Omron E5AK User manual

User's Manual
Cat. No. H088-E1-02
Digital Controller
(Programmable Type)

E5AK
I
The E5AK-T is a high-performance programmable digital controller. The E5AK-T
allows the user to carry out the following:
•Set program patterns to each step by time or ramp rise rate
•Execute advance, hold and reset step operations
•Execute continuous operation of all patterns and repeated operation of same pat-
terns
•Check the start of each step or program end time by signals.
•Count time from the beginning of each step (time signal)
•Select from many types of temperature and analog input (multi-input)
•Support position-proportional control (position-proportional type controllers only)
•Select output functions such as control output or alarm output (output assign-
ment)
•Use the HBA (heater burnout alarm) function (standard type controllers only)
•Monitor the control loop by LBA (Loop Break Alarm)
•Use the communications function
•Calibrate input or transfer output
•The E5AK-T also features a watertight construction (NEMA4: equivalent to
IP66).
This User’s Manual describes how to use the E5AK-T.
Before using your E5AK-T thoroughly read and understand this manual in order to
ensure correct use.
Also, store this manual in a safe place so that it can be retrieved whenever neces-
sary.
PRECAUTIONS IN USING THE PRODUCT
When the product is used under the circumstances or environment below, ensure
adherence to limitations of the ratings and functions. Also, take countermeasures
for safety precautions such as fail-safe installations.
(1) Use under circumstances or environments which are not described in this user’s manual.
(2) Use for nuclear power control, railway, air craft, vehicle, incinerator, medical equipment, enter-
tainment equipment, safety device, etc.
(3) Use for applications where death or serious property damage is possible and extensive safety
precautions are required.
About this manual
(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, or otherwise, with-
out the prior written permission of OMRON.
(2) Moreover, because OMRON is constantly striving to improve its high-quality products, the information in
this manual is subject to change without notice.
(3) Every precaution has been taken in the preparation of this manual. Nevertheless, if you find any errors or
omissions, please contact the branch of OMRON or sales office listed at the end of this manual, and inform
them of the catalog No. on the front cover.
Preface

E5AK
II
JMeanings of Abbreviations
Sometimes the following abbreviations are used in parameter names, figures and in text ex-
planations. These abbreviations mean the following:
Symbol Term
PV Process value
SP (Present) set point *1
LBA Loop break alarm
HB Heater burnout
AT Auto-tuning
EU Engineering unit *2
*1 In program pattern diagrams, the present SP is indicated.
*2 _C, m, g and other units are indicated for scaled data. However, “EU” is used as the mini-
mum unit for the data. For example, for “50.02 (m)”, 1EU is taken as the minimum unit
0.01 (m).
JHow to Read Display Symbols
The following tables show the correspondence between the symbols displayed on the displays
and alphabet characters.
ABCDEFGHI J KL M
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
JHow This Manual is Organized
Purpose Title Description
DLearning about the gener-
al features of the E5AK-T
Chapter 1 INTRODUC-
TION
This chapter describes the fea-
tures of the E5AK-T, names of
parts, and typical functions.
DSetting up Chapter 2 PREPARA-
TIONS
This chapter describes the op-
erations that you must carry
out (e.g. installation, wiring and
switch settings) before you can
use the E5AK-T.
DBasic E5AK-T operations Chapter 3 BASIC OPERA-
TION
Chapter 5 PARAMETERS
These chapters describe using
basic control examples how to
use the front panel keys and
how to view the display when
setting the parameters of the
major functions for the E5AK-T.
DApplied E5AK-T opera-
tions
Chapter 4 APPLIED OP-
ERATION
Chapter 5 PARAMETERS
These chapters describes the
important functions of the
E5AK-T and how to use the pa-
rameters for making full use of
the E5AK-T.
DUsing a Position-propor-
tional type controller
Chapter 4 APPLIED OP-
ERATION
/4.1 Selecting the Control
Method
This chapter describes how to
use the functions related specifi-
cally to position-proportional
type controllers.
DCommunications with a
host computer
Chapter 6 USING THE
COMMUNICATIONS
FUNCTION
This chapter mainly describes
how to use the communications
commands, and gives program
examples.
DCalibration Chapter 7 CALIBRATION This chapter describes how the
user should calibrate the
E5AK-T.
DTroubleshooting Chapter 8 TROUBLE-
SHOOTING
This chapter describes what to
do if any problems occur.

