Temperature Controllers E5❑J Advanced PID Controller with Fuzzy Logic-Based Adaptive Tuning Provides Optimum Performance ■ Available in 3 standard DIN sizes: Choose 1/4, 1/8 and 1/16 DIN ■ Fuzzy adaptive tuning continually optimizes PID control based on current process conditions ■ Field selectable sensor inputs, alarm functions and °F/°C scaling ■ Digital inputs allow Run/Stop operation and external selection of multiple set points on 1/4 and 1/8 DIN units ■ Plug-in outputs on 1/4 and 1/8 DIN units provide field interchangeability and easy servicing ■ 1/4 and 1/8 DIN units offer serial communication options for interfacing with PLCs and other host devices Ordering Information ■ 1/4 and 1/8 DIN CONTROLLERS Order control outputs separately below; for example, E5AJ-A2HB-F with E53-R output unit. All temperature controllers with communications capability have the designated board installed, except E5❑J-A2HM-F. The E5❑J-A2HM-F offers interchangeable communications boards that must be ordered separately. To order controllers marked for Celsius, drop the final "F" from the part number. Size 1/4 DIN 1/8 DIN Standard E5AJ-A2HB-F E5EJ-A2HB-F Part Number Serial communications board installed RS-232C RS-422 E5AJ-A2H01-F E5AJ-A2H02-F E5EJ-A2H01-F E5EJ-A2H02-F RS-485 E5AJ-A2H03-F E5EJ-A2H03-F Communications ready (no board installed) E5AJ-A2HM-F E5EJ-A2HM-F ■ 1/16 DIN CONTROLLERS Description Two alarm points; one event input, heater burnout alarm (except current) Two alarm points; without event input Without alarm and event input Part Number Relay output E5CJ-R2HB-F E5CJ-R2-F E5CJ-R-F Voltage output E5CJ-Q2HB-F E5CJ-Q2-F E5CJ-Q-F Current output E5CJ-C2B-F E5CJ-C2-F E5CJ-C-F ■ CONTROL OUTPUTS FOR 1/4 AND 1/8 DIN MODELS, CURRENT TRANSFORMERS Description Control outputs Feature SPDT relay, 5 A, 250 VAC* SSR, 1 A, 75 to 250 VAC Voltage, 12 VDC, NPN Voltage, 24 VDC, NPN Voltage, 24 VDC, PNP Linear current, 4 to 20 mA DC, 600 Ω Linear current, 0 to 20 mA, 600 Ω Linear voltage, 0 to 10 VDC, 1 KΩ Part number E53-R E53-S E53-Q E53-Q3 E53-Q4 E53-C3 E53-C3D E53-V34 E5❑J E5❑J ■ CONTROL OUTPUTS FOR 1/4 AND 1/8 DIN MODELS, CURRENT TRANSFORMERS(continued) Linear voltage, 0 to 5 VDC, 1 KΩ 5.8 mm (0.23 in) dia. hole 12.0 mm (0.47 in) dia. hole Current transformers for heater burnout function E53-V35 E54-CT1 E54-CT3 *Note: If control period is less than 5 seconds, use solid state relay or voltage relay. ■ COMMUNICATIONS BOARDS FOR E5AJ, E5EJ CONTROLLERS Output RS-232C RS-422 RS-485 Write to temperature controller Set temperature, alarm value proportional band, integral time, rate time, event input. Read from temperature controller Set temperature, alarm value, proportional band, reset time, rate time, output variable set limits, process value Part number E53-J01 E53-J02 E53-J03 ■ ACCESSORIES Description NEMA 4 covers Part number Y92A-48N Y92A-49N Y92A-96N For E5CJ, 1/16 DIN size For E5EJ, 1/8 DIN size For E5AJ, 1/4 DIN size ■ REPLACEMENT PARTS Description Panel mounting adapter for E5CJ, supplied with each unit Part number Y92F-30 ■ TEMPERATURE RANGES Input type (switch selectable) Temperature °C range °F Unit of measure (main setting and alarm Thermocouple Type K Type J and L -200 to 1,300 -100 to 850 -300 to 2,300 -100 to 1,500 1° C/F 1° C/F Type T and U -199.9 to 400.0 -199.9 to 700.0 0.1° C/F Type N -200 to 1,300 -300 to 2,300 1° C/F Platinum RTD 100 Ω -199.9 to 650.0 -199.9 to 999.9 