Process Controller ESM-7730 72x72 DIN Size ESM-7730 72 x 72 DIN Size Universal Input PID Process Controller - 4 digits process value (PV) and 4 digits process set value (SV) display - Universal process input (TC, RTD, mV Z, V Z, mA Z) - Dual or multi point calibration for ZVoltage / Current input - Configurable ON/OFF, P, PI, PD and PID control forms - Adaptation of PID coefficients to the system with Auto-tune and Self-tune - Manual/Automatic mode selection for control output - Bumpless transfer - Program
ABOUT INSTRUCTION MANUAL Instruction manual of ESM-7730 process controller consists of two main sections. Also, there are other sections which includes order information and technical specifications of the device. All titles and page numbers in instruction manual are in “CONTENTS” section. User can reach to any title with section number.
CONTENTS 1.PREFACE............................................................................................................................................ Page 1.1 GENERAL SPECIFICATIONS 1.2 ORDERING INFORMATION 1.3 WARRANTY 1.4 MAINTENANCE 5 2.INSTALLATION.................................................................................................................................... Page 2.1 GENERAL DESCRIPTION 2.2 DIMENSIONS 2.3 PANEL CUT-OUT 2.4 ENVIRONMENTAL RATINGS 2.5 PANEL MOUNTING 2.
EU DECLARATION OF CONFORMITY Manufacturer Company Name : Emko Elektronik A.S.. Manufacturer Company Address: DOSAB, Karanfil Sokak, No:6, 16369 Bursa, Turkiye The manufacturer hereby declares that the product conforms to the following standards and conditions.
1.Preface ESM series process controllers are designed for measuring and controlling temperature and any process value.They can be used in many applications with their universal process input, control outputs, selectable alarm functions. Some application fields and an application which they are used are listed below: Application Fields Application Glass PID Process Control Plastic Petro-Chemistry Textile Automative Machine production industries 1.
1.2 Ordering Information ESM-7730 A BC D E / FG HI / 0 1 / 01 02 / U V W Z (72x72 DIN Size) A Supply Voltage 1 2 9 100-240V V (-15%;+10%) 50/60Hz 24 V V (-15%;+10%) 50/60Hz 24V Z (-15%;+10%) Customer (Maximum 240V V (-15%;+10%))50/60Hz BC Input Type 20 Configurable (Table-1) Scale Table-1 D Serial Communication 0 None All order information of ESM-7730 are given on the table at left.
1.3 Warranty EMKO Elektronik warrants that the equipment delivered is free from defects in material and workmanship. This warranty is provided for a period of two years. The warranty period starts from the delivery date. This warranty is in force if duty and responsibilities which are determined in warranty document and instruction manual performs by the customer completely. 1.4 Maintenance Repairs should only be performed by trained and specialized personnel.
2.Installation c Before beginning installation of this product, please read the instruction manual and warnings below carefully. In package , - One piece unit - Two pieces mounting clamps - One piece instruction manual A visual inspection of this product for possible damage occured during shipment is recommended before installation. It is your responsibility to ensure that qualified mechanical and electrical technicians install this product.
2.1 General Description Terminal protection cover Product Label Mounting Clamp Front Panel IP65 protection NEMA 4X Panel surface (maximum thickness 15mm / 0.59 inch) 2.2 Dimensions Maximum 15mm / 0.59 inch ESM-7730 °F V PO AO1 AO2 M A PSET AT P AT ASET1 A/M ASET2 SET 72mm / 2.83 inch °C Process Controller 72mm / 2.83 inch 11.5 ± 1 mm /0.45 inch 76mm / 2.
2.3 Panel Cut-Out 69mm / 2.72 inch 97 mm / 3.82 inch (min) 97 mm / 3.82 inch (min) 69mm / 2.
2.4 Environmental Ratings Operating Conditions Operating Temperature : 0 to 50 °C Max. Operating Humidity : 90% Rh (non-condensing) Altitude c : Up to 2000m. Forbidden Conditions: Corrosive atmosphere Explosive atmosphere Home applications (The unit is only for industrial applications) 2.5 Panel Mounting 1-Before mounting the device in your panel, make sure that the cut-out is of the right size. 1 2-Check front panel gasket position 3-Insert the device through the cut-out.
