
Event Input Function
It is possible to select a set point out of a maximum of two set values on the
E5CJ-B and four set values on the E5AJ-B via their event input terminals
from the PCs connected to these Temperature Controllers. The control operation of the E5AJ-B via can be stopped with an event input signal.
Watertight Construction
The E5J can be used in places where water is sprayed onto the E5J, because the front panel of the E5J assures IP54 when the E5J is panelmounted (except for front panel of the E5CJ, which assures IP50). If greater watertightness is required, use the Y92A-N, a dedicated watertight cover (sold
separately).
Advanced PID
The E5J incorporates an advanced PID function, which is also incorporated by
the Thermac X Temperature Controller. The advanced PID function prevents
temperature overshooting the moment the Temperature Controller starts operating, assures a short startup time, and performs ideal temperature control by
quickly responding to external disturbances.
Output Units
The E53-R Relay Unit, E53-Q, E53-Q3, and E53-Q4 Voltage Output Units for
driving SSRs, and E53-C3, E53-C3D, E53-V34, and E53-V35 Linear Output
Unit can be connected to any E5J Temperature Controller (except the E5CJ)
with ease according to the desired output configuration and application.
1-2
Models
The thermocouples and platinum resistance thermometers listed in the following table can be connected to any Thermac E5J Temperature Controller.
Input
Selectable
internally.
Platinum resistance
thermometer
JPt100
Temperature
range (°C)
INPUT
Factory-set to 2 (K)
1300
1000
800
600
400
200
100
0
–100
–200
Setting
no.
2
Pt100
Thermocouple
K
J
T
L
U
1300
N
1300
850
650.0
850
650.0
400.0
400.0
–100
–199.9
–199.9
–200
0.8
1.9
2
–100
–199.9
3
4
5
–199.9
–200
6
7
Models
Section 1-2
E5AJ (Standard Model with Communications Function)
96 X 96mm
Alarm
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
Note
E5AJ-A2HM
1. No heater burnout alarm is output if the E53-C3 Current Output Unit is used
with the E5AJ.
2. The event input function is not incorporated by models that have a communications function.
E5EJ (Standard Model with Communications Function)
48 X 96mm
Alarm
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
Model
Replaceable Output Unit (sold separately)
Communications function
---
E5EJ-A2HB
RS-232C
E5EJ-A2H01
RS-422
E5EJ-A2H02
RS-485
E5EJ-A2H03
Communications Board add-on model
Note
E5EJ-A2HM
1. No heater burnout alarm is output if the Linear Output Unit is used with the
E5EJ.
2. The event input function is not incorporated by models that have a communications function.
3
Specifications
Section 1-3
E5CJ (Simple and Standard Models)
48 X 48mm
Type
Simple model type
Alarm
---
Heater burnout alarm
---
Event input
---
Model
Control output
Standard model
type
2 replay output points with the same
common. (see note 1)
Yes (see note)
Relay output
E5CJ-R
E5CJ-R2
1 point (set point
selection)
E5CJ-R2HB
Voltage output
E5CJ-Q
E5CJ-Q2
E5CJ-Q2HB
Current output
E5CJ-C
E5CJ-C2
E5CJ-C2B
Note No heater burnout alarm is output if a current control output is used.
Communications Boards
Communications
Model
RS-232C
E53-J01
RS-422
E53-J02
RS-485
E53-J03
Note For details, refer to the E5AJ/E5EJ Communications Manual (Z102).
1-3
Specifications
1-3-1 Ratings
E5J
Item
Specification
Supply voltage
100 to 240 VAC, 50 or 60 Hz
Operating voltage range
Power consumption
85 to 110% of supply voltage
E5AJ
E5EJ
E5CJ
Input
CT input
Control output
E5AJ/E5EJ
E5CJ
Relay output
SPST-NO, 3 A at 250 VAC (resistive load)
Voltage output
20 mA at 12 VDC (with short-circuit protection)
Current output
4 to 20 mA DC with a load of 600 Ω max. and a
resolution of approx. 2600
ON/OFF or advanced PID with fuzzy self-tuning and
auto-tuning
2 SPST-NO relay output points, 3 A at 250 VAC
(resistive load)
2 SPST-NO relay output points (with the same common),
1 A at 250 VAC (resistive load)
Digital setting with Up Key and Down Key
E5AJ/E5EJ
E5CJ
Setting method
4
10 VA (at 24 VAC)
10 VA (at 100 VAC) to
6 W (at 24 VDC)
C)
14 VA (at 240 VAC)
10 VA (at 100 VAC) to
14 VA (at 240 VAC)
10 VA (at 100 VAC) to
12 VA (at 240 VAC)
Thermocouples (K, J, T, L, U, and N) and platinum
resistance thermometers (JPt100 and Pt100)
Dedicated CT (E54-CT1 or E54-CT3)
Replaceable Output Unit (sold separately)
Control mode
Alarm output
24 V AC/DC,
50 or 60 Hz
Specifications
Section 1-3
Item
Indication method
Specification
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
mm)
Event input
Contact input: ON: 1 kΩ max. OFF: 100 kΩ min.
