RS PRO ESM-4430 User manual

ESM-4430 48x48 DIN 1/16 Process Controller
Instruction Manual. ENG ESM-4430 02 V11 07/13
- 4 4 digits process set (SV) display
(TC, RTD, mV Z, V Z, mA Z)
- Dual or multi point calibration for ZVoltage / Current input
- Adaptation of PID coefficients to the system with Auto-tune and
Self-tune
- Manual/Automatic mode selection for control outputs
- Bumpless transfer
- Programmable heating, cooling and alarm functions for control
outputs
digits process (PV) and
- Universal process input
- Configurable ON/OFF, P, PI, PD and PID control forms
ESM-4430 48 x 48 1/16 DIN
Universal Input PID Process Controller

2
Instruction manual of ESM-4430 Process Controller consists of two main sections.
Explanation of these sections are below. Also, there are other sections which include order
information and technical specifications of the device.All titles and page numbers in instruction
manualarein“CONTENTS”section.Usercanreachtoanytitlewithsectionnumber.
Installation:
Physical dimensions, panel mounting, electrical wiring of the device, physical and
electricalinstallationofthedevicetothesystemareexplainedinthissection.
OperationandParameters:
User interface of the device, how to access to the parameters, description of parameters
areexplainedinthissection.
Also in these sections, there are warnings to prevent serious injury while doing the
physicalandelectrical mountingorusingthedevice.
Explanationofthesymbolswhichareusedinthesesectionsaregivenbelow.
Thissymbolisusedtodeterminethedangeroussituationsasaresultofanelectric
shock.Usermustpayattentiontothesewarningsdefinitely.
a
cThis symbol is used for safety warnings. User must pay attention to these
warnings.
Thissymbolisusedtodeterminetheimportantnotesaboutfunctionsandusageof
thedevice
ABOUT INSTRUCTION MANUAL
i

1.PREFACE............................................................................................................................................
1.1 GENERAL SPECIFICATIONS
1.2 ORDERING INFORMATION
1.3 WARRANTY
1.4 MAINTENANCE
2.INSTALLATION....................................................................................................................................
2.1 GENERAL DESCRIPTION
2.2 DIMENSIONS
2.3 PANEL CUT-OUT
2.4 ENVIRONMENTAL RATINGS
2.5 PANEL MOUNTING
2.6 INSTALLATION MOUNTING CLAMP
2.7 REMOVING FROM THE PANEL
3.ELECTRICAL WIRINGS......................................................................................................................
3.1 TERMINAL LAYOUTAND CONNECTION INSTRUCTION
3.2 ELECTRICAL WIRING DIAGRAM
3.3 VIEW OF THE LABELS
3.4 CONNECTION OF DEVICE SUPPLY VOLTAGE INPUT
3.5 PROCESS INPUT CONNECTION
3.5.1 TC (THERMOCOUPLE) CONNECTION
3.5.2 RTD CONNECTION
3.5.3 PROCESS INPUT CONNECTION OF SERIALTRANSMITTERS WITH CURRENT
OUTPUT (LOOP POWERED)
3.5.4 PROCESS INPUT CONNECTION OF 3-WIRE TRANSMITTERS WITH CURRENT
OUTPUT
3.5.5 CONNECTION OF TRANSMITTERS WITH VOLTAGE OUTPUT TO PROCESS
INPUT
3.6 GALVANIC ISOLATION TEST VALUES OF ESM-4430 PROCESS CONTROLLER
4.OUTPUT CONNECTION FORMS IN ESM-4430 PROCESS CONTROLLER....................................
4.1 PROCESS OUTPUT (SSR DRIVER OUTPUT) CONNECTION
4.2 ALARM OUTPUT -1 RELAY CONNECTION
4.3 PROCESS OUTPUT ORALARM OUTPUT -2 RELAY CONNECTION
5.DEFINITION OF FRONT PANEL AND ACCESSING TO THE PARAMETERS..................................
5.1 DEFINITION OF FRONT PANEL
5.2 OBSERVATION OF SOFTWARE REVISION ON THE BOTTOM DISPLAY WHEN POWER
IS ON
5.3 ADJUSTMENT OF PROCESS AND ALARM SET VALUES
5.4 EASYACCESS DIAGRAM FOR PROGRAM PARAMETERS
5.5 ACCESSING TO THE TECHNICIAN MENU
5.6 CHANGING AND SAVING PARAMETERS
6.PARAMETERS.....................................................................................................................................
6.1 PROCESS / ALARM SET PARAMETERS
6.2 TECHNICIAN PARAMETERS
6.2.1 SELECTION OF PID TUNEAND OPERATION FORM
6.2.2 FUNCTION SELECTION FOR TOP AND BOTTOM DISPLAY
6.2.3 PROCESS INPUT TYPE AND RELEVANT PARAMETERS WITH PROCESS INPUT
6.2.4 PID CONFIGURATION PARAMETERS
6.2.5 PROCESS OUTPUT CONFIGURATION PARAMETERS
6.2.6 ALARM OUTPUT - 1 CONFIGURATION PARAMETERS
6.2.7 ALARM OUTPUT - 2 CONFIGURATION PARAMETERS
6.2.8 GENERAL PARAMETERS
6.2.9 TECHNICIAN PASSWORD
7.FAILURE MESSAGES IN ESM-4430 PROCESS CONTROLLERS...................................................
8.SPECIFICATIONS................................................................................................................................
9.OTHER INFORMATION.......................................................................................................................
CONTENTS Page 5
Page 41
Page 21
Page 13
Page 8
Page 23
Page 64
Page 65
3
Page 66