2.6 Installation Mounting Clamp 1 2 The unit is designed for panel mounting. 1-Insert the unit in the panel cut-out from the front side. 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 completely immobile within the panel c Montage of the unit to a system must be done with it’s own fixing clamps. Do not do the montage of the device with inappropriate fixing clamps.
3.Electrical Wiring c c c c You must ensure that the device is correctly configured for your application. Incorrect configuration could result in damage to the process being controlled, and/or personal injury. It is your responsibility, as the installer, to ensure that the configuration is correct. Parameters of the device has factory default values. These parameters must be set according to the system’s needs. Only qualified personnel and technicians should work on this equipment.
3.2 Electrical Wiring Diagram c Electrical wiring of the device must be the same as ‘Electrical Wiring Diagram’ below to prevent damage to the process being controlled and personnel injury. Universal Sensor or Transmitter Process Input Supply Input (TC, RTD, Z Voltage/Current) Standard Process Output SSR Driver Output Max.
3.
3.
3.5 Process Input Connection 3.5.1 TC (Thermocouple) Connection TC Connect the wires with the polarity as shown in the figure at left. Always use compensation wire corresponding to the thermocouple used. If present, the shield must be connected to a proper ground. 1 2 3 Always use compensation wire corresponding to the thermocouple used. If present, the shield must be connected to a proper ground. i i Input resistance is greater than 10M W 3.5.
3.5.3 Connection of Serial Transmitters With Current Output (Loop Powered) to the Process Input Transmitter connection by using supply voltage on the device 1 Transmitter connection by using external supply voltage source. 1 Transmitter 3 mA Z 4 Transmitter 3 PV 24 V Z Max. 50mA mA Z 4 PV External Supply Voltage Note 1 24 V Z Max. 50mA Note 1 : External power supply must be selected according to supply voltage range and required current for transmitter. i Input resistance is 2R7 W . 3.5.
3.5.5 Connection of Transmitters with Voltage Output to the Process Input Transmitter connection by using supply voltage on the device 1 2 4 24 V Z Max. 50mA Transmitter connection by using external supply voltage source. 1 mV, V Z PV Transmitter 2 mV, V Z 4 24 V Z Max. 50mA PV External Power Supply Note-1 Transmitter Note-1 : External power supply must be selected according to supply voltage range and required current for transmitter. i Input resistance is greater than 10M W for 0...
3.6 Galvanic Isolation Test Values of ESM-7730 Process Controller 2000V V ( For ESM-7730.1..... ) 500V V ( For ESM-7730.2.....
4. Output Connection Forms in ESM-7730 Process Controllers 4.1 Process Output ( SSR Driver Output ) Connection Device L N Last Control Element (SSR) 9 8 c Max. 25 V Z, Max. 17mA c Fuse Load Fuses must be selected according to the applications. 4.2 Alarm Output-1 Relay Connection L N Device C NC 5A V T Fuse 15 14 Last Control Element (Contactor) NO 13 c Fuse Load c Fuses must be selected according to the applications.
4.3 Process Output or Alarm Output-2 Relay Connection L N Device C 5A V T Fuse 12 NC 11 Last Control Element (Contactor) NO 10 c Fuse Load c Fuses must be selected according to the applications.
5. Definition of Front Panel and Accessing to the Menus 5.
5.2 Observation of Software Revision on the Bottom Display When Power in On When the power is applied to the device all led indicators and display segments are momentarily illuminated for testing. Software revision number of the controller is momentarily illuminated on the bottom display.
5.3 Adjustment of Process and Alarm SET Values Operation Screen °C °F V PO M Process Set Value Screen °C °F V A PO M AO1 A °C °F V PO M AO1 AO2 AO2 AT PSET AT P ASET1 A/M ASET2 °F V A AO1 AO2 PSET AT AT P ASET1 A/M ASET2 SET Alarm-2 Set Screen °C °F V PO M A AO1 A/M ASET2 V PO M A AT P ASET1 A/M ASET2 SET For saving Set v a l u e a n d accessing to the other Set values, press Set button.