No-contact input: ON: residual voltage of 3 V max; OFF:
current leakage of 1 mA max.
• Key protect
Other function
• Cooling operation/Heating operation
• Heater burnout alarm
Model with event input (E5J-B)
• Set point selection (set point x 2)
• RUN/STOP (E5AJ-B and E5EJ-B only)
Ambient operating temperature
–10°C to 55°C (with no condensation)
Ambient operating humidity
35 to 85%
Storage temperature
–25°C to 65°C (with no condensation)
Output Units
Model
Specification
E53-R Relay Output Unit
SPDT (SPST-NO when used with the
E5J), 5 A at 250 VAC (resistive load)
E53-Q Voltage Output Unit
NPN, 40 mA at 12 VDC (with
short-circuit protection)
E53-Q3 Voltage Output Unit
NPN, 20 mA at 24 VDC (with
short-circuit protection)
E53-Q4 Voltage Output Unit
PNP, 20 mA at 24 VDC (with
short-circuit protection)
E53-C3 Linear Output Unit
4 to 20 mA DC with a load of 600 Ω
max. (with a resolution of approximately
2600 when used with the E5J) (see
note)
E53-C3D Linear Output Unit
0 to 20 mA DC with a load of 600 Ω
max. (with a resolution of approximately
2600 when used with the E5J)
E53-V34 Linear Output Unit
0 to 10 VDC with a load of 1 kΩ min.
(with a resolution of approximately 2600
when used with the E5J)
E53-V35 Linear Output Unit
0 to 5 VDC with a load of 1 kΩ min.
(with a resolution of approximately 2600
when used with the E5J)
Note The E53-C cannot be used.
Current Transformer (CT)
Item
Specification
Maximum continuous heater current
50 A
Dielectric strength
1,000 VAC
Vibration resistance
50 Hz, approx. 98 m/s2 (10G)
Weight
E54-CT1: Approx. 11.5 g
E54-CT3: Approx. 50 g
5
Specifications
Section 1-3
1-3-2 Characteristics
E5J
Item
Specification
Indication accuracy
±0.5% or ±1°C whichever is larger ± 1 digit max.
Hysteresis (for ON/OFF control)
Thermocouple K, T, or N at a temperature of –100°C; thermocouple U at ± 2°C ± 1
digit max.
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)
Integral time
0 to 3999 s (in units of 1 s)
Derivative time
0 to 3999 s (in units of 1 s)
Control period
Relay or voltage output:1 to 99 s (in units of 1 s)
Manual reset value (I = 0)
0.0 to 100.0% (in units of 0.1%)
Alarm setting range
With K, J, L, or N input: –1999 to 9999° C/°F (in units of 1°C/°F)
With JPt100, Pt100, T, or U input: –199.9 to 999.9° C/°F (in units of 0.1°C/°F)
Sampling period
500 ms
Output refresh period
500 ms
Display refresh period
500 ms
Insulation resistance
20 MΩ min. at 500 VDC (measured with an Output Unit)
Dielectric strength
Malfunction
Destruction
Malfunction
2000 VAC, 50/60 Hz for 1 min. between charged terminals different from each other
in polarity
10 to 55 Hz, 9.8 m/s2 (1G) 10 min. in X, Y, and Z directions
10 to 55 Hz, 19.6 m/s2 (2G) 2 hr. in X, Y, and Z directions
196 m/s2 (20G) 3 times each in 3-axis 6 directions (98 m/s2 (10G) for the relay)
Destruction
294 m/s2 (30G) 3 times each in 3-axis 6 directions
E5AJ
Approx. 360 g; mounting bracket: approx. 65 g
E5EJ
Approx. 280 g; mounting bracket: approx. 65 g
E5CJ
Approx. 170 g; adapter: approx. 10 g
Vibration
resistance
i
Shock resistance
Weight
Enclosure rating
Front panel:
E5AJ/E5EJ: IEC standard IP54
E5CJ: IEC standard IP50 (see note 1)
Rear case:
IEC standard IP20
Terminals:
IEC standard IP00
Non-volatile memory
Memory Protection
EMC
Emission Enclosure:
Emission AC Mains:
Immunity ESD:
EN55011 Group 1 class A
EN55011 Group 1 class A
EN61000-4-2: 4 kV contact discharge (level 2)
8 kV air discharge (level 3)
Immunity RF-interference:
ENV50140: 10 V/m (amplitude modulated,
80 MHz to 1 GHz) (level 3)
10 V/m (pulse modulated,
900 MHz)
Immunity Conducted Disturbance: ENV50141: 10 V (0.15 to 80 MHz) (level 3)
Immunity Burst:
EN61000-4-4: 2 kV power-line (level 3)
2 kV I/O signal-line (level 4)
Approved standards
UL1092, CSA C22.2 No. 142
Conforms to EN50081-2, EN50082-2, EN61010-1 (IEC1010-1) (see note 2)
Conforms to VDE0106/part 100 (Finger Protection), when the separately-ordered
terminal cover is mounted.