4
Manufacturer’s Name : EMKO ELEKTRONIK A.S.
Manufacturer’s Address : DOSAB, Karanfil Sk., No:6,
16369 Bursa, TURKEY
The manufacturer hereby declares that the product:
Product Name : Process Controller Unit
Type Number : ESM-4430
Product Category : Electrical equipment for measurement, control and
laboratory use
Conforms to the following directives :
2006 / 95 / EC The Low Voltage Directive
2004 / 108 / EC The Electromagnetic Compatibility Directive
has been designed and manufactured to the following specifications :
EN 61000-6-4:2007 EMC Generic Emission Standard for the Industrial Environments
EN 61000-6-2:2005 EMC Generic Immunity Standard for the Industrial Environments
EN 61010-1:2001 Safety Requirements for electrical equipment for measurement, control
And laboratory use
When and Where Issued Authorized Signature
th
16 October 2009 Name : Serpil YAKIN
Bursa-TURKEY Position : Quality Manager
EU DECLARATION OF CONFORMITY

5
ESM series process controllers are designed for measuring and controlling temperature
andanyprocessvalue.They canbeusedinmany applicationswiththeiruniversalprocess input,
controloutputs,selectablealarmfunctions.
Someapplicationfieldsandapplicationswhichtheyareusedarebelow:
1.Preface
Application Fields Applications
Glass PID Process Control
Plastic
Petro-Chemistry
Textile
Automative
Machine production industries
Alarm Out-1
(Relay Output)
Process Input
Power Supply
Input
Standard
1.1 General Specifications
ESM-4430
Standard
Standard
Heating-Cooling Function
ON/OFF, PID Operation
Auto-Tune, Self-Tune
Automatic/Manual Operation
Process Out
(SSR Driver Output)
Process Out or
Alarm Out-2
(Relay Output)
Standard
Universal Supply Input
100-240 VV, 50/60Hz
Low Voltage (optional)
Supply Input
24VV50/60Hz ,24VZ
Universal Process Input
TC,RTD, ZVoltage/Current
Control Output
Alarm Output
Control Output

