Omron E5AK User manual

E5AK
Digital Controller
User's Manual
Cat. No. H083-E1-03

E5AK
I
Thank you for your purchase of your E5AK, intelligent digital controller.
The E5AK allows the user to carry out the following:
•Select from many types of temperature and analog input (multiple input)
•Support position-proportional control (position-proportional type controllers
only).
•Select output functions such as control output or alarm (output assignment)
•Use the HBA (heater burnout alarm) function (standard type controllers only).
•Use four setpoints (multi-SP function)
•UseremoteSPinput.
•Monitor the control loop by LBA (Loop Break Alarm)
•Use the communications function
•Calibrate input or transfer output
•It also features a watertight construction (NEMA4: equivalent to IP66)
This User’s Manual describes how to use the E5AK compact, high-function digital
controller.
Before using your E5AK, thoroughly read and understand this manual in order to
ensure correct use.
About this manual
EOMRON, 1996
(1) All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or trans-
mitted, in any form, or by any means, mechanical, electronic, photocopying, recording, recording, or other-
wise, without the prior written permission of OMRON.
(2) No patent liability is assumed with respect to the use of the information contained herein.
(3) Moreover, because OMRON is constantly striving to improve its high-quality products, the information in
this manual is subject to change without notice. Every precaution has been taken in the preparation of this
manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability
assumed for damages resulting from the use of the information contained in this publication.
Preface

E5AK
II
JMeanings of Abbreviations
Sometimes the following abbreviations are used in parameter names, figures and in text
explanations. These abbreviations mean the following.
Abbreviation Term
PV Process value
SP Set point
RSP Remote set point
LSP Local set point
LBA Loop break alarm
HB Heater burnout
AT Auto-tuning
ST Self-tuning
JHow to Read Display Symbols
The following tables show the correspondence between the symbols displayed on the displays
and alphabet characters.
ABCDEFGH I JKLM
NOPQRSTUVWXYZ
J“Reference” mark
This mark indicates that extra, useful information follows, such as supplementary explana-
tions and how to apply functions.
Conventions Used in This Manual

E5AK
III
JNotice:
OMRON products are manufactured for use according to proper procedures by a qualified
operator and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Al-
ways heed the information provided with them. Failure to heed precautions can result in inju-
ry to people or damage to the product.
Indicates information that, if not heeded, is likely to result in loss of
life or serious injury.
Indicates information that, if not heeded, could possibly result in
loss of life or serious injury.
Indicates information that, if not heeded, could result in relatively
serious or minor injury, damage to the product, or faulty operation.
!DANGER
!WARNING
!Caution

E5AK
IV
JHow this Manual is Organized
Purpose Title Description
DLearning about the gen-
eral features of the E5AK
Chapter 1 Introduction This chapter describes the fea-
tures of the E5AK, names of
parts, and typical functions.
DSetting up the E5AK Chapter 2 Preparations This chapter describes the
operations that you must carry
out (e.g. installation, wiring and
switch settings) before you can
use the E5AK.
DBasic E5AK operations Chapter 3 Basic Operation
Chapter 5 Parameters
These chapters describe how to
use the front panel keys and
how to view the display when
setting the parameters of the
major functions for the E5AK.
DApplied E5AK operations Chapter 4 Applied Opera-
tion
Chapter 5 Parameters
These chapters describe the
important functions of the
E5AK and how to use the
parameters for making full use
of the E5AK.
DUsing a Position-propor-
tional Type Controller
Chapter 4 Applied Opera-
tion/4.1 Selecting the Con-
trol Method
This chapter describes the func-
tions related specifically to posi-
tion-proportional type control-
lers.
DCommunications with a
host computer
Chapter 6 Using the Com-
munications Function
This chapter mainly describes
the communications commands,
and gives program examples.
DCalibration Chapter 7 Calibration This chapter describes how the
user should calibrate the E5AK.
DTroubleshooting Chapter 8 Troubleshooting This chapter describes what to
do if any problems occur.