5.4 Easy Access Diagram For Program Parameters Main Operation Screen °C °F V PO M A AO1 AO2 AT PSET ASET1 °C °C °F °F V V PO M A PO M AO1 AO2 AT PSET ASET1 P Run List menu °C °F V PO M ASET2 A AO1 Press SET/OK button for accessing to the password entering screen.
5.
5.5 Accessing to the Technician Menu The parameters have been divided into groups according to their functions. Every group has a title and firstly user must determine the title (menu) for accessing to the parameters. Refer to the parameters section for detailed information about parameters. Operation Screen °C °F V PO M Technician Menu Entering Screen °C °F V A PO M AO1 A AO1 AO2 AO2 AT P PSET AT ASET1 A/M ASET2 SET When “P” button is pressed, Technician Menu Entering screen is shown.
PINP CONF Menu Configuration parameters of process input °C °F V PO M A AO1 AO2 PSET AT Technician can access to the former menu by pressing menu changing back button. AT P ASET1 A/M ASET2 SET PID CONF Menu PID algorithm parameters °C °F V PO M Technician can access to the following menu by pressing menu changing next button A AO1 AO2 PSET AT Technician can access to the former menu by pressing menu changing back button.
°C GENN CONF Menu General parameters °F V PO M A AO1 AO2 PSET AT Technician can access to the former menu by pressing menu changing back button. AT P This menu is not accessible if Technician parameters are accessed by pressing SET button without entering technician password Technician can access to the former menu by pressing menu changing back button.
5.6 Changing and Saving Parameters Example-1 : To change Process Input Type parameter Process Input Type parameter accessed firstly in order to reach °C °C Operation Screen °F V PO M is in “PýnP Conf” menu, so PýnP ConF menu must be parameter. Technician Menu Entering Screen °F V A PO M AO1 A AO1 AO2 AO2 AT PSET AT P ASET1 A/M ASET2 PSET AT SET AT P When “P” button is pressed, Technician Menu Entering screen is shown.
Process Input Type Selection is means, input type is RTD. °C °F V PO M A AO1 AO2 PSET AT AT P ASET1 ASET2 A/M SET Process Input Type Selection TC input type is selected °C °F V PO M Parameter can be changed with increment and decrement buttons A AO1 AO2 PSET AT AT P ASET1 ASET2 A/M SET °C Press Set button to confirm the value and access to the next parameter.
Example-2 : Changing operation form from “Auto” to “Manual” and adjustment of % output. If operation form is Auto (Close-Loop Control) and there is an output with PID or ON/OFF control form, device controls the process outputs by calculating the % output values automaticaly. If operation form is Manual (Open-Loop Control) and there is an output with PID control form, then % output value can be adjusted with increment and decrement buttons.
Alarm-1 Set Screen °C °F V PO M ASET1 Led flashes A AO1 AO2 PSET AT AT P ASET2 Led flashes ASET1 A/M ASET2 SET °C °F V PO M A AO1 AO2 PSET AT AT P Manual Led flashes ASET1 A/M ASET2 SET °C Alarm-2 Set Screen This parameter is accessible if parameter in PCnF menu is . It is not accessible if Parameter is Press SET button Operation Screen °F V PO M Press SET button A AO1 AO2 AT PSET AT P ASET1 A/M ASET2 %Output value can be changed with increment and decrement buttons.
Example-3 : To change proportional band parameter Proportional band parameter firstly.
PINP CONF Menu Configuration parameters of process input °C °F V PO M A AO1 AO2 PSET AT Technician can access to the former menu by pressing menu changing back button. AT P ASET1 A/M ASET2 SET °C PID CONF Menu PID algorithm parameters °F V PO M Technician can access to the following menu by pressing menu changing next button A AO1 AO2 PSET AT Technician can access to the former menu by pressing menu changing back button.
°C Integral Time °F V PO M A AO1 Pid CONF Menu When Menu button is pressed, technician can access to the menu pages. AO2 PSET AT AT P ASET1 A/M ASET2 SET Press Set button to access to the next parameter °C °C °F °F V V PO M A PO M AO1 A AO1 AO2 AO2 AT P PSET AT ASET1 A/M ASET2 AT SET P For accessing to the other menus, press menu changing next and back buttons.
