Application Brief: E5CN

Temperature Controllers

Omron Innovation: 2-PID Control 2-PID control is an important advance on standard PID control. 2-PID control uses a powerful algorithm that enables the instrument to be tuned for optimum disturbance response without any compromise on the speed of reaction to changes in set point. The algorithm takes advantage of fuzzy logic processing to identify the type of response required then adjust settings accordingly. With an input sampling period as short as 250 ms, newer temperature controllers can deliver a control response within 0.5 second, fast enough to handle high-speed packaging equipment such as pouch form-fill-seal machines.

The best part is that the user doesn’t have to take any special action to select these functions. Manufacturers such as Omron preset their instruments at the factory with a default setting, suitable to give fast responses with minimal overshoot. This means faster start up production times and much more stable control during production leading to better quality products.

Additional Types of Tuning

Newer temperature controllers provide different types of tuning besides the fast and reliable Auto tuning and “process triggered” Self tuning. These are included in products such as Omron’s E5_N series temperature controllers:

Other developments focus on maximizing production up-time. Built-in diagnostics and pre-maintenance functions, like output ON/OFF counter and heater alarm, provide tools to anticipate and prevent unexpected machine failure and costly downtime.

Omron Industrial Automation • © 2011 Omron • www.omron247.com

New Temperature Controllers Improve Recovery Time for High-Speed, High-Sensitivity Processes Recent technology advances applied to on-panel temperature controllers have led to marked improvements in responsiveness to process disturbances to maintain top quality results in high-speed and high-sensitivity processes.

PID control set the standard for improving the response to common steady-state and disturbance recovery conditions. Auto-tuning continues to simplify setting without complex calculations and manual adjustments for most processes.

Cool gain adjustment When using Heat & Cool control the auto-tuning automatically calculates the cool gain.

Limited MV tuning Protect the system by limiting the output (MV) to 40% during the tuning cycles.

Robust tuning A unique feature enabling the operator to select a second mode of tuning to find the ideal set of control parameters for working over a wider temperature range.

Application Brief: E5CN

Temperature Status at a GlanceNewer temperature controllers offer PV display color change capability to indicate status changes at a glance. Operators can determine process status directly from the temperature controller without relying on additional hardware. For example, when one of the heaters is not at set-point, the PV display can change color providing an early alert to staff members that bad sealing is starting to take place. This can help reduce waste and prevent spilled contents from contaminating downstream processes. Up to three display colors can be assigned to match critical status limits.

Omron Industrial Automation • © 2011 Omron • www.omron247.com

Temperature Controllers

SEALING BAR APPLICATIONQuick and Accurate Temperature StabilizationRecover quickly from temperature changes to ensure a durable seal while maintaining high productivity.

ChallengeAs the seal bar jaws close, the temperature drops sharply from melting the layers of packaging film to form the seal. Rapid recovery is required in order to maintain high throughput.

SolutionOmron's temperature controller with 2-PID algorithm 'Adjustment disturbance overshoot function', enables fast ramp-up and quick recovery from temperature drops while at the same time minimizing stabilization time.

BenefitImproves throughput and seal quality remains high through stable temperature.

OVEN CONTROLExternal influences can cause the temperature to deviate from the required set value.

Temperature Status at a GlanceNewer temperature controllers offer PV display color change capability to indicate status changes at a glance. Operators can determine process status directly from the temperature controller without relying on additional hardware. For example, when one of the heaters is not at set-point, the PV display can change color providing an early alert to staff members that bad sealing is starting to take place. This can help reduce waste and prevent spilled contents from contaminating downstream processes. Up to three display colors can be assigned to match critical status limits.

Alarm options include deviation from set point, where if the set point is changes the alarm moves with it. Absolute alarms where they are referenced to 0, standby so the alarms will not be active during the set point has been reached. Latching which means that once triggered they can only be deactivated by removing power.

This is ideal for remote or unmanned processes, as the alarm will remain until the machinery is next visited.

Application Brief: E5CN

The capability built into basic temperature controllers such as Omron’s E5CN provides simple ramp/soak steps without the need to select an advanced controller with extensive ramp/soak programming.

Omron Industrial Automation • © 2011 Omron • www.omron247.com

Temperature Controllers

Rev. 5/11 APP_E5CN

BAKING OVEN

Basic (2-step) ProgrammerIn many thermal processes (food, brick, pottery etc.) a small element of timing is required. This feature enables you to ramp up to a set-point and set the dwell time period. A fixed minimum or maximum curing/baking time is assured in a smooth, controlled way.

In many applications it is important to control the speed of approach to set point as well as maintain it at a preset time once reached.

This rate of rise control helps to prevent over-cooking of the outside of the product. However multistage ramp/soak control is not normally required. The E5CN contains a simple two-stage function, controlling the rise to set-point and duration once reached.