Omron E5AJ-A2HB, E5AJ-A2H01, E5AJ-A2H02, E5AJ-A2HM, E5CJ-R Operation Manual

E5J 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

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serious injury.

Caution Indicates information that, if not heeded, could result in relatively serious or mi-

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nor 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.

 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.

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.

v

TABLE OF CONTENTS

SECTION 1

Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 Features 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3 Specifications 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2

Sensor and Mode Settings9. . . . . . . . . . . . . . . . . . . . . . . .

2-1 Disassembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2 Output Units 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3 Internal Switch Settings 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3

Settings Before Operation 17. . . . . . . . . . . . . . . . . . . . . . . . .

3-1 Nomenclature 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2 Setting Flowchart 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3 List of Parameters 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4 Parameters on Display Level 0 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5 Parameters on Display Level 1 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4

Fuzzy Self-tuning 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 Fuzzy Self-tuning Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 Troubleshooting 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 Terminology 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5

Installation and Wiring 35. . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 Installation 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 Wiring 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 Terminal Arrangement 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6

Troubleshooting 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 Error Display and Output 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 Troubleshooting 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7

Event Input Function 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 Event Input Function 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8

Heater Burnout Detection 49. . . . . . . . . . . . . . . . . . . . . . . . .

8-1 Heater Burnout Detection 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2 Heater Burnout Procedures 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3 Wiring the Current Transformer 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4 Heater Burnout Alarm Value 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9

Engineering Level Settings 55. . . . . . . . . . . . . . . . . . . . . . . .

9-1 Engineering Level 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2 Engineering Level Parameter List 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3 Engineering Level Parameters 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

TABLE OF CONTENTS

SECTION 10

Auto-tuning 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1 Starting Auto-tuning 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2 Conditions that Prevent Auto-tuning 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3 Force-ending Auto-tuning 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4 Changing Parameters during Auto-tuning 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendices

A Dimensions/Mounting Holes 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Revision History 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

viii

About this Manual:

This manual describes the installation and operation of the Thermac E5J 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 E5J Temperature Controller.

Section 1
Section 2

necessary before turning on the Thermac E5J Temperature Controller.

Section 3

operating the Thermac E5J Temperature Controller.

Section 4

to the characteristics of the device for ideal temperature control.

Section 5
Section 6
Section 7
Section 8

taken at the time of heater burnout, as well as the method of obtaining heater burnout alarm values.

Section 9

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

The
perature Controller Units.

describes the specifications and basic features of the Thermac E5J Temperature Controller.
describes the sensor and mode settings of the Thermac E5J Temperature Controller that are

describes the settings of the Thermac E5J Temperature Controller that are necessary before

provides the procedures required to adjust all PID constants using fuzzy self-tuning according

describes the installation and wiring of the Thermac E5J Temperature Controller.

describes the troubleshooting of the Thermac E5J Temperature Controller.
describes how the event input function of the Thermac E5J Temperature Controller works.
describes the basic features of heater burnout detection and necessary steps that should be

describes the parameters that can be changed on the engineering level. These parameters

describes how to execute auto-tuning.

Appendix

provides the dimensions and mounting specifications for the various Thermac E5J Tem-

!

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 E5J Temperature Controller.

1-1 Features 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3 Specifications 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-1 Ratings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-2 Characteristics 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Models

Section 1-2

1-1 Features

The basic features of the Thermac E5J 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 E5J 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
E5J 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 E5J can be used in places where water is sprayed onto the E5J, be-

cause the front panel of the E5J assures IP54 when the E5J 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 E5 J 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 E5J 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 E5J Temperature Controller.

Input

Temperature
range (°C)

INPUT

Factory-set to 2 (K)

Selectable
internally.

1300
1000
800
600
400
200
100
0
–100
–200

Setting
no.

Platinum resistance
thermometer

JPt100

650.0

–199.9 –200

0.8 1.9 2 3 4 5 6 7

Pt100

650.0

KJ T L U N

1300

–200–199.9 –199.9 –199.9

850

–100

Thermocouple

400.0

–100

1300

850

400.0

2

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 E5AJ-A2HM

Note 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 Replaceable Output Unit (sold separately)
Model Communications function --- E5EJ-A2HB

RS-232C E5EJ-A2H01
RS-422 E5EJ-A2H02
RS-485 E5EJ-A2H03

Communications Board add-on model E5EJ-A2HM

Note 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

6 (at C)

Specifications

Section 1-3

E5CJ (Simple and Standard Models)

48 X 48mm

Type Simple model type Standard model

type

Alarm --- 2 replay output points with the same

common. (see note 1)
Heater burnout alarm --- Yes (see note)
Event input --- 1 point (set point

selection)

Model Control output Relay output E5CJ-R E5CJ-R2 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

Note For details, refer to the

Communications RS-232C RS-422 RS-485

Model E53-J01 E53-J02 E53-J03

E5AJ/E5EJ Communications Manual (Z102).

1-3 Specifications

1-3-1 Ratings

E5J

Item Specification

Supply voltage 100 to 240 VAC, 50 or 60 Hz 24 V AC/DC,

50 or 60 Hz
Operating voltage range 85 to 110% of supply voltage
Power consumption E5AJ 10 VA (at 100 VAC) to

14 V A (at 240 VAC)

E5EJ 10 VA (at 100 VAC) to

14 V A (at 240 VAC)

E5CJ 10 VA (at 100 VAC) to

12 V A (at 240 VAC)

Input Thermocouples (K, J, T, L, U, and N) and platinum

resistance thermometers (JPt100 and Pt100)
CT input Dedicated CT (E54-CT1 or E54-CT3)
Control output E5AJ/E5EJ Replaceable Output Unit (sold separately)

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
Control mode ON/OFF or advanced PID with fuzzy self-tuning and

auto-tuning
Alarm output E5AJ/E5EJ 2 SPST-NO relay output points, 3 A at 250 VAC

(resistive load)

E5CJ 2 SPST-NO relay output points (with the same common),

1 A at 250 VAC (resistive load)
Setting method Digital setting with Up Key and Down Key

10 V A (at 24 VAC)
6 W (at 24 VDC)

4

Specifications

Item Specification

Indication method E5AJ All digital indication (PV: Red, 15 mm; SV: Green,

10.5 mm)

E5EJ All digital indication (PV: Red, 14 mm; SV: Green,

9.5 mm)

E5CJ All digital indication (PV: Red, 12 mm, SV: Green 8.0

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.
Other function • Key protect

• Cooling operation/Heating operation

• Heater burnout alarm

Model with event input (E5J-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)

Section 1-3

Output Units

Model Specification

E53-R Relay Output Unit SPDT (SPST-NO when used with the

E5J), 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 E5J) (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 E5J)

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 E5J)

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 E5J)

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

E5J

Item Specification

Indication accuracy ±0.5% or ±1°C whichever is larger ± 1 digit max.

Thermocouple K, T, or N at a temperature of –100°C; thermocouple U at ± 2°C ± 1

digit max.
Hysteresis (for ON/OFF control) 0.1 to 999.9°C/° F (in units of 0.1°C/°F)
Proportional band 0.1 to 999.9°C/°F (in units of 0.1°C/°F)
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 2000 VAC, 50/60 Hz for 1 min. between charged terminals different from each other

in polarity
Vibration

resistance
Shock resistance Malfunction 196 m/s2 (20G) 3 times each in 3-axis 6 directions (98 m/s2 (10G) for the relay)

Weight E5AJ Approx. 360 g; mounting bracket: approx. 65 g

Enclosure rating Front panel: E5AJ/E5EJ: IEC standard IP54

Memory Protection Non-volatile memory
EMC Emission Enclosure: EN55011 Group 1 class A

Approved standards UL1092, CSA C22.2 No. 142

Malfunction 10 to 55 Hz, 9.8 m/s2 (1G) 10 min. in X, Y, and Z directions
Destruction 10 to 55 Hz, 19.6 m/s2 (2G) 2 hr. in X, Y, and Z directions

Destruction 294 m/s2 (30G) 3 times each in 3-axis 6 directions

E5EJ Approx. 280 g; mounting bracket: approx. 65 g
E5CJ Approx. 170 g; adapter: approx. 10 g

E5CJ: IEC standard IP50 (see note 1)
Rear case: IEC standard IP20
Terminals: IEC standard IP00

Emission AC Mains: EN55011 Group 1 class A
Immunity ESD: 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)

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

Heater Burnout Alarm

Note 1. Use the K2CU-FA-GS (with gate input terminals) for the detection of

Model with
Communications Function

Model Life expectancy

E53-R Relay Output Unit Mechanical 10,000,000 times min.