0.1° C/F ■ GET THE ADVANTAGE OF ADAPTIVE TUNING USING THREE ALGORITHMS Omron's "J" series controllers use fuzzy adaptive tuning to continuously monitor and optimize PID constants while the controller operates. Three tuning algorithms are used to recalculate the PID constants within 500 ms after the process value stabilizes at set point: Step-Response Tuning Maximum Set Deviation immediately after set point • Step-response method • Disturbance tuning • Hunting tuning. Step-Response Method This tuning method takes place on startup and after an upward set point change heating applications or a downward set point change in a cooling application. Step-response tuning changes mainly impact the proportional band. Disturbance Tuning This tuning method takes place when the temperature exceeds the stable range between one and three times before settling back to set point. Changes in tuning are mainly made to the derivative (rate) time. Hunting Tuning This tuning method takes place when the temperature exeeds the stable range four or more times before settling back to set point. Changes in tuning are mainly made to the integral (reset) time. 204 Process Step-response Manipulated PID Disturbance Tuning Stable range SP Outside stable range here Disturbance tuning takes place here Hunting Tuning Extreme value Stable range SP Hunting waveform monitored PID before tuning PID after tuning Comparison of E5❑J and E5❑X Tuning Methods Omron's "X" series controllers attempt to optimize the PID constants by using a limit cycle auto-tune. Although effective in most applications, this method has some drawbacks. For example, the auto-tuning must induce an upset into the process in order to make the process oscillate four times. In many processes these types of artificial upsets are not desirable. Adaptive tuning controllers do not induce an upset; instead, they use information from the actual process, eliminating unnecessary oscillations and enabling quicker start-up time. Another drawback of the limit cycle autotune method is that PID constants will only be effective so long as the same basic conditions that were present when the auto-tune took place remain constant. Various factors such as a load change, heater performance degradation or set point changes can cause the auto-tuned values to be less than optimum. The new adaptive tuning method, however, is continually monitoring the process and will automatically adjust the PID constants whe nprocess parameters (i.e., heater degradation, load change, etc.) vary. E5❑J E5❑J Specifications Part number Supply voltage Operating voltage Power consumption E5AJ E5EJ 100 to 240 VAC, 50/60 Hz 85% to 110% of supply voltage range Approx. 10 VA at 100 VAC to 14 VA at 240 VAC Temperature input type Event Contact input input No-contact input Control output Type Relay (see note 1) Voltage Current Alarm output Heater burnout output Indication accuracy Hysteresis Update Output time Display Service Electrical life Mechanical Number Setting range Type Setting range Minimum detectable ON time General Exceptions Setting accuracy Display Range Control Type mode Proportional band (P) Reset time (I) Rate time (D) Control period Sampling period Memory protection Other Input shift functions Indicators Miscellaneous Present value Set value Other functions E5CJ Approx 10 VA at 100 VAC to 12 VA at 240 VAC Thermocouple types J, K, T, L, U, and N or platinum