Note
1. The model numbers of the exclusive watertight covers conforming to IP66,
NEMA4 are as follows:
For E5AJ: Y92A-96N; For E5CJ: Y92A-48N; For E5EJ: Y92A-49N
2. Basic insulation is between the input and output.
6
Specifications
Section 1-3
Output Unit
Model
Life expectancy
E53-R Relay Output Unit
Heater Burnout Alarm
Mechanical
10,000,000 times min.
Electrical
100,000 times min.
Item
Single-phase 50 A VAC (see note 1)
Heater current value display accuracy
±5% FS ± 1 digit max.
Heater burnout alarm setting range
0.1 to 49.9 A (in units of 0.1 A)
(see note 2)
190 ms (see note 3)
Min. detection ON time
Note
Model with
Communications Function
Specification
Max. heater current
1. Use the K2CU-FA-GS (with gate input terminals) for the detection of
three-phase heater burnout.
2. The heater burnout alarm is always OFF if the alarm is set to 0.0 A and always ON if the alarm is set to 50.0 A.
3. No heater burnout detection or heater current value measurement is possible if the control output is ON for less than 190 ms.
Refer to the E5AJ/E5EJ Communications Manual (Z102) for details.
Item
Specification
Interface
RS-232C, RS-422, RS-485
Communications method
Half duplex
Synchronization method
Start-stop synchronization
(non-synchronization)
1200, 2400, 4800, 9600, and 19200 bps
Communications speed
Communications
item
Writing to
Thermac J
Set point, alarm value, heater burnout alarm
value, proportional band, derivative time,
integral time, and input shift value
Reading from
Thermac J
Process value, set point, alarm value, heater
burnout alarm value, heater current value,
proportional band, derivative time, integral
time, output value, input shift and error code
7
SECTION 2
Sensor and Mode Settings
This section describes the sensor and mode settings of the Thermac E5J Temperature Controller that are necessary before
turning on the Thermac E5J Temperature Controller.
2-1
2-2
2-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3-1 Internal Switch Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3-2 Input Type Selector Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3-3 Alarm Mode Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3-4 Standby Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3-5 Function Selector Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3-6 Key Protection Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
11
11
12
13
14
14
15
9
Output Units
2-1
Section 2-2
Disassembly
Before turning on the E5J, set its sensor type and control mode with the internal selectors. Refer to the following illustrations for disassembling the E5J to
access the internal switch settings.
Hook
Press the hook and
pull the front panel.
After setting the internal switches, insert the internal mechanism into the case
until the front panel snaps with the hook.
2-2
Output Units
Select the Output Unit according to the application and mount the Output Unit
into the socket on the E5J PCB of the as shown in the following illustration. The
E5CJ does not require an Output Unit. Refer to 1-3 Specifications for the output
ratings of the E5J.
Bracket
Output Unit
Socket
Output Units
The following Output Units are available.
Model
Rating
E53-R Relay Output Unit
SPDT, 5 A at 250 VAC (resistive load)
E53-Q Voltage Output Unit
E53-C3 Linear Output Unit
NPN model, 40 mA at 12 VDC (with short-circuit
protecting circuit)
NPN model, 20 mA at 24 VDC (with short-circuit
protecting circuit)
PNP model, 20 mA at 24 VDC (with short-circuit
protecting circuit)
4 to 20 mA DC with a load of 600 Ω max.
E53-C3D Linear Output Unit
0 to 20 mA DC with a load of 600 Ω max.
E53-V34 Linear Output Unit
0 to 10 VDC with a load of 1 kΩ min.
E53-V35 Linear Output Unit
0 to 5 VDC with a load of 1 kΩ min.
E53-Q3 Voltage Output Unit
E53-Q4 Voltage Output Unit
After mounting the Output Unit, be sure to secure it with the mounting bracket
provided with the Output Unit.
If the E53-C3, E53-C3D, E53-V34, and E53-V35 Linear Output Unit is used for
control output, no heater burnout alarm is available.
Each Voltage Output Unit is used for driving an SSR as shown in the following
illustrations.