E5AK
V
FIf you remove the controller from its case, never touch nor apply shock to the elec-
tronic parts inside.
FDo not cover the area around the E5AK. (Ensure sufficient space around the control-
ler to allow heat radiation.)
FUse a voltage (AC100-240V or AC/DC24V at 50 to 60 Hz). At power ON, the pre-
scribed voltage level must be attained within two seconds.
FWhen wiring input or output lines to your controller, keep the following points in
mind to reduce the influence from inductive noise:
•Allow adequate space between the high voltage/current power lines and the input/
output lines.
•Avoid parallel or common wiring with high voltage sources and power lines carrying
large currents.
•Using separating pipes, duct, and shielded line is also useful in protecting the con-
troller, and its lines form inductive noise.
FAllow as much space as possible between the controller and devices that generate a
powerful, high frequency (high-frequency welders, high-frequency sewing machines,
and so forth) or surge. These devices may cause malfunctions.
FIf there is a large power-generating peripheral device and any of its lines, attach a
surge suppressor or noise filter to the device to stop the noise affecting the controller
system. In particular, motors, transformers, solenoids and magnetic coils have an
inductance component, and therefore can generate very strong noises.
FWhen mounting a noise filter, be sure to first check the filter’s voltage and current
capacity, then mount the filter as close as possible to the controller.
FDo not use the controller in places where icing, condensation, dust, corrosive gas
(especially sulfurized gas or ammonia gas), shock, vibration, splashing liquid, or oil
atmosphere occur. Also, avoid places where the controller can be subjected to intense
heat radiation (like from a furnace) or sudden temperature changes.
FAmbient temperature must be kept between -10_Cto55_C. Ambient humidity must
be kept between 35%RH to 85%RH (with no icing or condensation). If the controller
is installed inside a control board, the ambient temperature must be kept under
55_C, including the temperature around the controller. If the controller is subjected
to heat radiation, use a fan to cool the surface of the controller to under 55_C.
FStore the controller at an ambient temperature between -25_Cto65_C. The ambient
humidity must be between 35%RH to 85%RH (with no icing or condensation).
FNever place heavy objects on, or apply pressure to the controller that may cause it to
deform and deterioration during use or storage.
FAvoid using the controller in places near a radio, television set, or wireless installa-
tion. These devices can cause radio disturbances which adversely affect the perfor-
mance of the controller.
Pay
A
ttention to the Following when Installing
this Controller

Preface I......................................
Conventions Used in This Manual II...............
Pay Attention to the Following when Installing
this Controller V.................................
CHAPTER 1 INTRODUCTION 1--1...........................
This chapter introduces the E5AK. First-time users should read this chapter with-
out fail.
For details on how to use the controller and parameter settings, see Chapters 2
onwards.
1.1 Names of parts 1--2..........................................
1.2 Input and Output 1--4.........................................
1.3 Parameters and Menus 1--7...................................
1.4 About the Communications Function 1--10.......................
1.5 About Calibration 1--11........................................
CHAPTER 2 PREPARATIONS 2--1...........................
This chapter describes the operations you should carry out before turning the
E5AK ON.
2.1 Setting up 2--2...............................................
2.2 Installation 2--5..............................................
2.3 Wiring Terminals 2--8.........................................
CHAPTER 3 BASIC OPERATION 3--1........................
This chapter describes an actual example for understanding the basic operation
of the E5AK.
3.1 Convention Used in this Chapter 3--2...........................
3.2 Setting Input Specifications 3--4...............................
3.3 Setting Output Specifications 3--6..............................
3.4 Setting Alarm Type 3--9.......................................
3.5 Protect Mode 3--12............................................
3.6 Starting and Stopping Operation 3--13...........................
3.7 Adjusting Control Operation 3--14...............................
CHAPTER 4 APPLIED OPERATION 4--1......................
This chapter describes each of the parameters required for making full use of the
features of the E5AK. Read this chapter while referring to the parameter descrip-
tions in chapter 5.
4.1 Selecting the Control Method 4--2..............................
4.2 Operating Condition Restrictions 4--5...........................
4.3 How to Use Event Input 4--8..................................
4.4 How to Use the Remote SP 4--11...............................
4.5 How to Use the Heater Burnout Alarm 4--13......................
4.6 LBA 4--15....................................................
4.7 How to Use Transfer Output 4--17...............................
Table of Contents

