THE SUPERDRYER - Cactus Machinery · the extension tube to be lowered into the feedthroat. The...

THE SUPERDRYER PATENTED

CACTUS 5

CACTUS 10

CACTUS 15

CACTUS 25 CACTUS 50

INSTALLATION AND

OPERATING INSTRUCTIONS

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.

1570 Georgetown Rd Hudson, OH 44236

USA Phone: (330) 650-9280 Fax: (330) 653-3052

e-mail [email protected]

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 15 - 30 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.

CUT-AWAY VIEW

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.

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.

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, 50 - 60 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.

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.

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.

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 15 – 20 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 ( 55 – 70 DEGREES C) DEPENDING ON RESIN.

D) ADJUST INJECTION SPEED TO SLOW OR MEDIUM.

E) SET THE THE REAR BARREL ZONE APPROX. 15 – 20 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.

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.

THROUGHPUT GUIDE MODEL 5 10 15 25 50

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 1.0 1.5 2.0 3.0 3.0

ELECTRICAL kw .75 1.36 1.40 2.85 4.2

230V, 1 PHASE amps 3.3 5.9 6.1 12.4 18.25

HEATED CAPACITY lb/kg 1.0/0.5 3.5/1.5 6.0/2.8 30.0/12.7 60/27

TOTAL CAPACITY lb/kg 2.0/0.9 5.0/2.3 8.0/3.6 47.0/21.3 100/45.5

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).

*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 TDT @ 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 190 - 210 (85 - 100) ACETAL 225 (110) ACRYLIC 180 - 200 (80 - 95) BUTYRATE 140 - 170 (60 - 75) NYLON 200 - 270 (95 - 135) POLYCARBONATE 240 - 270 (115 - 135) POLYETHYLENE 180 - 190 (80 - 90) POLYESTER PBT 270 - 300 (135 - 150) PET 300 - 400 (150 - 200) POLYSTYRENE 180 - 200 (80 - 95) POLYSULPHONE 350 - 390 (175 - 200) POLYURETHANE 140 - 170 (60 -75) P.P.O. (NORYL) 220 - 230 (105 - 110) PVC 150 - 180 (65 - 80) SAN 180 - 200 (80 - 95) TPE 200 – 230 (94 – 108) ULTEM 350 - 400 (175 - 200) FOR OTHER MATERIALS, OR FOR FURTHER INFORMATION REFER TO CACTUS TECHNICAL DEPARTMENT FOR SUGGESTED SETTINGS AND THROUGHPUT CAPACITIES.

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 (0.1 - 0.2 bar) 10 2 - 4psi (0.2 - 0.3 bar) 15 2 - 5psi (0.2 - 0.4 bar) 25 4 - 8psi (0.3 - 0.6 bar) 50 5 – 8psi (0.4 – 0.6 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.

TROUBLE SHOOTING 1. Check the supply voltage, voltage must be between 220V and 240V, single phase, 50 -60 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. They are important for proper dryer operation.

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.

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.

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.

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.

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 430 220

SL-L 125 53

CNEL PID PID

S-HC STND STND

SE ON ON

PREL OFF OFF

CP 3 3

GREU 6R-R 6R-R

ALE-1 6 6

ALE-2 7 7

Press Level key and return to normal setup

Temp 200 93

r-5 run run

AL-1 10 6

AL-2 10 6

�

73

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 onpower

� Outline of operation procedures fordifferent levels

� Troubleshooting

� Fuzzy self-tuning

� Peripheral devices

� Precautions

Nomenclature� E5AN

Temperature Unit

The temperature unit is displayed when the dis-play unit parameter is set to a temperature. In-dication is determined by the currently selected“temperature unit” parameter set value. Whenthis parameter is set to “°C,” “�” is displayed, andwhen set to “°F,” “�” is displayed.

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 theheater burnout latch. To reset, turn the power supplyOFF and then ON or set the heater burnout alarm valueto “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 willalways be unlit.

4. STOP (stop)Lights when control of the E5AN has been stopped.During control, this indicator lights when an event or therun/stop function has become stopped. Otherwise, thisindicator is out.

5. CMW (communications writing control)Lights when communications writing is enabled and isout when it is disabled.

No. 1 Display

Displays the process value or param-eter type.

No. 2 Display

Displays the set point, manipulatedvariable, or set value (setup) of theparameter.

Up Key

Each press of this key increases val-ues displayed on the No.2 display.Holding down this key continuouslyincreases values.

Down Key

Each press of this key decreases val-ues displayed on the No.2 display.Holding down this key continuously de-creases values.

Level Key

Press this key to select the setup level. The setup level isselected in order “operation level” ←→ “adjustment level,”“initial setting level” ←→ “communications setting level.”

Mode Key

Press this key to select parameterswithin each level.

Level + Mode Keys

This key combination sets the E5ANto the “protect level.”

E5AN/E5EN/E5CN/E5GN E5AN/E5EN/E5CN/E5GN

74

� E5EN

Temperature Unit



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 theheater burnout latch. To reset, turn the power supplyOFF and then ON or set the heater burnout alarmvalue 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, OUT1will always be unlit.

4. STOP (stop)Lights when control of the E5EN has been stopped.During control, this indicator lights when an event orthe run/stop function has become stopped.Otherwise, this indicator is out.

5. CMW (communications writing control)Lights when communications writing is enabled andis out when it is disabled.

No. 1 Display

Displays the process value or param-eter type.

No. 2 Display

Displays the set point, manipulatedvariable, or set value (setup) of the pa-rameter.

Up Key

Each press of this key increases val-ues displayed on the No.2 display.Holding down this key continuouslyincreases values.

Down Key

Each press of this key decreases val-ues displayed on the No.2 display.Holding down this key continuouslydecreases values.