ESM-4430 (48x48 DIN 1/16)
Supply Voltage
A
A
20
1
0
Configurable (Table-1) Table-1
None
BC D E FG HI /
/
U V W Z/
/
Input Type
Output-1
Serial Communication
Scale
BC
E
HI
D
AllorderinformationofESM-4430are
given on the table at left. User may form
appropriate device configuration from
information and codes that at the table and
convertittotheorderingcodes.
Firstly, supply voltage then other
specifications must be determined. Please
fill the order code blanks according to your
needs.Please contact us, if your needs are
outofthestandards.
1.2 Ordering Information
1
01 Output-2
FG
Output-3
02
100-240V V(-15%;+10%) 50/60Hz
24 V V(-15%;+10%) 50/60Hz 24V Z(-15%;+10%)
1
2Customer (Maximum 240V V(-15%;+10%))50/60Hz
9
01 02
c
Table-1
21
39
41
40
42
43
44
45
22
23
25
27
28
29
31
33
35
37
24
26
30
32
34
36
38
L ,Fe Const DIN43710
PT 100 , IEC751(ITS90)
0...50 mV Z
PT 100 , IEC751(ITS90)
0...5 V Z
0...10 V Z
0...20 mA Z
4...20 mA Z
L ,Fe Const DIN43710
J ,Fe CuNi IEC584.1(ITS90)
K ,NiCr Ni IEC584.1(ITS90)
R ,Pt13%Rh Pt IEC584.1(ITS90)
S ,Pt10%Rh Pt IEC584.1(ITS90)
T ,Cu CuNi IEC584.1(ITS90)
B ,Pt30%Rh Pt6%Rh IEC584.1(ITS90)
E ,NiCr CuNi IEC584.1(ITS90)
N ,Nicrosil Nisil IEC584.1(ITS90)
C , (ITS90)
T ,Cu CuNi IEC584.1(ITS90)
B ,Pt30%Rh Pt6%Rh IEC584.1(ITS90)
E ,NiCr CuNi IEC584.1(ITS90)
N ,Nicrosil Nisil IEC584.1(ITS90)
C , (ITS90)
J ,Fe CuNi IEC584.1(ITS90)
K ,NiCr Ni IEC584.1(ITS90)
-100°C,850°C
-200°C,650°C
-1999,9999
-199.9°C,650.0°C
-100.0°C,850.0°C
-200°C,900°C
-200°C,1300°C
0°C,1700°C
0°C,1700°C
-200°C,400°C
44°C,1800°C
-150°C,700°C
-200°C,1300°C
0°C,2300°C
-199.9°C,900.0°C
-199.9°C,999.9°C
-199.9°C,400.0°C
44.0°C,999.9°C
-150.0°C,700.0°C
-199.9°C,999.9°C
0.0°C,999.9°C
-148°F ,1562°F
-328°F,1202°F
-199.9°F,999.9°F
-148.0°F,999.9°F
-328°F,1652°F
-328°F,2372°F
32°F,3092°F
32°F,3092°F
-328°F,752°F
111°F,3272°F
-238°F,1292°F
-328°F,2372°F
32°F,3261°F
-199.9°F,999.9°F
-199.9°F,999.9°F
-199.9°F,752.0°F
111.0°F,999.9°F
-199.9°F,999.9°F
-199.9°F,999.9°F
32.0°F,999.9°F
Input Type(TC)
Input Type(RTD)
Input Type( ZVoltage and Current)
Scale(°C)
Scale(°C)
Scale
Scale(°F)
Scale(°F)
BC
BC
BC
-1999,9999
-1999,9999
-1999,9999
-1999,9999
0
Relay Output (5A@250 VVat resistive load)
Relay Output (5A@250 VVat resistive load)
SSR Driver Output ( Maximum 17mA, 25VZ)
6
VSymbolmeans Vac,
ZSymbolmeans Vdc
SymbolmeansVacandVdcW

7
1.3 Warranty
EMKO Elektronik warrants that the equipment delivered is free from defects in material and
workmanship.Thiswarrantyisprovidedforaperiodoftwoyears.Thewarrantyperiodstartsfrom
the delivery date. This warranty is in force if duty and responsibilities which are determined in
warrantydocumentandinstructionmanualperformsbythecustomercompletely.
1.4 Maintenance
Repairsshouldonlybeperformedby trained and specializedpersonnel.Cutpowertothedevice
beforeaccessinginternalparts.
Do not clean the case with hydrocarbon-based solvents (Petrol, Trichlorethylene etc.). Use of
thesesolventscan reducethemechanicalreliability ofthedevice.Use aclothdampenedinethyl
alcoholorwatertocleantheexternalplasticcase.