RTD (JPt 100/Pt100), selectable ON: 1 kΩ max., OFF: 100 kΩ min. ON: residual voltage: 3 V max., OFF: Leakage current 1 mA max. SPST-NO, 5 A, 250 VAC using E53-R output unit SPST-NO, 3 A, 250 VAC NPN, 40 mA at 12 VDC using E53-Q output unit NPN, 20 mA at 12 VDC NPN, 20 mA at 24 VDC using E53-Q3 output unit PNP, 20 mA at 24 VDC using E53-Q4 output unit All offer short-circuit protection 4-20 mA, DC, 600 Ω max., resolution of 2,600 4-20 mA, 600 Ω max., resolution using E53-C output unit (see note 1) of 2,600 0.1° to 999.9° C/F in units of 0.1°C/°F during ON/OFF control action 500 ms for pulse output 500 ms 100,000 operations minimum for E53-R and alarm 10 million moperations minimum for E53-R and alarm Two SPST-NO relay,s 3 A, 250 VAC Two, SPST-NO relays, 1 A, 250 VAC Thermocouple types J, K, L, N: -1999 to 9,999 °C/°F in units of 1 °C/°F Platinum RTD and thermocouple types T and U: -199.9 to 999.9 °C/°F in units of 0.1 °C/°F SPST-NO relay, 1 A, 250 VAC 0.1 to 49.9 A in units of 0.1 A 0.0 setting disables the output 50.0 setting turns output ON continuously 200 ms; heater current is not measured when the control output is ON less than 200 ms ±0.5% of set point or ±1°, whichever is greater, ±1 digit max. Accuracy of types K, N and T thermocouples is ±2°C (3.6°F) from -100°C or below (-240°F or below), ±1 digit. Accuracy of type U thermocouple at any temperature is ±2°C (3.6°F), ±1 digit. Set value coincides with the indicated value, since no relative error exists between both values -9999 to 9999 (limited by output type) PID with automatic fuzzy self-tuning, PID, or ON/OFF 0.1 to 999.9 °C/°F in units of 0.1 °C/°F 0 to 3,999 seconds in 1-second units 0 to 3,999 seconds in 1-second units Pulse output: 1 to 99 seconds in 1-second units 500 ms Non-volatile memory Offsets input value and display to accommodate a sensor input that deviates by a known value. Thermocouple range: -999 to 9999 °C/°F Platinum RTD range: -99.9 to 999.9 °C/°F Upper and lower set value limits, setting protection, Normal and Reverse output 15 mm (0.59 in) 14 mm (0.55 in) 12 mm (0.47 in) red LED digits red LED digits red LED digits 10.5 mm (0.41 in) 9.5 mm 0.37 in) 8 mm (0.32 in) green LED digits green LED digits green LED digits LED indicators Note: 1. If control period is less than 5 seconds, use solid state relay or voltage relay. Note: 2. The E53-C3 Current Output Unit cannot be used if heater burnout alarm is used. 205 E5❑J E5❑J Specifications, continued Materials Mounting Weight Fits 1/8 DIN panel cutouts, includes two panel mounting brackets Approx. 280 g (9.9 oz.) Fits 1/16 DIN panel cutouts, includes Y92F-30 panel mounting adapter Controller Plastic case Fits 1/4 DIN panel cutouts, includes two panel mounting brackets Approx. 360 g (12.7 oz.) Mounting hardware Brackets 65 g (2.3 oz.) Brackets 65 g (2.3 oz.) Adapter 10 g (0.35 oz.) Connections Enclosure Front panel ratings Rear case Terminals Approvals UL CSA Ambient Operating temperature Storage Humidity Insulation resistance Dielectric strength Vibration Mechanical durability Malfunction durability Shock Mechanical durability Malfunction durability Note: Approx. 