Level Key

Press this key to select the setup lev-el. The setup level is selected in order“operation level” ←→ “adjustmentlevel,” “initial setting level” ←→ “com-munications setting level.”

Level + Mode Keys

This key combination sets the E5ENto the “protect level.”

Mode Key

Press this key to select parameters withineach level.

� E5CN

Temperature Unit



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 isdetected.The heater burnout alarm remainsON by setting the heater burnoutlatch. To reset, turn the power supplyOFF and then ON or set the heaterburnout alarm value to “0.0A.”

3. OT1, OT2 (control output 1, controloutput 2)Lights when control output 1 and/orcontrol output 2 (cool) are ON.However, if control output 1 is currentoutput, OT1 will always be unlit.

4. STP (stop)Lights when control of the E5CN hasbeen stopped.During control, this indicator lightswhen an event or the run/stopfunction has become stopped. Other-wise, this indicator is out.

5. CMW (communications writing con-trol)Lights when communications writingis enabled and is out when it isdisabled.

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 valuesdisplayed on the No.2 display. Holdingdown this key continuously increasesvalues.

Down Key

Each press of this key decreases valuesdisplayed on the No.2 display. Holdingdown this key continuously decreasesvalues.

Mode Key

Press this key to select parameters withineach level.Level Key

Press this key to select the setup level. The setup level isselected in order “operation level” ←→ “adjustment level,”“initial setting level” ←→ “communications setting level.”

Level + Mode Keys

This key combination sets the E5CN to the“protect level.”


75

� E5GN

Temperature Unit



1. AL (alarm)Lights when alarm output is ON.

2. CMW (communications writing control)Lights when communications writing isenabled and is out when it is disabled.

3. STP (stop)Lights when control of the E5GN hasbeen stopped.During control, this indicator lightswhen an event or the run/stop functionhas been stopped. Otherwise, thisindicator is out.

4. OUT (control output)Lights when control output is ON.

No. 1 Display

Displays the process value or parameter type.

No. 2 Display

Displays the set point, manipulated variable orset value (setup) of the parameter.

Up Key

Each press of this key increases values displayed onthe No.2 display. Holding down this key continuouslyincreases values.

Down Key

Each press of this key decreases values displayed onthe No.2 display. Holding down this key continuouslydecreases values.

Mode Key

Press this key to select parameterswithin each level.

Level Key

Press this key to select the setup level. The set-up level is selected in order “operation level”←→ “adjustment level,” “initial setting level”←→ “communications setting level.”

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 panelfrom the front.

2. Push the mounting bracket along the E5AN/E5EN body fromthe terminals up to the panel, and secure it temporarily.

3. Tighten the fixing screw on each mounting bracket alternatelyuntil the ratchet stops tightening.

Mounting bracket

Panel

Waterproofpacking

E5AN Mounting bracketPanel

Waterproofpacking

E5EN


76

� DRAWING OUTFor drawing out the Unit, use a suitable Philips screwdriver for thescrew located at the bottom on the front panel.

1. While pressing down on the hook located at the top of the frontpanel, 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 Unittowards you.

3. When inserting the Unit, confirm that the waterproof packingis in place. While pressing down on the hook located at the topof the front panel, turn the screw (located at the bottom on thefront panel) clockwise using a Philips screwdriver and tightento a torque of 0.3 to 0.5 N�m. Make sure that electronic partsdo not come in contact with the case.

(1)

(2)

(3)

(1)(3)

(3)

(2)

(1)

� ACCESS TO E5CN TO INSTALL OPTION UNITSIf communications, event input, or heater burnout functions arerequired, mount the E53-CNH03 Communications Unit or theE53-CNHB Event Input Unit. The heater burnout function issupported 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-CNHBand run/stop functionality) Event input (for current output models) E53-CNB

Assembling a Unit

Flat-blade screwdriver (unit: mm)

20 m

in.

(1)

(1)

(2)

(4)

(3)

1. Insert the tools (see drawing at left) into the slots (one on thetop and one on the bottom) and release the hooks.

2. Insert the tool in the space between the front and rear panelsand slightly pull out the front panel. Hold the top and bottom ofthe front panel and pull toward yourself to remove it.

3. Match up the upper and lower claws with the connectionpoints and insert the Option Unit. Mount the Option Unit in thecenter.

4. Before inserting the Unit, confirm that the waterproof packingis in place. Insert the Unit into the rear case until you hear aclick. When inserting the Unit, press down the hooks on thetop and bottom of the rear case so that they firmly hook on theinserted Unit. Make sure that electronic parts do not come incontact with the case.

5. Push the adapter along the E5CN body from the terminals upto the panel, and secure it temporarily.

6. Tighten the two fixing screws on the adapter. When tighteningscrews, tighten the two screws alternately keeping the torqueto between 0.29 and 0.39 N�m (2.9 kgf�cm to 3.9 kgf�cm).

� MOUNTING E5CN

AdapterPanel

Attaching the E5CN to a PanelInsert the E5CN into the mounting hole in the panel.

Attaching the Terminal CoverMake sure that the “UP” mark is facing up, and then fit theTerminal Cover (E53-COV10) into the holes on the top andbottom. A E5CN-�-500 Controller is provided with a TerminalCover.


77

� MOUNTING E5GN1. Insert the E5GN into the mounting hole in the panel from the

front.

2. Push the adapter along the E5GN body from the terminals upto the panel, and secure it temporarily.

3. Tighten the two fixing screws on the adapter. When tighteningscrews, tighten the two screws alternately keeping the torqueto within approximately 0.29 to 0.39 N�m.