8
Inpackage,
-Onepieceunit
-Twopiecesmountingclamps
-Onepieceinstructionmanual
A visual inspection of this product for possible damage occured during shipment is
recommended before installation. It is your responsibility to ensure that qualified
mechanicalandelectricaltechniciansinstallthisproduct.
If there is danger of serious accident resulting from a failure or defect in this unit, power
offthesystem andseparatetheelectricalconnectionofthedevicefromthesystem.
Theunitisnormallysuppliedwithouta powerswitch ora fuse.Usepowerswitchandfuse
asrequired.
Be sure to use the rated power supply voltage to protect the unit against damage and to
preventfailure.
Keep the power off until all of the wiring is completed so that electric shock and trouble
withtheunitcanbeprevented.
Never attempt to disassemble, modify or repair this unit. Tampering with the unit may
resultsinmalfunction,electricshockorfire.
Donotusetheunitincombustibleorexplosivegaseousatmospheres.
During the equipment is putted in hole on the metal panel while mechanical installation
somemetalburrscancauseinjuryonhands,youmustbecareful.
Montage of the product on a system must be done with it’s fixing clamps. Do not do the
montage of the device with inappropriate fixing clamp. Be sure that device will not fall
whiledoingthemontage.
It is your responsibility if this equipment is used in a manner not specified in this
instructionmanual.
Before beginning installation of this product, please read the instruction
manualandwarningsbelowcarefully.
2.Installation
c

2.1 General Description
2.2 Dimensions
Maximum 5mm / 0.2 inch
48 mm/ 1.89 inch
48mm/ 1.89 inch 76mm / 2.99 inch
11.5 ± 1 mm /0.45 inch
9
Product Label
Terminal protection cover
Mounting Clamp
Front Panel
IP65 protection
NEMA 4X
Panel surface
(maximum thickness 5mm / 0.2 inch)
°C
°F
VV
PO
AO1
AO2
A
AT PSET ASET1 ASET2
M
SET
P
ESM-4430
Process Controller
AT A/M

65 mm/2.56 inch (min)
46 mm/1.81 inch (min)
46 mm/1.81 inch (min)
2.3 Panel Cut-Out
10
65 mm/2.56 inch (min)

c
1
2
3
11
During installation into a metal panel, care should be taken to avoid injury from
metal burrs which might be present. The equipment can loosen from vibration
and become dislodged if installation parts are not properly tightened. These
precautionsforthesafetyofthepersonwhodoesthepanelmounting.
2.5 Panel Mounting
Operating Temperature : 0 to 50 °C
Max. Operating Humidity : 90% Rh (non-condensing)
Altitude : Up to 2000m.
Operating Conditions
ForbiddenConditions:
Corrosiveatmosphere
Explosiveatmosphere
Homeapplications(Theunitisonlyforindustrialapplications)
2.4 Environmental Ratings
c
1-Before mounting the device in your
panel, make sure that the cut-out is of the
rightsize.
2-Checkfrontpanelgasketposition
3-Insert the device through the cut-out. If
the mounting clamp are on the unit, put out
thembeforeinsertingtheunittothepanel.