Example-4 : To change ZVoltage / Current Input Calibration Type Selection parameter In “PýnP Conf” menu Parameter is in “PýnP ConF” menu. For accessing to this parameter, technician must access to “PýnP ConF” menu firstly. In this example, changing input type of a device from thermocouple to ZVoltage / Current and dual point calibration selection is shown.
PINP CONF Menu Configuration parameters of process input °C °F V PO M A AO1 AO2 PSET AT Technician can access to the former menu by pressing menu changing back button. AT P ASET1 A/M ASET2 SET °C °F V PO M A AO1 AO2 PSET AT AT P ASET1 A/M ASET2 SET Process Input Type Selection For accessing to parameter, parameter must be .If it is not ,change the value as With increment button.
Z Voltage / Current Input Calibration Type Selection °C °F V PO M A AO1 AO2 PSET AT AT P ASET1 A/M ASET2 SET Minimum value for selectable dual point calibration °C °F V PO M Press Set button to confirm the value and access to the next parameter A AO1 AO2 PINP CONF Menu When Menu button is pressed, technician can access to the menu pages PSET AT AT P ASET1 A/M ASET2 SET Press Set button to access to the next parameter °C °C °F °F V V PO M A PO M AO1 A AO1 AO2 AO2 AT
6. Parameters Parameters are divided into two groups. They are Process / Alarm Set parameters and Technician parameters. Technician parameters are grouped into subgroups according to their functions. The subgroups are named as menu pages. 6.
6.2 Technician Parameters 6.2.1 Selection of PID Tune and Operation Form TUNE SELECTION By selecting one of the methods below, device can determine the PID parameters. Device operates according to the defined PID parameters Auto tune (Limit Cycle Tuning) operation Self tune (Step Response Tuning) operation Auto-Self Tune Self Tune operation is performed, if the conditions are realized when power on firstly. In normal operation, it controls the tune conditions in Auto Tune selection which explained below.
TUNE METHODS There are 2 different methods for determining PID parameters by the device. These are Auto tune ( Limit Cycle Tuning) and Self Tune (Step Response Tuning) methods. Determining of PID parameters with Auto Tune is started in these conditions : 1- By the user in any time, 2- By the device when system gets unstable and starts oscillation If process value is out of Set ± Process value stabilisation value (Please refer to Section 6.2.
Auto Tune (Limit Cycle Tuning) operation ; if heating or heating-cooling function and PID control form is selected, process control output runs according to heating if cooling function and PID control form is selected, process control output runs according to cooling .
Process Value PID coefficients are determined and system becomes stable. Process Set Value ( ) Start Value + [ ( Set - Start Value) ] 2 Stun Start Value Time Process Output 100% If cooling function and PID control form is selected for the system; If set value is less than process value, process output becomes active till to the Temperature - [(Temperature-Set) / 2] value. When process value reaches to this value, process output is reduced to 0% and it calculates PID coefficients.
If Self Tune operation is finished without any problem, device saves new PID parameters to memory and runs. It changes parameter. If parameter is it is changed to , if it is , it is changed to If Self Tune operation is interrupted at half, PID parameters and parameter are not changed, device continues to run with former PID parameters. When power is off and then on, device starts to complete the Self Tune operation.
BUMPLESS TRANSFER Process output value in manual control is not taken into consideration while passing from manual control to automatic control. New control output that is measured in automatic control is applied to process output. Last %output value is taken output value of manual control and manual control continues while passing from automatic control to manual control.
6.2.3 Process Input Type and Relevant Parameters with Process Input Defines the process input type. TC input type selection RTD input type selection ZVoltage / Current input type selection. Defines type and scale of the thermocouple for TC input. It is active if TC input type is selected. L (-100°C;850°C) or (-148°F;1562°F) L (-100.0°C;850.0°C) or (-148.0°F;999.9°F) J (-200°C;900°C) or (-328°F;1652°F) J (-199.9°C;900.0°C) or (-199.9°F;999.9°F) K (-200°C;1300°C) or (-328°F;2372°F) K (-199.9°C;999.