CHAPTER 5 PARAMETERS 5--1.............................
This chapter describes the parameters of the E5AK. Use this chapter as a refer-
ence guide.
Protect Mode 5--3................................................
Manual Mode 5--5................................................
Level 0 Mode 5--6................................................
Level 1 Mode 5--10................................................
Level 2 Mode 5--18................................................
Setup Mode 5--25.................................................
Expansion Mode 5--32.............................................
Option Mode 5--37.................................................
Calibration Mode 5--46.............................................
CHAPTER 6 USING THE COMMUNICATIONS FUNCTION 6--1..
This chapter mainly describes communications with a host computer and com-
munications commands.
6.1 Outline of the Communications Function 6--2....................
6.2 Preparing for Communications 6--3............................
6.3 Command Configuration 6--5..................................
6.4 Commands and Responses 6--6...............................
6.5 How to Read Communications Error Information 6--12.............
6.6 Program Example 6--14.......................................
CHAPTER 7 CALIBRATION 7--1.............................
This chapter describes procedures for each calibration operation.
Read this chapter only when the controller must be calibrated.
7.1 Structure of Parameters 7--2..................................
7.2 Calibrating Thermocouple 7--4.................................
7.3 Calibrating Platinum Resistance Thermometer 7--7..............
7.4 Calibrating Current Input 7--9..................................
7.5 Calibrating Voltage Input 7--10..................................
7.6 Checking Indication Accuracy 7--12.............................
CHAPTER 8 TROUBLESHOOTING 8--1......................
This chapter describes how to find out and remedy the cause if the E5AK does
not function properly.
8.1 Initial Checks 8--2............................................
8.2 How to Use the Error Display 8--3..............................
8.3 How to Use Error Output 8--5..................................
8.4 Checking Operation Restrictions 8--6...........................
APPENDIX
SPECIFICATIONS A--2........................
ABOUT CURRENT TRANSFORMER (CT) A--5...
CONTROL BLOCK DIAGRAM A--6..............
SETTING LIST A--8...........................
MODEL LIST A--11.............................
PARAMETER OPERATIONS LIST A--12..........
FUZZY SELF-TUNING A--14....................
XFORMAT A--17...............................
ASCII CODE LIST A--20........................
INDEX
REVISION HISTORY

CHAPTER 1 INTRODUCTION
E5AK
1--1
CHAPTER 1
INTRODUCTION
This chapter introduces the E5AK. First-time users should read this
chapter without fail.
For details on how to use the controller and parameter settings, see
Chapters 2 onwards.
CHAPTER1
1.1 Names of parts 1-2........................
Main parts 1-2............................
Front panel 1-2...........................
About the displays 1-3.....................
How to use keys 1-3.......................
1.2 Input and Output 1-4......................
Input 1-4.................................
Output 1-5................................
1.3 Parameters and Menus 1-7.................
Parameter types 1-7.......................
Selecting modes 1-8........................
Selecting parameters 1-9...................
Fixing settings 1-9.........................
1.4 About the Communications Function 1-10....
1.5 About Calibration 1-11......................

CHAPTER 1 INTRODUCTION
E5AK
1--2
1.1 Names of parts
JMain parts
P2-8
Terminals
Rear case Front panel
This page
JFront panel
OUT1
SUB1
MANU
STOP
RMT
RST
AT
Operation indicators
A/M key Display key Down key Up key
No.2 display
No.1 display
E5AK
PV
SV
OUT1 OUT2
MANU
STOP
RMT
AT
SUB2
A/M
Bar graph
OUT2
SUB2
RSP SUB1