10
Internal Switch Settings
Section 2-3
NPN Model: E53-Q (40 mA at 12 VDC) and E53-Q3 (20 mA at 24 VDC)
+
LOAD
SSR
+
INPUT
–
–
+
+
PNP Model: E53-Q4 (20 mA at 24 VDC)
LOAD
SSR
INPUT
–
2-3
–
Internal Switch Settings
2-3-1 Internal Switch Positions
E5AJ
Top view
ALM2
Alarm mode selector 2
ALM1
Alarm mode selector 1
PROTECT
Key protection
switch
INPUT
Input type
selector
Bottom view
ALL
OFF
SP
FUNCTION
Function selector
E5EJ
Top view
ALM2
Alarm mode selector 2
PROTECT
ALL
Key protection
switch
OFF
ALM1
Alarm mode
SP
selector 1
INPUT
Input type selector
FUNCTION
Function selector
11
Internal Switch Settings
Section 2-3
E5CJ
ALM2
Alarm mode selector 2
Top view
Bottom view
PROTECT
Key protection
switch
ALM1
Alarm mode selector 1
INPUT
Input type selector
SP
OFF
FUNCTION
Function selector
ALL
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). Refer to the following table for the selection
of the desired sensor.
INPUT
Selector no.
Input
Set temperature range
°C
°F
Specified temperature range
°C
°F
0, 8
JPt100
–199.9 to 650.0
–199.9 to 999.9
–199.9 to 735.0
–199.9 to 999.9
1, 9
Pt100
–199.9 to 650.0
–199.9 to 999.9
–199.9 to 735.0
–199.9 to 999.9
2
K
–200 to 1300
–300 to 2300
–350 to 1450
–560 to 2560
3
J
–100 to 850
–100 to 1500
–195 to 945
–260 to 1660
4
T
–199.9 to 400.0
–199.9 to 700.0
–199.9 to 460.0
–199.9 to 790.0
5
L
–100 to 850
–100 to 1500
–195 to 945
–260 to 1660
6
U
–199.9 to 400.0
–199.9 to 700.0
–199.9 to 460.0
–199.9 to 790.0
7
N
–200 to 1300
–300 to 2300
–350 to 1450
–560 to 2560
Note The resistance of the JPt100 at a temperature of 100°C is 139.16 Ω and that of
the Pt100 at a temperature of 100°C is 138.50 Ω.
1, 2, 3...
1. To use Fahrenheit, set function selector 4 to ON, which is usually set to OFF.
2. Insert the internal mechanism into the case.
3. Turn on the E5J so that d-u will be displayed on the process value display.
Then press the Up Key so that f will be displayed on the set value display.
4. Turn off the power in two seconds.
5. Draw the internal mechanism from the case and set function selector 4 to
OFF and turn on the E5J.
12
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 following table for the selection of the desired alarm mode.
ALM2
Selector
no.
0
1
Alarm mode
ALM1
Alarm output
Positive alarm set
value
OFF
No alarm function
X X
Upper and lower limit
alarm (deviation)
Setting range
Negative alarm set
value
--Always ON
–1999 to 9999 or –199.9
to 999.9 (the decimal
position varies with the
input type)
SP
2
X
Upper limit alarm
(deviation)
X
SP
3
Lower limit alarm
(deviation)
SP
X
X
SP
SP
X X
Always OFF
4
Upper and lower limit
range alarm (deviation)
5
Upper and lower limit
alarm with standby
sequence (deviation)
X X
Upper limit alarm with
standby sequence
(deviation)
X
SP
6
7
SP
Absolute value upper
limit alarm
9
Absolute value lower
limit alarm
X
SP
Lower limit alarm with
standby sequence
(deviation)
8
Always OFF
SP
X
X
SP
SP
X
X
0
0
X
X
0
0
If the alarm mode switch is set to 1 to 7, the alarm value is set with the deviation
width from the set point as shown in the following diagram.
Alarm value
10°C/°F
Set point (SP)
100°C/°F
If the alarm mode switch is set to 8 or 9, the alarm value is set with the absolute
value from 0°C/°F as shown in the following diagram.
Alarm value
110°C/°F
0°C/°F
13
Internal Switch Settings
Section 2-3
2-3-4 Standby Sequence
The alarm output is ON the moment the E5J 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. The following diagram shows the operation of the E5J in lower limit alarm mode with a standby sequence.
Standby sequence releasing
point
OFF point due to
alarm hysteresis
Alarm point
Alarm output
It is possible to change the alarm hysteresis (set to 0.2°C before shipping) on the
engineering level.
2-3-5 Function Selector Settings
All the function selector pins are factory-set to OFF.
ON
OFF
To set these pins to
ON, use a small flatblade screwdriver.
FUNCTION
Refer to the following table for function switch setting.
Pin no.
1
Output
Cooling operation (Normal)
ON
operation
Heating operation (Reverse)
OFF
Control
ON/OFF control
mode
Level
2
3
4
---
---
---
---
ON
See note
Advanced PID
---
OFF
ON
Advanced PID with fuzzy self-tuning
---
OFF
OFF
Engineering level
---
---
---
ON
Normal operation
---
---
---
OFF
Note The E5J will be in ON/OFF control mode regardless of the setting of pin 3 if pin
2 is set to ON.