Electrical 100,000 times min.

Item Specification

Max. heater current 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)

Min. detection ON time 190 ms (see note 3)

(see note 2)

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

Interface RS-232C, RS-422, RS-485
Communications method Half duplex
Synchronization method Start-stop synchronization

Communications speed 1200, 2400, 4800, 9600, and 19200 bps
Communications

item

E5AJ/E5EJ Communications Manual (Z102)

Item Specification

(non-synchronization)

Writing to
Thermac J

Reading from
Thermac J

Set point, alarm value, heater burnout alarm
value, proportional band, derivative time,
integral time, and input shift value

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

for details.

7

SECTION 2

Sensor and Mode Settings

This section describes the sensor and mode settings of the Thermac E5J Temperature Controller that are necessary before
turning on the Thermac E5J Temperature Controller.

2-1 Disassembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2 Output Units 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3 Internal Switch Settings 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3-1 Internal Switch Positions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3-2 Input Type Selector Setting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3-3 Alarm Mode Setting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3-4 Standby Sequence 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3-5 Function Selector Settings 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3-6 Key Protection Switch Settings 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Output Units

2-1 Disassembly

2-2 Output Units

Section 2-2

Before turning on the E5J, set its sensor type and control mode with the inter­nal selectors. Refer to the following illustrations for disassembling the E5J 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.

Select the Output Unit according to the application and mount the Output Unit
into the socket on the E5J PCB of the as shown in the following illustration. The
E5CJ does not require an Output Unit. Refer to
ratings of the E5J.

1-3 Specifications

for the output

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 NPN model, 40 mA at 12 VDC (with short-circuit

protecting circuit)

E53-Q3 Voltage Output Unit NPN model, 20 mA at 24 VDC (with short-circuit

protecting circuit)

E53-Q4 Voltage Output Unit PNP model, 20 mA at 24 VDC (with short-circuit

protecting circuit)
E53-C3 Linear Output Unit 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.

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

NPN Model: E53-Q (40 mA at 12 VDC) and E53-Q3 (20 mA at 24 VDC)

++

LOAD INPUT

PNP Model: E53-Q4 (20 mA at 24 VDC)

LOAD INPUT

SSR

––

++

SSR

––

Section 2-3

2-3 Internal Switch Settings

2-3-1 Internal Switch Positions

E5AJ

Top view

E5EJ

Top view

ALM2

Alarm mode selector 2

ALM1

Alarm mode selector 1

PROTECT

Key protection
switch

INPUT

Input type
selector

ALM2

Alarm mode selector 2

PROTECT

Key protection
switch

ALM1

Alarm mode
selector 1

INPUT

Input type selector

ALL
OFF
SP

ALL
OFF
SP

Bottom view

FUNCTION

Function selector

FUNCTION

Function selector

11

Internal Switch Settings

E5CJ

Top view

ALM2

Alarm mode selector 2

Section 2-3

Bottom view

ALM1

Alarm mode selector 1

INPUT

Input type selector

FUNCTION

Function selector

PROTECT

Key protection
switch

SP
OFF
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 Specified temperature range

°C °F °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 E5J 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 E5J.

12

Internal Switch Settings

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.

Section 2-3

ALM2 ALM1

Selector

Alarm mode Alarm output Setting range

no.

Positive alarm set

value

Negative alarm set

value

0 No alarm function OFF --­1 Upper and lower limit

alarm (deviation)

XSPX

Always ON –1999 to 9999 or –199.9

to 999.9 (the decimal
position varies with the
input type)

2 Upper limit alarm

(deviation)

3 Lower limit alarm

(deviation)

4 Upper and lower limit

SP

X

SP

XSPX

X

Always OFF

X

SP

X

SP

range alarm (deviation)

5 Upper and lower limit

XSPX

Always OFF
alarm with standby
sequence (deviation)

6 Upper limit alarm with

standby sequence
(deviation)

7 Lower limit alarm with

standby sequence
(deviation)

8 Absolute value upper

limit alarm

9 Absolute value lower

limit alarm

X

SP

X

SP

X

0

X

0

X

SP

X

SP
X

0
X

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

2-3-4 Standby Sequence

The alarm output is ON the moment the E5J 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 E5J in lower limit alarm mode with a standby sequence.

OFF point due to
alarm hysteresis

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.

Section 2-3

Standby sequence releasing
point

Alarm point

Alarm output

ON
OFF

To set these pins to

FUNCTION

ON, use a small flat­blade screwdriver.

Refer to the following table for function switch setting.

Pin no. 1 2 3 4

Output Cooling operation (Normal) ON --- --- --­operation Heating operation (Reverse) OFF
Control ON/OFF control --- ON See note
mode Advanced PID --- OFF ON

Advanced PID with fuzzy self-tuning --- OFF OFF

Level Engineering level --- --- --- ON

Normal operation --- --- --- OFF

Note The E5 J 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 E5J is set to OFF, when the process temperature is lower than the

set point, the E5J will operate so that the heater output will increase.

Cooling Operation If pin 1 of the E5J is set to ON, when the process temperature is higher than the

set point, the E5J 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 E5J 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 E5J 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)

14

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.

Internal Switch Settings

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.

Mode Protection

SP

OFF All keys are available.
ALL Prohibits all set value changes. The Level Key, Down Key, and

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.

Up Key are not available.

Section 2-3

SP OFF ALL

PROTECT

15

SECTION 3

Settings Before Operation

This section describes the settings of the Thermac E5J Temperature Controller that are necessary before operating the
Thermac E5J Temperature Controller.

3-1 Nomenclature 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2 Setting Flowchart 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3 List of Parameters 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4 Parameters on Display Level 0 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5 Parameters on Display Level 1 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Nomenclature Section 3-1

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.

Process Value (PV) display

Displays not only the process
value but also indicates the pa-

Stop indicator

Lit when the E5J 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 E5J 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.

rameter being displayed on the
SV display and error messages.

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.

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.

Note Refer to the

E5AJ/E5EJ Communications Manual

models incorporating a communications function.

for the operation of E5J

18

Setting Flowchart

Section 3-2

3-2 Setting Flowchart

The Thermac E5J 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 E5J after inputting all the set values, turn the
power supply to the Temperature Controller off and then on again.

All parameters for the E5J 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 parame-

ters.

Display level 1 Parameters that are not changed frequently are ranked as display level 1 pa-

rameters.

Engineering Level Parameters that are changed with only a few applications are ranked as engi-

neering level parameters.

OFF ON

Level Key
Press for 1 s min.

Display level 0 Display level 1

Set point setting

Alarm 1 setting

Alarm 2 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.

Level Key
Press for 1 s min.

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

Pin 4 of the func-

tion selector

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

Settings

on the engineering level and how to
change them.

Section 9 Engineering Level

for details on each parameters

19

List of Parameters

3-3 List of Parameters

Display Level 0

Display Name Setting range Setting

--- Process value
display and set
point setting

AL-1 Alarm set value 1 –1999 to 9999 °C/°F

AL-2 Alarm set value 2 –1999 to 9999 °C/°F

To go to the next level, press the Level Key for 1 s min.

Note The values shown in Fahrenheit are applicable only for E5J--F Mod-

els.

Set point lower limit
to set point upper
limit (°C/°F)

The decimal position
varies with the kind
of input.

The decimal position
varies with the kind
of input.

Section 3-3

Remarks

before

shipping

0 The present set point is

displayed and can be
changed if the E5J
incorporates an event input
function

0 Not displayed if alarm mode

switch 1 is set to 0.

0 Not displayed if alarm mode

switch 2 is set to 0.

Display Level 1

Display Name Setting/Display

0 Output value

display

CP Control period 1 to 99 s 20 Displayed and can be set if

HYS Hysteresis 0.1 to 999.9 °C/°F 1.0 (1.8) Displayed and can be set

SP-0 Set point 0 Set point lower limit

SP-1 Set point 1 Set point lower limit

SP-2 Set point 2 Set point lower limit

SP-3 Set point 3 Set point lower limit

in-S Input shift value –199.9 to 999.9 °C/°F 0.0 Displayed and can be set if

0.0 to 100.0 %

to set point upper
limit (°C/°F)

to set point upper
limit (°C/°F)

to set point upper
limit (°C/°F)

to set point upper
limit (°C/°F)

Range

Setting

before

shipping

the E5J in PID control
operation has relay control
output or voltage control
output.

when the E5J is in ON/OFF
control operation.