2.6 Installation Mounting Clamp
2.7 Removing from the Panel
c
c
12
1-Loosenthescrews.
2-Pullmountingclampsfromtopandbottom
fixingsockets.
3-Pull the unit through the front side of the
panel
Before starting to remove the unit from panel, power off the unit and the
relatedsystem.
Montageoftheunit to asystemmustbe done withit’sown fixing clamps. Do
not do the montage of the device with inappropriate fixing clamps. Be sure
thatdevicewillnotfallwhiledoingthemontage.
Theunitisdesignedforpanelmounting.
1-Inserttheunitinthepanelcut-outfromthe
frontside.
2- Insert the mounting clamps to the holes
that located top and bottom sides of device
and screw up the fixing screws until the unit
completelyimmobilewithinthepanel
12
21
3

1
7
2
8
3
9
4
10
5
11
6
12
0.5Nm
aa
13
3.Electrical Wirings
3.1 Terminal Layout and Connection Instructions
You must ensurethatthedevice is correctlyconfiguredfor your application.
Incorrect configuration could result in damage to the process being
controlled,and/orpersonalinjury. It isyourresponsibility, as theinstaller,to
ensurethattheconfigurationiscorrect.
Parametersofthedevice has factorydefaultvalues. These parameters must
besetaccordingtothesystem’sneeds.
Only qualified personnel and technicians should work on this equipment.
This equipment contains internal circuits with voltage dangerous to human
life. There is severe danger for human life in the case of unauthorized
intervention.
Be sure to use the rated power supply voltage to protect the unit against
damageandtopreventfailure.
Keep the power off until all of the wiring is completed so that electric shock
andtroublewiththeunitcanbeprevented.
c
c
c
c
6mm/0.236inch
WireSize:
18AWG/1mm²
Solid/Stranded
12screwsterminalM3
Torque0.5Nm
Screw driver 0.8x3mm

1
7
2
8
3
9
4
10
5
11
6
12
TC
Pt-100
0 to 20mA Z
0 to 50mV Z
0 to 10V Z
CAT II
P/N : ESM-4430
Y
a
c
5A@250V V
Process Out
(Alarm Out-2)
Process Out
Alarm Out-1
5A@250V V
ProcessinputisinCATIIclass
ii
CNO CNO
14
3.2 Electrical Wiring Diagram
Universal
Process Input
(TC, RTD,ZVoltage / Current)
Sensor or Transmitter
Supply Voltage
Process Output
SSR Driver Output
Electrical wiring of the device must be the same as ‘Electrical Wiring Diagram’
belowtopreventdamagetotheprocessbeingcontrolledandpersonnelinjury.
c
Process Output or
Alarm Output-2 Relay Alarm Output-1
Relay
Max. 17mA, 25VZ
Supply Voltage Input
100-240VV(- ) 50/60Hz
24 VV(- 50/60Hz - 6VA
24VZ(-
(It must be determined in order)
15%;+10%
15%;+10%)
15%;+10%) - 6W
- 6VA
24V Z±10%
Max 50mA

3.3 View of the Labels
15
mA Z
Max. 17mA, 25VZ
Max.50mA
24 VZ ±10%

3.4 Connection of Device Supply Voltage Input
16
c
c
c
100 - 240 V V
(-15%;+10%) 50/60 Hz 24V V(-15%;+10%) 50/60Hz
11
NL
12
Note-1
Y
11 L 12
Y
c
or 24V Z(-15%;+10%)
c
aa
External
Fuse
(1 A VT)
External
Fuse
(24V V: 1 A VT)
(24V Z: 1 A ZT)
Note-2
N
Fuse Fuse
Note-3 Note-3
Universal Supply
Voltage Connection Low Voltage 24 VW
Supply Voltage Input
Supply Voltage
Power
Supply
Switch
Power
Supply
Switch
Note-1
Supply Voltage
Note-1 :Thereisaninternal33RW fusibleflameproofresistor in 100-240 VV50/60Hzsupply
voltageinput
Thereisaninternal4R7W fusibleflameproofresistorin24VV50/60Hz,24VZsupplyvoltage
input
Note-2:“L”is(+),”N” is(-)for24VZ supplyvoltage
Note-3 :Externalfuseisrecommended.
Make sure that the power supply voltage is the same indicated on the
instrument.
Switch on the power supply only after that all the electrical connections have
beencompleted.
Supply voltage range must be determined in order. While installing the unit,
supply voltage range must be controlled and appropriate supply voltage must
be applied to the unit. Controlling prevents damages in unit and system and
possibleaccidentsasaresultofincorrectsupplyvoltage.
There is no power supply switch on the device. So a power supply switch must
beaddedtothesupply voltageinput.Inaccordancewiththesafetyregulations,
the power supply switch shall bring the identification of the relevant
instrument.Powersupplyswitchshallbeeasilyaccessiblebytheuser.
Power switch must be two poled for seperating phase and neutral. On/Off
condition of power switch is very important in electrical connection. On/Off
conditionofpowerswitchmustbesignedforpreventingthewrongconnection.
Ifanexternalfuseisused,itmustbeonphaseconnectioninVsupplyinput.
Ifanexternalfuseisused,itmustbeon(+)lineconnectioninZsupplyinput.
The instrument is protected with an internal fuse (Please refer to Note1 for
information). In case of failure it is suggested to return the instrument to the
manufacturerforrepair.