Defines type and scale of sensor for RTD input. It is active if RTD input is selected. PT-100 ( -200°C ; 650°C ) or ( -328°F ; 1202°F) PT-100 ( -199.9°C ; 650.0°C ) or ( -199.9°F ;999.9°F) Defines input range and scale of ZVoltage / Current input.It is active if ZVoltage / Current is selected. 0...50mV Z ( -1999 ; 9999 ) 0...5V Z ( -1999 ; 9999 ) 0...10V Z ( -1999 ; 9999 ) 0...20mA Z ( -1999 ; 9999 ) 4...20mA Z ( -1999 ; 9999 ) Defines point position for displays.
Process Set value Po10 Po11 Po12 Po09 Po08 Po13 Po14 Po07 Po15 Po06 Po16 Po05 Po04 Po03 Po02 Po01 Po00 = 0 50 3.125 6.25 9.375 12.5 15.625 18.75 21.825 25 28.125 31.25 34.375 37.5 40.625 43.75 46.875 mV Z 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 3.125 0-50 mVZ range are divided into 16 egual parts. Every “Poxx” SET value is defined 50 / 16 = 3.125 mVZ range. Coefficient value for ZVoltage / Current input.
6.2.4 PID Configuration Parameters If any output is configured as heating PID ; , , , , , , , , , , If no output is configured as PID ; Only , , , CONF menu. , , , , , , parameters are accessible , parameters are accessible in PID PROPORTIONAL BAND ( 000.0% , 999.9% ) Full Scale ( ) %. If = 1000 °C, = 0 °C and = 50.0 then Proportional Band = ( )* / 100.0 Proportional Band = (1000-0)*50.0/100.0 = 500 °C INTEGRAL TIME (0000 sec, 3600 secs) It can be changed by the user.
MÝNÝMUM CONTROL OUTPUT ( 0.0% , ) It is % of minimum output. Even as a result of the PID calculation device calculates the %output value less than this parameter, heating or cooling output is active minimum for OLL parameter. CALCULATED OUTPUT OLL GIVEN OUTPUT OUTPUT PERIOD MAXIMUM CONTROL OUTPUT ( IF , 100.0%) It is % of maximum output.
ANTI-RESET WINDUP (0, SCALE HIGH POINT) While PID operation is running if <= process value <= + condition is true, integral value is calculated. If the condition is not true, integral value is not calculated and last calculated integral value is used. If Ar Parameter is selected , heating proportional band is used for heating PID process instead of Ar Parameter and cooling proportional band is used for cooling PID process instead of Ar Parameter.
PID OUTPUT OFFSET (FOR HEATING PID 0.0%, 100.0%) (FOR COOLING PID -100.0%, 0.0%) This parameter is added to “Output %” which is calculated at the end of the PID. Process Output 100% PoFS = 5.0% 5% 50% 5% PoFS = -5.0% 0% 500 Process Value OUTPUT OFFSET RELATED TO PID SET IF (FOR HEATING PID 0.0%, 100.0%) (FOR COOLING PID -100.0%, 0.0%) This parameter is added to the %process output that is calculated at the end of the PID according to process set value. * / ( ) Example If = 500°C , = 1000°C , =0, = 5.
PROCESS VALUE STABILIZATION ( 1, SCALE HIGH POINT) It is used for controlling if process value oscillates or not when Parameter is or If; <= Process Value <= + condition is not true and process value starts to oscillate (as shown in the diagram). If parameter is or ,then parameter is selected And then Limit Cycle Tune operation starts for determining new PID parameters.
If > 0 (Dead Band) Process Output 100% 50% Process Value 0% Heating Set Value ( If Cooling Set + Value ( ) ) < 0 (Overlap Band) Process Output 100% 50% Process Value 0% Cooling Set + Value( ) Heating Set Value ( ) SENSOR BREAK OUTPUT VALUE (FOR HEATING PID 0.0%, 100.0%) (FOR COOLING PID -100.0%, 0.0%) When sensor breaks, controlling of the process can continue by entering %output value to parameter. If this parameter 0.
