Emerson TESCOM 44-6800 E Series User manual

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

October 2020

TESCOM™ 44-6800 E Series

Electrically Heated Vaporizing Regulator

Installation, Operations and Maintenance Manual

Do not attempt to select, install,

use or maintain this product until

you have read and fully understood

this manual.

2TESCOM™ 44-6800 E Series

October 2020

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

Installation, Operations and Maintenance Manual

Content

October 2020

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

Contents

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Symbols.........................................................................................................................4

Safety Precautions and Repair.........................................................................................4

2.1 44-6800E Series Regulator Safety.......................................................................................4

3. Installation, Operations and Maintenance...................................................................7

3.1 General Information..........................................................................................................7

3.1.1. Operating Parameters/Special Conditions For Safe Use............................................8

3.2.Installation........................................................................................................................9

3.2.1.InstallationPrecautions............................................................................................9

3.3.Operation........................................................................................................................12

3.3.1RegulatorAdjustment.............................................................................................12

3.3.2 Heater Temperature Controller Status.....................................................................12

3.4 Maintenance and Repair Service.......................................................................................13

3.4.1RepairService..........................................................................................................13

3.4.2 Mechanical Pressure Regulator Function.................................................................13

3.4.3 Electric Heater Function..........................................................................................15

4. Certifications and Warranty.....................................................................................16

4.1 Hazardous Location Ratings.......................................................................................16

4.2 Declaration of Conformity..........................................................................................17

4.3LimitedWarranty........................................................................................................18

4TESCOM™ 44-6800 E Series

Content

October 2020

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

1Symbols

WARNING

Paragraphs highlighted by the WARNING icon contain information about practices or

circumstances that can lead to personal injury or death, property damage or economic

loss.

CAUTION

Paragraphs highlighted by the CAUTION icon contain information that must be followed

to maintain a safe and successful operating environment.

Safety Precautions and Repair

44-6800E Series Regulator Safety

WARNING

Do not attempt to select, install, use or maintain this regulator until you have read and

fully and understood these instructions. Do not permit untrained persons to install, use

or maintain this regulator.

The 44-6800E Series regulator should not be installed in an enclosure that is heated above

the regulator’s maximum rated ambient temperature.

Be sure this information reaches the operator and stays with the product after installation.

Improper selection, improper installation, improper maintenance, misuse or abuse of

regulator can cause death, serious injury and property damage.

Possible consequences include but are not limited to:

•High velocity uid (gas or liquid) discharge

•Parts ejected at high speed

•Contact with uids that may be hot, cold, toxic or otherwise injurious

•Explosion or burning of the uid

•Lines/hoses whipping dangerously

•Damage or destruction to other components or equipment in the system

2.1

Installation, Operations and Maintenance Manual

Content

October 2020

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

CAUTION

Safety Precautions

•Inspect the regulator before each use.

•Never connect regulators to a supply source having a pressure greater than the

maximum rated pressure of the regulator, valve or accessory.

•Refer to product label (model specic) for maximum inlet pressures . If this rated

pressure cannot be found, contact your local TESCOM representative for the designed

pressure rating of all equipment (e .g., supply lines, ttings, connections, lters,

valves, gauges, etc.) in your system . All must be capable of handling the supply and

operating pressure.

•Install circuit protection on input voltage to electrical controls of the regulator per

local and environment codes.

•Clearly establish ow direction of the uid before installation of regulators, valves

and accessories. It is the responsibility of the user to install the equipment in the

correct direction

•Remove pressure from the system before tightening ttings, gauges or component.

•Never turn regulator or valve body. Instead hold regulator or valve body and turn

tting nut.

•Take precautions before touching the regulator while in operation.

•If a regulator or valve leaks or malfunctions, take it out of service immediately.

•Do not modify equipment or add attachments not approved by the manufacturer.

•Do not open enclosures when energized. Do not open enclosures when explosive

atmosphere may be present.

•For pressure reducing regulators, it is highly recommended that the control knob

or adjusting screw be turned fully counterclockwise before applying inlet pressure.

•Apply pressure to the system gradually, avoiding a sudden surge of uid or pressure

shock to the equipment in the system.