1.1 Names of parts
E5AK
1--3
JAbout the displays
Displays the process value or parameter symbols.
Displays the set point, manipulated variable or parameter settings.
•OUT1 : Lit when the pulse output function assigned to “control
output 1” is ON.
•OUT2 : Lit when the pulse output function assigned to “control
output 2” is ON.
•SUB1 : Lit when the output function assigned to “auxiliary output
1” is ON.
•SUB2 : Lit when the output function assigned to “auxiliary
output 2” is ON.
•MANU : Lit in the manual operation mode.
•STOP : Lit when operation has stopped.
•RMT : Lit during remote operation.
•RSP : Lit during remote SP operation.
•AT : Flashes during auto-tuning.
On a standard type controller (E5AK-AA2), this bar graph indicates the
manipulated variable (heat) in 10% increments per single segment. On
a position-proportional type controller (E5AK-PRR2), this bar graph
indicates the valve opening in 10% increments per single segment.
The following describes basic key operations.
Each press of this key switches between the auto and manual opera-
tions.
The functions of this key change according to how long it is pressed. If
the key is pressed for less than one second, the parameters are switched.
If the key is pressed for one second or more, the menu display appears.
In key operations from here on, “press the key” refers to pressing the
key for less than one second.
For details on parameter switching and menu display items, see page
1-8.
Each press of the key increments or advances the values or settings
on the No.2 display, while each press of the key decrements or
returns the values or settings on the No.2 display.
Functions vary, for example, when the A/M key is held down simulta-
neously with the display key, or a key is held down continuously. For
details, see page 1-8. Also, chapters 3 and 4 describe examples using
various key combinations.
FNo.1 display
FNo.2 display
FOperation indica-
tors
FBar graph
JHow to use keys
Fkey
A/M
Fkey
Fkey

CHAPTER 1 INTRODUCTION
E5AK
1--4
1.2 Input and Output
Temperature input
Voltage input
Current input
CT input
Potentiometer
Remote SP input
Event input
Controller Control output
(heat)
Control output
(cool)
Alarm 1
Alarm 2
Alarm 3
HBA
LBA
Error 1
Error 2
Error 3
Control output 1
Control output 2
Auxiliary output 1
Auxiliary output 2
Transfer output
The E5AK supports following inputs: temperature input, current input,
voltage input, CT input/Potentiometer, remote SP input and event
input.
FTemperature input/Voltage input/Current input
•Only one of temperature input, voltage input and current input can
be selected and connected to the controller. The above figure shows
temperature input connected to the controller.
•The following input sensors can be connected for temperature input:
Thermocouple:K,J,T,E,L,U,N,R,S,B,W,PLII
Platinum resistance thermometer: JPt100, Pt100
•The following currents can be connected for current input:
4to20mA,0to20mA
•The following voltages can be connected for voltage input:
1to5VDC,0to5VDC,0to10VDC
•Connect CT input when using the HBA (heater burnout alarm) func-
tion on a standard type controller (E5AK-AA2).
•Connect the potentiometer when monitoring the valve opening on a
position-proportional type controller (E5AK-PRR2).
When the remote SP function is enabled, inputs within the range 4 to
20 mA are used as the remote SP.
JInput
FCT input/Poten-
tiometer
FRemote SP input

1.1 Names of parts
E5AK
1--5
When using event input, add on the input unit (E53-CKB).
You can select from the following five event inputs:
Multi-SP
Run/Stop
Remote/Local
Auto/Manual
SP mode
JOutput
The E5AK supports the following five outputs.
Control output 1
Control output 2
Auxiliary output 1
Auxiliary output2
Transfer output
When using control outputs 1 and 2, set the output unit (sold sepa-
rately). Nine output units are available to suit the output circuit config-
uration.
When using transfer output, add on the communication unit
(E53-AKF).
Note: The output functions of the E5AK do not operate for five seconds
after the E5AK is turned ON.
The E5AK supports the following ten output functions.
Control output (heat)
Control output (cool)
Alarms 1 to 3
HBA
LBA
Error 1 (input error)
Error 2 (A/D converter error)
Error 3 (RSP input error)
Assign these output functions to control output 1, control output 2,
auxiliary output1, and auxiliary output2.
However, note that as control output 1 is used as the open output and
control output 2 is used as close output on a position-proportional type
controller (E5AK-PRR2), control outputs 1 and 2 cannot be used as
assignment destinations. Also, of the output functions, control output
(heat), control output (cool), HBA and LBA are disabled.
On a standard type controller, there are restrictions on how assignment
destinations (control output 1, control output2, auxiliary output1, and
auxiliary output2) can be used. For details, see 3.3 Setting Output Spec-
ifications.
In the example on the previous page, “control output (heat)” is assigned
to “control output 1”, “alarm 1” is assigned to “control output 2”, and
“alarm 2” is assigned to “auxiliary output 1”. Accordingly, the configu-
ration is such that heating control output is connected to control output
1, and alarm output is connected to control output 2 and auxiliary out-
put 1.
FEvent input
FOutput assign-
ments