6.2.5 Process Output Configuration Parameters It determines if Process Output ( SSR Driver Output ) and Alarm Output-2 operates together or not. Process Output (SSR Driver Output) and Alarm Output-2 operates separately. Process Output (SSR Driver Output) and Alarm Output-2 operates together.
6.2.6 ALARM Output-1 Configuration Parameters It determines logic output function for Alarm Output-1 Alarm output Manual / Automatic data output Sensor break alarm output Output is active when the process value is out of the band which is defined with minimum value of operating scale And maximum value of operating scale It determines alarm type for Output-1. It is active if logic output function of Alarm Output-1 is alarm output.
Deviation low alarm Alarm Output Process Set - Alarm Set Process Set ON OFF HYS Process Value Deviation band alarm Alarm Output Process Set - Alarm Set Process Process Set + Alarm Set Set ON OFF HYS HYS Process Value Deviation range alarm Alarm Output Process Set - Alarm Set Process Process Set + Alarm Set Set ON OFF HYS HYS Process Value Alarm- 1 hysteresis value.
6.2.7 ALARM Output-2 Configuration Parameters i “Aln2 Conf” Menu is accessible if “PCnF ConF” is parameter in It determines logic output function for Alarm Output-2 Alarm output Manual / Automatic data output Sensor break alarm output Output is active when the process value is out of the band which is defined with minimum value of operating scale And maximum value of operating scale It determines alarm type for Output-2. It is active if logic output function of Alarm Output-2 is alarm output.
Deviation low alarm Alarm Output Process Set Process Set - Alarm Set ON OFF HYS Process Value Deviation band alarm Alarm Output Process Set - Alarm Set Process Process Set + Alarm Set Set ON OFF HYS HYS Process Value Deviation range alarm Alarm Output Process Set - Alarm Set Process Process Set + Alarm Set Set ON OFF HYS HYS Process Value Alarm- 2 hysteresis value.
6.2.8 General Parameters Minimum value for process set and alarm set values. It is named as low limit of set scale. It can be adjusted from low limit of input selected with parameter to parameter. Please refer to Section 6.2.3 Process Input Type and Relevant Parameters with Process Input for parameter Maximum value for process set and alarm set values. It is named as high limit of set scale. It can be adjusted from to high limit of input selected with Parameter. Please refer to Section 6.2.
6.2.9 Technician Password It is used for accessing to the technician parameters. It can be adjusted from 0 to 9999. If it is ; there is no password protection while entering to the technician parameters. If it is different from “ 0” and user wants to access to the technician parameters; 1- If technician does not enter password correctly: It turns to operation screen without entering to operator parameters.
7. Failure Messages in ESM-7730 Process Controllers 1 - Sensor failure in analogue inputs. Sensor connection is wrong or there is no sensor connection. °C °F V PO M A AO1 AO2 AT PSET AT P ASET1 A/M ASET2 SET 2 - If value on top display blinks : If analogue input value is less than minimum value of operating scale value on the top display starts to blink. °C °F V PO M A AO1 AO2 AT PSET AT P ASET1 A/M ASET2 SET In “PýnP Conf” Menu if; Þ ; Þ Þ ; Þ Adjust Þ ; Þ are defined.
°C 5 - If tuning operation can not be completed in 8 hours, AT led starts to blink.Blinking can be canceled by pressing Enter button. °F V PO M A AO1 AO2 AT PSET AT P ASET1 ASET2 A/M For details on parameters, refer to Section 6.2.1 SET 6 - If user does not do anything for 120 seconds while device is on technician menus, device turns to operation screen.
Accuracy Cold Junction Compensation Line Compensation Sensor Break Protection Sampling Cycle Input Filter Control Forms Relay Output Standard SSR Driver Output Process Display Set Display Led Indicators Approvals : ± 0,25% of full scale for thermocouple, thermoresistance and voltage, ± 0,70% of full scale for current. : Automatically ± 0.1°C/1°C. : Maximum 10 W . : Upscale : 3 samples per second : 0.0 to 900.0 seconds : Programmable ON / OFF, P, PI, PD or PID.