THE SUPERDRYER CACTUS 5 CACTUS 10 CACTUS 15 CACTUS 25 CACTUS 50 INSTALLATION AND OPERATING INSTRUCTIONS PATENTED

Transcription

1 THE SUPERDRYER PATENTED CACTUS 5 CACTUS 10 CACTUS 15 CACTUS 25 CACTUS 50 INSTALLATION AND OPERATING INSTRUCTIONS

2 CACTUS SUPERDRYER OPERATION MANUAL INTRODUCTION Your Cactus Superdryer has been designed, tested and manufactured to provide years of reliable, consistent operation. It is different from ordinary dryers so it is important to understand how to use it. As a part of the molding system, it should be considered as a component of that system, not a separate independent machine. Adjustments to the molding machine may have an effect on the dryer because it uses the screw and barrel to assist the drying process. Please spend a few moments reviewing the contents of this booklet to ensure that your Cactus Dryer performs at its best. DESIGN The manufacturers of the dryer may introduce design improvement from time to time, resulting in some deviation from the information given in this booklet. While every effort will be made to update the literature as required, the manufacturers cannot accept liability for situations arising from such discrepancies. CACTUS MACHINERY LLC Georgetown Rd Hudson, OH USA Phone: (330) Fax: (330) info@cactusmachinery.com

3 METHOD OF OPERATION The Cactus dryer is mounted directly on the feedthroat of the molding machine. A hopper or loader is mounted to the top of the dryer to provide a continuous supply of resin to the dryer. The resin is supplied directly from the bag, barrel or gaylord and does not require predrying. In operation the plastic resin feeds continuously from the hopper (1) into the throat (2) and down through the body (3) of the dryer. The resin is heated by conduction and radiated heat at this stage. The heat is supplied by electric heater bands (4) mounted on the body. Heat is precisely controlled by a closed loop P.I.D. temperature controller (5). Simultaneously a partial vacuum is generated inside the body of the dryer. The vacuum is generated by a compressed air powered venturi (6). The fast heating causes moisture trapped within the plastic pellet to be forced to the pellet surface. This moisture is carried away by air. Ambient air enters through an inlet (7) in the lower flange (8), passes over the heater bands, through slots in the body (9) across the plastic resin, picking up the moisture, then, exits via the filter basket (10) and though the venturi to the atmosphere. By the time plastic resin is processed though the body of the dryer and down in the screw of the molding machine, most of the moisture has been removed. Should any remain, the action of the screw causes it to vaporize in the rear zone. These vapors are extracted by the extension tube (11) and out through the venturi. As a result, all moisture is removed before plasticization and dry resin is injected into the mold. Residence time of the resin in the Cactus dryer is normally minutes. The key elements of the system are; Precise temperature control, accurate air flow by the venturi, injection settings, and throughput lbs. (kg) per hour. If these elements are considered and adjusted for each setup, the Cactus will provide reliable and economical drying of most thermoplastic resins.

4 CUT-AWAY VIEW

5 INSTALLATION 1. Unpacking The dryer is shipped from the factory in preformed packing. The venturi assembly is wrapped separately and placed in the box. Also, the extension tube may be packed separately. Any shipping damage must be reported to the carrier immediately. Claims for damage should be made by the customer against the carrier. Unpack the dryer carefully, ensuring that the venturi assembly and extension tube are not thrown out with the wrappings. 2. Preparing the dryer for mounting Due to the large difference between molding machines, only general guidance for mounting the dryer can be given. In most cases it is recommended that an adapter be fitted between the lower flange of the dryer and feed opening of the molding machine. Whether the adapter can be a simple plate or a more sophisticated flanged tube depends upon the nature of the molding machine. It is important to have a smooth transition between the bottom opening of the dryer and feed throat of the molding machine to prevent material from hanging up. It is normal to mount the dryer so that the control instrument faces the operator. NEVER LOCATE THE INSTRUMENT OVER THE HOT BARREL OF THE MACHINE. Do not mount the dryer until operation 3 is complete (setting the tube length). Note: Adapters to suit some molding machines are available from Cactus. Check with your local representative or contact Cactus directly.

6 3. Setting the Extension Tube Length I. Lay the dryer assembly down horizontally. II. For Cactus Models 5, 10 and 15 slide the extension tube over the fixed tube inside the bottom flange. Push the adjusting rod up through the main body and through the small hole and lock handle (fastened to the top casting). For the Cactus 25, the adjusting rod - extension tube assembly slides up inside the fixed tube. The adjusting rod will guide itself through the small hole and lock handle in the top casting. III.Measure the distance from the top face of the mounting surface on the molding machine, including adapters etc. (if used) to the top of the screw flight in the feed throat as shown. IV. Subtract approximately 3/8" (1 cm) from the dimension obtained in III, so that when the dryer is mounted, the tube will then be 3/8 (1 cm) above the top of the screw flight. V. Set the bottom end of the extension tube to the dimension offered in IV. VI. Tighten the small allen screw on the lock-handle assembly sufficiently to hold the extension tube in place. VII. By loosening the thumb screw on the lock handle assembly, the extension tube can be raised and lowered without altering the fixed settings. Note: Longer extension tubes are available from the factory should the standard tube not have sufficient length.

7 4. Mounting the Dryer The dryer is now ready to be mounted onto the molding machine. It should be lifted into place carefully and BOLTED to the machine with whatever adapters, spacers, slides etc. that are being used. A proper fit is required to ensure that no air can enter between the dryer, adaptor, etc. and the feedthroat opening. Should gaps appear at this location, cool, moist air can enter and cause incomplete drying. 5. Mounting the Venturi Assembly The venturi assembly mounts to the horizontal outlet of the top casting. The pressure regulator may be set in any desired direction, but the preferred position is downward. Tighten the venturi with the hardware supplied. 6. Pneumatic Connection The venturi assembly is supplied with a quick connect assembly at the pressure regulator. A 1/4" (6mm) inside diameter flexible air supply hose should now be connected to the female end of the quick connect. The air supply should be reasonably clean and dry in order to minimize service of the air regulator. 7. Connecting the Electrical Service A power cord is supplied and is should be fitted with a plug to suit the customer's electrical requirements. VOLTAGE MUST BE BETWEEN 220V AND 240V, SINGLE PHASE, HZ. 8. Fitting Hoppers and Loaders The top flange for the dryer is supplied pre-drilled. It matches the AL200 Auto Loader or the RL500 Ratio Loader. These items must be bolted together directly using four bolts, with suitable nuts and washers.

8 9. Magnets If a magnet is used, it MUST be mounted ABOVE the dryer to allow the extension tube to be lowered into the feedthroat. The Cactus Drawer Magnets have pre-drilled holes that match the AL200 Auto Loader or the RL500 Ratio Loader. 10. Air Assisted Jet Clean Out (if equipped) A jet clean out (optional for the Cactus 5, 10, and 15, standard on Cactus 25) enables the operator to drain material from the dryer with the aid of compressed air. The jet clean out is shipped with the venturi and mounts to the hole located on the bottom casting at the back of the dryer. By removing the quick connect air line from the venturi and connecting it to the fitting supplied with the jet clean, the material will be "sucked" from the dryer. It will be necessary to put a hose around the end of the jet clean to carry the material to a bag. NOTE: WHEN THE JET CLEAN OUT IS NOT IN USE, BE SURE THAT THE END OF THE HOLE IS PLUGGED OR COVERED WITH THE HARDWARE PROVIDED. FAILURE TO KEEP THE HOLE PLUGGED WILL ALLOW MOIST, COOL AIR TO ENTER AND MAY RESULT IN INCOMPLETE DRYING.