Adapter

Panel

Waterproof seal

� REMOVING AND ATTACHING E5GN’S TERMINAL PLATE

1. Press down hard on the fastenerson both sides of the terminals tounlock the terminal plate and pullupwards.

3 Before you insert the terminal plate again, makesure that the pins match the positions of the holes inthe terminal plate.

2 Draw out the terminal plateas it is.

The E5GN can be replaced by removing 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 theE5AN/E5EN/E5CN.

• Tighten the terminal screws using a torque between 0.74 and0.90 N � m.

• Use the following type of solderless terminals for M3.5screws.

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 AWG14 2.1 dia. max.

7 to 9 AWG28 to AWG22 1.3 dia. max.

• The exposed current-carrying part to be inserted into terminalsmust be 5 to 6 mm.

Electrical wire Pin terminal

5 to 6 mm 5 to 6 mm

• Tighten the terminal screws to the torque specified below.

Terminal No. Screw Maximum tighteningtorque

1 to 6 M2.6 0.23 to 0.25 N � m

7 to 9 M2 0.12 to 0.14 N � m


78

Operation� INITIAL SETUPOn previous Controllers, sensor input type, alarm type and controlperiod were set on DIP switches. These hardware settings are nowset in parameters in setup menus. The and keys are used toswitch between setup menus, and the amount of time that you hold

the keys down for determines which setup menu you move to. Thissection describes two typical examples.

Note: On the E5EN/E5GN, the Key is the Key.

� 1. ON/OFF CONTROLTypical Application Examples

indicates that there is a parameter. Keepon pressing the mode key until the de-sired parameter is selected.

Changing Set Values

Use the or keys tochange the set value displayedin the setup menu.

E5CN

E5GN

No. 1 display

No. 2 display

No. 1 display

No. 2 display

Changing Parameters

E5EN

No. 1 display

No. 2 display

Display

E5AN

No. 1 display

No. 2 display

Typical Example

Input type : 0 K thermocouple -200 to 1300°CControl 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.

Setup procedure

Power ON

Set input specifications

Set control specifications

Set alarm type

Set alarm values

Start operation

Power ON

Operation level

Initial setting level

Process value/set point

Input type�

In ON/OFF control��

Alarm 1type �

Check inputtype.

Check that con-trol is ON/OFFcontrol.

Check alarmtype.

Press key for at leastthree seconds. Control stops.

Process value/set point ��

Make sure thatcontrol is running.

Press key for atleast one second.Control starts.

During run�

During stop

Alarm val-ue 1

Press keysto set set point to“100�C.”

Press keysto set alarm valueto “20�C.”

Start operation

Set the set point

Check operationstate

Operation level


79

� 2. PID CONTROL USING AUTO-TUNING

indicates that there is a pa-rameter. Keep on pressingthe mode key until the de-sired parameter is selected.

Changing Set Values

Use the or keysto change the set valuedisplayed in the setupmenu.

Display

E5CN

E5GN

No. 1 display

No. 2 display

No. 1 display

No. 2 display

Input type: 4 T thermocouple -200 to 400°CControl method:PID controlST (self-tuning):OFFCalculate PID constants by AT (auto-tuning).Alarm type: 2 upper limitAlarm value 1: 30°C (For setting deviation)Set point: 150°C

Setup procedure

Power ON

Set inputspecifica-tions

Set controlspecifications

Self-tuning

Set alarm values

Start operation

Power ON

Operation level

In PID control

To cancel ST

Check thecontrol period.

Check alarmtype.

Press key for at least one second.

Press keysto set set point to“150�C.”

Execute AT (auto-tuning).

Presskeys to selectinput type.

Presskeys to selectPID control.

Presskeys to set STto OFF.

Control period(heat) (unit: se-conds)


Press key for less than one second.Adjustment level

Operation level

To execute AT

Press key for less than one second.

Make sure thatset point is“150�C.”

Make sure thatcontrol is running.

Presskeys to setalarm value to“30�C.”


During run

Alarmvalue 1��

Start program execution

Operation level

Check controlperiod

Check alarm type

Set the set point

Set operation status

(upper-limit alarm)

Typical Example

When set to ON,self-tuning operates.Recommended set-tings: 20 seconds forthe relay output and2 seconds for theSSR output.

Set to �� for execut-ing AT and to ��for stopping AT.

AT execution

Process value/set point

Input type

Press key for at least threeseconds. Control stops.


Alarm 1 type �

After AT execution.

During AT execution.

While AT is being executed, SP will flash.

PV/SP

After AT execution.

During AT execution.

Changing Parameters

E5EN

No. 1 display

No. 2 display

E5AN

No. 1 display

No. 2 display


80

Specification Setting after Turning ON Power� OUTLINE OF OPERATION PROCEDURESKey Operation

In the following descriptions, all the parameters are introduced in the display sequence. Some parameters may not be displayed depending onthe protect settings and operation conditions.

Note: 1. Of these levels, the initial setting level, communica-tions setting level, advanced function setting level andcalibration level can be used only when control hasstopped. Note that control is stopped when these fourlevels are selected. When switched back to the opera-tion level from one of these levels, control will start.

2. For the calibration mode, refer to the relevant Opera-tion Manual (H100 or H101).

3. On the E5EN/E5GN, the Key is the Key.

Power ON

Operation level Adjustment level

+ key1 second min.

key1 secondmin.

key3 secondsmin.

Less than 1 second

key

Control stops

Protect level

Communica-tions settinglevel


key1 second min.

Less than 1 second

key

Advanced function setting level

Calibration level

Password input set value “1201”

Password input set value “–169”

Control in progress

Control stopped

Level change

+ key3 seconds min.

+ keyDisplay flashes when key pressed.

keyDisplay flashes when key helddown for more than 1 second.