•Regulators are not shut-off devices. Install a pressure relief device downstream of the

regulator to protect the process equipment from overpressure conditions. Shut off

the supply pressure when the regulator is not in use.

•Periodic inspection and scheduled maintenance of your equipment is required for

continued safe operation.

•The frequency of servicing is the responsibility of the user based on the application.

Never allow problems or lack of maintenance to go unreported.

•Read and follow precautions on compressed gas cylinder labels.

•It is important that you analyze all aspects of your application and review all available

information concerning the product or system. Obtain, read and understand the

Material Safety Data Sheet (MSDS) for each uid used in your system.

•Never use materials for regulators, valves or accessories that are not compatible with

the uids being used.

•Users must test components for material compatibility with the system operating

conditions prior to use in the system.

•Vent uids to a safe environment and in an area away from personnel. Be sure that

venting and disposal methods are in accordance with Federal, State and Local requirements.

Locate and construct vent lines to prevent condensation or gas accumulation. Make

sure the vent outlet is not obstructed by rain, snow, ice, vegetation, insects, birds, etc.

6TESCOM™ 44-6800 E Series

Content

October 2020

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

•Do not interconnect vent lines; use separate lines if more than one vent is needed.

Do not locate regulators, valves or accessories controlling ammable uids near open

ames or any other source of ignition.

•Some uids when burning do not exhibit a visible ame. Use extreme caution when in

specting and/or servicing systems using ammable uids to avoid death or serious

injury to personnel. Provide a device to warn personnel of these dangerous conditions.

•Many gases can cause suffocation. Make certain the area is well ventilated. Provide a

device to warn personnel of lack of Oxygen.

•Never use oil or grease on these regulators unless recommended as specied in Operations

and Service procedures. Oil and grease are easily ignited and may combine violently

with some uids under pressure.

•Have emergency equipment in the area if toxic or ammable uids are used.

•Upstream lters are recommended for use with all uids.

•Do not bleed system by loosening ttings.

•Prevent icing of the equipment by removing excess moisture from the gas.

•Always use proper thread lubricants and sealants on tapered pipe threads.

Installation, Operations and Maintenance Manual

Content

October 2020

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

Installation, Operations and Maintenance

Assembly & installation drawings, Bill of Materials, and parts lists for your product may

be obtained by contacting Emerson. Emerson will provide these by email, fax or mail.

Your local TESCOM™ sales representative can provide additional assistance. Be sure to

have your complete model number ready. See back page for contact information.

General Information

TESCOM™ 44-6800E Series Electrically Heated Vaporizing diaphragm-sensed pressure

reducing regulators are specically engineered for applications requiring dependable

pressure regulation. These regulators are especially appropriate for installations where

high system pressures (up to 6000 psi) must be reduced to levels suitable for actuating

low pressure (0 psig/0 bar to 500 psig/35 bar) instruments and related equipment.

In addition, the 44-6800E Series “Vaporizing” regulator is designed to offset the effects

of the Joule-Thompson cooling effect that occurs when there is a pressure drop in a gas.

It can also be used to vaporize a liquid into a gas in some applications.

The electrical board inside the housing powers an electrical heater that indirectly heats

the process media. This heater is controlled by the electrical board for temperatures

ranging from 122 °F/50 °C to 752 °F/400 °C. There is a thermocouple within the heater

core to provide temperature feedback. There is a secondary thermal device, thermal cut

off (TCO), within the regulator assembly. See Figure 1.

Figure 1:

ELECTRIC (Shown with optional LED display).

3.1

8TESCOM™ 44-6800 E Series

Content

October 2020

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

Operating Parameters/Special Conditions For Safe Use

Maximum Inlet Pressure:

3,500 psig / 241 bar / 24,132 kPa Standard

6,000 psig / 414 bar / 41368 kPa Optional

Maximum Outlet Pressure:

500 psig / 34 5 bar / 3,448 kPa

Outlet Pressure Ranges:

0-25, 0-50, 0-100, 0-250, 0-500 psig

0-17, 0-34, 0-69, 0-172, 0-345 bar

0-172, 0-345, 0-690, 0-1724, 0-3448 kPa

Design Proof Pressure

150% maximum rated

Leakage:

Internal: Bubble-tight

External: Designed to meet ≤ 2x10-8 atm cc/sec He

Voltage:

100 - 240 VAC, 50/60 Hz, 400W at 240VAC, 100W at 120VAC

Full Load Amps:

2.0 Amps at 240VAC, 1.1 Amps at 120 VAC*

*Controller has 3 Amp fuse rated for 350 VAC

Flow Capacity:

Cv = 0.02 - Standard

Refer to catalog and part number for options.