9 OPERATING PROCEDURE A. START UP 1. With extension tube raised, close shut off gate at the injection machine throat (if fitted). If there is no shut off gate, lower extension tube into feed throat and lock in place using thumb screw on lock handle. 2. Fill the hopper/loader and dryer with resin. There should be a minimum depth of 4 inches (10 cm) of material above the top flange of the dryer. 3. Turn on the compressed air supply to the venturi and adjust to the operating setting (see accompanying chart). If the venturi is installed correctly, air will be exhausted into the atmosphere. 4. Turn controller on. Controller will automatically start sending power to the heater bands. The factory setting of 200 degrees F. (93 degrees C)will be displayed on the lower display. The actual temperature will appear in the upper display. 5. By pressing either ARROW key, you are able to raise or lower the operating temperature. Refer to the temperature guide in this manual for the recommended temperature to ensure proper drying of your material. NOTE: CACTUS 25 Set desired temperature in both upper and lower zone. Cactus recommends the same temperatures to be set in both zones. FOR DETAILED INFORMATION ON THE FEATURES OF THE OMRON TEMPERATURE CONTROLLER, PLEASE REFER TO THE INFORMATION SHEETS LATER IN THIS MANUAL OR CONSULT THE FACTORY.

10 B. OPERATION 1. Turn the unit ON. Select the operating temperature by pressing the UP or DOWN key, which will appear in the LOWER display in GREEN. 2. After the dryer has reached temperature, let the material warm up for minutes. 3. Open shut off gate if closed and lower extension tube. Commence molding by purging several shots. Note: Purged material may display sign of aeration degradation. This is normal at this stage and will disappear after the first few molding shots. 4. Observe the following molding machine settings: A) SET THE SCREW ROTATION SPEED AS SLOW AS THE APPLICATION PERMITS B) SET THE SCREW BACK PRESSURE TO 50 psi (3.5 bar) MINIMUM. THE BEST RANGE IS 50 TO 100 psi (3.5 to 6.5 bar). C) THE FEED THROAT OF THE MOLDING MACHINE MUST BE WARM: 130 TO 160 DEGREES F ( DEGREES C) DEPENDING ON RESIN. D) ADJUST INJECTION SPEED TO SLOW OR MEDIUM. E) SET THE THE REAR BARREL ZONE APPROX DEGREES F (8-12 DEGREES C) HOTTER THAN NORMAL. (The front zone may be lowered if necessary). 5. Continue molding, any traces of moisture will disappear. If moisture traces remain in the molded parts, refer to the Problem solving section of this booklet. 6. It is recommended that the dryer be left empty after the molding operation has been completed. The air and power should be shut off. When restarting if the dryer has been left full of material, it may require more warm up time. Note: Only general quidelines can be given for start up and operation. Some applications may require variations with respect to time and temperature during this stage.

11 Changing Temperature When changing temperature of the Superdryer, you need only to press either the UP or DOWN keys Note: The OMRON temperature controller has been factory set for over and under temperature alarm limit of 10 degrees F (6 degerees C) with 1 (one) standby. If you are lowering the temperature by mara than the factory set limit for the second (or more) time without turning the controller off, you may activate the alarm. THERE IS A MANUAL RESET FOR ALL ALARM CONDITIONS. THE MANUAL RESET BUTTON WILL NOT WORK UNTIL THE CONTROLLER IS OUT OF AN ALARM CONDITION. Should this occour, you must turn the controller OFF, which will reset the unit. You will then be able to resume normal operation. Audible Alarm If you have ordered the Superdryer with the audible alarm option, the buzzer will activate should the temperature exeed your upper limit or fall bellow yout lower limit (factory set at 10 degrees F or 6 degrees C). THE BUZZER WILL NOT CEASE UNTIL THE ALARM INDICATOR ON THE CONTROL IS OFF AOND THE RESET BUTTON IS PUSHED. If the alarm is sounding and the alarm indicator on the OMRON controller is on, you will need to turn the controller OFF to disengage the alarm, which will reset the unit. Note: There are many alarm options available. Consult the OMROM instruction manual or the factory for details. SHOULD YOU HAVE THE CACTUS SUPERDRYER DEDICATED TO ONE MACHINE AND MATERIAL AT ALL TIMES (OPERATING AT THE SAME TEMPERATURE), YOU CAN LOCK ALL SETTINGS TO ELIMINATE ANY OPERATOR ERROR. PLEASE CONSULT OMRON MANUAL OR FACTORY FOR DETAILS.

12 THROUGHPUT GUIDE MODEL HEIGHT in/cm 18/46 28/71 28/71 46/117 46/117 SHIP WEIGHT lb/kg 26/12 47/21 54/25 192/87 250/12 AIR CONSUMPTION cfm ELECTRICAL kw V, 1 PHASE amps HEATED CAPACITY lb/kg 1.0/ / / / /27 TOTAL CAPACITY lb/kg 2.0/ / / / /45.5 MATERIAL lb/kg TO BE USED AS A GUIDE ONLY ABS 7/3 18/8 30/14 75/35 150/70 ACETAL 15/7 45/20 75/35 125/60 250/115 ACRYLIC 7/3 18/8 30/14 75/35 150/70 BUTYRATE 3/1.5 9/4 15/7 40/18 80/40 NYLON 7/3 18/8 30/14 75/35 150/70 PBT 7/3 18/8 30/14 75/35 150/70 PET 3/1.5 9/4 15/7 40/18 80/40 POLYCARBONATE 7/3 18/8 30/14 75/35 150/70 POLYETHYLENE 15/7 45/20 75/35 125/60 250/115 POLYSTYRENE 15/7 45/20 75/35 125/60 250/115 POLYSULPHONE 3/1.5 9/4 15/7 40/18 80/40 POLYURETHANE 3/1.5 9/4 15/7 40/18 80/40 PPO (NORYL) 7/3 18/8 30/14 75/35 150/70 PVC 7/3 18/8 30/14 75/35 80/40 SAN 7/3 18/8 30/14 75/35 150/70 ULTEM 3/1.5 9/4 15/7 40/18 150/70 THESE THROUGHPUTS ARE BASED ON AVERAGE SUMMERTIME CONDITIONS USING NORMALLY STORED VIRGIN MATERIAL. THROUGHPUT MIGHT VARY DEPENDING ON APPLICATION. REGRIND MAY AFFECT THROUGHPUT (SEE SECTION ON REGRIND).

13 *FOR MATERIAL NOT LISTED, CONSULT CACTUS MACHINERY LLC. TEMPERATURE GUIDE (SETPOINT) The operating temperature of the Cactus dryer is higher than the resin manufacturers recommended drying temperature, but, lower than the Thermal Deflection Temperature at 66psi. The 66psi should be determined by considering the unfilled material. Filled material will be listed at a higher temperature and that may cause pellets to stick together or bridge. The Cactus operating temperature should NEVER EXCEED 15 degrees F or 10 degrees C below the rated "Thermal Deflection Temperature@ 66psi,as specified in the thermal properties listed by the resin manufacturer. MATERIAL DEGREES F DEGREES C ABS (85-100) ACETAL 225 (110) ACRYLIC (80-95) BUTYRATE (60-75) NYLON (95-135) POLYCARBONATE ( ) POLYETHYLENE (80-90) POLYESTER PBT ( ) PET ( ) POLYSTYRENE (80-95) POLYSULPHONE ( ) POLYURETHANE (60-75) P.P.O. (NORYL) ( ) PVC (65-80) SAN (80-95) TPE (94 108) ULTEM ( ) FOR OTHER MATERIALS, OR FOR FURTHER INFORMATION REFER TO CACTUS TECHNICAL DEPARTMENT FOR SUGGESTED SETTINGS AND THROUGHPUT CAPACITIES.

