Emerson Tescom ER5000 Series User manual

ER5000 Series User Manual

Operations Manual

DOPSM2064X012

April 2019

www.emerson.com

WARNING

If your application is rated as a Hazardous Location,

you MUST use model ER5050. Models ER5000,

ER5020, ER5040, ER5100 and ER5110 are not

intended for or rated for use in Hazardous Locations.

Do not attempt to select, install, use or maintain

this product until you have read and fully

understood the Safety, Installation & Operations

Precautions section of this manual.

Safety, InStallatIon &

operatIonS precautIonS

ER5000 —

Safety, Installation & Operations Precautions

TESCOM™ ELECTRONIC CONTROLLERS

WARNING

DO NOT ATTEMPT TO SELECT, INSTALL, USE OR MAINTAIN THIS

CONTROLLER OR ACCESSORY UNTIL YOU HAVE READ AND FULLY

UNDERSTOOD THESE INSTRUCTIONS.

BE SURE THIS INFORMATION REACHES THE OPERATOR AND STAYS WITH THE

PRODUCT AFTER INSTALLATION.

DO NOT PERMIT UNTRAINED PERSONS TO INSTALL, USE OR MAINTAIN THIS

CONTROLLER OR ACCESSORY.

IMPROPER SELECTION, IMPROPER INSTALLATION, IMPROPER MAINTENANCE,

MISUSE OR ABUSE OF THIS CONTROLLER OR RELATED ACCESSORIES CAN CAUSE

DEATH, SERIOUS INJURY AND/OR PROPERTY DAMAGE.

OXYGEN SERVICE REQUIRES SPECIAL EXPERTISE AND KNOWLEDGE OF SYSTEM

DESIGN AND MATERIAL COMPATIBILITY IN ORDER TO MINIMIZE THE POTENTIAL

FOR DEATH, SERIOUS INJURY AND/OR PROPERTY DAMAGE.

Possible consequences include but are not limited to:

• High velocity uid (gas or liquid) discharge

• Electrocution

• 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

CAUTION

SAFETY PRECAUTIONS

1. Read and understand the user’s manual before operating the controller.

2. Inspect the controller and accessories before each use.

3. Operate the unit only under specied environmental conditions.

4. Follow instructions in the manuals for proper wiring.

5. Never connect the controller or accessories to a supply source having a voltage

greater than the maximum rated voltage of this controller or accessory.

6. Never connect the controller or accessories to a supply source having a pressure

greater than the maximum rated pressure of this controller or accessory.

7. Never use anything but clean dry inert gases or air into the

electropneumatic controller.

8. Start up sequence for electropneumatic controllers is:

a. Feedback loop must be installed and operational.

b. Electrical power should be applied and system setpoint reduced to

its lowest pressure output before turning on the pneumatic supply to

the controller.

9. Refer to product label (modication specic) for maximum inlet pressures. If

this rated pressure cannot be found, contact your local TESCOM representative

for the rated pressure prior to installation and use. Verify 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.

ER5000 —

Safety, Installation & Operations Precautions

10. Clearly establish ow direction of the uid before installation of controllers,

regulators, valves and accessories. It is the responsibility of the user to install

the equipment in the correct direction.

11. Remove pressure from the system before tightening ttings, gauges

or components.

12. Never turn controller, regulator or valve body. Instead, hold the controller body

and turn tting nut.

13. If a controller, regulator or valve leaks or malfunctions, take it out of

service immediately.

14. Do not modify equipment or add attachments not approved by

the manufacturer.

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

pressure shock to the equipment in the system.

16. Regulators are not shut-off valves. Install a pressure relief device downstream

of the regulator to protect the process equipment from operating pressure

increases. Shut off the supply pressure when the regulator is not in use.

17. Periodic inspection and scheduled maintenance of your equipment is required

for continued safe operation.

18. The frequency of servicing is the responsibility of the user based on the

application. Never allow problems or lack of maintenance to go unreported.

19. Read and follow precautions on compressed gas cylinder labels.

20. 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.

21. Never use materials for controllers, regulators, valves or accessories that are

not compatible with the uids being used.

22. Users must test under normal operating conditions to determine suitability of

materials in an application.

23. Vent uids to a safe environment and in an area away from employees. 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. Do not interconnect vent lines; use separate

lines if more than one vent is needed.

24. Do not locate controllers, regulators, valves or accessories using ammable

uids near open ames or any other source of ignition. Use of Hazardous Location

controllers may be necessary to be in accordance with local electric codes.

25. Some uids, when burning, do not exhibit a visible ame. Use extreme caution

when inspecting and/or servicing systems using ammable uids to avoid

death or serious injury to employees. Provide a device to warn employees of

these dangerous conditions.

26. Many gases can cause suffocation. Make certain the area is well ventilated.

Provide a device to warn employees of lack of Oxygen.

27. Never use oil or grease on these controllers, regulators, valves or accessories.

Oil and grease are easily ignited and may combine violently with some uids

under pressure.