The time taken to move to the protect levelcan be adjusted by changing the “Move toprotect level time” setting.

� DESCRIPTION OF EACH LEVELOperation LevelThis level is displayed when you turn the power ON. You can moveto the protect level, initial setting level and adjustment level from thislevel.

Normally, select this level during operation. During operation, theprocess value, set point and manipulated variable can be moni-tored, and the alarm value and upper- and lower-limit alarms can bemonitored and modified.

Adjustment LevelTo select this level, press the key once for less than one second.

This level is for entering set values and offset values for control. Thislevel contains parameters for setting the set values, AT (auto-tun-ing), 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 initialsetting level from here.

Initial Setting LevelTo select this level, press the key for at least three seconds in theoperation level. This level is for specifying the input type, selectingthe control method, control period, setting direct/reverse action andalarm type. You can move to the advanced function setting level orcommunications setting level from this initial setting level. To returnto the operation level, press the key for at least one second. Tomove to the communications setting level, press the key once forless than one second.

Protect Level

To select this level, simultaneously press the and keys forat least 3 seconds. This level is to prevent unwanted or accidentalmodification of parameters. Protected levels will not be displayed,and so the parameters in that level cannot be modified.

Communications Setting LevelTo select this level, press the key once for less than one second inthe initial setting level. When the communications function is used,set the communications conditions in this level. Communicatingwith a personal computer (host computer) allows set points to beread and written, and manipulated variables to be monitored.

Advanced Function Setting LevelTo select this level, you must enter the password (“-169”) in the ini-tial 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 lim-iter, event input assignment, standby sequence, alarm hysteresis,ST (self-tune) and to move to the user calibration level.

Calibration LevelTo select this level, you must enter the password (“1201”) in theadvanced function setting level. This level is for offsetting deviationin the input circuit.

You cannot move to other levels by operating the keys on the frontpanel from the calibration level. To cancel this level, turn the powerOFF then back ON again.


81

� SPECIFICATION SETTING AFTER TURNING ON POWERInitial Setting LevelThis level is used for setting basic specifications of the TemperatureController. Using this level, set the input type for selecting the inputto be connected such as the thermocouple or platinum resistancethermometer and set the range of set point and the alarm mode.

Power ON

Operation level Adjustment levelkey

Less than 1 second

key3 secondsmin.

key1 second min.

Communica-tions setting levelkey

Less than 1 second

Control stops.


key1 second min.

Password input set value “-169”



Calibration level

Protect level

key

1 second min.

+

key+

key+

Control in progress

Control stopped

Level change

Display flasheswhen key pressed.

3 secondsmin.

The time taken to moveto the protect level canbe adjusted by chang-ing the “Move to protectlevel 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/communica-tions protection” is set to “2.” This initial setting level can be usedwhen “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 selectedas the input type.


Input type

Scaling upper limit

Scaling lower limit

Decimal point

Set point upper limit

Set point lower limit

PID / ON/OFF

Standard/heating and cooling

ST

Control period (heat)

Control period (cool)

Direct/reverse operation

Alarm 1 type

Alarm 2 type

Move to advanced function setting level

Temperatureunit

��: ON/OFF control��: PID control

��: Standard��: Heating/cooling

��: Enabled��: Disabled

��: Reverseoperation��: Directoperation

Alarm 3 type((E5AN/E5EN)

For analog input (Input type: 16) 0- to 50-mV setting

(PID control)(Heating/cooling setting)

(PID control)

Alarm output type (Other than E5GN)

Set the pulse outputcycle.

Select the alarm mode.(Models with alarmfunction)

(When initial/communications protect is set to “0”.)

To return to the operation level, press the key for longer than onesecond* Not displayed as default setting.


82

� INPUT TYPEWhen using a thermocouple input type, follow the specifications listed in the following table.

Input type Specifications Switch setting Input temperature range

Thermocouple K 0 –200 to 1300 (°C) /–300 to 2300 (°F)

1 –20.0 to 500.0 (°C) /0.0 to 900.0 (°F)

J 2 –100 to 850 (°C) /–100 to 1500 (°F)

3 –20.0 to 400.0 (°C) /0.0 to 750.0 (°F)

T 4 –200 to 400 (°C) /–300 to 700 (°F)

E 5 0 to 600 (°C) /0 to 1100 (°F)

U 17 –199.9 to 400.0 (°C) /–199.9 to 700 (°F)

L 6 –100 to 850 (°C) /–100 to 1500 (°F)

U 7 –200 to 400 (°C) /–300 to 700 (°F)

U 18 –199.9 to 400.0 (°C) /–199.9 to 700 (°F)

N 8 –200 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 11 100 to 1800 (°C) /300 to 3200 (°F)

Non-contact temperature K10 to 70�C 12 0 to 90 (°C) /0 to 190 (°F)sensor ES1A K60 to 120�C 13 0 to 120 (°C) /0 to 240 (°F)

K115 to 165�C 14 0 to 165 (°C) /0 to 320 (°F)

K160 to 260�C 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, 199.9 to 999.9

Note: The initial settings are: 0: –200 to 1300�C/–300 to 2300�F.

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 Pt100 0 –200 to 850 (°C) /–300 to 1500 (°F)thermometer 1 –199.9 to 500.0 (°C) /–199.9 to 900.0 (°F)

2 0.0 to 100.0 (°C) /0.0 to 210.0 (°F)

JPt100 3 –199.9 to 500.0 (°C) /–199.9 to 900.0 (°F)

4 0.0 to 100.0 (°C) /0.0 to 210.0 (°F)

Note: The initial settings are: 0: Pt100 –200 to 850�C/–300 to 1500�F.