0 For models incorporating an

event input function.

0 For models incorporating an

event input function.

0 For models incorporating an

event input 2 function.
Displayed and can be set if

the default value is changed
on the engineering level.

0 For models incorporating an

event input 2 function.
Displayed and can be set if

the default value is changed
on the engineering level.

the default value is changed
on the engineering level.

Remarks

20

List of Parameters

Section 3-3

Display RemarksSetting

Ct Heater current

Hb Heater burnout

P Proportional band 0.1 to 999.9 °C/°F 8.0 (14.4) Displayed and can be set

8.0

i Integral time 0 to 3999 s

d Derivative time 0 to 3999 s

oFr Manual reset value 0.0 to 100.0 % 50.0 Displayed and can be set if

Name

value display

alarm value

Setting/Display

Range

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: Always OFF

50.0: Always ON

0: No integral

operation

0: No derivative

operation

before

shipping

0.0 For models incorporating a

233 Displayed and can be set

40 Displayed and can be set

For models incorporating a
heater burnout alarm.

Nothing is displayed if the
E5J has current control
output.

heater burnout alarm.
Nothing is displayed if the

E5J has current control
output.

when the E5J is in
advanced PID operation.

when the E5J is in
advanced PID operation.

when the E5J is in
advanced PID operation.

the integral time is set to 0
when the E5J is in
advanced PID operation.

Note The value in the parentheses is the E5J--F setting before shipping.

21

Parameters on Display Level 0

3-4 Parameters on Display Level 0

Note: The process value will not be displayed if the

alarm mode switch is set to 0 or if the E5J does
not incorporate any alarm.

Section 3-4

The value set before
shipping appears

(Set point setting)

Displays when the E5J incorporates
an alarm function (see note).

(Alarm 1 setting)

Displays when the E5J incorporates
an alarm function (see note).

(Alarm 2 setting)

Set Point Setting (°C or °F) It is possible to alter the present set point (SP0 or SP1).
al1 and al2 (°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

Mode Setting

. The alarm value can be set with the deviation width or absolute

2-3-3 Alarm

value according to the alarm mode.

Deviation alarm Absolute value 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

Set point (SP) 100°C/°F

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

22

Parameters on Display Level 1

3-5 Parameters on Display Level 1

Section 3-5

The value set before
shipping appears

(Output value display)

Displays when the E5J in PID control
operation has a relay or voltage output.

(Control period setting)

Displays when the E5J is in ON/
OFF control operation.

(Hysteresis setting)

Displays if the E5J 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 E5J in ad­vanced PID operation.

8.0

(Proportional
band setting)*
*In case of °F:

(Integral time setting)

(Derivative time setting)

Displays if I is 0 .

(Manual reset value
setting)

14.4

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 peri-

od is the period required by the E5J 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 %.

5 s 10 s

ON

ON

hys Hysteresis Setting (°C
or °F)

sp0, sp1, sp2, and sp3
(E5J-B Only)

OFF

Control period: 10 s Control period: 20 s

It is possible to set the hysteresis for the E5J in ON/OFF control operation with­in a range of 0.1° to 999.9°C/°F.

Heating
control
(Reverse)

Cooling
control
(Normal)

ON

OFF

Low temperature Set point High temperature

ON

OFF

Low temperature Set point High temperature

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 se-

OFF

Hysteresis

Hysteresis

lected. To select the set point, open or short-circuit terminals EV1 and EV2. Re-

Section 7 Event Input Function

fer to

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 Input shift value Process value

100°C 0 (no compensation) 100°C

10.0 (compensation value) 110°C
–10.0 (compensation value) 90°C

ct Heater Current Value
Display (E5J-H Only)

hb Heater Burnout Alarm
Value Setting (E5J-H
Only)

24

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.

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.

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 E5J 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.

Parameters on Display Level 1

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.

Section 3-5

ofr Manual Reset Value
Setting

It is possible to set the necessary output value when the E5J is in constant op­eration within a range of 0.0% to 100.0%. The E5J 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 Fuzzy Self-tuning Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1-1 Step Response Tuning (SRT) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1-2 Disturbance Tuning (DT) 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1-3 Hunting Tuning (HT) 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 Troubleshooting 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 Terminology 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3-1 Stable Value, Stable Range, and Stability Judgement Time 32. . . . . . . . . . . . . . . . .

4-3-2 Hunting 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3-3 Characteristics and Characteristics Change 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3-4 External Disturbance 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3-5 Interference 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3-6 Startup 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

Fuzzy Self-tuning Operation Section 4-1

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

Max. tempera­ture slope R

Dead time L

Tuning at startup

P X 1.27

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.

Output (%)

100

100% imposed
step-wise control
amount.

Note Be sure to turn on the power supply to the load either before or simultaneously

Advanced PID

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

Fuzzy Self-tuning Operation Section 4-1

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.

Imposition Completion
Condition of Step Control
Amount

PID Constant Refreshing
Conditions

At the time the Temperature Controller

starts operating

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).

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.

At the time set point is changed

1) The new set point is different from
the set point used at the time SRT
was executed last (see note).

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.
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.
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

Set point

PID before tuning PID after tuning

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 aft e r i t i s deemed that there has been a characteristics change in the con­trol system.

Stable range (set to 15.0°C before shipping)

Stability judge­ment time

Measurement of
set point response
waveform

The set point response waveform
at the time the Temperature Con­troller restarts operation will be
closer to the most ideal response
waveform.

29

Fuzzy Self-tuning Operation Section 4-1

DT at the Time of External
Disturbance Response

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.

Stable range
(set to 15.0°C before shipping)

Set point

External disturbance

Stability judge­ment time

Measurement of
external disturbance
response waveform

External disturbance

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 tuningPID before tuning

Startup Conditions of DT 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 E5J--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.

Set point

PID before tuning PID after tuning

Extreme value

Stable range
(set to 15.0°C before shipping)

Measurement of
hunting waveform

Startup Conditions of HT 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 a ffected 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

External disturbance

Figure A: Waveform with HT turned ON

External disturbance

9-1 Engineering Level

for details.

Note The stable range is set to 27°F with the E5J--F.

4-2 Troubleshooting

Fuzzy self-tuning may not exhibit its full capability due to the characteristics and
conditions of the controlled object.

Refer to the following table for troubleshooting when Unit operation is not
smooth.

Phenomenon Probable cause Countermeasure

The temperature does not reach the
set point.

T1 T2

Figure B: Waveform with HT turned OFF

The dead time measured was longer
than the actual value and
inappropriate PID constants were
obtained because the load (such as a
heater) was turned on after the
Temperature Controller started
operating. (Refer to
details.)

The PID constants were changed from
the most ideal value because HT is
ON continuously when there was a
periodic temperature change larger
than the stable range due to an
external disturbance. Refer to the note
under 4-1-3.

4-3-6 Startup

for

T1<T2

Do the following to execute SRT
again.

1) Set the control mode to the
advanced PID and set the
proportional band to 0.1°C.

2) Set the control mode to the
advanced PID with fuzzy
self-tuning again.

3) Wait until the temperature of the
control system is stable, and then
turn on the Temperature Controller
and the load simultaneously or
turn on the load first for SRT.

Do either one of the following so that
HT will not be ON.

• Change the stable range to a
wider setting than the range of the
temperature change and execute
SRT again by executing steps 1)
to 3) above.

• After obtaining the most ideal PID
constants by executing steps 1) to

3) above, set the control mode to
advanced PID.

31

Terminology

Phenomenon CountermeasureProbable cause

Hunting does not stop. The control period is too long for the

characteristics of the controlled
device, which causes hunting in
synchronization with the control
period.

The temperature is influenced by
continuous external disturbance (i.e.,
the temperature is affected by an
external disturbance before a previous
disturbance has be stabilized. and it
looks as if hunting did not stop at all).

The response fluctuates, becoming
good and bad.

The response fails to reach
operational requirements.

There is a heater or cooling device not
controlled by the control output of the
Temperature Controller (e.g., forced
heating or cooling is executed using
alarm outputs).

There are continuous characteristics
changes.

The response speed of the controlled
device is so fast that it cannot be
retrieved by a sampling period of 500
ms.

The temperature is affected by
devices near the system.

Section 4-3

Shorten the control period.

In this case, however, 100%
improvement will not be possible
because the temperature is influenced
by a continuous external disturbance
instead of hunting. Change the stable
range to a wider setting than the
range of the temperature change so
that HT will not be ON.