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

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

30. Do not bleed system by loosening ttings.

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

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

ER5000 —

Safety, Installation & Operations Precautions

INSTALLATION

Inspect the controller and accessories for physical damage and contamination.

Do not connect the controller or accessory if you detect oil, grease or damaged

parts. If the controller or accessory is damaged, contact your local TESCOM™

representative to have the controller cleaned or repaired.

WARNING

Make sure that the components and materials used in the fluid handling

system are compatible with the fluid and have the proper pressure rating.

Make sure that the components used in the electronic system are

compatible with and have the proper voltage rating.

REPAIR SERVICE

If a controller leaks or malfunctions, take it out of service immediately. You must

have instructions before doing any maintenance. Do not make any repairs you do

not understand. Have qualied personnel make repairs. Return any equipment

in need of service to your equipment supplier for evaluation and prompt service.

Equipment is restored to the original factory performance specications, if

repairable. There are at fee repair charges for each standard model. The original

equipment warranty applies after a complete overhaul.

WARNING

SAFE COMPONENT SELECTION

1. Consider the total system design when selecting a component to ensure safe,

trouble-free performance.

2. The user is responsible for assuring all safety and warning requirements of the

application are met through his/her own analysis and testing.

3. TESCOM may suggest material for use with specic media upon request.

Suggestions are based on technical compatibility resources through

associations and manufacturers. TESCOM does NOT guarantee materials to be

compatible with specic media — THIS IS THE RESPONSIBILITY OF THE USER!

4. Component function, adequate ratings, proper installation, operation and

maintenance are the responsibilities of the system user.

5. The user is responsible to be in accordance with all the necessary mechanical

and electrical codes required for installation and operation of the system. These

requirements include but are not limited to all Hazardous Location controllers.

6. The user is responsible for the selection of the proper model number of the

controller that would meet the application’s possible hazardous environment

or conditions.

WARNING

Do not modify equipment or add attachments not approved by

the manufacturer.

ER5000 —

Safety, Installation & Operations Precautions

TESCOM™ REGULATORS

WARNING

DO NOT ATTEMPT TO SELECT, INSTALL, USE OR MAINTAIN THIS

REGULATOR, VALVE OR ACCESSORY UNTIL YOU HAVE READ AND FULLY

UNDERSTAND THESE INSTRUCTIONS.

BE SURE THIS INFORMATION REACHES THE OPERATOR AND STAYS WITH THE

PRODUCT AFTER INSTALLATION.

DO NOT PERMIT UNTRAINED PERSONS TO INSTALL, USE OR MAINTAIN THIS

REGULATOR, VALVE OR ACCESSORY.

IMPROPER SELECTION, IMPROPER INSTALLATION, IMPROPER MAINTENANCE,

MISUSE OR ABUSE OF REGULATORS, VALVES OR RELATED ACCESSORIES CAN CAUSE

DEATH, SERIOUS INJURY AND/OR PROPERTY DAMAGE.

OXYGEN SERVICE REQUIRES SPECIAL EXPERTISE AND KNOWLEDGE OF SYSTEM

DESIGN AND MATERIAL COMPATIBILITY IN ORDER TO MINIMIZE THE POTENTIAL

FOR DEATH, SERIOUS INJURY AND/OR 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.

CAUTION

SAFETY PRECAUTIONS

1. Inspect the regulator, valve and accessories before each use.

2. Never connect regulators, valves or accessories to a supply source having a

pressure greater than the maximum rated pressure of the regulator, valve

or accessory.

3. 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 rated pressure prior to installation and use. Verify 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.

4. 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.

5. Remove pressure from the system before tightening ttings, gauges

or components.

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

turn tting nut.

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

8. Do not modify equipment or add attachments not approved by

the manufacturer.

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

pressure shock to the equipment in the system.

ER5000 —

Safety, Installation & Operations Precautions

10. 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.

11. Periodic inspection and scheduled maintenance of your equipment is required

for continued safe operation.

12. The frequency of servicing is the responsibility of the user based on

the application.

13. Never allow problems or lack of maintenance to go unreported.

14. Read and follow precautions on compressed gas cylinder labels.

15. 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.

16. Never use materials for regulators, valves or accessories that are not

compatible with the uids being used.

17. Users must test components for material compatibility with the system

operating conditions prior to use in the system.

18. Vent uids to a safe environment and in an area away from employees. 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. Do not interconnect vent lines; use separate

lines if more than one vent is needed.

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

open ames or any other source of ignition. Use of Hazardous Location controllers

may be necessary to be in accordance with local electric

codes.

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

when inspecting and/or servicing systems using ammable uids to avoid

death or serious injury to employees. Provide a device to warn employees of

these dangerous conditions.

21. Many gases can cause suffocation. Make certain the area is well ventilated.

Provide a device to warn employees of lack of Oxygen.

22. Never use oil or grease on these regulators, valves or accessories. Oil and grease

are easily ignited and may combine violently with some uids under pressure.