14 RECOMMENDED VENTURI SETTINGS The venturi on the Cactus is used to generate air flow through the dryer. This air flows through the resin bed and strips away the moisture that has been released from the plastic pellet. Generally, the gauge settings will fall in the following ranges; CACTUS MODEL RECOMMENDED GAUGE SETTINGS 5 1-3psi ( bar) psi ( bar) psi ( bar) psi ( bar) psi ( bar) FACTORS WHICH MAY AFFECT THROUGHPUT AND TEMPERATURE Virgin / Regrind Ratio Maximum throughput is very dependant on the quality and percentage of regrind. Pellet size and consistency are critical. A 3/16" - 1/4" (4-6 mm) grinder screen is recommended for regrind. Good regrind up to 25% should have little effect on throughput. Good regrind up to 50% may reduce throughput by 25%. Good regrind up to 100% may reduce throughput by 50%. Coarse regrind up to 25% may reduce the throughput up to 50%. Coarse regrind up to 50% may cause incomplete drying. Filled Material Materials filled with glass, flame retardants, etc. may require temperatures which fall closer to the high end of the recommended temperature range.

15 TROUBLE SHOOTING 1. Check the supply voltage, voltage must be between 220V and 240V, single phase, Hz, or unit will not operate properly. Check fuses inside control cabinet. 2. Make sure that the throughput is within the recommended rates. 3. Review the factors affecting throughput. 4. Check the temperature setting. If drying is incomplete, the temperature must be as high as possible without bridging occurring. 5. Check for bridging. Bridging in one or more chambers will cause incomplete drying. Bridging may be caused by setting operating temperature too high or large chunks in regrind. 6. Check the electrical and mechanical components of the dryer to make certain they are functioning normally. 7. Check for blockages of air flow. If material being dried is heavy with fines, clogging may occur in the venturi, filter basket, extension tube or air slots in the body. This will restrict the proper flow of air through the dryer and cause incomplete drying. CLEAN DRYER PERIODICALLY. 8. Check for air gaps between the base of Cactus and feed throat of molding machine. The vacuum generated by the venturi will cause moist, cool air to be drawn into the plastic pellets through air gaps. This can actually cause moisture to be added to the plastic. 9. Check "Jet Cleanout" (if fitted), to be sure spout is plugged with plug supplied. This could also be a source of moist, cool air. 10.Check supply of resin. If the supply falls below the top flange of the Cactus, air will be sucked in through the hopper. This can result in loss of vacuum in the dryer and cause incomplete drying. 11.Review the injection machine settings. for proper dryer operation. They are important

16 DISASSEMBLY AND CLEANING PROCEDURE Before attempting disassembly always disconnect from power source. 1. Remove the socket head screws connecting the top casting to the dryer body. 2. Loosen the Phillips screws holding the outer stainless steel shroud to the top casting. ( approx. 2-3 turns.) 3. Grasp the top flange and pull it upward to remove the assembly from the body. The top casting, filter basket and extension tube will then be removed as one assembly. This may be cleaned using cloth, brush or air gun. If the unit is hot, metal expansion may cause a tight fit. 4. The main body of the unit is now exposed for easy access to cleaning. 5. Access to the heater bands may be obtained by loosening the Phillips screws at the bottom. The shroud and insulation will then lift clear of the main body. 6. The radial slots in the main body should be cleaned and any resin pellets should be removed. 7. To reassemble, reverse the procedure. For Cactus Models 5, 10 & 15, the top flange and the venturi may be assembled to face any of four directions as seen from a top view. The Cactus 25 must be re-assembled with the top flange and venturi pointing to the right as you face the temperature controller.

17 DISASSEMBLY AND CLEANING PROCEDURE Before attempting disassembly always disconnect from power source. 1. Remove the socket head screws connecting the top casting to the dryer body. 2. Loosen the Phillips screws holding the outer stainless steel shroud to the top casting. ( approx. 2-3 turns.) 3. Grasp the top flange and pull it upward to remove the assembly from the body. The top casting, filter basket and extension tube will then be removed as one assembly. This may be cleaned using cloth, brush or air gun. If the unit is hot, metal expansion may cause a tight fit. 4. The main body of the unit is now exposed for easy access to cleaning. 5. Access to the heater bands may be obtained by loosening the Phillips screws at the bottom. The shroud and insulation will then lift clear of the main body. 6. The radial slots in the main body should be cleaned and any resin pellets should be removed. 7. To reassemble, reverse the procedure. For Cactus Models 5, 10 & 15, the top flange and the venturi may be assembled to face any of four directions as seen from a top view. The Cactus 25 must be re-assembled with the top flange and venturi pointing to the right as you face the temperature controller.

18 CACTUS AL200 SUPERLOADER INSTALLATION AND OPERATING INSTRUCTIONS The Cactus AL200 Superloader combines large capacity, low maintenance, and solid state electronics to ensure operating efficiency and reliability. It can be supplied for operation on 115 or 230 volt 50-60Hz single phase power. This has been set at the factory at the time of order, and is indicated on the label affixed to the power cord. The hopper contains 2 proximity sensors to maintain a constant resin supply. The hopper has been offset to enable the extension tube on the Cactus Super Dryer to be raised and lowered without interfering with the Superloader. Your Superloader package includes: 1 Hopper Loader with control cabinet and water trap 1 Hopper lid and filter assembly 1 Length of 1.25" flexible material hose (10'standard) 1 Length of 0.25" flexible air hose (10'standard) 1 Stainless steel pick-up wand CAUTION: The AL200 uses 2 high quality proximity sensors. These have been carefully located to maintain an optimun level of material inside the hopper. Care must be used not to strike these sensors with any objects - either inside or outside the hopper. When cleaning, hand cloths should only be used. The AL200 Superloader has been designed to bolt directly to the top flange of your Cactus Super Dryer. It can also be mounted onto the feed throat of your molding machine in place of the existing hopper.

19 INSTALLATION 1. Bolt the AL200 Superloader directly to the top flange of your Cactus Super Dryer or directly to the feed throat of your machine if a dryer is not being used. The normal mounting will have the control cabinet facing the operator. 2. Connect a suitable 1/4" compressed air line hose to the quick disconnect attached to the water trap at the rear of the control cabinet and secure with an appropriate clamp. The air supply should be clean - oil and moisture free - for optimum results. 80 psi minimum is required. 3. Connect the 1/4" air line hose (supplied) from the barbed fitting at the rear of the cabinet to the stainless steel pick-up wand air tube. Secure with the clamps provided. 4. Connect the 1 1/4" material hose from the upper hopper inlet to the pick-up wand. This is a snug fit so clamps are not required. 5. Attach a suitable electric plug to the 3 wire 18 guage power cord and plug in, or connect directly to a suitable power supply. The Superloader is now ready for operation. OPERATION 1. Place the pick-up wand into the resin supply. It should be pushed as deeply as possible to ensure that material is always available for loading. 2. With the loader empty, the green "LOADING" indicator lamp will light indicating that air is being supplied to the wand. 3. Once the hopper has been filled, the green "LOADING" lamp will be extinguished and the air supply to the pick-up wand will be switched off. The orange "STAND-BY" lamp will remain on. NOTE: THE EXHAUST FILTER SHOULD BE CLEANED ON A REGULAR BASIS.