CHAPTER 1 INTRODUCTION
E5AK
1--6
Control outputs 1 and 2 are used depending on the differences in con-
trol method as follows.
Control Method Model Control Output 1/
Control Output 2
Standard control E5AK-AA2 AC100-240
E5AK-AA2 AC/DC24
Control output (heat) /
Alarm, etc.,
Heating and cooling
control
E5AK-AA2 AC100-240
E5AK-AA2 AC/DC24
Control output (heat) /
Control output (cool)
Position-proportional
control
E5AK-PRR2 AC100-240
E5AK-PRR2 AC/DC24
Open/Close
The E5AK supports the following six transfer outputs.
Set point
Set point during SP ramp
Process value
Heating side manipulated variable
Cooling side manipulated variable
Valve opening
However, note that heating/cooling side manipulated variables can be
output only standard type controllers, and valve opening can be output
on position-proportional type controllers
These transfer outputs can be output after being scaled. Setting of an
upper limit value smaller than the lower limit value is allowed, so
reverse scaling can also be carried out.
FTransfer output

1.1 Names of parts
E5AK
1--7
1.3 Parameters and Menus
E5AK parameters are distributed between the following nine modes.
Protect mode
Manual mode
Level 0 mode
Level 1 mode
Level 2 mode
Setup mode
Expansion mode
Option mode
Calibration mode
The settings of parameters in each of seven modes (excluding the pro-
tect mode and manual mode) can be checked and modified by selection
on the menu display.
This mode is used to limit use of the menu and A/M keys. The protect
function is for preventing unwanted modification of parameters and
switching between the auto and manual operation.
In this mode, the controller can be switched manual operation. The
manipulated variable can be manipulated manually only in this mode.
Set the controller to this mode during normal operation. In this mode,
you may change the set point during operation, and stop and start op-
eration. You can also monitor (not change) the process value, ramp SP
and manipulated variable.
This is the main mode for adjusting control. In this mode, you can
execute AT (auto-tuning), and set alarm values, the control period and
PID parameters.
This is the auxiliary mode for adjusting control. In this mode, you can
set the parameters for limiting the manipulated variable, switch
between the remote and local modes, switch between the SP modes, and
set the loop break alarm (LBA), alarm hysteresis and the digital filter
value of inputs.
This is the mode for setting the basic specifications. In this mode, you
can set parameters that must be checked or set before operation such as
the input type, scaling, output assignments and direct/reverse opera-
tion.
This is the mode for setting expanded functions. In this mode, you can
set ST (self-tuning), SP setting limiter, selection of advanced PID or
ON/OFF control, specification of the standby sequence resetting
method, time for automatic return to the monitoring display.
This is the mode for setting option functions. You can select this mode
only when the option unit is set in the controller. In this mode, you can
JParameter types
FProtect mode
FManual mode
FLevel 0 mode
FLevel 1 mode
FLevel 2 mode
FSetup mode
FExpansion mode
FOption mode

CHAPTER 1 INTRODUCTION
E5AK
1--8
set the communications conditions, transfer output and event input
parameters to match the type of option unit set in the controller. Heater
burnout latch function, position-proportional travel time and remote
SP scaling parameters are also located in this mode.
This mode is provided so that the user can calibrate inputs and transfer
output.
When calibrating input, the selected input type is calibrated. Whereas,
transfer output can be calibrated only when the communications unit
(E53-AKF) is set in the controller.
The following diagram shows the order in which modes are selected.
A/M
A/M
A/M
A/M
A/M ++
+
1 second min.
Level 0 mode
Level 1 mode
Level 2 mode
Setup mode
Expansion mode
Option mode
Calibration mode
1secondmin.
Manual mode
1secondmin.
1 second min. 1 second min.
Protect mode
1secondmin.
1 second min.
Power ON
1 second min.
1 second min.
1 second min.
1 second min.
1 second min.
•To select the menu display in any of the above modes (excluding the
protect mode and manual mode), press the key for 1 second mini-
mum. If you select the desired mode using the or keys and
press the key, the top parameter in the specified mode is dis-
played.
•When you have selected the menu display, the previous mode is
selected. For example, if you selected the menu display while in the
level 0 mode, the No.2 display changes to [ ] as shown on the left.
•Protected modes cannot be selected. Also, the menu display does not
appear when modes are protected up to the level 1 mode.
•If you select [ ][ ]or[ ] in the menu display, the level 0,
level 1 and level 2 modes, respectively, are selected.
•These modes are selected with control still continuing.
FCalibration mode
JSelecting modes
FMenu display
FLevel 0 to 2
modes