17
3.5 Process Input Connection
3.5.2 RTD Connection
Note 1 : In 3-wire system, use always cables of the same diameter (min 1mm²) Always use
wires of the same gauge and type whether a 2-wire or 3-wire system.
Note 2 : Install a jumper between terminals 2 and 3 when using a 2-wire RTD.
Note 3 : If the distance is longer than 10 meters, use 3-wire system
3-wire Pt-100 connection
(with line compensation)
(Max. Line impedance is 10 W)
2-wire Pt-100 connection
(without line compensation)
1 12 23 3
Note 1 Note 2
3.5.1 TC (Thermocouple) Connection
123
TC Connect the wires with the polarity as shown in the
figureatleft.
Always use compensation wire corresponding to the thermocouple used. If
present,theshieldmustbeconnectedtoaproperground.
ii
Inputresistanceisgreaterthan10MW
ii
Inputresistanceisgreaterthan10MW
ii
Pt-100 Pt-100

18
3.5.4 Process Input Connection of 3-wire Transmitters with Current Output
Transmitter connection by using supply
voltage on the device Transmitter connection by using external supply voltage source.
Transmitter Transmitter
External
Power
Supply
Note-1
mAZ
PV PV
1 1
3 3
4 4
3.5.3 Process Input Connection of Serial Transmitters with Current Output (Loop
Powered)
Transmitter connection by using supply
voltage on the device Transmitter connection by using external supply voltage source.
Transmitter Transmitter
External
Power
Supply
Note-1
mAZmAZ
PV PV
1 1
3 3
4 4
Note 1 : External power supply must be selected according to supply voltage range and
required current for transmitter.
Note-1 : External power supply must be selected according to supply voltage range and
required current for transmitter.
Inputresistanceis2R7W.
ii
Inputresistanceis2R7W.
ii
mAZ
24 VZ
Max. 50mA
±10% 24 VZ
Max. 50mA
±10%
24 VZ
Max. 50mA
±10%
24 VZ
Max. 50mA
±10%

19
3.5.5 Connection of Transmitters with Voltage Output to Process Input
Transmitter connection by using supply
voltage on the device Transmitter connection by using external supply voltage source.
Transmitter Transmitter
External
Power
Supply
Note-1
mV, VZmV, VZ
PV PV
1 1
2 2
4 4
Note-1 : External power supply must be selected according to supply voltage range and
required current for transmitter.
Inputresistanceisgreaterthan10MW for0...50mVZ
Inputresistanceisgreaterthan43KW for0...10VZ
ii
24 VZ
Max. 50mA
±10% 24 VZ
Max. 50mA
±10%

20
3.6 Galvanic Isolation Test Values of 4430ESM- Process Controller
Supply Input
Process Output
(SSR Driver Output)
Process Output or
Alarm Output-2
Relay
Analogue
Inputs
Alarm Output-1
Relay
24V ZVoltage
Output
11
12 Ground 1
2
3
2000VV(For ESM-4430.1..... )
500V V( For ESM-4430.2..... )
2000V V
2000V V
2000V V
2000V V
2000V V
2000V V
2000V V
5
6
5
6
7
8
2
3
44
7
8
9
10
9
10