Output Operation (Pin 1)
Heating Operation
If pin 1 of the E5J is set to OFF, when the process temperature is lower than the
set point, the E5J will operate so that the heater output will increase.
Cooling Operation
If pin 1 of the E5J is set to ON, when the process temperature is higher than the
set point, the E5J will operate so that the output of cooling water will increase.
Control Mode (Pins 2 and 3)
ON/OFF Control
The ON/OFF control is also called two-position operation.
Advanced PID
Set the E5J in this mode for P, PI, or PD control or if the most suitable PID
constants for the controlled device are already known.
Advanced PID with Fuzzy
Self-tuning
Set the E5J in this mode so that Fuzzy self-tuning adjusts the PID constants to
the most suitable values according to the controlled device for ideal temperature
control. Refer to Section 4 Fuzzy Self-tuning for details.
Level (Pin 4)
Set pin 4 to ON if it is necessary to change any parameter on the engineering
level. Set this pin to OFF for normal operation.
14
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.
SP
OFF
ALL
PROTECT
Mode
Protection
SP
Prohibits all set value changes except the set point. The Level
Key is not available. The Down Key and Up Key are available
only for set point setting.
OFF
All keys are available.
ALL
Prohibits all set value changes. The Level Key, Down Key, and
Up Key are not available.
15
SECTION 3
Settings Before Operation
This section describes the settings of the Thermac E5J Temperature Controller that are necessary before operating the
Thermac E5J Temperature Controller.
3-1
3-2
3-3
3-4
3-5
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameters on Display Level 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameters on Display Level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
19
20
22
23
17
Section 3-1
Nomenclature
3-1
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.
Stop indicator
Lit when the E5J is not operating.
The E5CJ does not incorporate this
indicator.
Output indicator
Lit when the control output is ON.
This indicator is, however, not lit
when the E5J has a current output.
Level Key
Press for 1 s minimum to change levels to set different groups of parameters.
Display Key
Use this key when shifting the
display to the next parameter.
Process Value (PV) display
Displays not only the process
value but also indicates the parameter being displayed on the
SV display and error messages.
Set Value (SV) display
Displays the set temperature
and other parameters.
Alarm 1 indicator
Lit when alarm output 1 is ON.
Alarm 2 indicator
Lit when alarm output 2 is ON.
Heater burnout alarm
Lit when there is heater burnout.
Once heater burnout is detected, the
alarm output will be on hold.
Down Key and Up Key
The Down Key, when pressed, decreases the set temperature or other parameters. The value successively decreases
when the Down Key is held down for 1 s minimum. The Up
Key, when pressed, increases the set temperature or other
parameters. The value successively increases when the Up
Key is held down for 1 s minimum. The value set will be effective on pressing the Display Key or Level Key or 2s after it
is set if Display Key or Level Key is not pressed.
Note Refer to the E5AJ/E5EJ Communications Manual for the operation of E5J
models incorporating a communications function.
18
Setting Flowchart
3-2
Section 3-2
Setting Flowchart
The Thermac E5J 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 E5J after inputting all the set values, turn the
power supply to the Temperature Controller off and then on again.
All parameters for the E5J Temperature Controller are divided into three levels
according to how frequently they are used.
Display Level 0
Parameters that are changed frequently are ranked as display level 0 parameters.
Display level 1
Parameters that are not changed frequently are ranked as display level 1 parameters.
Engineering Level
Parameters that are changed with only a few applications are ranked as engineering level parameters.
OFF
ON
Pin 4 of the function selector
Level Key
Press for 1 s min.
Display level 0
Display level 1
Level Key
Press for 1 s min.
Set point setting
Alarm 1 setting
Alarm 2 setting
Output display
Control period setting
Hysteresis setting
Set point 0 setting
Set point 1 setting
(Set point 2 setting)
(Set point 3 setting)
(Input shift value setting)
Heater current value display
Heater burnout alarm setting
Proportional band setting
Integral time setting
Derivative time setting
Manual reset value setting
Each parameter is set with the Up Key or Down
Key. Each value set will be effective on pressing
the Display Key or Level Key or 2 s after it is selected if Display Key or Level Key is not pressed.
No value can be, however, changed when the
key protection switch is ON.
The parameters in parentheses are changed if their initial
values are changed on the engineering level.
Engineering level
°C/°F selection
Stable range
Alpha
Automatic return of display mode
Standby sequence reset method
Input shift display selection
Alarm 1 hysteresis
Alarm 2 hysteresis
Set point lower limit
Set point upper limit
Event input 2 function selection
Refer to Section 9 Engineering Level
Settings for details on each parameters
on the engineering level and how to
change them.