170 g (6.0 oz.) Plated steel screw terminals mounted on rear of unit IEC IP54, NEMA 4 with optional Y92A covers (see note) IEC IP20 IEC IP00 Recognized, File number E68481 Certified, File number LR59623 -10° to 55° C (14° to 131°F) -25° to 65°C (-13° to 149°F) 35 to 85% RH 20 MΩ minimum at 500 VDC, measured with an output unit installed 2,000 VAC, 50/60 Hz for 1 minutes between terminals of different polarities 10 to 55 Hz, 19.6 m/s2 (2 G) in X, Y, and Z directions for 2 hours each 10 to 55 Hz, 9.8 m/s2 (1 G) in X, Y, and Z directions for 10 minutes 294 m/s2 (30 G) in 6 directions, 3 times each 196 m/s2 (20 G) in 6 directions, 3 times each Optional NEMA 4 panel covers are available for E5–J controllers: Y92A-96N for E5AJ, Y92A-49N for E5EJ, and Y92A-48N for E5CJ ■ CURRENT TRANSFORMERS FOR E5AJ, E5EJ, E5CJ❑2HB-F Part number Heater current Dielectric strength Vibration resistance Weight Accessories included E54-CT1 Maximum 50 A continuous service, single-phase 1,000 VAC 50 Hz (approx. 10 G) 11.5 g (0.41 oz.) — E54-CT3 50 g (1.8 oz.) 2 contacts, 2 plugs ■ COMMUNICATIONS FOR E5AJ, E5EJ Protocol Transmission method Maximum cable length Synchronization method Baud rate Transmission code Write to temperature controller Read from temperature controller System limits Note: 206 RS-232C RS-422 RS-485 4-wire half duplex 4-wire half duplex 2-wire half-duplex 15 m (49.2 ft) 500 m (1,640 ft) 500 m (1,640 ft) Start-stop synchronization (asynchronous method) 1,200/2,400/4,800/9,600/19,200 bps ASCII (7 bits) Set point, alarm value, remote/local selection, proportional band, integral time, rate time (see note) Process value, output value, set point, alarm value, heater current value, initial status, proportional band, reset time, rate time, error codes, etc. (see note) Peer to peer only A maximum of 32 controllers can be connected to one host computer in serial communication If E5AJ is in ON/OFF control mode or PID control mode with fuzzy self-tuning, an undefined error will result if the proportional band, integral time, or derivative time command is transmitted. E5❑J E5❑J Dimensions Unit: mm (inch) 109.7 (4.32) ■ E5AJ 96 x 96 (3.78 x 3.78 ) 11.7 98 (3.86) 112 (4.41) Panel cutout 91 x 91 (3.58 x 3.58) 92 (3.62) Side-by-side mounting of several controllers Recommended panel thickness is 1 to 8 mm (0.04 to 0.32 in). 92 (3.62) 120 (4.72) min. 92 (3.62) For side-by-side mounting: L = 96 mm x number of units - 3.5 mm (3.78 in x number of units - 0.14 in) ■ E5EJ 109.7 (4.32) 48 (1.89) 98 (3.86) 11.7 96 (3.78) 112 (4.41) Panel cutout Side-by-side mounting of several controllers 45 (1.77) 44 (1.73) 92 (3.62) 91 (3.58) 120 (4.72) min. 92 (3.62) For side-by-side mounting: L = 48 mm x number of units - 2.5 mm = (1.89 in x number of units - 0.10 in) Recommended panel thickness is 1 to 8 mm (0.04 to 0.32 in). 207 E5❑J E5❑J ■ E5CJ 109.2 (4.30) 48 x 48 (1.89 x 1.89) 9.2 100 (3.94) 58 (2.28) Side-by-side mounting of several controllers Panel cutout 44.8 x 44.8 (1.76 x 1.76) 45 (1.77) Recommended panel thickness is 1 to 4 mm (0.04 to 0.16 in). Mounting bracket Y92F-30 allows close side-by-side mounting. 45 (1.77) 60 (2.36) min. 45 (1.77) For side-by-side mounting: L = 48 mm x number of units - 2.5 mm = (1.89 in x number of units - 0.10 in) 208 E5❑J E5❑J Nomenclature ■ E5EJ with communications ■ E5AJ without communications 1. Process value display 2. Set value display 11. Stop (STOP) indicator 10. Output (OUT) indicator 3. Alarm output 1 (ALM1) indicator 9. Level key 4. Alarm output 2 (ALM2) indicator 12. Remote (RMT) indicator 8. Mode key 5. Heater burnout (HB) indicator 6. Up key 7. Down key ■ E5CJ without communications 1. Process value display 2. Set value