In this case fuzzy self-tuning may not
work. Set the control mode to the
advanced PID and adjust the PID
constants manually.

Do either one of the following.

• Adjust the stable range so that
fuzzy self-tuning will not be turned
ON.

• Set the control mode to the
advanced PID and adjust the PID
constants manually.

The Thermac E5J Temperature
Controller cannot support a sampling
period of less than 500 ms. Use an
ES100-series Digital controller, which
has a shorter sampling period.

Fuzzy self-tuning does not support
any countermeasure against
interference. Set the control mode to
the advanced PID and adjust the PID
constants manually.

4-3 Terminology

4-3-1 Stable Value, Stable Range, and Stability Judgement Time

If the measured value continuously coincides with the set point, it can be said
that the measured value is stable. The measured value will not continuously
coincide perfectly with the set point if there is noise inference. It is, however, pos­sible to make the measured value stay within a permissible range called the
stable range. Even if the temperature is within the stable range, the Temperature
Controller may respond to external disturbance or hunting. Therefore, it cannot
be said that the temperature is stable unless the temperature stays within the
stage range continuously for a certain time. This time is called stability judge­ment time. Like PID constants, stability judgement time is adjusted with fuzzy
self-tuning according to the characteristics of the object to be controlled. Fuzzy

32

Terminology

Section 4-3

self-tuning will not be activated if the temperature is stable because the Temper­ature Controller deems that temperature control is smooth.

Shorter than the stability judgement time.

Set point

4-3-2 Hunting

Set pointSet point

Stable range
Stable range

(Set to 15.0°C before shipping)

Stability judgement time

Stable Stable

Note The stable range is set to 27°F with the E5J--F.

If the PID constants are not suitable to the controlled device, the measured value
will fluctuate and will not coincide with the set point, this phenomenon is called
hunting. Hunting is also called cycling.

4-3-3 Characteristics and Characteristics Change

The angle of the maximum temperature slope (R) of the controlled device (i.e.,
whether the temperature rise of the device is fast or slow) and the dead time (L)
of the controlled device (i.e., how fast the change in the output of the Tempera­ture Controller influences the temperature) vary with the characteristics of the
controlled device. The PID constants must be set according to the characteris­tics of the controlled device. A characteristics change is the change of the char­acteristics of the c o n t r o l l e d device due to the change of its thermal capacity and
the change of the supply voltage. If there is a characteristics change, the PID
constants must be adjusted according to the new characteristics.

4-3-4 External Disturbance

External disturbance is an external factor that disturbs the temperature that has
been stable within the most ideal PID constants for the controlled device.

4-3-5 Interference

If devices, such as heaters, controlled by different temperature controllers are
physically close to one another, the heaters are mutually influenced and the tem­perature of each heater are affected. This phenomenon is called interference. If
there is serious interference, it will be difficult for each temperature controller to
control the device, and special controlled methods taking this interference into
consideration will be required.

33

Terminology

4-3-6 Startup

Section 4-3

Startup means that the Temperature Controller starts operating. The following
conditions are required to operate the Temperature Controller.

• The Temperature Controller must be turned ON.

• No sensor error has occurred.

• If a model with event input 2 is used, event input 2 must be set to RUN.

Event input 2 is set to RUN before shipping.

The Temperature Controller will not start operating until all the above conditions
are satisfied.

34

Installation and Wiring

This section describes the installation and wiring of the Thermac E5J Temperature Controller.

5-1 Installation 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1-1 Dimensions and Mounting Holes 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1-2 Mounting Method 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 Wiring 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2-1 Connection 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 Terminal Arrangement 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5

35

Installation Section 5-1

5-1 Installation

Install the E5J in the following places.

1, 2, 3...

1. Where there is little mechanical vibration or shock.

2. Where there is no corrosive gas such as sulfide gas.

3. Where the ambient temperature is within –10° to 55°C.

4. Where there is no high heat radiation.

5. Where there is no high tension lines, welding machines or other devices
generating electrical noise.

6. Where the E5J is not influenced by any electromagnetic field.

7. Where there is little dust or oily smoke.

8. Where the E5J is not sprayed with water.

5-1-1 Dimensions and Mounting Holes

Refer to the

Appendix Dimensions and Mounting Holes

.

5-1-2 Mounting Method

E5AJ and E5EJ Open a square hole in the panel to which the E5J is to be mounted, mount the

E5J, attach the two mounting brackets provided with the E5J to the upper
and lower sides of the E5J, and secure them with a Phillips screwdriver by
turning the Phillips screwdriver clockwise until the ratchets of the mounting
brackets click.

Mounting bracket

Panel

Watertight packing

E5CJ Open a square hole in the panel to which the E5CJ is to be mounted, mount the

E5CJ, attach the adapter provided with the E5CJ as shown in the following il­lustration to reduce the space between the E5CJ and panel, and secure the
adapter with the tightening screw.

Panel

Adapter

36

Mounting screw

Wiring

5-2 Wiring

Section 5-2

Refer to the terminal arrangements to wire the E5J. Before wiring, observe the
following.

1, 2, 3...

1. When connecting extension wires to the thermocouple, use proper compen­sating lead wires.

2. When connecting extension wires to the platinum resistance thermometer,
use three low-resistance wires of equal resistance.

3. The power supply must not be influenced by noise. If necessary use a noise
filter.

4. All the wires connected to the input circuitry must be separated from the
wires connected to the power supply or output circuitry.

5. Use shielded wires where static inductance noise is present.

6. Twist the input wires evenly and closely if there is any electromagnetic in­ductance noise.

5-2-1 Connection

With Solderless Terminals Use solderless terminals for M3.5 screws. The terminal screws are M3.5 x 8 self-

up screws.

7.1 max.

Solder-dipped Leads It is possible to connect solder-dipped leads to the terminals with ease. The

length of each bare lead wire should be 6 to 8 mm.

7.3

6 to 8

For side-by-side mounting, Thermac J-series Temperature Controllers are de­signed so that all the lead wires can be connected to the terminals in the same
direction.

37

Terminal Arrangement

5-3 Terminal Arrangement

E5AJ/E5EJ Standard Model

Relay Output Unit

E53-R

8

250 VAC
5 A

100 to 240 VAC, 50 or 60 Hz, 14 V A
or
24 VAC, 50 or 60 Hz, 10 VA
24 VDC 6 W

Control outputSee note 1.

Alarm output 2

(ALM2)

(ALM1)

See note 3.

Alarm output 1
(Heater burnout
alarm and tem­perature alarm)

10

7

Current Output Unit

+53-C3

8

9
8

7
6
5
4

3
2
1

4 to 20 mA DC

7

– (600 Ω max.)

Voltage Output Unit

+E53-Q

8

12 VDC

7

– (40 mA max.)
+E53-Q3

8

– 24 VDC

7

(20 mA max.)

250 VAC
3A

250 VAC
3A

Q4

Write the name
of the Output
Unit to be used
on the name­plate on the
side of the
case.

20

29
28
27
26
25
24
23
22

21

+

19

+

18
17

–

16
15

14
13
12
11

CT

Section 5-3

See note 2.

Event input 1 (EV1)
Externally selects the set point.

Open
Short-circuit

Event input 2 (EV2)
Selects RUN or STOP.

Open
Short-circuit

A

–

B

+

B

Use the E54-CT1 with a hole diameter of

5.8 mm or E54-CT3 with a hole diameter
of 12 mm (both sold separately).

: Set point 0
: Set point 1

: RUN
: STOP

Note 1. The E53-C cannot be used.

2. The event input terminals and voltage output and current output terminals
are not insulated.

3. Only the heater burnout alarm will be output from the alarm output 1 termi­nals if alarm mode switch 1 is set to 0. Only the temperature alarm will be
output if the heater burnout alarm value is set to 0.0 A.

E5AJ/E5EJ with Communications Function

Relay Output Unit

8

10

7

Current Output Unit

+53-C3

8

9
8

7
6
5
4

3
2
1

4 to 20 mA DC

7

– (600 Ω max.)

Voltage Output Unit

+E53-Q

8
7

– 40 mA max.
+E53-Q3

8

– 24 VDC

7

250 VAC
3A

250 VAC
3A

100 to 240 VAC, 50 or 60 Hz, 14 V A
or
24 VAC, 50 or 60 Hz, 10 VA
24 VDC 6 W

Control outputSee note 1.

Alarm output 2

(ALM2)

(ALM1)

Alarm output 1

See note 2.

(Heater burnout
alarm and tem­perature alarm)

E53-R
250 VAC
5 A

12 VDC

Q4

(20 mA max.)