E5AK
IV
PRECAUTIONS ON SAFETY
FMarks For Ensuring Safe Use and Their Meanings
This manual uses the following marks to indicate precautions for ensuring that the
E5AK-T is used safely.
The precautions indicated below describe important information regarding safety.
Be sure to follow the instructions described in these precautions.
WARNING Incorrect handling may cause death or injury.
WARNING
Do not touch the terminals while the power is
ON.
This may cause an electric shock.

E5AK
V
NOTICE
Be sure to observe these precautions to ensure safe use.
FDo not use the product in places where explosive or flammable gases may be present.
FNever disassemble, repair or modify the product.
FTighten the terminal screws properly.
FUse the specified size of solderless terminals for wiring.
FUse the product within the rated supply voltage.
FUse the product within the rated load.
FThe life expectancy of the output relay varies considerably according to its switching capacity
and operating conditions. Be sure to use the output relay within its rated load and electrical life
expectancy. If the output relay is used beyond its life expectancy, its contacts may become fused or
burned.
FIf you remove the controller from its case, never touch nor apply shock to the electronic parts
inside.
FDo not cover the E5AK-T. (Ensure sufficient space around the controller to allow heat radiation.)
FDo not use the controller in the following places:
•Places subject to icing, condensation, dust, corrosive gas (especially sulfide gas or ammonia gas).
•Places subject vibration and large shocks.
•Places subject to splashing liquid or oil atmosphere.
•Places subject to intense temperature changes.
•Places subject to heat radiation from a furnace.
FBe sure to wire properly with correct polarity of terminals.
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 cur-
rents.
•Using separating pipes, ducts, and shielded line is also useful in protecting the controller, and its
lines from inductive noise.
FCleaning: Do not use paint thinner or organic solvents. Use standard grade alcohol to clean the
product.
FUse a voltage (100 to 240 VAC at 50 to 60 Hz). At power ON, the prescribed voltage level must be
attained within two seconds.
FAllow as much space as possible between the controller and devices that generate a powerful high
frequency (high-frequency welders, high-frequency sewing machines, etc.) or surge. These devices
may cause malfunctions.
FIf there is a large power-generating peripheral device and any of its lines near the controller, at-
tach a surge suppressor or noise filter to the device to stop the noise affecting the controller sys-
tem. In particular, motors, transformers, solenoids and magnetic coils have an inductance compo-
nent, and therefore can generate very strong noise.
FWhen mounting a noise filter on the power supply to the controller, be sure to first check the fil-
ter’s voltage and current capacity, and then mount the filter as close as possible to the controller.

E5AK
VI
FUse within the following temperature and humidity ranges:
•Temperature: -10_Cto55_C, humidity: 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 to un-
der 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 within the following temperature and humidity ranges:
•Temperature: -25_Cto65_C, humidity: 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
deteriorate during use or storage.
FAvoid using the controller in places near a radio, television set, or wireless installation. These
devices can cause radio disturbances which adversely affect the performance of the controller.

E5AK
Preface I......................................
Conventions Used in This Manual II...............
Precautions on Safety V.........................
CHAPTER 1 INTRODUCTION 1--1...........................
This chapter introduces the names of parts on the E5AK-T and their functions.
For details on how to use the controller and parameter settings, see Chapter 2
onwards.
1.1 Names of parts 1--2..........................................
1.2 Input and Output 1--5.........................................
1.3 Program 1--8................................................
1.4 Parameters and Menus 1--9...................................
1.5 About the Communications Function 1--12.......................
1.6 About Calibration 1--13........................................
CHAPTER 2 PREPARATIONS 2--1...........................
This chapter describes the operations (e.g. setup, installation and wiring) you
should carry out before turning the E5AK-T ON.
2.1 Setup 2--2..................................................
2.2 Installation 2--5..............................................
2.3 Wiring Terminals 2--8.........................................
CHAPTER 3 BASIC OPERATION 3--1........................
This chapter describes actual examples for understanding the basic operation of
the E5AK-T.
3.1 Convention Used in this Chapter 3--2...........................
3.2 Setting Input Specifications 3--4...............................
3.3 Setting Output Specifications 3--7..............................
3.4 Setting Alarm Type 3--10.......................................
3.5 Setting Patterns 3--14.........................................
3.6 Protect Mode 3--19............................................
3.7 Starting and Stopping Operation 3--21...........................
3.8 Adjusting Control Operation 3--22...............................
CHAPTER 4 APPLIED OPERATION 4--1......................
This chapter describes each of the parameters required for making full use of the
features of the E5AK-T.
Read this chapter while referring to the parameter descriptions in chapter 5.
4.1 Selecting the Control Method 4--2..............................
4.2 Operating Condition Restrictions 4--7...........................
4.3 Ramp Rise Rate Setup Program 4--9...........................
4.4 Program Operation 4--13......................................
Table of Contents