20 TROUBLESHOOTING Should the Superloader fail to load the material check the following; Resin supply is empty. Material pick-up wand is not in supply or is clogged. Compressed air supply is off or disconnected. Exhaust air filter is blocked with dust or fines. Sensitivity is adjusted too low on the proximity sensor Should the Superloader fail to shut off the resin supply, check the following; Proximity switch had been damaged. Red LED on the back of the proximity sensor is on. Connections for the proximity sensor to the control cabinet. WARNING: ALWAYS DISCONNECT POWER WHEN SERVICING THE CONTROL CABINET.

21 Setup of Temperature Controller To program the E5CN press and hold the Level Key until the display changes to CN-E Use the up and down arrows to change values Use The Mode Key to shift between entries. The settings are as follow F C CN-E 8 (old 3) 8 (old 3) d-u F C SL-H SL-L CNEL PID PID S-HC STND STND SE ON ON PREL OFF OFF CP 3 3 GREU 6R-R 6R-R ALE ALE Press Level key and return to normal setup Temp r-5 run run AL AL

22 Technical Reference for E5AN/E5EN/E5CN/E5GN The following information applies to all the controller series listed above. Nomenclature Installation directions Initial setup for control Setting parameters after turning on power Outline of operation procedures for different levels Troubleshooting Fuzzy self-tuning Peripheral devices Precautions Nomenclature E5AN Operation Indicators 1. ALM1 (alarm 1) Lights when alarm 1 output is ON. ALM2 (alarm 2) Lights when alarm 2 output is ON. ALM3 (alarm 3) Lights when alarm 3 output is ON. 2. HB (heater burnout alarm display) Lights when a heater burnout is detected. The heater burnout alarm remains ON by setting the heater burnout latch. To reset, turn the power supply OFF and then ON or set the heater burnout alarm value to 0.0A. 3. OUT1, OUT2 (control output 1, control output 2) Lights when control output 1 and/or control output 2 (cool) are ON. However, if control output 1 is current output, OUT1 will always be unlit. 4. STOP (stop) Lights when control of the E5AN has been stopped. During control, this indicator lights when an event or the run/stop function has become stopped. Otherwise, this indicator is out. 5. CMW (communications writing control) Lights when communications writing is enabled and is out when it is disabled. Temperature Unit The temperature unit is displayed when the display unit parameter is set to a temperature. Indication is determined by the currently selected temperature unit parameter set value. When this parameter is set to C, is displayed, and when set to F, is displayed. No. 1 Display Displays the process value or parameter type. No. 2 Display Displays the set point, manipulated variable, or set value (setup) of the parameter. Up Key Each press of this key increases values displayed on the No.2 display. Holding down this key continuously increases values. Down Key Each press of this key decreases values displayed on the No.2 display. Holding down this key continuously decreases values. Level Key Press this key to select the setup level. The setup level is selected in order operation level adjustment level, initial setting level communications setting level. Mode Key Press this key to select parameters within each level. Level + Mode Keys This key combination sets the E5AN to the protect level. 73

23 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN E5EN Operation Indicators 1. ALM1 (alarm 1) Lights when alarm 1 output is ON. ALM2 (alarm 2) Lights when alarm 2 output is ON. ALM3 (alarm 3) Lights when alarm 3 output is ON. 2. HB (heater burnout alarm display) Lights when a heater burnout is detected. The heater burnout alarm remains ON by setting the heater burnout latch. To reset, turn the power supply OFF and then ON or set the heater burnout alarm value to 0.0A. 3. OUT1, OUT2 (control output 1, control output 2) Lights when control output 1 and/or control output 2 (cool) are ON. However, if control output 1 is current output, OUT1 will always be unlit. 4. STOP (stop) Lights when control of the E5EN has been stopped. During control, this indicator lights when an event or the run/stop function has become stopped. Otherwise, this indicator is out. 5. CMW (communications writing control) Lights when communications writing is enabled and is out when it is disabled. Temperature Unit The temperature unit is displayed when the display unit parameter is set to a temperature. Indication is determined by the currently selected temperature unit parameter set value. When this parameter is set to C, is displayed, and when set to F, is displayed. No. 1 Display Displays the process value or parameter type. No. 2 Display Displays the set point, manipulated variable, or set value (setup) of the parameter. Up Key Each press of this key increases values displayed on the No.2 display. Holding down this key continuously increases values. Down Key Each press of this key decreases values displayed on the No.2 display. Holding down this key continuously decreases values. Mode Key Press this key to select parameters within each level. Level Key Press this key to select the setup level. The setup level is selected in order operation level adjustment level, initial setting level communications setting level. Level + Mode Keys This key combination sets the E5EN to the protect level. E5CN Operation Indicators 1. AL1 (alarm 1) Lights when alarm 1 output is ON. AL2 (alarm 2) Lights when alarm 2 output is ON. 2. HB (heater burnout alarm display) Lights when a heater burnout is detected. The heater burnout alarm remains ON by setting the heater burnout latch. To reset, turn the power supply OFF and then ON or set the heater burnout alarm value to 0.0A. 3. OT1, OT2 (control output 1, control output 2) Lights when control output 1 and/or control output 2 (cool) are ON. However, if control output 1 is current output, OT1 will always be unlit. 4. STP (stop) Lights when control of the E5CN has been stopped. During control, this indicator lights when an event or the run/stop function has become stopped. Otherwise, this indicator is out. 5. CMW (communications writing control) Lights when communications writing is enabled and is out when it is disabled. Temperature Unit The temperature unit is displayed when the display unit parameter is set to a temperature. Indication is determined by the currently selected temperature unit parameter set value. When this parameter is set to C, is displayed, and when set to F, is displayed. No. 1 Display Displays the process value or parameter type. No. 2 Display Displays the set point, manipulated variable, or set value (setup) of the parameter. Up Key Each press of this key increases values displayed on the No.2 display. Holding down this key continuously increases values. Down Key Each press of this key decreases values displayed on the No.2 display. Holding down this key continuously decreases values. Level Key Press this key to select the setup level. The setup level is selected in order operation level adjustment level, initial setting level communications setting level. Mode Key Press this key to select parameters within each level. Level + Mode Keys This key combination sets the E5CN to the protect level. 74

24 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN E5GN Operation Indicators 1. AL (alarm) Lights when alarm output is ON. 2. CMW (communications writing control) Lights when communications writing is enabled and is out when it is disabled. 3. STP (stop) Lights when control of the E5GN has been stopped. During control, this indicator lights when an event or the run/stop function has been stopped. Otherwise, this indicator is out. 4. OUT (control output) Lights when control output is ON. Temperature Unit The temperature unit is displayed when the display unit parameter is set to a temperature. Indication is determined by the currently selected temperature unit parameter set value. When this parameter is set to C, is displayed, and when set to F, is displayed. No. 1 Display Displays the process value or parameter type. No. 2 Display Displays the set point, manipulated variable or set value (setup) of the parameter. Up Key Level Key Press this key to select the setup level. The setup level is selected in order operation level adjustment level, initial setting level communications setting level. Mode Key Press this key to select parameters within each level. Each press of this key increases values displayed on the No.2 display. Holding down this key continuously increases values. Down Key Each press of this key decreases values displayed on the No.2 display. Holding down this key continuously decreases values. Level + Mode Key This key combination sets the E5GN to the protect level. Installation MOUNTING E5AN/E5EN 1. Insert the E5AN/E5EN into the mounting hole in the panel from the front. 2. Push the mounting bracket along the E5AN/E5EN body from the terminals up to the panel, and secure it temporarily. E5AN Panel 3. Tighten the fixing screw on each mounting bracket alternately until the ratchet stops tightening. E5EN Mounting bracket Panel Mounting bracket Waterproof packing Waterproof packing 75