Write the name
of the Output
Unit to be used
on the name­plate on the side
of the case.

Communications
terminal

29

28
27
26
25

24

23
22

21

CT

Communications terminal

RS-232C RS-422 RS-485

20

RD
SG
SD
SG

29
19

28
18

27
17

26
16

25

RDB
RDA

SG
SDA

SDB

20

29
19

28
18

27
17

26
16

25

20
19
18

17
16

20

29
19

28
18

27
17

26
16

25

15
14

13
12
11

A

–

B

+

B

Use the E54-CT1 with a hole diameter of

5.8 mm or E54-CT3 with a hole diameter
of 12 mm (both sold separately).

B(+)
A(–)

SG
A(–)
B(+)

38

Note 1. The E53-C cannot be used.

Terminal Arrangement

E5CJ Standard Model

100 to 240 VAC, 50 or 60 Hz, 12 V A
or
24 VAC, 50 or 60 HZ, 10 VA
24 VDC 6 W

See note 2.

(Heater burnout alarm
and temperature alarm)

2. Only the heater burnout alarm will be output from the alarm output 1 termi­nals if alarm mode switch 1 is set to 0. Only the temperature alarm will be
output if the heater burnout alarm value is set to 0.0 A.

Event input 1 (EV1) Exter­nally selects the set point.

open
short-circuit

Alarm
output 1

Alarm output 2
1 A (resistive load)

at 250 VAC

(ALM1)

See note 1.

5
4
3

2

1

Control output (OUT)

+

10

12 VDC

–

9

+

10

–

9

14

13
12

11

+
–

CT

10

9
8

7

6

Use the E54-CT1 with a hole
diameter of 5.8 mm or E54-CT3 with a hole
diameter of 12 mm (both sold separately).

Voltage Output Unit
(20 mA max.)

Current Output Unit
4 to 20 mA DC
(with a load of 600 Ω max.)

Relay Output Unit
3 A (resistive load)
at 250 VAC

A

–

B

B

+

Section 5-3

Note 1. The event input terminals and voltage output and current output terminals

are not insulated.

2. Only the heater burnout alarm will be output from the alarm output 1 termi­nals if alarm mode switch 1 is set to 0. Only the temperature alarm will be
output if the heater burnout alarm value is set to 0.0 A.

3. A simple model with no alarm does not incorporate any event input or alarm
output. A simple model with an alarm function does not incorporate any
event input.

39

This section describes the troubleshooting of the Thermac E5J Temperature Controller.

6-1 Error Display and Output 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 Troubleshooting 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6

Troubleshooting

41

Troubleshooting

6-1 Error Display and Output

The Thermac E5J Temperature Controller incorporates a self-diagnostic func­tion. The following table lists the process values and outputs that the E5J has
when errors result.

PV display Error Output Items to be checked

Control

output

Abnormal input OFF (2 mA

max.)

Abnormal memory OFF (2 mA

max.)

Abnormal A/D
converter

OFF (2 mA
max.)

Alarm

output

Processed
as an
abnormally
high
temperature.

OFF

OFF

• Whether or not the input has exceeded the
possible controlling range (±10% of the set
temperature range) (see note).

• Whether or not the setting of the input type is
incorrect.

• Whether or not the input has been incorrectly
wired, broken, or short-circuited.

Turn the E5J OFF and ON. If the display does
not change, the E5J need repairs. If the display
returns to normal, the E5J may have been
influenced by noise. Check for noise interference.

Section 6-2

Abnormal
calibration data.
Displayed for 2 s
when the E5J is
turned on.

Normal operation (accuracy
not guaranteed)

The E5J needs calibration. Contact your
OMRON representative.

Note If the input is within the possible controlling range but exceeding the possible

display range (–1999 to 9999),
–1999 and

will be displayed if the value is larger than 9999, at which time, the

))))

(((( will be displayed if the value is smaller than

control output and alarm output will work normally.

6-2 Troubleshooting

Refer to the following table for troubleshooting.

Phenomenon Probable cause Countermeasure

Nothing is displayed when the E5J
is turned on.

No setting is possible. The key protection switch is set to ON. Set the key protection switch to OFF.

When the Up Key is pressed for set
point value setting, the value flashes
within the set temperature range and
the setting is not possible.

No alarm, heater current value display ,
or heater burnout alarm is displayed.

The internal mechanism is not
inserted properly into the housing.

The power supply is not connected to
the power supply terminals properly.

No power is supplied or the supplied
power is not within the specified
range.

The E5J with a communications
function is in remote mode.

The set point limit function is active. Properly set the set point lower limit

The alarm mode switch is set to 0. Select the proper alarm mode.

A Current Output Unit is used for
control output.

Properly insert the internal mechanism
into the housing.

Properly connect the power supply to
the power supply terminals.

Supply a voltage of 85 to 264 VAC to
the power supply terminals of the
E5J.

The E5J must be in local mode or
no front key is available.

and set point upper limit values.

No heater burnout is detected if the
Current Output Unit is used for control
output.

42

Troubleshooting

Phenomenon CountermeasureProbable cause

The process value is abnormal or not
obtained.

No control output is obtained. No Control Output Unit is connected. Connect a Control Output Unit (sold

The heater burnout detecting function
is abnormal.

The input polarity is wrong or the
connection is wrong.

The input-type setting is incorrect. Properly set the input with the

No compensating lead wires are used
for the extension of the thermocouple.

The thermocouple and E5J is
connected via wires other than proper
lead wires.

The sensor is broken or
short-circuited.

The E5J is influenced by noise or
other induction.

°C is used instead of °F or vice versa. Use the proper temperature unit.
The process value is shifted because

the input shift function is used.

Event input 2 of the E5J is set to
STOP.

No Current Transformer (CT) is used. Properly connect the dedicated

The heater burnout alarm value is not
proper.

The heater is turned ON or OFF with
an output other than the control
output.

Properly wire the terminals.

input-type selector.
Use proper compensating lead wires.

Use a dedicated thermocouple
connector. If a metal material dif ferent
from the thermocouple is used to
connect the thermocouple and E5J,
a temperature error may result.

Use a good sensor.

Separate the input wires as far as
possible from the origin of the noise.

Set the input shift value to 0.

separately).
Open event input 2 and set the E5J

to RUN.

E54-CT1 or E54-CT3 (sold
separately) to the E5J.

Set the proper heater burnout alarm
value taking into consideration the
fluctuation of the heater supply
voltage and measurement error.

Use the control output. Heater burnout
detection synchronizes with the
control output. Any other output
cannot be used.

Section 6-2

Simple Method to Determine Temperature Controller Error or Sensor Error

When Thermocouple is Used If the temperature displayed by the E5J is close to the room temperature when

E5J is short-circuited, the E5J deemed to be normal

E5J is close to 0.0°C when a resistor with a

When Platinum Resistance
Thermometer is Used

the input terminals of the
and it is presumed that the sensor is broken, short-circuited, or incorrectly wired.

If the temperature displayed by the
resistance of approximately 100 Ω is inserted between terminals A and –B of the

E5J and terminals +B and –B of the E5J are short-circuited, the E5J

deemed to be normal and it is presumed that the sensor is broken, short-cir­cuited, or incorrectly wired.

43

SECTION 7

Event Input Function

This section describes how the event input function of the Thermac E5J Temperature Controller works.

7-1 Event Input Function 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1-1 Set Point Selection 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1-2 RUN/STOP Selection (E5AJ-B, E5EJ-B) 46. . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1-3 Signal Input Method 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

Event Input Function Section 7-1

7-1 Event Input Function

The E5J-B with an event input function is operated with ease with external
relay signal selection.

Set Point Selection It is possible to select one of the set points previously set for control operation.
RUN/STOP Selection It is possible to enable the E5AJ-B and E5EJ-B to RUN or STOP.

7-1-1 Set Point Selection

Select the set point by opening or short-circuiting event input 1 (EV1). Refer to
the following table. No set point can be selected with key operation.

EV1 Set point to be selected

Open Set point 0 (SP0)
Short-circuited Set point 1 (SP1)

The following illustration shows the operation of the E5J-B with its EV1 ter­minal short-circuited (i.e., set point 1 is selected).

EV1

Short-circuit

COM

Set point 0 and 1 (2 and 3) set
in advance on display level 1.

Display level 0

Displays the set point
currently selected.