1.1 Names of parts
E5AK
1--9
•If you select [ ][ ][ ]or[ ]inthe menudisplay,
the setup, expansion, option and calibration modes, respectively, are
selected.
•When these modes are selected, the control is reset. So, control out-
puts and auxiliary output are turned OFF. When another mode is
selected while in these modes, reset is canceled.
•To set the controller to the protect mode or to return to the level 0
mode from the protect mode, press the A/M key and key for 1 se-
cond minimum simultaneously.
•To set the controller to the manual mode, press the A/M key for 1 se-
cond minimum in the level 0 to 2 mode. To return to the level 0 mode
from the manual mode, press the A/M key for 1 second minimum.
•When not in the manual mode, each press of the key switches the
parameter.
•If you press the key when at the final parameter, the display re-
turns to the first parameter.
Parameter
1
Parameter
2
Parameter
3
Parameter
n
•When you have changed a parameter setting, specify the parameter
using the or keys, and either leave the setting for at least two
seconds or press the key. This fixes the setting.
•When another mode is selected, the content of the parameters before
the mode was selected is fixed.
•When turning the power OFF, you must first fix the settings and
parameter contents (by pressing the key or selecting another
mode). The settings and parameter contents are sometimes not
changed by merely pressing the or keys.
FSetup mode
FExpansion mode
FOption mode
FCalibration mode
FProtect mode
FManual mode
JSelecting
parameters
JFixing settings

CHAPTER 1 INTRODUCTION
E5AK
1--10
1.4 About the Communications Function
The E5AK can be provided with a communications function that allows
you to check and set controller parameters from a host computer. If the
communications function is required, add on the communications unit.
For details on the communications function, refer to Chapter 6.
When using the communications function on the RS-232C interface,
add on the communications unit (E53-AK01).
When using the communications function on the RS-422 interface, add
on the communications unit (E53-AK02).
When using the communications function on the RS-485 interface, add
on the communications unit (E53-AK03).
FRS-232C
FRS-422
FRS-485

1.1 Names of parts
E5AK
1--11
1.5 About Calibration
The E5AK controller is calibrated before shipment from the factory. So,
the user need not calibrate the E5AK controller during regular use.
However, if the E5AK controller must be calibrated by the user, use the
parameters provided for user to calibrate temperature input, analog
input (voltage, current) and transfer output.
Also, note that calibration data is updated to the latest value each time
the E5AK controller is calibrated. Calibration data set before shipment
from the factory cannot be returned to after calibration by the user.
The input type selected in the parameter is the item to be calibrated.
The E5AK is provided with the following four calibration parameters.
•Thermocouple
•Platinum resistance thermometer
•Current input
•Voltage input
Two parameters are provided for thermocouple and voltage input.
Transfer output can be calibrated when the communications unit
(E53-AKF) is added on.
When calibrating each item, the calibration data is temporarily regis-
tered. This data can be registered as final calibration data only when all
items have been newly calibrated. So, all items must be temporarily
registered when calibrating the E5AK controller.
When registering data, information regarding whether or not calibra-
tion has been carried out is also registered.
To calibrate these items, the user must prepare separate measuring
devices and equipment. For details on handling these measuring devices
and equipment, refer to the respective manuals.
For details, see Chapter 7 Calibration.
FCalibrating
inputs
FCalibrating trans-
fer output
FRegistering cal-
ibration data

CHAPTER 1 INTRODUCTION
E5AK
1--12