E5AK
4.5 Wait Operation 4--16..........................................
4.6 Program output 4--17..........................................
4.7 Setting Running Conditions 4--19...............................
4.8 How to Use Event Input 4--21..................................
4.9 How to Use the Heater Burnout Alarm 4--23......................
4.10 LBA 4--26....................................................
4.11 How to Use Transfer Output 4--28...............................
CHAPTER 5 PARAMETERS 5--1.............................
This chapter describes the parameters of the E5AK-T.
Use this chapter as a reference guide.
Conventions Used in this Chapter 5--2..............................
Protect Mode 5--3................................................
Manual Mode 5--5................................................
Level 0 Mode 5--6................................................
Program Mode 5--11...............................................
Level 1 Mode 5--17................................................
Level 2 Mode 5--24................................................
Setup Mode 5--30.................................................
Expansion Mode 5--38.............................................
Option Mode 5--46.................................................
Calibration Mode 5--52.............................................
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 Structure 6--5......................................
6.4 Commands and Responses 6--7...............................
6.5 How to Read Communications Error Information 6--15.............
6.6 Program Example 6--17.......................................
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 Parameter Structure 7--2.....................................
7.2 Calibrating Thermocouples 7--4................................
7.3 Calibrating Platinum Resistance Thermometers 7--7.............
7.4 Calibrating Current Input 7--9..................................
7.5 Calibrating Voltage Input 7--10..................................

E5AK
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-T does
not function properly.
Remedy E5AK-T trouble in the order of the descriptions in this chapter
8.1 Initial Checks 8--2............................................
8.2 How to Use the Error Display 8--3..............................
8.3 How to Use the 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--12.............................
PARAMETER OPERATIONS LIST A--13..........
ASCII CODE LIST A--15........................
INDEX
REVISION HISTORY

CHAPTER 1 INTRODUCTION
E5AK
1--1
CHAPTER 1
INTRODUCTION
This chapter introduces the names of parts on the E5AK-T and their
functions.
For details on how to use the controller and parameter settings, see
Chapter 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 1-4.......................
1.2 Input and Output 1-5......................
Input 1-5.................................
Output 1-6................................
1.3 Program 1-8..............................
How programs are structured 1-8...........
Program operation 1-8.....................
Alarm output 1-8..........................
Program output 1-8........................
1.4 Parameters and Menus 1-9.................
Parameter types 1-9.......................
Selecting modes 1-10........................
Selecting parameters 1-11...................
Fixing settings 1-11.........................
1.5 About the Communications Function 1-12....
1.6 About Calibration 1-13......................

CHAPTER 1 INTRODUCTION
E5AK
1--2
1.1 Names of parts
JMain parts
P2-6
Terminals
Rear case Front panel
This page
JFront panel
OUT1
SUB1
MANU
HOLD
WAIT
Operation status indicators
Run/Reset key Display key Down key Up key
No.2 display
No.1 display
E5AK
RUN/RST
Bar graph
OUT2
SUB2
RMT
RST
AT
Program state indica-
tors
Pattern No.

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.
Displays pattern No..
Indicate how the present-SP of the operating step changes.
•OUT1
Lights when the pulse output function assigned to “control output 1”
is ON.
•OUT2
Lights when the pulse output function assigned to “control output 2”
is ON.
•SUB1
Lights when the pulse output function assigned to “auxiliary output
1” is ON.
•SUB2
Lights when the pulse output function assigned to “auxiliary output
2” is ON.
•MANU
Lights in the manual operation mode.
•RST
Lights when the control is in reset status.
•RMT
Lights during remote operation.
•HOLD
Lights when the program is in hold status.
•WAIT
Lights when the program is in wait status.
•AT
Flashes during auto-tuning.
•This bar graph indicates how much of the pattern has elapsed in 20%
increments (five stages) per single segment.
FNo.1 display
FNo.2 display
FPattern No.
FProgram status
indicators
FOperation status
indicators
FBar graph