25 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN DRAWING OUT For drawing out the Unit, use a suitable Philips screwdriver for the screw located at the bottom on the front panel. 1. While pressing down on the hook located at the top of the front panel, turn the screw (located at the bottom on the front panel) counterclockwise using a Philips screwdriver. 2. Hold both sides of the front panel and draw out the Unit towards you. 3. When inserting the Unit, confirm that the waterproof packing is in place. While pressing down on the hook located at the top of the front panel, turn the screw (located at the bottom on the front panel) clockwise using a Philips screwdriver and tighten to a torque of 0.3 to 0.5 Nm. Make sure that electronic parts do not come in contact with the case. (1) (2) (3) (1) (1) (3) (2) (3) ACCESS TO E5CN TO INSTALL OPTION UNITS If communications, event input, or heater burnout functions are required, mount the E53-CNH03 Communications Unit or the E53-CNHB Event Input Unit. The heater burnout function is supported on either of these two Option Units. Option Units Description Specifications Part number Computer communications RS-485 and heater burnout alarm (for relay and voltage output models) E53-CNH03 RS-485 (for current output models) E53-CN03 Event input (for remote set point Event input and heater burnout alarm (for relay and voltage output models) E53-CNHB and run/stop functionality) Event input (for current output models) E53-CNB Assembling a Unit (1) (4) (2) (1) Flat-blade screwdriver (unit: mm) (3) 20 min. 1. Insert the tools (see drawing at left) into the slots (one on the top and one on the bottom) and release the hooks. 2. Insert the tool in the space between the front and rear panels and slightly pull out the front panel. Hold the top and bottom of the front panel and pull toward yourself to remove it. 3. Match up the upper and lower claws with the connection points and insert the Option Unit. Mount the Option Unit in the center. 4. Before inserting the Unit, confirm that the waterproof packing is in place. Insert the Unit into the rear case until you hear a click. When inserting the Unit, press down the hooks on the top and bottom of the rear case so that they firmly hook on the inserted Unit. Make sure that electronic parts do not come in contact with the case. 5. Push the adapter along the E5CN body from the terminals up to the panel, and secure it temporarily. 6. Tighten the two fixing screws on the adapter. When tightening screws, tighten the two screws alternately keeping the torque to between 0.29 and 0.39 Nm (2.9 kgfcm to 3.9 kgfcm). MOUNTING E5CN Adapter Panel Attaching the E5CN to a Panel Insert the E5CN into the mounting hole in the panel. Attaching the Terminal Cover Make sure that the UP mark is facing up, and then fit the Terminal Cover (E53-COV10) into the holes on the top and bottom. A E5CN--500 Controller is provided with a Terminal Cover. 76

26 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN MOUNTING E5GN 1. Insert the E5GN into the mounting hole in the panel from the front. 2. Push the adapter along the E5GN body from the terminals up to the panel, and secure it temporarily. 3. Tighten the two fixing screws on the adapter. When tightening screws, tighten the two screws alternately keeping the torque to within approximately 0.29 to 0.39 Nm. Adapter Waterproof seal Panel REMOVING AND ATTACHING E5GN S TERMINAL PLATE The E5GN can be replaced by removing the terminal plate 1. Press down hard on the fasteners on both sides of the terminals to unlock the terminal plate and pull upwards. 2 Draw out the terminal plate as it is. 3 Before you insert the terminal plate again, make sure that the pins match the positions of the holes in the terminal plate. WIRING PRECAUTIONS FOR E5AN/E5EN/E5CN Separate input leads and power lines to protect the E5AN/E5EN/E5CN and its lines from external noise. We recommend using solderless terminals when wiring the E5AN/E5EN/E5CN. Tighten the terminal screws using a torque between 0.74 and 0.90 N m. Use the following type of solderless terminals for M3.5 screws. 7.2 mm max. 7.2 mm max. WIRING PRECAUTIONS FOR E5GN Connect the terminals as specified below. Terminal No. Cables Pin terminals 1 to 6 AWG24 to AWG dia. max. 7 to 9 AWG28 to AWG dia. max. The exposed current-carrying part to be inserted into terminals must be 5 to 6 mm. Tighten the terminal screws to the torque specified below. Terminal No. Screw Maximum tightening torque 1 to 6 M to 0.25 N m 7 to 9 M to 0.14 N m 5 to 6 mm 5 to 6 mm Electrical wire Pin terminal 77

27 E5AN/E5EN/E5CN/E5GN Operation INITIAL SETUP On previous Controllers, sensor input type, alarm type and control period were set on DIP switches. These hardware settings are now set in parameters in setup menus. The and keys are used to switch between setup menus, and the amount of time that you hold 1. ON/OFF CONTROL Typical Application Examples Changing Parameters E5AN/E5EN/E5CN/E5GN the keys down for determines which setup menu you move to. This section describes two typical examples. Note: On the E5EN/E5GN, the Key is the Key. Typical Example Input type : 0 K thermocouple -200 to 1300 C Control method:on/off control Alarm type: 2 upper limit Alarm value 1: 20 C (For setting deviation) Set point: 100 C Change only the alarm value 1 and set point. The rest must be left as default settings. indicates that there is a parameter. Keep on pressing the mode key until the desired parameter is selected. Setup procedure Power ON Operation level Power ON Process value/ set point Changing Set Values Display Use the or keys to change the set value displayed in the setup menu. Set input specifications Initial setting level Check input type. Press key for at least three seconds. Control stops. Input type E5AN No. 1 display Set control specifications Check that control is ON/OFF control. In ON/OFF control No. 2 display Set alarm type Check alarm type. Alarm 1 type E5EN No. 1 display No. 2 display E5CN E5GN No. 1 display No. 2 display No. 1 display No. 2 display Set the set point Check operation state Set alarm values Operation level Press keys to set set point to 100C. Make sure that control is running. Press keys to set alarm value to 20C. Press key for at least one second. Control starts. Process value/ set point During run During stop Alarm value 1 Start operation Start operation 78

28 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN 2. PID CONTROL USING AUTO-TUNING Changing Parameters Typical Example Input type: 4 T thermocouple -200 to 400 C Control method: PID control ST (self-tuning): OFF Calculate PID constants by AT (auto-tuning). Alarm type: 2 upper limit Alarm value 1: 30 C (For setting deviation) Set point: 150 C indicates that there is a parameter. Keep on pressing the mode key until the desired parameter is selected. Setup procedure Power ON Power ON Operation level Changing Set Values Process value/ set point Display E5AN Use the or keys to change the set value displayed in the setup menu. No. 1 display No. 2 display Set input specifications Set control specifications Initial setting level Press keys to select input type. Press keys to select PID control. Press key for at least three seconds. Control stops. Input type In PID control E5EN Self-tuning Press keys to set ST to OFF. To cancel ST E5CN No. 1 display No. 1 display No. 2 display PV/SP After AT execution. Check control period Check alarm type Check the control period. Check alarm type. Operation level Press Control period (heat) (unit: seconds) Alarm 1 type (upper-limit alarm) key for at least one second. When set to ON, self-tuning operates. Recommended settings: 20 seconds for the relay output and 2 seconds for the SSR output. No. 2 display During AT execution. Set the set point Press keys to set set point to 150C. Process value/ set point E5GN No. 1 display While AT is being executed, SP will flash. After AT execution. AT execution Adjustment level Execute AT (auto-tuning). Press key for less than one second. To execute AT Set to for executing AT and to for stopping AT. No. 2 display During AT execution. Operation level Make sure that set point is 150C. Press key for less than one second. Process value/ set point Set operation status Make sure that control is running. During run Set alarm values Press keys to set alarm value to 30C. Alarm value 1 Start operation Start program execution 79