83

� ALARM 1 AND ALARM 2For 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 hasthree 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 standbysequence (deviation)

*5*4

6 Upper-limit with standby sequence(deviation)

7 Lower-limit with standby sequence(deviation)

8 Absolute-value upper-limit

9 Absolute-value lower-limit

10 Absolute-value upper-limit withstandby sequence

11 Absolute-value lower-limit withstandby sequence

*1: With set values 1, 4 and 5, the upper and lower limit values canbe 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” ornegative.

*2: Set value: 1, Upper- and lower-limit alarm

Case 1 Case 2 Case 3 (Always ON)

=

=

*3: Set value: 4, Upper- and lower-limit range

Case 1 Case 2 Case 3 (Always OFF)

=

=

*4: Set value: 5, Upper- and lower-limit with standby sequence

Case 1 Case 2

Same as for the upper- and lower-limitalarm. However, when the upper-limitand lower-limit hysteresis overlaps: Always OFF

Example

*5: Set value: 5, Upper- and lower-limit with standby sequencealarm. Always OFF when the upper-limit and lower-limit hysteresisoverlaps.

Set the alarm types for alarm 1 and alarm 2 independently in the ini-tial setting level. The default setting is 2 (upper limit). With theE5AN/E5EN, perform settings similarly for alarm 3.

Example: When the alarm is set ON at 110�C/�F or higher.When an alarm type otherthan the absolute-valuealarm is selected

(For alarm types 1 to 7)The alarm value is set as adeviation from the set point.

When the absolute-valuealarm is selected

(For alarm types 8 to 11)The alarm value is set asan absolute value from thealarm value of 0�C/F.

Alarm value

Set point100°C/°F

Alarm value

0°C/°F


84

� PARAMETERSParameters related to setting items for each level are marked in boxes in the flowcharts and brief descriptions are given as required. At the endof each setting item, press the mode key to return to the beginning of each level.



Calibration level

Password input set value “-169”

Control stops.


Less than 1 secondkey

Communica-tions settinglevel

Power ON

Operation level

1 secondmin.

+ key

Protect level

Control in progress

Control stopped

Adjustment level

1 secondmin.

key

1 second min.

key

3 secondsmin.

key

Level change

Less than 1 second

key

3 secondsmin.

+ key

+ keyDisplay flashes when key helddown for more than 1 second.

+ key

The time taken tomove to the protectlevel can be adjustedby changing the “Moveto protect level time”setting.

Display flasheswhen key pressed.

Display

E5CN E5GNNo. 1 display

No. 2 display

No. 1 display

No. 2 display

E5EN

No. 1 display

No. 2 display

E5AN

No. 1 display

No. 2 display

Power ON

Operation LevelInitial Setting LevelAdvanced FunctionSetting Level

Adjustment Level

Note: To select advanced functionsetting level, you must enterthe password (“-169”) in theinitial setting level.

1 second min.1 second min.

3 seconds min.

key

keykey




85

� ADVANCED FUNCTION SETTING LEVEL

Parameter initialize

Alarm 2 hysteresis

Alarm 2 open in alarm

Alarm 1 hysteresis


Multi-SP uses

Event input assignment 2

Event input assignment 1

Number of multi-SP uses

HBA ON/OFF

MV upper limit

α

ST stable range

Heater burnout hysteresis

Heater burnout latch

SP ramp set value

Input setting: Multiple SP/RUN/STOP

Resets to the default value.

ON/OFF setting of alarmoutput 1


2-PID parameter

Limitations to MV

For setting deviation.

Alarm 3 hysteresis



�

�

�

��

�

�

�

�

�

�

�

��

��

��

��

�

�

�

�

�

Restarting condition afterclearing standby sequence

Standby sequence reset

MV lower limit

��

�

Alarm 1 latch

Alarm 2 latch

Alarm 3 latch

Move to protect level time

Input error output

Cold junction compensating method

MB command logic switching

Alarm ON latches

�

��

�

�

�

Move to calibration level�

�

Input digital filterFor setting time constant in seconds.

Additional PV displayDisplayed first in the operation level

Manipulated variable display

Automatic return of display modeAutomatically reset to the operation levelwhen no key operation are performed.

�

�

�

�

Note: These diagrams show all the parameters that may be dis-played. Depending on the specifications of the model used,there may be some parameters that are not displayed. Thefollowing symbols are used to distinguish between theseparameters.�: 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

� INITIAL SETTING LEVEL

Input type

Scaling upper limit

Decimal point

Temperature unit

Set point upper limit

PID ON/OFF

Standard/heating and cooling

ST

Control period (heat)

Alarm 1 type

Move to advanced functionsetting level

Set the pulseoutput cycle.

Direct/reverse operation

Alarm 2 type

Limit the set point.

Select the control system.

Self-tuning

Select the alarmmode.

Control period (cool)

For analog input(Input type: 16)0- to 50-mV setting

Number of displayed digits

�: °C

��: ON/OFF control

��: Standard

��: Enabled

��: Reverse

Set point lower limit

Scaling lower limit

Alarm 3 type

�

��

�

��

�

��

�

��

�

�

�

�

��

��

��

�

�

�

�

��

Note: To select advanced function set-ting level, you must enter the pass-word (“-169”) in the initial settinglevel.

OUT1

OUT2

�: °F

��: PID control

��: Heating/cooling

��: Disabled

��: Direct

� OPERATION LEVEL

PV

PV/SP

Add in the “additionalPV display” parameter.

Multi-SP

Set point during SP ramp

Heater current value monitor

Run/stop

Alarm value 1

Upper-limitalarm value 1

Lower-limitalarm value 1

Set either oftheseparameters.

Alarm value 2



Set either oftheseparameters.