Set point 0
(SP0)

Set point 1
(SP1)

Set point 2
(SP2)

Set point 3
(SP3)

SP2 and SP3 can be displayed
only when the set point selec­tion is selected with the event
input 2 selection (set to RUN/
STOP before shipping) on the
engineering level. Refer to

tion 9 Engineering Level Set­tings

The set point on display level 0 and that on display level 1 are synchronized. In
the above example, if the set point on display level 0 is changed from 200°C to
250°C, the set point 1 value on display level 1 will also change to 250°C.

7-1-2 RUN/STOP Selection (E5AJ-B, E5EJ-B)

RUN or STOP operation is selected by opening or short-circuiting event input 2
(EV2). Refer to the following table. RUN or STOP operation cannot be selected
with key operation.

Sec-

for details.

46

EV2 Operation

Open RUN
Short-circuited STOP

When the E5J stops operating, its control output will be 0% and fuzzy self-tun­ing will stop but its alarm output will operate normally.

The operation of the E5J the moment the E5J is turned on is determined by
the condition of event input 2.

Event Input Function Section 7-1

7-1-3 Signal Input Method

The event input terminals can be short-circuited using a relay or transistor as
shown in the following diagram.

+24 V

Signal Input Types

Internal circuitry

0 V

Contact Input No-contact Input

EV*

COM
ON: A resistance of 1 kΩ max.

OFF: A resistance of 100 kΩ min.

470 Ω

3 kΩ

VF = 1.2 VF = 0.6

(Open collector)

EV*

COM
ON: A residual voltage of 3 V max.

OFF: A current leakage of 1 mA max.

EV*

Flow current:
7 mA approx.

COM

The following table lists the event input terminal numbers for each model.

Model E5AJ/E5EJ E5CJ

Input terminal

EV1 20 14
EV2 19 --­COM 17 13

47

SECTION 8

Heater Burnout Detection

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

8-1 Heater Burnout Detection 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2 Heater Burnout Procedures 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3 Wiring the Current Transformer 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4 Heater Burnout Alarm Value 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4-1 Setting Examples 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

Heater Burnout Procedures

8-1 Heater Burnout Detection

To detect heater burnout, wire one of the lead wires for each heater through the
hole of the Current Transformer (CT). The CT generates an AC current accord­ing to the current flow of the lead wire. The Thermac E5J Temperature Control­ler measures the AC current to check the current flowing to the heater. If any one
of the heaters burns out, the AC current value will decrease so that the E5J
turns its heater burnout alarm ON, comparing the AC current value with the heat­er burnout alarm value.

8-2 Heater Burnout Procedures

The E5J starts heater burnout detection from the moment the E5J is turned
on. If any one of the heaters is turned on after the E5J is turned on, the heater
burnout alarm output will be ON because the E5J judges that the heater is
burnt out. Therefore, all the heaters must be turned on simultaneously with the
E5J or before the E5J is turned on. This is essential for smooth temperature
control and fuzzy self-tuning.

The E5J will continue temperature control even if the heater burnout alarm is
ON because the E5J will continue temperature control using the heaters that
are not burnt out.

Heater burnout detection is possible when the control output is ON. No heater
burnout detection is, however, possible if the control output is ON for less than
190 ms.

The heater burnout alarm output will be held once the heater burnout is de­tected. To reset the heater burnout alarm output, replace the burnout heater with
a good one and take one of the following steps.

Section 8-2

1, 2, 3...

1. Set the heater burnout alarm value to 0.0 A.

2. Turn the E5J off and on.

If the difference between the normal heater current value and heater burnout
current value is comparatively small, heater burnout detection will not be stable.
For stable detection, the difference must be 1.0 A minimum if the heater current
consumption is less than 10.0 A and 2.5 A minimum if the heater current con­sumption is 10.0 A or more.

Heater burnout detection is not possible if the E5J has current output, the
heater current is DC, or three-phase heaters are used.

Use the K2CU-FA-GS (with gate input terminals) for three-phase heater
burnout. Refer to the K2CU-FA-GS data sheet specifications for details.

If no heater burnout detection is executed or if no CT is used, set the heater burn­out alarm value to 0.0 A. The heater burnout alarm value is factory-set to 0.0 A.

50

Heater Burnout Alarm Value

8-3 Wiring the Current Transformer

Refer to the following diagram for the wiring the CT.

Relay driven with
control output

Heater

Section 8-4

To the CT input terminals of the E5J.
The CT input terminals have no polarity.

AC power supply

CT

To the CT input terminals of the
E5J

8-4 Heater Burnout Alarm Value

To obtain the proper heater burnout alarm value, check the normal heater cur­rent value and heater burnout current value with the heater current value display
on display level 1 first and set the heater burnout alarm value to the mean value
of these two values. If more than one heater is used, check the burnout value of
the heater with the smallest current consumption value.

To heater

CT

Heater burnout
alarm value

Normal heater
current value

=

Heater burnout

+

current value

2

If the difference between the normal heater current value and heater burnout
current value is comparatively small, heater burnout detection will not be stable.
For stable detection, the difference must be 1.0 A minimum if the heater current
consumption is less than 10.0 A and it must be 2.5 A minimum if the heater cur­rent consumption is 10.0 A or more.

If normal current value  10.0 A
Then normal current value – heat burnout current value  1.0 A

If normal current value  10.0 A
Then normal current value – heater burnout current value  2.5 A

The heater burnout alarm value can be set within a range of 0.0 to 50.0 A. If the
alarm value is set to 0.0 A or 50.0 A, no heater burnout detection is possible. The
alarm output is always OFF if the alarm value is set to 0.0 A and always ON if th e
alarm value is set to 50.0 A.

51

Heater Burnout Alarm Value

Section 8-4

The normal heater current value should be 50.0 A max. The heater current value
can, however, display up to 55.0 A. If the current value exceeds 55.0 A, CT input
overflow will result and ffff will be displayed.

CT input
overflow

8-4-1 Setting Examples

Example 1 In this example, 1-kW, 2-kW, and 3-kW heaters at 200 VAC are connected in par-

allel.

1, 2, 3...

1. Turn the control output ON and check the normal heater current value from
the heater current value display.

Normal current = (1000 + 2000 + 3000)  200 = 30.0 A

Heater current value display

Normal heater
current value

Heater Control

output ON

1KW 2KW 3KW

200 VAC

CT

2. Disconnect the heater whose current consumption is smallest and compare
the heater current value from the heater current value display.

Heater burnout current = 30.0 – 1000  200  25.0 A

Heater current value display

Heater burnout
current value

Heater Control

1KW 2KW 3KW

Disconnect

output ON

200 VAC

CT

Normal current – heater burnout current = 30.0 – 25.0 = 5 A ( 2.5 A)

3. Set the heater burnout alarm value to the mean value of the normal current
value and heater burnout current value.

Heater burnout alarm value = (30.0 + 25.0)  2 = 27.5 A

Example 2 In this example, 400-W, 1700-W, and 2000-W heaters at 200 VAC are con-

nected in parallel and the difference between the normal current value and heat­er burnout current value is less than 2.5 A.

1, 2, 3...

1. Obtain the normal current value and heater burnout current value in ad­vance as follows:

Normal current = (400 + 1700 + 2000)  200 = 20.5 A
Heater burnout current = 20.5 – 400  200 = 18.5 A
Normal current – heater burnout current = 20.5 – 18.5 = 2.0 A (Stable detec-

tion is not possible because the value is not 2.5 A or more.)

2. For stable hater burnout detection, in such a case, increase the number of
turns of the wire passing through the CT as if apparent current value in-

52

Heater Burnout Alarm Value

Section 8-4

creases. The displayed heater current value increases in proportion to the
number of turns of the wire passing through the CT.

Heater wire

The wire passes
through the CT
twice.

3. Obtain the heater burnout alarm value using the method in example 1.
Apparent normal current = (400 + 1700 + 2000)  200 x 2 = 41.0 A

Normal heater
current value

Apparent heater burnout current = (41.0 – 400  200) x 2 = 37.0 A

Heater burnout
current value

Normal current – heater burnout current = 41.0 – 37.0 = 4.0 A ( 2.5 A)
Heater burnout alarm value = (41.0 + 37.0)  2 = 39.0 A

Heater burnout
alarm setting

53

SECTION 9

Engineering Level Settings

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

9-1 Engineering Level 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2 Engineering Level Parameter List 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3 Engineering Level Parameters 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

Engineering Level Parameter List

9-1 Engineering Level

To go to engineering level, set pin 4 of the internal function switch of the E5J to
ON before turning the E5J on. After this setting, set pin 4 of the internal func­tion switch to OFF.

Turn on the E5J.