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

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

25. Do not bleed system by loosening ttings.

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

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

ER5000 —

Safety, Installation & Operations Precautions

INSTALLATION

WARNING

Investigate and apply the most recent standards for Hazardous Locations for

your area set by ANSI, ISO and OSHA, as well as all electrical codes and fire and

safety standards, to determine if your application will require a Hazardous

Location model.

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, Verification Type 1, Test 1 and

Test 2. With periodic verification of cleaning process to MIL-STD-1330D.

WARNING

Make sure that the components and materials used in the fluid handling

system are compatible with the fluid and have the proper pressure rating.

Failure to do so can result in death, serious injury and/or property damage.

Inspect the regulator, valve and accessories for physical damage and contamination.

Do not connect the regulator, valve or accessory 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.

REPAIR SERVICE

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

You must have instructions before doing any maintenance. Do not make any

repairs you do not understand. Have qualied personnel make repairs. Return any

equipment in need of service to your equipment supplier for evaluation and prompt

service. Equipment is restored to the original factory performance specications,

if repairable. There are at fee repair charges for each standard model. The original

equipment warranty applies after a complete overhaul.

CAUTION

PROPER COMPONENT SELECTION

1. Consider the total system design when selecting a component for use in

a system.

2. The user is responsible for assuring all safety and warning requirements of the

application are met through his/her own analysis and testing.

3. TESCOM may suggest material for use with specic media upon request.

Suggestions are based on technical compatibility resources through

associations and manufacturers. TESCOM does NOT guarantee materials to be

compatible with specic media -- THIS IS THE RESPONSIBILITY OF THE USER!

4. Component function, adequate ratings, proper installation, operation and

maintenance are the responsibilities of the system user.

WARNING

Do not modify equipment or add attachments not approved by the

manufacturer. Failure to do so can result in death, serious injury and/or

property damage.

table of contentS

ER5000 —

Table of Contents

Safety, Installation & Operations

Precautions 2

TESCOM™ ELECTRONIC CONTROLLERS . . . . . 3

TESCOM REGULATORS . . . . . . . . . . . . . 6

Table of Contents 9

Table of Contents . . . . . . . . . . . . . . . 10

Conventions of This Manual. . . . . . . . . . 13

Navigating This Manual. . . . . . . . . . . . 13

Features and Specifications 14

ER5000 Series Part Numbering System . . . . 15

ER5000 Standard Features . . . . . . . . . . 15

ER5000 Dimensions – Side Views . . . . . . . 16

ER5000 Dimensions – Top and Bottom View. . 17

ER5050 Hazardous Location Model . . . . . . 18

Dimensions – Side Views . . . . . . . . . . . 18

ER5050 Hazardous Location Model . . . . . . 19

Dimensions – Top and Bottom View. . . . . . 19

ER5000 Specifications . . . . . . . . . . . . 20

Hazardous Location Model (ER5050)

Specifications . . . . . . . . . . . . . . . . 22

Accessories. . . . . . . . . . . . . . . . . . 24

What’s New 25

New Features. . . . . . . . . . . . . . . . . 26

Replacing an ER3000 with an ER5000 . . . . . 27

How It Works 29

The ER5000: How It Works . . . . . . . . . . 30

Understanding PID Controllers . . . . . . . . 31

PID Controllers: Three Components

Are Better Than One 32

A Typical PID Control System 33

Tuning a PID Controller 35

Rules of Thumb for PID Tuning 35

The ER5000: Typical Application

(Non-Hazardous Location) . . . . . . . . . . 39

Controlling System Pressure 39

A Note Concerning Non-Venting

Regulators in Closed Loop Applications 41

Monitoring System Control Limits 42

The ER5000: Control Modes. . . . . . . . . . 43

Internal Feedback Mode 43

External Feedback Mode 43

Cascade Mode 43

Glossary of Terms 44

Terms Relating to PID Controllers

and Controller Tuning . . . . . . . . . . . . 45

Terms Relating to Regulators . . . . . . . . . 52

Getting Started 57

Before You Begin . . . . . . . . . . . . . . . 58

ER5000 Quick Reference: Jumpers,

Terminal Blocks and Wires and LEDs . . . . . 59

Verify your shipment. . . . . . . . . . . . . 60

Additional items not included: 61

Tools you will need for the installation: 61

Additional items and tool you will need for

an installation in a Hazardous Location: 61

Verify the configuration of your application. . . . 62

Verify that all operational requirements

have been met . . . . . . . . . . . . . . . . 63

Verify that all safety requirements

have been met . . . . . . . . . . . . . . . . 63

Mount the ER5000 on the regulator . . . . . 64

Connect and verify the power supply . . . . . 65

Verify the Jumper J6 configuration . . . . . . 68

Connect the USB cable (not supplied with ER5050) 71

Install the ERTune™program . . . . . . . . . 72

Connect pressure to the system. . . . . . . . 73

Start up and tune the system . . . . . . . . . 75

Installation Variations 76

Before You Begin . . . . . . . . . . . . . . . 77

ER5000 Installation Variations —

Wiring Diagrams . . . . . . . . . . . . . . . 78

Terminal Blocks and Wires . . . . . . . . . . 79

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