MV monitor (OUT 2)

Current valuemonitor of HBA

Select SP.

�: RUN��: STOP

Set either of theseparameters.

The displays for parameters which can be switched(i.e., parameters other than simply numerical ones)show the contents of those parameters.

��

�

�

��

��

�

�

�

�

�

�

�

�

�

�

�

��

��

MV monitor (OUT 1)

Alarm value 3



Note: These diagrams show all the parameters that may be dis-played. Depending on the specifications of the model used,there may be some parameters that are not displayed. Thefollowing symbols are used to distinguish between theseparameters.�: 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.


87

� ADJUSTMENT LEVEL

Hysteresis (OUT 1)

AT execute/cancel

Communications writing

Heater currentvalue monitor

HBAfunction

Set point 0

Set point 1

Set points usedby multi-SP

Temperature input shift 1-point shift

2-point shift (see note)

Proportional band

PID settings

Cooling coefficient

Dead band

Used in heating andcooling control

Manual reset value

Auto-tuning

Heater burnoutdetection

Set point 2

Set point 3

Lower-limit temperatureinput shift value

Upper-limit temperatureinput shift value

Derivative time

Integral time

Clear the offset duringstabilization of P or PDcontrol.

Set hysteresis.

P

I

D

Hysteresis (OUT 2)

��: Enabled��: Disabled

The 2-point shift setting is only possible when theinput type is a non-contact temperature sensor.

�

��

�

�

�

�

�

��

��

��

�

��

��

��

��

��

�

��

��

��

��

��

Note: These diagrams show all the parameters that may be dis-played. Depending on the specifications of the model used,some parameters may not be displayed. The followingsymbols distinguish between these parameters.�: Displayed for all models regardless of the setting ofother parameters.�: Not displayed for some models.��: Depending on the settings of other parameters, maynot be displayed.

� PROTECT LEVEL

Operation/adjustment protection

Restricts display and modification of menus in the opera-tion and adjustment levels.

Initial setting/communications protectionRestricts display and modification of menus in the initial set-ting, operation level and adjustment levels.

Setting change protection

Protects changes to setups by operating the front panelkeys.

� INITIAL SETTING/COMMUNICATIONSPROTECTION

This protect level restricts movement to the initial setting level, com-munications setting level and advanced function setting level.

Setvalue

Initial settinglevel

Communicationssetting level

Advancedfunction

setting level

0 � � �

1 � � X

2 X X X

Default setting: 1

� : Move to other levels possible� : Move to other levels not possible

� OPERATION/ADJUSTMENT PROTECTION

The following table shows the relationship between set values andthe range of protection.

Level Set value

0 1 2 3

Operation PV � � � �level PV/SP �

Other X X

Adjustment level X X X

When this parameter is set to “0,” parameters are not protected.

Default setting: 0

: Can be displayed and changed� : Can be displayed� : Cannot be displayed and move to other levels not possible

� SETTING CHANGE PROTECTIONThis protect level protects setup from being changed by operatingthe 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


88

� COMMUNICATIONS SETTING LEVELSet the E5AN/E5EN/E5CN/E5GN communications specifications in the communications setting level. For setting communications parame-ters, 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 99 0.1 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., throughkey operations as described below. As for other operations, referto relevant Operation Manual.

1. Press the key for at least three seconds in the “operationlevel.” The level moves to the “initial setting level.”

2. Press the key for less than one second. The “initial settinglevel” moves to the “communications setting level.”

3. Pressing the key advances the parameters as shown inthe following figure.

4. Press the or keys to change the parameter setups.

Communicationsunit 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 commu-nicating personal computer.

� COMMUNICATIONS UNIT NO. (��)When communicating with the host computer, the unit number mustbe set in each Temperature Controller so that the host computer canidentify each Temperature Controller. The number can be set in arange from 0 to 99 in increments of 1. The default setting is 1. Whenusing more than one Unit, be careful not to use the same numbertwice. Duplicate settings will cause malfunction. This valuebecomes valid when the power is turned OFF and ON again.

� BAUD RATE (��)Use this parameter to set the speed of communications with thehost 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 ONagain.

� DATA BITS (��)Use this parameter to change the communications data bit length to7 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.

� TROUBLESHOOTINGWhen an error occurs, an error code will be displayed on the No. 1 display. Check the contents of an error and take appropriate countermea-sures.

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 Unitmust be repaired. If the display is restored, then a probable cause can be external noiseaffecting the control system. Check for external noise.

Display range over Though not error, this is displayed when the process value exceeds the display rangewhen the control range is larger than the display range.

• When less than “-1999” (–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, theE5EN/E5CN/E5GN must be repaired. If the display is restored, then a probable cause canbe 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.


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Fuzzy Self-tuningThe fuzzy self-tuning (ST) is a function that automatically calculates an optimum PID constant depending on items to be controlled.

� FEATUREThe Temperature Controller determines when to execute this fuzzy self-tuning.

� FUNCTIONSStep-Response Tuning (SRT): Performs PID tuning according to the step response method when the SP is changed.

� REQUIREMENTS FOR SRT FUNCTIONALITYThe ST will be executed according to the step response method when the following conditions are satisfied when operation is started or whenthe 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 theprevious SRT was executed. (See Note.)

2. The temperature upon startup is smaller than the SP in thereverse 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 theprevious SRT.

1. The SP after change is different from the SP at the time theprevious SRT was executed. (See note.)

2. In the reverse operation, the value obtained by deducting the SPbefore change from the SP after change is larger than the STstable range. In the direct operation, the value obtained bydeducting the SP after change from the SP before change islarger than the ST stable range.

3. The SP change width is larger than the current proportional bandx 1.27 + 4.

4. The temperature is in the stable state. (It can be in the balancedstate 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.