29 E5AN/E5EN/E5CN/E5GN Specification Setting after Turning ON Power OUTLINE OF OPERATION PROCEDURES Key Operation E5AN/E5EN/E5CN/E5GN In the following descriptions, all the parameters are introduced in the display sequence. Some parameters may not be displayed depending on the protect settings and operation conditions. Power ON Operation level key 1 second min. key 3 seconds min. key Less than 1 second Adjustment level + key 1 second min. key Display flashes when key held down for more than 1 second. Control stops + key Display flashes when key pressed. + key 3 seconds min. Initial setting level key 1 second min. key Less than 1 second Advanced function setting level Calibration level Password input set value 169 Password input set value 1201 Communications setting level Protect level Control in progress Control stopped Note: The time taken to move to the protect level can be adjusted by changing the Move to protect level time setting. 1. Of these levels, the initial setting level, communications setting level, advanced function setting level and calibration level can be used only when control has stopped. Note that control is stopped when these four levels are selected. When switched back to the operation level from one of these levels, control will start. 2. For the calibration mode, refer to the relevant Operation Manual (H100 or H101). 3. On the E5EN/E5GN, the Key is the Key. Level change DESCRIPTION OF EACH LEVEL Operation Level This level is displayed when you turn the power ON. You can move to the protect level, initial setting level and adjustment level from this level. Normally, select this level during operation. During operation, the process value, set point and manipulated variable can be monitored, and the alarm value and upper- and lower-limit alarms can be monitored and modified. Adjustment Level To select this level, press the key once for less than one second. This level is for entering set values and offset values for control. This level contains parameters for setting the set values, AT (auto-tuning), communications writing enable/disable, hysteresis, multi-sp, input shift values, heater burnout alarm (HBA) and PID constants. You can move to the top parameter of the operation level or initial setting level from here. Initial Setting Level To select this level, press the key for at least three seconds in the operation level. This level is for specifying the input type, selecting the control method, control period, setting direct/reverse action and alarm type. You can move to the advanced function setting level or communications setting level from this initial setting level. To return to the operation level, press the key for at least one second. To move to the communications setting level, press the key once for less than one second. Protect Level To select this level, simultaneously press the and keys for at least 3 seconds. This level is to prevent unwanted or accidental modification of parameters. Protected levels will not be displayed, and so the parameters in that level cannot be modified. Communications Setting Level To select this level, press the key once for less than one second in the initial setting level. When the communications function is used, set the communications conditions in this level. Communicating with a personal computer (host computer) allows set points to be read and written, and manipulated variables to be monitored. Advanced Function Setting Level To select this level, you must enter the password ( -169 ) in the initial setting level. You can move only to the calibration level from this level. This level is for setting the automatic return of display mode, MV limiter, event input assignment, standby sequence, alarm hysteresis, ST (self-tune) and to move to the user calibration level. Calibration Level To select this level, you must enter the password ( 1201 ) in the advanced function setting level. This level is for offsetting deviation in the input circuit. You cannot move to other levels by operating the keys on the front panel from the calibration level. To cancel this level, turn the power OFF then back ON again. 80

30 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN SPECIFICATION SETTING AFTER TURNING ON POWER Initial Setting Level Initial setting level This level is used for setting basic specifications of the Temperature Controller. Using this level, set the input type for selecting the input to be connected such as the thermocouple or platinum resistance Input type thermometer and set the range of set point and the alarm mode. Power ON Operation level Adjustment level key Less than 1 second key 1 second min. Initial setting level key 1 second min. key 3 seconds min. Advanced function setting level Calibration level Control stops. Communications key setting level Less than 1 second Password input set value -169 Password input set value key 1 second min. + key Display flashes when key pressed. Protect level Control in progress Control stopped Level change + key 3 seconds min. The time taken to move to the protect level can be adjusted by changing the Move to protect level time setting. The move from the operation level to the initial setting level, press key for three seconds or more. The initial setting level is not displayed when initial/communications protection is set to 2. This initial setting level can be used when initial setting/communications protection is set to 0 or 1. The scaling upper limit, scaling lower limit, and decimal point parameters are displayed when an analog voltage input is selected as the input type. Scaling upper limit Scaling lower limit Decimal point Temperature unit Set point upper limit Set point lower limit PID / ON/OFF Standard/heating and cooling Alarm output type (Other than E5GN) ST (PID control) Control period (heat) Control period (cool) (PID control) (Heating/cooling setting) Direct/reverse operation Alarm 1 type For analog input (Input type: 16) 0- to 50-mV setting : ON/OFF control : PID control : Standard : Heating/cooling : Enabled : Disabled Set the pulse output cycle. : Reverse operation : Direct operation Alarm 2 type Alarm 3 type ((E5AN/E5EN) Select the alarm mode. (Models with alarm function) Move to advanced function setting level (When initial/communications protect is set to 0.) To return to the operation level, press the second * Not displayed as default setting. key for longer than one 81

31 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN INPUT TYPE When using a thermocouple input type, follow the specifications listed in the following table. Input type Specifications Switch setting Input temperature range Thermocouple K to 1300 ( C) / 300 to 2300 ( F) to ( C) /0.0 to ( F) J to 850 ( C) / 100 to 1500 ( F) to ( C) /0.0 to ( F) T to 400 ( C) / 300 to 700 ( F) E 5 0 to 600 ( C) /0 to 1100 ( F) U to ( C) / to 700 ( F) L to 850 ( C) / 100 to 1500 ( F) U to 400 ( C) / 300 to 700 ( F) U to ( C) / to 700 ( F) N to 1300 ( C) / 300 to 2300 ( F) R 9 0 to 1700 ( C) /0 to 3000 ( F) S 10 0 to 1700 ( C) /0 to 3000 ( F) B to 1800 ( C) /300 to 3200 ( F) Non-contact temperature K10 to 70C 12 0 to 90 ( C) /0 to 190 ( F) sensor ES1A K60 to 120C 13 0 to 120 ( C) /0 to 240 ( F) K115 to 165C 14 0 to 165 ( C) /0 to 320 ( F) K160 to 260C 15 0 to 260 ( C) /0 to 500 ( F) Analog input 0 to 50mV 16 One of following ranges depending on the results of scaling: 1999 to 9999, to Note: The initial settings are: 0: 200 to 1300C/ 300 to 2300F. When using the platinum resistance thermometer input type, follow the specifications listed in the following table. Input type Specifications Switch setting Input temperature range Platinum resistance Pt to 850 ( C) / 300 to 1500 ( F) thermometer to ( C) / to ( F) to ( C) /0.0 to ( F) JPt to ( C) / to ( F) to ( C) /0.0 to ( F) Note: The initial settings are: 0: Pt to 850C/ 300 to 1500F. 82