19
List of Parameters
3-3
Section 3-3
List of Parameters
Display Level 0
Display
Name
Setting range
Setting
before
shipping
Remarks
---
Process value
display and set
point setting
Set point lower limit
to set point upper
limit (°C/°F)
0
The present set point is
displayed and can be
changed if the E5J
incorporates an event input
function
AL-1
Alarm set value 1
–1999 to 9999 °C/°F
0
Not displayed if alarm mode
switch 1 is set to 0.
0
Not displayed if alarm mode
switch 2 is set to 0.
The decimal position
varies with the kind
of input.
AL-2
Alarm set value 2
–1999 to 9999 °C/°F
The decimal position
varies with the kind
of input.
To go to the next level, press the Level Key for 1 s min.
Note The values shown in Fahrenheit are applicable only for E5J--F Models.
Display Level 1
Display
Name
Setting
before
shipping
Remarks
0
Output value
display
0.0 to 100.0 %
CP
Control period
1 to 99 s
20
Displayed and can be set if
the E5J in PID control
operation has relay control
output or voltage control
output.
HYS
Hysteresis
0.1 to 999.9 °C/°F
1.0 (1.8)
Displayed and can be set
when the E5J is in ON/OFF
control operation.
SP-0
Set point 0
Set point lower limit
to set point upper
limit (°C/°F)
0
For models incorporating an
event input function.
SP-1
Set point 1
Set point lower limit
to set point upper
limit (°C/°F)
0
For models incorporating an
event input function.
SP-2
Set point 2
Set point lower limit
to set point upper
limit (°C/°F)
0
For models incorporating an
event input 2 function.
Set point lower limit
to set point upper
limit (°C/°F)
0
SP-3
in-S
20
Setting/Display
Range
Set point 3
Input shift value
–199.9 to 999.9 °C/°F 0.0
Displayed and can be set if
the default value is changed
on the engineering level.
For models incorporating an
event input 2 function.
Displayed and can be set if
the default value is changed
on the engineering level.
Displayed and can be set if
the default value is changed
on the engineering level.
List of Parameters
Section 3-3
Display
Name
Ct
Hb
Heater current
value display
Heater burnout
alarm value
Setting/Display
Range
Setting
before
shipping
0.0 to 55.0 A
If the current exceeds
55.0 A, ffff will be
displayed on the set
value display.
0.0 to 50.0 A
0.0
0.0:
Always OFF
50.0: Always ON
Remarks
For models incorporating a
heater burnout alarm.
Nothing is displayed if the
E5J has current control
output.
For models incorporating a
heater burnout alarm.
Nothing is displayed if the
E5J has current control
output.
Displayed and can be set
when the E5J is in
advanced PID operation.
P
Proportional band
0.1 to 999.9 °C/°F
8.0 (14.4)
i
Integral time
0 to 3999 s
233
Displayed and can be set
when the E5J is in
advanced PID operation.
40
Displayed and can be set
when the E5J is in
advanced PID operation.
50.0
Displayed and can be set if
the integral time is set to 0
when the E5J is in
advanced PID operation.
8.0
0: No integral
operation
d
Derivative time
0 to 3999 s
0: No derivative
operation
oFr
Manual reset value
0.0 to 100.0 %
Note The value in the parentheses is the E5J--F setting before shipping.
21
Parameters on Display Level 0
3-4
Section 3-4
Parameters on Display Level 0
The value set before
shipping appears
(Set point setting)
Displays when the E5J incorporates
an alarm function (see note).
(Alarm 1 setting)
Displays when the E5J 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 E5J does
not incorporate any alarm.
Set Point Setting (°C or °F)
It is possible to alter the present set point (SP0 or SP1).
al1 and al2 (°C or °F)
The alarm mode is factory-set to the upper limit alarm (deviation). It is possible to
change the alarm mode with the alarm mode selector. Refer to 2-3-3 Alarm
Mode Setting. The alarm value can be set with the deviation width or absolute
value according to the alarm mode.
Deviation alarm
Upper and lower limit alarm, upper limit
alarm, lower limit alarm and upper and
lower limit range alarm.
Set with the deviation width from
the set point
Alarm value
10°C/°F
Absolute value alarm
Absolute value upper limit alarm and
absolute value lower limit alarm.
Set with the absolute value from 0°C/°F.
Alarm value
110°C/°F
0°C/°F
Set point (SP) 100°C/°F
22
Parameters on Display Level 1
3-5
Section 3-5
Parameters on Display Level 1
The value set before
shipping appears
(Output value display)
Displays when the E5J in PID control
operation has a relay or voltage output.
(Control period setting)
Displays when the E5J is in ON/
OFF control operation.
(Hysteresis setting)
Displays if the E5J has an
event input.
(Set point 0 setting)
(Set point 1 setting)
Displays only if the event input 2
function is used for set point selection (see note 1).
(Set point 2 setting)
(Set point 3 setting)
Displays if the input shift value display is selected (see note 1).
(Input shift value setting)
Displays if the heater burnout
alarm function is selected. (see
note 2).