Set pin 4 of the
function switch to
ON.

9-2 Engineering Level Parameter List

The following is a list of engineering level parameters.

Section 9-2

This display will appear.

Display Name Setting range Setting before

shipping

d-U °C/°F selection

LEn Data bit length 7: Data length of 7 bits

PrtY Parity check

Sbit Stop bit length 1: 1 bit

S.t-b Stable range 0.1 to 999.9 °C/°F 15.0 (27.0)

15.0

ALFA Alpha 0.00 to 1.00 0.65

rEt Automatic return of

display mode

rESt Standby sequence reset

method

c: °C
f: °F

8: Data length of 8 bits

none: No parity
eUen: Even
odd: Odd

2: 2 bits

0 to 99 s
0: No automatic return

0: Reset method 0
1: Reset method 1

c

7

eUen

2

0

0

User’s remarks

56

in-S Input shift display

ALH1 Alarm 1 hysteresis 0.1 to 999.9 °C/°F 0.2 (0.4)

ALH2 Alarm 2 hysteresis 0.1 to 999.9 °C/°F 0.2 (0.4)

SL-L Set point lower limit

value

off: Not displayed
on: Displayed

Set range lower limit to
set point upper limit
value (see note 1).
(°C/°F)

off

–200 (–300)

Engineering Level Parameter List

Section 9-2

Display User’s remarksSetting before

SL-H Set point upper limit

value

EV-2 Event input 2 type

selection

Setting rangeName

Set range lower limit
value to set range
upper limit value (see
note 1). (°C/°F)

0: Set point selection
(SP2, SP3)

1: RUN/STOP

shipping

1300 (2300)

1

Note 1. The decimal position varies with the input type.

2. The value in the parentheses is the E5J--F setting before ship­ping.

57

Engineering Level Parameters

9-3 Engineering Level Parameters

15.0

Section 9-3

The value set before shipping
appears. (see note 1)

(°C/°F selection)

Displayed if the E5J with a com­munications function is used.

(Data bit length setting)

(Parity check setting)

(Stop bit length setting)

Displayed if the E5J is in advanced
PID operation with fuzzy self-tuning.

(Stable range setting)

Displayed if the E5J is in advanced
PID operation.

(Alpha setting)

(Automatic return of display mode)

Displayed if the E5J with an alarm
function is used (see note 2).

(Standby sequence
reset method setting)

(Input shift display selection)

Displayed if the E5J with an alarm
function is used (see note 2).

(Alarm 1 hysteresis
setting)

Displayed if the E5J with an alarm
function is used (see note 2).

(Alarm 2 hysteresis
setting)

(Set point lower limit setting)

(Set point upper limit setting)

Displayed if the E5J with
event input 2 is used.

(Event input 2 function
selection)

58

Note: 1. The E5J--F values set before shipping may be

different. Refer to

2. The value will not be displayed if the alarm mode switch is
set to 0 or if the E5J does not incorporate any alarm.

9-2 Engineering Level Parameter List.

Engineering Level Parameters

Section 9-3

rdu °C/°F Selection To change the temperature display unit from °C to °F, press the Up Key so that f

will be displayed in the set value display.

E5J with
Communications Function

SV SV

The communications specifications of the E5J are as follows:
Data bit length: ASCII 7- (set before shipping) or 8-bit code

c: °C
f: °F

Parity check: None, even (set before shipping), or odd
Stop bit length: 1 or 2 (set before shipping)
Use the following parameters to change the above setting.

len Data Bit Length Use this parameter to change the communications data bit length.
prty Parity Check Use this parameter to change the communications parity check.

SV SV

SV

none : None
eUen : even
odd : odd

sbit Stop Bit Use this parameter to change the stop bit length.
s.t-b Stable Range (°C/°F) This parameter is used to decide conditions under which fuzzy self-tuning oper-

ates and can be set within a range of 0.1 to 999.9. If the absolute value of the
deviation (the difference between the process value and set point) is within the
stable range, temperature control operation is deemed smooth and fuzzy self­tuning will not start.

Stable

Set point

Stable

PID before tuning

It is deemed that the characteristics
of the control device have been
changed so that the response wave­form is processed to tune the PID
constants.

Fuzzy self-tuning

PID after tuning

range

alfa (α) PID Control Type By adjusting internal parameter α of advanced PID within a range of 0.00 to 1.00,

PID control such as derivative preceding PID or proportional preceding PID (I­PD) control will be possible.

α = 0.00 (Derivative preceding PID)

Set point

α = 0.65

α = 1.00

(Proportional preceding PID)

Difference in set point response due to α.

To increase the set point response speed, decrease the value of parameter α. If
the value of parameter α is decreased, however, the overshooting value will in­crease.

59

Engineering Level Parameters

Section 9-3

ret Automatic Return of
Display Mode (Return Time)

rest Standby Sequence
Reset Method

By setting automatic return of display mode, the display will return to the normal
operation display (on level 0 displaying the process value or set point) if no key is
operated for the time set with this parameter . The return time can be set within a
range of 0 to 99 s. If the return time is set to 0 s, this function will not work. The
return time is set to 0 s before shipping.

It is possible to select the restart conditions of the standby sequence of the alarm
attached with standby sequence. If this parameter is set to 0, the standby se­quence will restart when the set point, alarm value, or input shift value is
changed or the moment the E5J starts operating including the moment the
E5J is turned on. If this parameter is set to 1, the standby sequence will restart
only the moment the E5J is turned on. The following timing chart is an example
of a lower limit alarm attached with standby sequence.

Standby sequence releasing point

Standby
sequence
releasing

OFF point due to
alarm hysteresis

Alarm point

(Standby sequence reset method 0)

Alarm output

(Standby sequence reset method 1)

Alarm output

point

Standby sequence
restart

Set value
change

ins Input Shift Display It is possible to select to display or not to display the input shift function on display

level 1 with this parameter.

alh1 Alarm 1 Hysteresis
and alh2 Alarm 2
Hysteresis

SV SV

It is possible to adjust alarm sensitivity with both these parameters within a range
of 0.1 to 999.9. Change the alarm sensitivity of the E5J if the alarm output chat­ters.

Upper limit alarm

ON
OFF

Low

temperature

Alarm point

Hysteresis

High

temperature

off : Not displayed
on : Displayed

Lower limit alarm

ON
OFF
Low

temperature

Hysteresis

Alarm point

High

temperature

The alarm output will be OFF when the process value is within the alarm hystere­sis range when the E5J restarts (e.g., when the E5J is turned on).

sll Set Point Lower Limit
Value (°C/°F) and slh Set
Point Upper Limit Value
(°C/°F)

It is possible to limit the set point changeable range with both these parameters.
For example, if the set point lower limit value is set to 0°C and the set point upper
limit value is set to 400°C, the set point can be changed only between 0°C and
400°C.

60

Engineering Level Parameters

Section 9-3

eu2 Event Input 2 Type
Selection

It is possible to select the function of event input 2. If 0 (set point value selection)
is selected, sp2 and sp3 will be displayed on display level 1 and if 1 is selected
RUN/STOP will be selected. When 0 is selected, the set point can be selected
from the following.

EV1

20

EV2

19

COM

17

EV1 EV2 Set point to be selected

Open Open SP0
Short-circuit Open SP1
Open Short-circuit SP2
Short-circuit Short-circuit SP3

61

This section describes how to execute auto-tuning.

10-1 Starting Auto-tuning 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2 Conditions that Prevent Auto-tuning 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3 Force-ending Auto-tuning 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4 Changing Parameters during Auto-tuning 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10

Auto-tuning

63

Changing Parameters during Auto-tuning

10-1 Starting Auto-tuning

Auto-tuning can be started by using the following procedure. Use this procedure
when appropriate results are not achieved via fuzzy self-tuning.

Section 10-4

1, 2, 3...

1. Turn ON pin 3 of the function selector switch to select the advanced PID con­trol mode (refer to

2. Press the Level Key and the Display Key simultaneously for 1 s or longer to
start auto-tuning.

Section 2-3-5

).

10-2 Conditions that Prevent Auto-tuning

You will not be able to start auto-tuning when any of the following conditions ex­ist.

• When the control mode is set for ON/OFF control or advanced PID control with
fuzzy self-tuning.

• When an engineering level parameter is displayed.

• When the key protection switch is set to SP

• When the remote/local setting is set to remote.

• When the RUN/STOP setting is set to STOP.

• When a sensor error, memory error, or A/D converter error has occurred.