32 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN ALARM 1 AND ALARM 2 For the alarm 1 and alarm 2, select alarm types out of the 12 alarm types listed in the following table. (The alarm 3 for E5AN/E5EN, which has three alarms, can also be selected from this table.) Set value Alarm type Alarm output operation When X is positive When X is negative 0 Alarm function OFF Output OFF 1 *1 Upper- and lower-limit (deviation) *2 2 Upper-limit (deviation) 3 Lower-limit (deviation) 4 *1 Upper- and lower-limit range (deviation) *3 5 *1 Upper- and lower-limit with standby sequence (deviation) 6 Upper-limit with standby sequence (deviation) 7 Lower-limit with standby sequence (deviation) 8 Absolute-value upper-limit *5 *4 9 Absolute-value lower-limit 10 Absolute-value upper-limit with standby sequence 11 Absolute-value lower-limit with standby sequence *1: With set values 1, 4 and 5, the upper and lower limit values can be set independently for each alarm type, and are expressed as L and H. Following operations are for cases when an alarm set point is X or negative. *2: Set value: 1, Upper- and lower-limit alarm Case 1 Case 2 Case 3 (Always ON) *4: Set value: 5, Upper- and lower-limit with standby sequence Case 1 Case 2 Same as for the upper- and lower-limit alarm. However, when the upper-limit and lower-limit hysteresis overlaps: Always OFF Example *3: Set value: 4, Upper- and lower-limit range Case 1 Case 2 Case 3 (Always OFF) = = = = *5: Set value: 5, Upper- and lower-limit with standby sequence alarm. Always OFF when the upper-limit and lower-limit hysteresis overlaps. Set the alarm types for alarm 1 and alarm 2 independently in the initial setting level. The default setting is 2 (upper limit). With the E5AN/E5EN, perform settings similarly for alarm 3. Example: When the alarm is set ON at 110C/F or higher. When an alarm type other When the absolute-value than the absolute-value alarm is selected alarm is selected (For alarm types 1 to 7) The alarm value is set as a deviation from the set point. Alarm value (For alarm types 8 to 11) The alarm value is set as an absolute value from the alarm value of 0C/F. Alarm value Set point 100 C/ F 0 C/ F 83

33 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN PARAMETERS Parameters related to setting items for each level are marked in boxes in the flowcharts and brief descriptions are given as required. At the end of each setting item, press the mode key to return to the beginning of each level. Display Power ON + key Display flashes when key pressed. E5AN Operation level Adjustment level key + key Less than 1 second 1 second + key min. key key Display flashes when key held 1 second 3 seconds down for more than 1 second. min. min. Control stops. Initial setting level key 1 second min. Advanced function setting level Communications setting level key Less than 1 second Password input set value -169 Password input set value key 3 seconds min. Protect level The time taken to move to the protect level can be adjusted by changing the Move to protect level time setting. E5EN E5CN No. 1 display No. 1 display No. 2 display No. 1 display No. 2 display E5GN No. 1 display Calibration level Control in progress Control stopped Level change No. 2 display No. 2 display Power ON Advanced Function Setting Level key 1 second min. Initial Setting Level key 1 second min. key 3 seconds min. Operation Level key Less than 1 second key Less than 1 second Adjustment Level Note: To select advanced function setting level, you must enter the password ( -169 ) in the initial setting level. 84

34 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN ADVANCED FUNCTION SETTING LEVEL Parameter initialize Resets to the default value. Input digital filter For setting time constant in seconds. Number of multi-sp uses Additional PV display Displayed first in the operation level Event input assignment 1 Manipulated variable display Event input assignment 2 Input setting: Multiple SP/RUN/STOP Automatic return of display mode Automatically reset to the operation level when no key operation are performed. Multi-SP uses Alarm 1 latch SP ramp set value Alarm 2 latch Alarm ON latches Standby sequence reset Restarting condition after clearing standby sequence Alarm 3 latch Alarm 1 open in alarm Move to protect level time Alarm 1 hysteresis ON/OFF setting of alarm output 1 Input error output Alarm 2 open in alarm Cold junction compensating method Alarm 2 hysteresis ON/OFF setting of alarm output 2 MB command logic switching Alarm 3 open in alarm Move to calibration level Alarm 3 hysteresis HBA ON/OFF Heater burnout latch Heater burnout hysteresis ON/OFF setting of alarm output 3 Note: These diagrams show all the parameters that may be displayed. Depending on the specifications of the model used, there may be some parameters that are not displayed. The following symbols are used to distinguish between these parameters. : Displayed for all models regardless of the settings of other parameters. : Not displayed for some models. : Depending on the settings of other parameters, may not be displayed. ST stable range For setting deviation. α 2-PID parameter MV upper limit MV lower limit Limitations to MV 85

35 E5AN/E5EN/E5CN/E5GN INITIAL SETTING LEVEL OPERATION LEVEL E5AN/E5EN/E5CN/E5GN Input type PV Add in the additional PV display parameter. Scaling upper limit PV/SP Scaling lower limit For analog input (Input type: 16) 0- to 50-mV setting Multi-SP Select SP. Decimal point Number of displayed digits Set point during SP ramp Temperature unit : C : F Heater current value monitor Current value monitor of HBA Set point upper limit Limit the set point. Run/stop : RUN : STOP Set point lower limit Alarm value 1 PID ON/OFF Select the control system. Standard/heating and cooling : ON/OFF control : PID control : Standard : Heating/cooling Upper-limit alarm value 1 Lower-limit alarm value 1 Set either of these parameters. ST Self-tuning : Enabled : Disabled Alarm value 2 Control period (heat) OUT1 Control period (cool) OUT2 Set the pulse output cycle. Upper-limit alarm value 2 Lower-limit alarm value 2 Set either of these parameters. Direct/reverse operation : Reverse : Direct Alarm value 3 Alarm 1 type Alarm 2 type Select the alarm mode. Upper-limit alarm value 3 Lower-limit alarm value 3 Set either of these parameters. Alarm 3 type MV monitor (OUT 1) Move to advanced function setting level MV monitor (OUT 2) Note: To select advanced function setting level, you must enter the password ( -169 ) in the initial setting level. The displays for parameters which can be switched (i.e., parameters other than simply numerical ones) show the contents of those parameters. Note: These diagrams show all the parameters that may be displayed. Depending on the specifications of the model used, there may be some parameters that are not displayed. The following symbols are used to distinguish between these parameters. : Displayed for all models regardless of the settings of other parameters. : Not displayed for some models. : Depending on the settings of other parameters, may not be displayed. 86

36 E5AN/E5EN/E5CN/E5GN ADJUSTMENT LEVEL PROTECT LEVEL E5AN/E5EN/E5CN/E5GN AT execute/cancel Communications writing Auto-tuning : Enabled : Disabled Operation/adjustment protection Restricts display and modification of menus in the operation and adjustment levels. Initial setting/communications protection Restricts display and modification of menus in the initial setting, operation level and adjustment levels. Heater current value monitor Heater burnout detection Set point 0 HBA function Setting change protection Protects changes to setups by operating the front panel keys. INITIAL SETTING/COMMUNICATIONS PROTECTION Set point 1 This protect level restricts movement to the initial setting level, communications setting level and advanced function setting level. Set point 2 Set points used by multi-sp Set value Initial setting level Communications setting level Advanced function setting level Set point 3 Temperature input shift Upper-limit temperature input shift value 1-point shift 2-point shift (see note) 0 1 X 2 X X X Default setting: 1 : Move to other levels possible : Move to other levels not possible Lower-limit temperature input shift value Proportional band Integral time Derivative time Cooling coefficient Dead band P I D PID settings Used in heating and cooling control OPERATION/ADJUSTMENT PROTECTION The following table shows the relationship between set values and the range of protection. Level Set value Operation PV level PV/SP Other X X Adjustment level X X X When this parameter is set to 0, parameters are not protected. Manual reset value Hysteresis (OUT 1) Clear the offset during stabilization of P or PD control. Default setting: 0 : Can be displayed and changed : Can be displayed : Cannot be displayed and move to other levels not possible Note: Hysteresis (OUT 2) Set hysteresis. The 2-point shift setting is only possible when the input type is a non-contact temperature sensor. These diagrams show all the parameters that may be displayed. Depending on the specifications of the model used, some parameters may not be displayed. The following symbols distinguish between these parameters. : Displayed for all models regardless of the setting of other parameters. : Not displayed for some models. : Depending on the settings of other parameters, may not be displayed. SETTING CHANGE PROTECTION This protect level protects setup from being changed by operating the keys on the front panel. Set value Description OFF Setup can be changed by key operation. ON Setup cannot be changed by key operation. (The protect level, can be changed.) Default setting: OFF 87