CHAPTER 1 INTRODUCTION
E5AK
1--4
The following describes basic key operations.
To change to run operation from the reset status, press this key for one
second minimum.
To change to the reset status from run operation, press this key for two
seconds minimum.
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 minimum, the menu display ap-
pears. In key operations from here on, “press the key” refers to pressing
the key for less than one second.
For details on switching of parameters and menu display items, see
page 1-10.
Each press of 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 RUN/RST key is held down simul-
taneously with the key, or a key is held down continuously. For de-
tails, see page 1-10. Also, chapters 3 and 4 describe examples using vari-
ous key combinations.
JHow to use keys
Fkey
RUN/RST
Fkey
Fkey

1.2 Input and Output
E5AK
1--5
1.2 Input and Output
Temperature input
Voltage input
Current input
CT input
Potentiometer
Event input
Controller Control output
(heat)
Control output
(cool)
Alarm 1
Alarm 2
Alarm 3
HBA
LBA
Error 1
Error 2
Control output 1
Control output 2
Auxiliary output 1
Auxiliary output 2
Transfer output
Time signal 1
Time signal 2
Program end
Stage output
The E5AK-T supports the following inputs:
Temperature input, Current input, Voltage input, CT input/potentiom-
eter, and Event input.
FTemperature input/Voltage input/Current input
•Only one of temperature input, current input and voltage input can
be selected and 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-TAA2). Note that CT input
cannot be used when the linear output unit is mounted.
•Connect the potentiometer when monitoring the valve opening on a
position-proportional type controller (E5AK-TPRR2).
JInput
FCT input/Poten-
tiometer

CHAPTER 1 INTRODUCTION
E5AK
1--6
Add on the input unit (E53-CKB) when using event input. You can se-
lect from the following six event inputs:
Run/Reset, Remote/Local, Auto/Manual, Hold/Hold Cancel, Advance,
Pattern
The output functions of the E5AK-T do not operate for five seconds after the
E5AK-T is turned ON.
The E5AK-T supports the following five outputs:
Control output 1
Control output 2
Auxiliary output 1
Auxiliary output 2
Transfer output
When using control output 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).
•The E5AK-T supports the following thirteen output functions:
Control output (heat), Control output (cool), Alarms 1 to 3, HBA,
LBA, Time Signals 1 and 2, Program End, Stage Output,
Error 1 (input error), Error 2 (A/D converter error)
•Assign these output functions to control output 1, control output 2,
auxiliary output 1, and auxiliary output 2.
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-TPRR2), 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 assign-
ment destinations (control output 1, control output 2, auxiliary out-
put 1, and auxiliary output 2) can be used. For details, see Chapter 3
Basic Operation/3.3 Setting Output Specifications (page 3-7).
•In the example on the previous page, “control output (heat)” is as-
signed to “control output 1”, “alarm 1” is assigned to “control output
2”, and “alarm 2” is assigned to “auxiliary output 1”. Accordingly, the
configuration is such that heating control output is connected to con-
trol output 1, and alarm output is connected to control output 2 and
auxiliary output 1.
•Control outputs 1 and 2 are used depending on the differences in con-
trol method as follows:
FEvent input
JOutput
FOutput assign-
ments

1.2 Input and Output
E5AK
1--7
Control Method Model Control Output 1/
Control Output 2
Standard control E5AK-TAA2 AC100-240
E5AK-TAA2 AC/DC24
Control output (heat)
/ Alarm, etc.
Heating and
cooling control
E5AK-TAA2 AC100-240
E5AK-TAA2 AC/DC24
Control output (heat)
/ Control output (cool)
Position-propor-
tional control
E5AK-TPRR2 AC100-240
E5AK-TPRR2 AC/DC24
Open/Close
•The E5AK-T supports the following five transfer outputs:
Set point, Process value, Heating side manipulated variable,
Cooling side manipulated variable, Valve opening
However, note that heating/cooling side manipulated variables can be
output only on standard type controllers, and valve opening can be out-
put only 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 re-
verse scaling can also be carried out.
FTransfer output