(Heater current value
display)
(Heater burnout alarm
value setting)
Displays when the E5J in advanced PID operation.
8.0
(Proportional
band setting)*
*In case of °F:
14.4
(Integral time setting)
(Derivative time setting)
Displays if I is 0.
(Manual reset value
setting)
Note
1. Displayed if the initial value is changed on the engineering level.
2. Not displayed if current output is used as control output or a model with no
heater burnout alarm function is used.
23
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 period is the period required by the E5J to turn ON and OFF its relay output or voltage output. The ON period increases in proportion to the output value. If the control period is short, smooth control operation will be possible although a short
control period shortens the life of the relay if relay output is used. Therefore, the
control period should not be less than 20 s if relay output is used. The following
are output examples with an output value of 50.0 %.
5s
10 s
ON
ON
OFF
OFF
Control period: 10 s
hys Hysteresis Setting (°C
or °F)
Control period: 20 s
It is possible to set the hysteresis for the E5J in ON/OFF control operation within a range of 0.1° to 999.9°C/°F.
Hysteresis
Heating
control
(Reverse)
ON
OFF
Low temperature
Set point
High temperature
Hysteresis
Cooling
ON
control
OFF
(Normal)
Low temperature
Set point
High temperature
sp0, sp1, sp2, and sp3
(E5J-B Only)
It is possible to set sp-0 (set point 0), sp-1 (set point 1), sp-2 (set point 2), and sp-3
(set point 3) all in Celsius or Fahrenheit regardless of the set point presently selected. To select the set point, open or short-circuit terminals EV1 and EV2. Refer to Section 7 Event Input Function for details.
in-s Input Shift Value
It is possible to set the input shift value within a range of –199.9° to 999.9°C/°F.
When an input shift value is set, the process value will be the input value added
with the shift value.
Example
Input
100°C
Input shift value
Process value
0 (no compensation)
100°C
10.0 (compensation value)
110°C
–10.0 (compensation value)
90°C
After the input shift value is set, the it is effective even if the input shift value display is turned off on the engineering level.
ct Heater Current Value
Display (E5J-H Only)
It is possible to set the heater current value within a range of 0.0 to 55.0 A. If the
current value exceeds 55.0 A, ffff will be displayed on the set value display.
The heater current will be processed and displayed if the control output is ON.
hb Heater Burnout Alarm
Value Setting (E5J-H
Only)
It is possible to set the heater burnout alarm value within a range of 0.0 to 50.0 A,
which will be used to detect heater burnout. If the heater burnout alarm value is
set to 0.0 A, the heater burnout alarm output will be always OFF. If the heater
burnout alarm value is set to 50.0 A, the heater burnout alarm output will be always ON. Refer to Section 8 Heater Burnout Detection for details.
When the E5J is in advanced PID with fuzzy self-tuning mode, the following
parameters (p, i, d, ofr) will not be displayed (i.e., there is no need to set the
following parameters). The fuzzy self-tuning always adjusts the PID constants to
the most suitable values according to the characteristics of the controlled device.
24
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.
ofr Manual Reset Value
Setting
It is possible to set the necessary output value when the E5J is in constant operation within a range of 0.0% to 100.0%. The E5J will be balanced with a deviation between the set point and process value in P or PD control mode. This
deviation is called offset. The offset can be removed by changing the manual
reset value.
25
SECTION 4
Fuzzy Self-tuning
This section provides the procedures required to adjust all PID constants using fuzzy self-tuning according to the characteristics of the device for ideal temperature control.
4-1
4-2
4-3
Fuzzy Self-tuning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1-1 Step Response Tuning (SRT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1-2 Disturbance Tuning (DT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1-3 Hunting Tuning (HT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3-1 Stable Value, Stable Range, and Stability Judgement Time . . . . . . . . . . . . . . . . .
4-3-2 Hunting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3-3 Characteristics and Characteristics Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3-4 External Disturbance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3-5 Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3-6 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
29
30
31
32
32
33
33
33
33
34
27
Section 4-1
Fuzzy Self-tuning Operation
4-1
Fuzzy Self-tuning Operation
The fuzzy self-tuning function has three features, step response tuning (SRT),
disturbance tuning (DT), and hunting tuning (HT).
4-1-1 Step Response Tuning (SRT)
SRT is used to obtain all PID constants using a step response method when the
Temperature Controller starts operations.
SRT is also used when the set point changes value exceeding a set range while
the Temperature Controller is operating. After SRT has been executed, no SRT
will be executed the next time the Temperature Controller starts operating, unless the set point has been changed.
Set point
P X 1.27
Max. temperature slope R
Tuning at startup
Dead time L
Output (%)
100
100% imposed
step-wise control
amount.
In step response tuning, control is completely imposed stepwise to measure the maximum temperature slope (R) and
dead time (L), and the most ideal PID constants for the device are obtained from R and L.