Temperature

SRT completion

Time

ST stable range

This inclination isreferred to as R.


90

Peripheral Devices� CONNECTION EXAMPLE WITH SSR

Temperature controller

Voltage outputterminal (for driving SSR)

Load

Heater

Load power

Direct connection possible

3 units5 units(E5AN/E5EN)



1 unit2 units(E5AN/E5EN)


Rated input voltage: 5 to 24 VDC

Compact and slim models with abuilt-in radiator

G3PA: 240 VAC (10 A, 20 A, 40 A)400 VAC (20 A, 30 A)

E5EN

E5GN

E5CN

E5AN

For controlling high-power heater

G3NH: 440 VAC (75 A, 150 A)

Standard models with screw terminals

G3NA: 240 VAC (5 A, 10 A, 20 A, 40 A)480 VAC (10 A, 20 A, 40 A)

Simultaneous three-phase control witha built-in radiator

G3PB (Three-phase): 240 VAC/400 VAC (15 A, 25 A, 35 A, 45 A)

Compact and low-cost modelswith tab terminals

G3NE: 240 VAC (5 A, 10 A, 20 A)

G3PB (Single-phase): 240 VAC15 A, 25 A, 35 A, 45 A)

Rated input voltage:12 to 24 VDC

Compact and slim models with abuilt-in radiator


4 unitsfor480-VACmodels

Rated input voltage:12 to 24 VDC


Rated input voltage: 12 VDC


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Precautions� GENERAL PRECAUTIONSThe user must operate the product according to the performancespecifications described in the operation manuals.Before using the product under conditions which are not describedhere or applying the product to nuclear control systems, railroadsystems, aviation systems, vehicles, combustion systems, medicalequipment, amusement machines, safety equipment, and othersystems, machines, and equipment that may have a serious influ-ence on lives and property if used improperly, consult your OMRONrepresentative.Make sure that the ratings and performance characteristics of theproduct are sufficient for the systems, machines, and equipment,and be sure to provide the systems, machines, and equipment withdouble safety mechanisms.

� SAFETY PRECAUTIONS

Definition of Precautionary Information

DANGER Indicates an imminently hazardous situationwhich, if not avoided, will result in death orserious injury.

WARNING Indicates a potentially hazardous situationwhich, if not avoided, could result in death orserious injury.

Caution Indicates a potentially hazardous situationwhich, if not avoided, may result in minor ormoderate injury, or property damage.

Installation Precautions

WARNING Do not attempt to take any TemperatureController apart while the power is applied.Doing so may result in electric shock.

WARNING Do not touch any of the terminals or terminalblocks while the power is being supplied.Doing so may result in electric shock.

WARNING Do not allow pieces of metal or wire cuttingsto get inside the Temperature Controller.Failure to do so may result in malfunction,electric shock or fire.

WARNING Do not attempt to disassemble, repair, ormodify the Temperature Controller. Anyattempt to do so may result in malfunction,fire, or electric shock.

Caution Do not use the Temperature Controller inlocations subject to flammable gases. Doingso may result in an explosion.

Caution The switching capacity and switching condi-tions will have a great effect on the longevityof the output relays. Use the TemperatureController within the rated load and do notuse the Temperature Controller beyond thenumber of operations specified under elec-trical life. Using the Temperature Controllerbeyond its electrical life may result in contactwelding or burning.

Caution Do not use the Temperature Controller atloads greater than the rated value. Doing somay result in burning or other damage.

Caution Use a power supply voltage within the speci-fied range. Failure to do so may result inburning or other damage.

Caution Tighten the terminal screws to the followingtorques:E5AN, E5EN, E5CN: 0.74 to 0.90 N�mE5GN: Terminals 1 to 6: 0.23 to 0.25 N�m

Terminals 7 to 9: 0.12 to 0.14 N�mFailure to tighten terminal screws to the cor-rect torque may result in fire or malfunction.

Caution Make settings for the Temperature Control-ler that are suitable for the controlled sys-tem. Failure to do so may cause unexpectedoperation resulting in damage to equipmentor personal injury.

Caution Prepare a circuit with an overheating pre-vention alarm and take other safety mea-sures to ensure safe operation in the eventof a malfunction. Loss of operational controldue to malfunction may result in a seriousaccident.

� OPERATING ENVIRONMENT PRECAUTIONS

Caution In order to ensure the safe operation, ob-serve the following precautions.

• Do not use the Temperature Controller in the following places:• Locations exposed to radiated heat from heating devices• Locations subject to direct sunlight• Locations subject to temperatures or humidity outside the

range specified in the specifications• Locations subject to condensation as the result of severe

changes in temperature• Locations subject to corrosive or flammable gases• Locations subject to dust (especially iron dust) or salts• Locations subject to exposure to water, oil, or chemicals• Locations subject to shock or vibration

• Use and store the Temperature Controller within the rated tem-perature and humidity specified for each model. When two ormore Temperature Controllers are mounted horizontally closeto each other or vertically next to one another, the internal tem-perature will increase due to heat radiated by the TemperatureControllers and the service life will decrease. In such a case,forced cooling by fans or other means of air ventilation will berequired to cool down the Temperature Controllers. When pro-viding forced cooling, however, be careful not to cool down theterminal sections alone to avoid measurement errors.

• Allow enough space around the Temperature Controller toensure proper heat dissipation. Do not block the ventilatingholes.

• Check polarities and orientation when connecting terminals.Not doing so may result in malfunction.

• When wiring the E5AN, E5EN, or E5CN, use crimp terminalswith the specified dimensions (M3.5, width 7.2 mm max.).