display 10. Output (OUT) indicator 3. Alarm output 1 (ALM1) indicator 4. Alarm output 2 (ALM2) indicator 9. Level key 6. Up key 5. Heater burnout (HB) indicator 7. Down key 8. Mode key Key 1 2 3 4 5 6 Description Process value indicator displays the present temperature, parameter being set and error messages. Set value indicator displays the set values, messages and output value. Indicator lights when alarm output 1 is turned ON. Indicator lights when alarm output 2 is turned ON. Heater burnout indicator lights when a heater burnout is detected and stays lit until reset. Up key increments the numeric value in the display. Pressed for 1 second or more, the set value increases by 50 units in 1 second until the upper-limit value has been reached. Key 7 8 9 10 11 12. Description Down key decrements the numeric value in the display. Pressed for 1 second or more, the display value deceases by 50 units in a second until the lower-limit value has been reached. Mode key changes the display mode within display levels. Level key changes the display level when depressed for at least 2 seconds. Output indicator lights when the control output is ON. It does not light when the output selector switch is set for a current output. Stop indicator lights when the temperature controller is not in operation. Indicator lights when the controller is in remote (on-line) communication mode. Note: 1. E5AJ and E5EJ models without communications have a Stop indicator. 2. E5CJ-❑2HB models have all indicators shown. E5CJ-❑2 models have OUT, ALM1 and ALM2 indicators. E5CJ-❑ models have OUT indicator only. 209 E5❑J E5❑J Connections ■ E5AJ, E5EJ CONTROLLERS For current output For voltage output For relay output RS-232C 100 to 240 VAC, 50/60 Hz 4 to 20 mA 12 VDC, 40 mA RS-422 RS-485 Event 1* Control output Event 2* Note: * E5AJ/E5EJ models with communications do not have an event input. ** Alarm output 1 is ON when the E5AJ/ E5EJ detects a sensor abnormality or heater burnout. Alarm output 2 Use these terminals when connecting a platinum RTD. Use these terminals when connecting a thermocouple. Alarm output 1** ■ E5CJ-❑2❑B CONTROLLERS Two Alarm Outputs, One Event Input, Heater Burnout Alarm For relay output For voltage output 12 VDC, 20 mA 100 to 240 VAC, 50/60 Hz For current output 4 to 20 mA Control output Event 1* Alarm output 1* CT Alarm output 2 Note: * Alarm output 1 is ON when the E5AJ/ E5EJ detects a sensor abnormality or heater burnout. 210 Use these terminals when connecting a thermocouple. Use these terminals when connecting a platinum RTD. E5❑J E5❑J ■ E5CJ-❑2 CONTROLLERS Two Alarm Outputs, No Event Input For voltage output For relay output 4 to 20 mA 12 VDC, 20 mA 100 to 240 VAC, 50/60 Hz For current output Control output Alarm output 1 Use these terminals when connecting a platinum RTD. Use these terminals when connecting a thermocouple. Alarm output 2 ■ E5CJ-❑ CONTROLLERS No Alarm Outputs, No Event Input For voltage output For relay output 4 to 20 mA 12 VDC, 20 mA 100 to 240 VAC, 50/60 Hz For current output Control output Use these terminals when connecting a thermocouple. Use these terminals when connecting a platinum RTD. OMRON ELECTRONICS, INC. OMRON CANADA, INC. One East Commerce Drive Schaumburg, IL 60173 885 Milner Avenue Scarborough, Ontario M1B 5V8 1-800-55-OMRON 416-286-6465 Cat. No. GC TC13 08/00 Specifications subject to change without notice. Printed in the U.S.A. 9