Supply Voltage

(VAC)

Heater Watts

(W)

Max. Ambient

Temperature

100 - 240 100 - 400 Electrical Housing

149 °F/65 °C

Regulator Body

185 °F/85 °C

All cables, cable glands and conductors need >95 °C rating.

For integral applications the electronics enclosure must engage the regulator assembly by

at least 5 full threads made wrench tight.

3.1.1

Installation, Operations and Maintenance Manual

Content

October 2020

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

Installation

Installation Precautions

WARNING

Make sure that the components and materials used in the uid handling system are

compatible with the uid and have the proper pressure rating. Failure to do so can result

in death, serious injury and/or property damage.

A regulator is not intended to be used as a shutoff device. When the regulator is not in

use, the inlet supply should be turned off. As a safety precaution, a pressure relief device

should be installed downstream of the regulator.

CAUTION

Do not open packaging until ready for installation or in a clean environment. Product is

cleaned in accordance with CGA 4.1 and ASTM G93, Verication Type 1, Test 1 and Test

2. With periodic verication of cleaning process to MIL-STD-1330D.

Inspect the regulator for physical damage and contamination. Do not connect the regulator

if you detect oil, grease or damaged parts. If the regulator, valve or accessory is damaged,

contact your local TESCOM representative to have the regulator cleaned or repaired.

CAUTION

Follow all laws, regulations and industry requirements for electrical wiring. All electrical

wiring must be terminated in an inaccessible location. Where the electrical housing is

separate from the regulator body appropriate wiring to connect the two assemblies shall

follow hazardous location requirements per applicable laws and regulations.

Possible consequences include but are not limited to:

a. Make sure the regulator and electrical housing is mounted securely.

b. Make sure the electrical power is turned off and locked out.

c. Connect external ground if required to electrical housing.

d. Remove electrical housing cover.

e. Remove power supply connector and (if used) the 4-20 mA output connector from

the electrical board. See Figure 2.

f. Feed power supply wires and (if used) the 4-20 mA output wires through the 1/2” NPT

port. See Figure 2.

g. Screw the power supply and (if used) 4-20 mA output wires to the connectors and

internal ground. See Figure 2.

h. Verify all connections before applying power. Make sure the supply power is in working

range of unit purchased.

i. If the 4-20 mA output is used, an isolated excitation voltage of 20-28 volts is needed.

The 4-20 mA output correlates to a thermocouple temperature reading of 50 to

400 °C / 122 to 752 °F. See Figure 2.

Notice

Should the thermocouple fail the analog output would read greater than 25 mA

and no electrical power will be supplied to the heating element. Disconnect

power and check wiring.

3.2

3.2.1

10 TESCOM™ 44-6800 E Series

Content

October 2020

Installation, Operations and Maintenance Manual

TR000058ENUS-02_10-20

j. Adjust the temperature with the TRIM1 potentiometer. TRIM1 potentiometer, located

on the electrical board, provides a 270° of adjustment. The temperature set point

range is from 50 °C /122 °F (fully counter clockwise position) to 400 °C /752 °F (fully

clockwise position). See Figure 3.

Product does not provide actual media temperature. Actual media temperature

should be taken from a different device.

k. Heater Temperature Feedback Display (Optional):

The display reads the temperature of the heater in degrees Celsius.

l. Temperature Set Button (Only with Optional Display):

This button is located on the control board. See Figure 4.

When pressed down the display will show the heater set point temperature.

m. Place stopping plugs in any unclosed conduit entry.

Figure 2:

Figure 2

Separated assembly is supplied with

electrical housing shipped separately from

the regulator assembly. Extra wire is

provided. Connectors J4 and J2 from the

regulator assembly must be attached to

the corresponding control board terminals.

For integral applications the electronics

enclosure must engage the regulator

assembly by at least 5 full threads made

wrench tight.

(J4)

(J5)

(J2)

(J1)

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