• When wiring the E5GN, use cables of a thickness AWG24(0.205 mm2) to AWG14 (2.081 mm2) for terminals 1 to 6 anduse cables of a thickness AWG28 (0.081 mm2) to AWG22(0.326 mm2) for terminals 7 to 9. The exposed current-carryingpart to be inserted into terminals must be 5 to 6 mm.

• Do not use empty terminals.• To avoid inductive noise, keep the wiring for the Temperature

Controller’s terminal board away from power cables carry highvoltages or large currents. Also, do not wire power lines togeth-er with or parallel to Temperature Controller wiring. Usingshielded lines to separate pipes and ducts is recommended.Attach surge absorbers or noise filters to peripheral devicesthat may generate noise, such as inductance devices (e.g.,motors, transformers, solenoids, magnetic coils etc.). If using anoise filter with the power supply, in addition to confirming thevoltage and the current, mount the power supply as near aspossible to the Temperature Controller. Set up the Tempera-ture Controller, along with its power supply, as far away aspossible from devices that generate strong, high-frequencywaves (high-frequency welders, high-frequency machines etc.)and devices that generate surges.

• Set up the power supply so that the voltage will reach the ratedvoltage within 2 seconds after turning ON.

• Allow at least 30 minutes for the Temperature Controller towarm up.

• When using auto-tuning, turn ON power for the load (e.g., heat-er) at the same time as or before supplying power to the Tem-


• In order that power can be turned OFF in an emergency by theperson operating the Temperature Controller, install the ap-propriate switches and circuit breakers and label them accord-ingly.

• With the E5AN, E5EN, or E5CN, when drawing out the Tem-perature Controller body, do not touch or apply excessiveforce. After the body is drawn out do not touch the terminals orelectronic parts. When inserting, make sure that electronicparts do not come in contact with the case.

• When the terminal block for the E5GN is detached, do nottouch or apply excessive force to any electronic parts.

• Use alcohol to clean the Temperature Controller. Do not usethinner or other solvent-based substances.

� CORRECT USE

Service LifeUse the Temperature Controller within the following temperatureand humidity ranges:Temperature: –10°C to 55°C (with no icing or condensation)Humidity: 25% to 85%When the Temperature Controller is installed inside a control panel,ensure that the temperature around the Temperature Controller, notthe temperature around the control panel, does not exceed 55°C.

The service life of relays used for the control output or alarm outputlargely varies depending on switching conditions. Be sure to confirmtheir performance under actual operating conditions and do not usethem beyond the allowable number of switching operations. If theyare used in a deteriorated condition, insulation between circuits maybe damaged and, as a result, the Temperature Controller itself maybe damaged or burnt.

The service life of electronic devices such as Temperature Control-lers is determined not only by the number of switching operations ofrelays but also by the service life of internal electronic components.Component service life is affected by the ambient temperature: thehigher the temperature becomes, the shorter the service lifebecomes and, the lower the temperature becomes, the longer theservice life becomes. Therefore, the service life can be extended bylowering the temperature of the Temperature Controller using fansor other means of air ventilation. When providing forced cooling,however, be careful not to cool down the terminals sections alone toavoid measurement errors.

Measurement AccuracyWhen extending or connecting the thermocouple lead wire, be sureto use compensating wires that match the thermocouple types.

When extending or connecting the lead wire of the platinum resis-tance thermometer, be sure to use wires that have low resistance.

When wiring the platinum resistance thermometer to the Tempera-ture Controller, keep the wire route as short as possible. Separatethis wiring away from the power supply wiring and load wiring toavoid inductive or other forms of noise.

Mount the Temperature Controller so that it is horizontally level.

If the measurement accuracy is low, check that input shift has beenset correctly.

WaterproofingThe degree of protection is as shown below. Sections without anyspecification on their degree of protection or those with IP�0 have

not been waterproofed.Front panel: NEMA 4X indoor use (equivalent to IP66)Rear case: IP20Terminal section: IP00

Operating PrecautionsIt takes approximately four seconds for the outputs to turn ON fromthe moment the power is turned ON. Due consideration must begiven to this time when incorporating Temperature Controllers in asequence circuit.

When using auto-tuning, supply power to the load (e.g., heater) atthe same time as or before supplying power to the TemperatureController. If power is turned ON for the Temperature Controller be-fore turning ON power for the load, auto-tuning will not be performedproperly and optimum control will not be achieved.

When starting operation after the Temperature Controller haswarmed up, turn OFF the power and then turn it ON again at thesame time as turning ON power for the load. (Instead of turning theTemperature Controller OFF and ON again, switching from STOPmode to RUN mode can also be used in this case.)

If the Temperature Controller is used close to radios, television setsor wireless devices it may affect reception.

In the case of Temperature Controllers with alarm outputs, alarmoutput may not be generated properly when an abnormality occursin the device. It is suggested that a separate alarm device be incor-porated in the system.

To ensure proper performance, parameters of the TemperatureControllers are set to default values before they are shipped.Change these parameters depending on actual applications. If leftunchanged, the Temperature Controller will operate under thedefault settings.

Crimp Terminal ConnectionUse crimp terminals that match M3.5 screws. M3.5 x 8 self-risingscrews are used.

E5AN/E5EN/E5CN

7.2 mm max.

Be careful not to excessively tighten the terminals screws.

Soldering ConnectionThe self-rising screws provide easy soldering connection. Strip thelead wire by a length of 6 to 8 mm and properly treat the terminal tip.

Cat. No. GCTC13 8/00 Specifications subject to change without notice. Printed in U.S.A.

OMRON ELECTRONICS, INC.One East Commerce DriveSchaumburg, IL 60173

1-800-55-OMRON

OMRON CANADA, INC.885 Milner AvenueScarborough, Ontario M1B 5V8

416-286-6465

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