Advanced PID
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.
Dead time will be measured from the time the Temperature Controller starts
operating. If a load such as a heater is turned on after the Temperature Controller is turned on, dead time longer than the actual value will be measured and
inappropriate PID constants will be obtained. If an extremely large amount of
dead time is measured, the control amount will be set to 0% for a short period of
time before being returned to 100%, and the constants will then be retuned.
Retuning is performed only for large amounts of dead time, so be sure to follow
the precaution given above when starting operation.
28
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
starts operating
At the time set point is changed
1) The set point at the time the
Temperature Controller starts operating
is different from the set point used at
the time SRT was last executed (see
note).
1) The new set point is different from
the set point used at the time SRT
was executed last (see note).
2) The difference between the set point
and the process value at the time the
Temperature Controller starts operating
is larger than the present proportional
band value (P) x 1.27 + 4.
3) The process value at the time the
Temperature Controller starts operating
is smaller than the set point in reverse
operation and larger than the set point
in normal operation.
2) The set point changing range is
larger than the present
proportional band value (P) x 1.27
+ 4.
3) The process value is in stable
condition before the set point is
changed.
4) A larger set point value is set in
reverse operation and a smaller
set point is set in normal operation.
Note The last SRT-executed set point is set to 0 before shipping and when changing
from advanced PID control to advanced PID control with fuzzy self-tuning.
Imposition Completion
Condition of Step Control
Amount
In order to prevent overshooting, the step controlled amount must be imposed
continuously only while the present deviation is the same as or greater than the
value obtained from the proportional band (P)1.27. The step control will not be
applied when the deviation becomes smaller than this value.
PID Constant Refreshing
Conditions
If the step control amount is applied before the maximum temperature slope (R)
is obtained, SRT will not renew any PID constant. If the proportional band obtained from the R and L values that were measured before the imposition had
been completed is larger than the present proportional band, the PID constants
will be renewed because the measured value is in the direction towards the suitable proportional band value, and the set point at that time will be the SRTexecuted set point.
4-1-2 Disturbance Tuning (DT)
DT is used to measure the control waveform and adjust the PID constants when
the measured temperature becomes unstable. When there are control characteristic changes after the PID constants are refreshed with SRT or when the PID
constants are not suitable to the object to be controlled because SRT was not
executed, the PID constants will be adjusted with DT.
DT at the Time of Operation
Start and Set Value Change
If there is overshooting at the time the Temperature Controller restarts operating
after SRT has been executed, DT adjusts the PID constants so that the set point
response waveform will be as close as possible to the most ideal response waveform after it is deemed that there has been a characteristics change in the control system.
Stable range (set to 15.0°C before shipping)
Set point
Stability judgement time
The set point response waveform
at the time the Temperature Controller restarts operation will be
closer to the most ideal response
waveform.
Measurement of
set point response
waveform
PID before tuning
PID after tuning
29
Section 4-1
Fuzzy Self-tuning Operation
After the process value reaches the set point and becomes stable, if the process
value is disturbed and the disturbance exceeds the stable range, the disturbance is regarded as external disturbance At the time of disturbance, DT measures 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.
DT at the Time of External
Disturbance Response
External disturbance
External disturbance
Stable range
(set to 15.0°C before shipping)
Set point
Stability judgement time
Measurement of
external disturbance
response waveform
PID before tuning
Startup Conditions of DT
The external disturbance response waveform is approaching to
the most ideal response waveform even if the same kind of
external disturbance reoccurs. The waveform will not, however,
change if the most ideal PID constants are already set.
PID after tuning
DT is used to monitor the control waveform if there is external disturbance or
SRT does not work at the time the Temperature Controller starts operating or at
the time of set point change. If the measured waveform is not an ideal waveform,
DT will be ON. If either one of the following conditions is satisfied, the control
waveform will be monitored.
1, 2, 3...
1. SRT Startup conditions 3 and 4 on page 29 are satisfied but neither 1 nor 2 is
satisfied.
2. There has been an external disturbance exceeding the stable range after
the process value was in stable condition.
Note The stable range is set to 27°F with the E5J--F.
4-1-3 Hunting Tuning (HT)
If there is hunting due to characteristics changes of the control system, HT is
used to measure the hunting waveform and adjust the PID constants to suppress the hunting.
Extreme value
Stable range
(set to 15.0°C before shipping)
Set point
Measurement of
hunting waveform
PID before tuning
Startup Conditions of HT
PID after tuning
HT will be ON when there is hunting with four or more maximum temperature
values while SRT is not being executed.
Note If the periodic temperature changes of the application exceed the stable range
(set to 15.0°C at the factory) due to continuous external disturbance (i.e., the
temperature is affected by an external disturbance before stabilizing after a previous external disturbance (refer to figure A below)), the user should change the
stable range to a value greater than the temperature changing range, otherwise
30
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
T1
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