CHAPTER 1 INTRODUCTION
E5AK
1--8
1.3 Program
E5AK-T allows you to configure programs made up of a maximum of
eight patterns (pattern 0 to 7).
The number of steps (16 maximum) in each pattern can be specified in
parameters.
Pattern 7
Pattern 1
Pattern 0
Step 0 Step 1 Step 2 Step 15
•Generally, the “time setup method” is used to configure programs. By
this method, set points at each step and time are used as program ele-
ments. However, the “ramp rise rate setup method” can also be used.
By this method, the set point, ramp time and soak times are used as
program elements.
•Generally, the target patterns are specified before the program is
executed.
•In parameter setup, you can specify repeated execution of the same
pattern (Repeat) or consecutive execution of all patterns 0 to 7 (Run
all).
•During program operation, steps can be skipped (Advance) and the
control monitoring can be paused (Hold).
•When the wait width is specified in parameter setup, the program
does not go to the next step and waits until the PV reaches the speci-
fied time (wait width) at the end of each step.
•Alarms that are assigned as outputs operate referenced to the alarm
values preset to each pattern.
•Time signals, program end and stage output can be output according
to output assignment.
•ON/OFF signals are output as time signals according to the timer
that takes a specified step as its start point.
JHow programs
are structured
JProgram opera-
tion
FStep operation
FWait operation
JAlarm output
JProgram output

1.4 Parameters and Menus
E5AK
1--9
1.4 Parameters and Menus
E5AK-T parameters are distributed between the following ten modes:
Protect mode
Manual mode
Level 0 mode
Program mode
Level 1 mode
Level 2 mode
Setup mode
Expansion mode
Option mode
Calibration mode
The settings of parameters in each of eight modes (excluding the protect
mode and manual mode) can be checked and modified by selection on
the menu display.
The protect function is for preventing unwanted modification of param-
eters, and switching between run and reset operation or auto and
manual operation.
In this mode, the controller can be switched to 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 can change the set point and pattern during operation, and execute
step operation (e.g. advance). You can only monitor (not change) the
process value, step No., standby time, pattern elapsing time, pattern
execution count and manipulated variable.
This is the programming mode. In this mode, you can set the number of
steps used in each pattern, pattern execution count, alarm values, set
points for each step, step time, and time signals for two steps.
This is the main mode for adjusting control. In this mode, you can
execute AT (auto-tuning), and set up the control period, PID parame-
ters and heater burnout alarm (HBA) conditions.
This is the auxiliary mode for adjusting control. In this mode, you can
set the parameters for limiting the manipulated variable, switch be-
tween the remote and local 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.
JParameter types
FProtect mode
FManual mode
FLevel 0 mode
FProgram mode
FLevel 1 mode
FLevel 2 mode
FSetup mode

CHAPTER 1 INTRODUCTION
E5AK
1--10
This is the mode for setting expanded functions. In this mode, you can
set SP setting limitter, switching between advanced PID control or ON/
OFF control, program time unit, selection of step time/rate of rise pro-
gramming, time unit of ramp rise rate, and the time for automatic re-
turn to the monitoring display.
This is the mode for setting optional functions. You can select this mode
only when an option unit is mounted in the controller. In this mode,
you can set the communications conditions, transfer output and event
input parameters to match the type of option unit mount in the control-
ler. Heater burnout alarm function and position-proportional travel
time are also located in this mode.
This mode is provided so that the user can calibrate inputs and output.
When calibrating input, the selected input type is calibrated. Whereas,
transfer output can be calibrated only when the communication unit
(E53-AKF) is set in the controller.
The following diagram shows the order in which modes are selected.
1 second min.
1 second min.
1 second min.
1 second min.
1 second min.
1 second min.
1 second min.
1 second min.
Level 0 mode
Program mode
Level 2 mode
Setup mode
Expansion mode
Option mode
Calibration mode
Power ON
Level 1 mode
Manual mode
Protect mode
1secondmin.
1 second min.
1secondmin.
1 second min.
1 second min.
+
+
+
+
+
RUN/RST
RUN/RST
RUN/RST
•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. 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.
•To move to the desired mode after you have entered the menu display,
select the desired mode using the keys and hold down the
key for one second minimum. The display switches to the first
parameter of the mode that you specified.
FExpansion mode
FOption mode
FCalibration mode
JSelecting modes