10-3 Force-ending Auto-tuning

Auto-tuning will be forced to end for any of the following conditions.

• When the Temperature Controller is turned off.

• When the RUN/STOP setting is changed to STOP.

• When a sensor error occurs.

• When the Level Key and the Display Key are pressed simultaneously for 1 s or

longer.

or ALL.

10-4 Changing Parameters during Auto-tuning

• Parameters cannot be changed during auto-tuning, but the remote/local set­ting can be changed.

• The SP also cannot be changed via the event input during auto-tuning, but the
event input status can be changed and the SP will be changed after auto-tun­ing has been completed.

Auto-tuning

Open

SP0

SP0 selected.

Auto-tuning started.
Scale changes disabled here.

Shorted

SP1 selected.

Set point

Event input
terminal

64

SP1

E5AJ

Dimensions

Appendix A

Dimensions/Mounting Holes

96 x 96

Mounting Holes

120 min.

92

12 98

112

+0.8
0

+0.8

92

0

(96 x units – 3.5)

91 x 91

+1
0

+0.8

92

0

Note 1. All dimensions shown are in millimeters.

2. Side-by-side close mounting is not possible for E5AJs equipped with the Watertight Cover (sold sepa­rately).

65

E5EJ

Dimensions

Appendix ADimensions/Mounting Holes

48

96

Mounting Holes

120 min.

45

+0.6
0

12 98

112

+0.8

92

0

(48 x units – 2.5)

44

91

+1
0

+0.8

92

0

Note 1. All dimensions shown are in millimeters.

2. Side-by-side close mounting is not possible for E5EJs equipped with the Watertight Cover sold sepa­rately).

E5CJ

Dimensions

48 x 48

66

9.5

58

100

44.8 x 44.8

Appendix ADimensions/Mounting Holes

Mounting Holes

+0.6

45

60 min.

0

45

+0.6
0

(48 x units – 2.5)

+1
0

+0.6

45

0

Note 1. All dimensions shown are in millimeters.

2. Side-by-side close mounting is not possible for E5CJs equipped with the Watertight Cover (sold sepa­rately).

Terminal Covers

E53-COV02 E5AJ with Terminal Cover

12 115

112

E53-COV04 E5CJ with Terminal Cover

9.5

115

58

67

E53-COV03 E5EJ with Terminal Cover

12 115

112

Appendix ADimensions/Mounting Holes

68

Index

A

advanced PID

function, 2
setting, 14
setting with fuzzy self-tuning, 14

alarm mode

changing, 22
setting. See settings
standby sequence. See settings

auto-tuning

force-ending, 64
parameters, 64
preventing, 64
starting, 64

automatic return of display mode. See engineering level

C

communications function, specifications, 7
control period, setting range, 24
CT. See current transformer
current transformer

specifications, table, 6
wiring, 51

cycling. See hunting

D

E

engineering level

alarm hysteresis, 60
automatic return of display mode, 60
communications, 59
data bit length, 59
input shift display, 60
parameters, 19
parameters table, 56
parity check, 59
PID control type, 59
selecting temperature display, 59
settings, 56
stable range, 59
standby sequence reset, 60
stop bit, 59

event input 2, 33

selecting, 61

event input function, 2

parameters, 24
selecting RUN/STOP, 46
selecting set point, 46
signal input method, 47

external disturbance, definition, 32

F

features, 2
front panel, features, 18
functions

control mode, 14
level setting, 14
output operation, 14
selector settings, 14

fuzzy self-tuning

features, 28
function, 2

derivative time range, 25
dimensions, 65, 66, 67
display levels

level 1, 23
parameters, 22, 23

displays

engineering level, 19
levels, 19

disturbance tuning

conditions, 29
measuring external disturbance response waveform, 29
measuring set point response waveform, 29
startup conditions, 29

DT. See disturbance tuning

H

heater burnout

detection, 50
procedures, 50

heater burnout alarm

current value, 24
determining value, 51
operating characteristics, 7
parameters, 24
setting examples, 52

setting value, 24
HT. See hunting tuning
hunting, definition, 32
hunting tuning, startup conditions, 30
hysteresis, setting range, 24

69

Index

I

installation

mounting, 36

precautions, 36
integral time range, 25
interference, definition, 33
internal switches, sensor type and control mode, 10

K-M

key protection switch, setting, 15
manual reset value, 25
models, 2

Communications Boards, 4

communications function, limitations, 3, 4

standard, 3
mounting. See installation
mounting holes, 65, 66, 67

N-O

nomenclature, 18
output unit

life expectancy, 7

npn type, 11

pnp type, 11

selecting, 10

specifications, table, 6

types and models, 2
output value, setting range, 24

set point

See also event input function
adjusting changeable range, 60
setting type, 22

settings

advanced PID control, 14
alarm mode selection, 13
functions. See functions
fuzzy self-tuning, 14
internal switches, 11, 12
key protection switch, 15
selecting input type, 12
selecting output unit, 10
sensor type and control mode, 10

specifications

general, table, 5
operating characteristics, table, 6

output unit, table, 6
SRT. See step response tuning
stability judgement time, 32
stable range, 32
stable value, 32
standby sequence, resetting. See engineering level
startup, 33
step response tuning

See also SRT

operating conditions, 28

PID constant refreshing conditions, 29

startup conditions, 28

step controlled amount, 29
STOP, selection, 46
stop bit, changing length. See engineering level

P

parameters

engineering level, 19
levels, 19
setting, 19

tables, 20
PID, setting constants, 32
proportional band range, 25

R

return time, 60
RUN, selection, 46

S

self-diagnostic function, 42

70

T

terminal arrangement, 38
Terminal Covers, 67
troubleshooting, 30

controller and sensor error, 43
table, 42

W

watertight cover, 2
wiring

current transformer, 51
precautions, 37
terminal arrangement, 38, 39
using solder-dipped leads, 37
using solderless terminals, 37

Revision History

E5J Temperature Controller

Operation Manual

A manual revision code appears as a suffix to the catalog number on the front cover of the manual.

Cat. No. WZ103-E3-1

Revision

code

The following table outlines the changes made to the manual during each revision. Page numbers refer to the
previous version for manuals designated as E1 revisions.

Revision code Date Revised content

Z103-E1-1 November 1993 Original production
Z103-E1-1A January 1994 Page 20: Hysteresis row in the table corrected. Note added.

Page 21: Proportional band row in the table corrected. Note added.
Page 23: Proportional band setting in the diagram corrected.
Page 29: Stable range in both diagrams corrected. Note added.
Pages 30, 32: Stable range in top diagram corrected.
Page 51: “Heater current value level 1” corrected to “Heater burnout value” in

the equation.
Page 56: Stable range, alarm hysteresis 1, alarm hysteresis 2, and set point

lower limit value rows in the table corrected.

Page 57: Note added.
Z103-E1-2 March 1994 Major revision. Most of the pages have been changed or revised.
Z103-E1-3 June 1995

Z103-E1-4 November 1996 Page 2: Auto-tuning added to

Section 10 Auto-tuning

Page 2:

Page 4: Note 1 corrected.

Page 6: Models added to the Output Units table.

Page 10: Models added to the Output Units table and second sentence after

the table corrected.

Page 28: First note on the page corrected.

Page 38: The polarities for RS-485 in

tion

Page 5: Auto-tuning added to

Page 7:

ratings

Page 38: “+” added to terminals 20 and 19 and “–” added to terminal 17 in the

E5AJ/E5EJ Standard Model terminal arrangement.

Page 39: “+” added to terminal 17 and “–” added to terminal 16 in the E5BJ

terminal arrangement. “+” added to terminal 14 and “–” added to terminal 13 in

the E5CJ Standard Model terminal arrangement.

Pages 65 to 68: Terminal Covers and their dimensions added.

Output Units

.

EMC

and

changed. Notes added also.

added.

corrected.

1-1 Features
Control mode

Approved standards

E5AJ/E5EJ with Communications Func-

.

in the table.

added to the top table and

Enclosure

71

Revision History

Revision code Revised contentDate
Z103-E1-5 February 1998 Page 4: Supply voltage and power consumption specifications changed.

Page 19: Thermac E5J information added to the beginning of

Flowchart

Pages 38, 39: Terminal arrangement diagrams changed.

Page 56: Information added to

Z103-E3-1 March 1998 All references to model E5BJ removed.

Pages 38,39: Corrected power consumption in terminal arrangement draw-

ings (based on revision E1-5); kept terminal arrangement drawings the same

as revision E1-4.

.

9-1 Engineering Level

.

3-2 Setting

72