37 E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN COMMUNICATIONS SETTING LEVEL Set the E5AN/E5EN/E5CN/E5GN communications specifications in the communications setting level. For setting communications parameters, use the E5AN/E5EN/E5CN/E5GN panel. The communications parameters and their settings are listed in the following table. Parameter Displayed characters Set (monitor) value Set value Communications unit No. 0 to to 99 Baud rate 1.2/2.4/4.8/9.6/19.2 (kbps) 1.2/2.4/4.8/9.6/19.2 Data bits 7/8 (bit) 7/8 (bit) Stop bits 1/2 1/2 (bit) Parity None, even, odd // Note: The highlighted values indicate default settings. Before executing communications with the E5AN/E5EN/E5CN/ E5GN, set the communications unit No., baud rate, etc., through key operations as described below. As for other operations, refer to relevant Operation Manual. 1. Press the key for at least three seconds in the operation level. The level moves to the initial setting level. 2. Press the key for less than one second. The initial setting level moves to the communications setting level. 3. Pressing the key advances the parameters as shown in the following figure. 4. Press the or keys to change the parameter setups. Communications unit No. Baud rate Data bits Stop bits Parity Note: On the E5AN/E5EN/E5GN, the Key is the Key. Set each communications parameter to match those of the communicating personal computer. COMMUNICATIONS UNIT NO. () When communicating with the host computer, the unit number must be set in each Temperature Controller so that the host computer can identify each Temperature Controller. The number can be set in a range from 0 to 99 in increments of 1. The default setting is 1. When using more than one Unit, be careful not to use the same number twice. Duplicate settings will cause malfunction. This value becomes valid when the power is turned OFF and ON again. BAUD RATE () Use this parameter to set the speed of communications with the host computer. It can be set to one of the following values; 1.2 (1200 bps), 2.4 (2400 bps), 4.8 (4800 bps), 9.6 (9600 bps), and 19.2 (19200 bps). This setting becomes valid when the power is turned OFF and ON again. DATA BITS () Use this parameter to change the communications data bit length to 7 bits or 8 bits. STOP BITS () Use this parameter to change the communications stop bit to 1 or 2. PARITY () Use this parameter to set the communications parity to None, Even, or Odd. TROUBLESHOOTING When an error occurs, an error code will be displayed on the No. 1 display. Check the contents of an error and take appropriate countermeasures. No. 1 display Type of error Countermeasures Input error Check the wiring of inputs for wiring errors, disconnections, short-circuits, and the input type. Memory error First, turn the power OFF then back ON again. If the display remains the same, the Unit must be repaired. If the display is restored, then a probable cause can be external noise affecting the control system. Check for external noise. Display range over Though not error, this is displayed when the process value exceeds the display range when the control range is larger than the display range. When less than ( 199.9) When larger than 9999 (999.9) HB error First, turn the power OFF then back ON again. If the display remains the same, the E5EN/E5CN/E5GN must be repaired. If the display is restored, then a probable cause can be electrical noise affecting the control system. Check for electrical noise. Note: Error will be displayed only when the display is set for the PV or PV/SP. 88

38 E5AN/E5EN/E5CN/E5GN Fuzzy Self-tuning E5AN/E5EN/E5CN/E5GN The fuzzy self-tuning (ST) is a function that automatically calculates an optimum PID constant depending on items to be controlled. FEATURE The Temperature Controller determines when to execute this fuzzy self-tuning. FUNCTIONS Step-Response Tuning (SRT): Performs PID tuning according to the step response method when the SP is changed. REQUIREMENTS FOR SRT FUNCTIONALITY The ST will be executed according to the step response method when the following conditions are satisfied when operation is started or when the SP is changed. When operation is started When SP is changed 1. The SP at the startup is different from the SP at the time the previous SRT was executed. (See Note.) 2. The temperature upon startup is smaller than the SP in the reverse operation and larger than the SP in the direct operation. 3. Restarting of operation is not due to an input error. Note: The SP that existed when the previous SRT was executed refers to the SP used for obtaining the PID constant in the previous SRT. 1. The SP after change is different from the SP at the time the previous SRT was executed. (See note.) 2. In the reverse operation, the value obtained by deducting the SP before change from the SP after change is larger than the ST stable range. In the direct operation, the value obtained by deducting the SP after change from the SP before change is larger than the ST stable range. 3. The SP change width is larger than the current proportional band x The temperature is in the stable state. (It can be in the balanced state if no output is generated when the power is turned ON.) If the SP is changed while SRT is being executed and if SRT completion conditions are satisfied, no PID change will take place. Stabilization State Measured values remain in the stable range for a certain period of time. Balanced State Output is 0% for 60 seconds and measured values fluctuate within the width of the stable range. This inclination is referred to as R. Temperature ST stable range SRT completion Time 89

39 E5AN/E5EN/E5CN/E5GN Peripheral Devices CONNECTION EXAMPLE WITH SSR E5AN/E5EN/E5CN/E5GN Temperature controller Load Voltage output terminal (for driving SSR) Heater Load power Direct connection possible E5AN 3 units 5 units (E5AN/ E5EN) G3PB (Single-phase): Rated input voltage: 12 to 24 VDC 240 VAC 15 A, 25 A, 35 A, 45 A) Compact and slim models with a built-in radiator 2 units 4 units (E5AN/ E5EN) G3PB (Three-phase): 240 VAC/400 VAC (15 A, 25 A, 35 A, 45 A) Rated input voltage: 12 to 24 VDC E5EN Simultaneous three-phase control with a built-in radiator 3 units 5 units (E5AN/ E5EN) G3PA: 240 VAC (10 A, 20 A, 40 A) 400 VAC (20 A, 30 A) Rated input voltage: 5 to 24 VDC E5CN 3 units 5 units (E5AN/ E5EN) 4 units for 480-VAC models 1 unit 2 units (E5AN/ E5EN) Compact and slim models with a built-in radiator G3NA: 240 VAC (5 A, 10 A, 20 A, 40 A) 480 VAC (10 A, 20 A, 40 A) Rated input voltage: 5 to 24 VDC Standard models with screw terminals G3NE: 240 VAC (5 A, 10 A, 20 A) Rated input voltage: 12 VDC E5GN 4 units 8 units (E5AN/ E5EN) Compact and low-cost models with tab terminals G3NH: 440 VAC (75 A, 150 A) Rated input voltage: 5 to 24 VDC For controlling high-power heater 90