Emerson Tescom ER5000 Series, Tescom ER5100, Tescom ER5040, Tescom ER5000, Tescom ER5050 User Manual
...
Operations Manual
DOPSM2064X012
April 2019
ER5000 Series User Manual
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.
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.
www.emerson.com
Safety, InStallatIon &
o
peratIonS precautIonS
2
ER5000 — 3Safety, 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 REQ UIRES SPECIAL EXPER TISE AND KNOWLE DGE OF SYSTEM
DESIGN AND MATERIAL COMPATIBILITY IN ORDER TO MINIMIZE THE POTENTIAL
FOR DEATH, SERIOUS I NJURY 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 understa nd the user’s manual b efore operati ng the controll er.
2. Inspe ct the control ler and accessor ies before each use.
3. Operate the uni t only under specied environm ental conditi ons.
4. Follow instructions in the manuals for proper wiring.
5. Never co nnect the cont roller or accessories t o a supply source ha ving a voltage
greater t han the maximum rated voltage of t his controller o r accessory.
6. Nev er connect the c ontroller or a ccessories to a su pply source hav ing a pressure
greater t han the maximum rat ed pressure of this co ntroller or acces sory.
7. Never use anyt hing but clean dr y inert gases o r air into the
electropneumatic controller.
8. Star t up sequence for e lectropne umatic control lers is:
a. Fe edback loop mus t be installed a nd operationa l.
b. Elec trical power should be applied and system setpoint reduced to
its low est pressure ou tput before turning on t he pneumatic sup ply to
the controller.
9. Refer to produc t label (modicat ion specic) for ma ximum inlet pressures . If
this rated pressure cannot be found, contac t your local TE SCOM representative
for the ra ted pressure pr ior to installation and use. Verif y the designed pr essure
rating of all equipment (e.g., supp ly lines, tt ings, connections, lters, v alves,
gauges, etc.) in your sy stem. All must be capable of handling the supp ly and
operating pressure.
ER5000 — 4Safety, Installation & Operations Precautions
10. Cl early establ ish ow direct ion of the uid before inst allation of cont rollers,
regulators, valves and accessories. It is the responsibility of the user to install
the equipment in the correct direction.
11. Remove pres sure from the system before tightening ttings, gauges
or components.
12. Ne ver turn controller, regulator or val ve body. Instead, hold the controller body
and turn ttin g nut.
13. If a controller, regulat or or valve leak s or malfuncti ons, take it out of
service immediately.
14. Do n ot modify equ ipment or add at tachments not approved by
the manufacturer.
15. Apply pre ssure to the system gradu ally, avoiding a sudd en surge of uid or
pressure shock to the equipment in th e system.
16. Reg ulators are not shut-of f valves. Inst all a pressure relief device downs tream
of the regulator to protec t the process eq uipment from op erating pressure
increas es. Shut off the supply pr essure when the regulator is not in us e.
17. Periodic inspection and scheduled maintenance of your equipment is required
for continued safe operation.
18. Th e frequency of serv icing is the resp onsibility of the user based on the
applic ation. Never allow problems or lac k of maintenance to go unreported.
19. Read and follow precautions on compressed gas cylinder labels.
20. It is impor tant that you analyze all aspects of your application and review
all available information concer ning the product or system. Obt ain, read
and understand the Material Safety Dat a Sheet (MSDS) for each uid used in
your system.
21. Never use materials for controllers, regulators, valves or accessories that are
not compa tible with the uids being used.
22. Users must test under normal operating conditions to determine suitability of
materials in an application.
23. Vent u ids to a safe environment an d in an area away from employe es. Be sure
that vent ing and disposal m ethods are in acco rdance with Fed eral, State and
Local requirements. L ocate and const ruct vent line s to prevent condensation
or gas accumulatio n. Make sure the vent o utlet is not obst ructed by rain, snow,
ice, vegetation, insects, birds, etc. Do not interconnect vent lines; use separate
lines if m ore than one vent is n eeded.
24. Do not lo cate controllers, regulator s, valves or accesso ries using ammabl e
uids near open ames or an y other source of ignition. Use of Haz ardous Location
contro llers may be ne cessary to be i n accordance wit h local elec tric codes.
25. So me uids, when burning, do not exhibit a visible ame. Us e extreme ca ution
when inspecting and/or ser vicing sys tems using ammab le uids to avoid
death or serious injury t o employees. Provide a device to warn employ ees of
these dangerous conditions.
26. Many gases can cause suf focation. M ake certain the area is well ventilat ed.
Provide a device to warn employees of lack of Ox ygen.
27. Ne ver use oil or grease on these co ntrollers, r egulators, v alves or accesso ries.
Oil and gr ease are easily ign ited and may combi ne violently w ith some uids
under pressure.
28. Have emergency equ ipment in the area if toxic or ammable uids are used.
29. Up stream lters are reco mmended for use w ith all uids.
30. Do n ot bleed system by loose ning ttings.
31. Pr event icing of the e quipment by removing excess mois ture from the gas.
32. Always use proper t hread lubrica nts and sealant s on tapered pipe threads.
ER5000 — 5Safety, Installation & Operations Precautions
INSTALLATION
Inspec t the controll er and accessories for phy sical damage and co ntamination .
Do not connect th e controller or a ccessory if yo u detect oil, gr ease or damaged
part s. If the controller or acc essory is damaged, cont act your loca l TESCOM™
representative to have the contro ller cleaned or r epaired.
WARNING
Make sure t hat the compone nts and materia ls used in the fluid handl ing
system a re compatible w ith the fluid an d have the proper pr essure rating .
Make sure t hat the compone nts used in the electro nic system are
compatible with and have the proper voltage rating.
REPAIR SERVICE
If a controller lea ks or malfunc tions, take it ou t of service im mediately. You must
have inst ructions before doing any maint enance. Do not make any r epairs you do
not understan d. Have qualied p ersonnel make r epairs. Retur n any equipment
in need of s ervice to your equipment supplier for eva luation and pro mpt service.
Equipment is restored to th e original fac tory performance specications, if
repair able. There are at fee repa ir charges for each s tandard mode l. The original
equipment warranty applies after a complete overhaul.
WARNING
SAFE COMPONENT SELECTION
1. Consid er the total sys tem design when select ing a component to ensure safe,
trouble-free performance.
2. The use r is responsible for assuri ng all safety and warning requirement s of the
application are met through his/her own analysis and testing.
3. TESCOM may sugge st material for use w ith specic media upon request.
Suggestions are based on technical compatibility resources through
associations and manufacturers. TESCOM does NOT guarantee materials to be
compatible with specic media — THIS IS T HE RESPONSIBILIT Y OF THE USER !
4. Component function, adequate ratings, proper installation, operation and
maintenance are the responsibilities of the system user.
5. The user is responsib le to be in accordance with all the necessary mechani cal
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 use r is responsible for the sel ection of the proper mo del number of the
controller that would meet the application’s possible hazardous environment
or conditions.
WARNING
Do not mod ify equipme nt or add attachments n ot approved by
the manufacturer.
ER5000 — 6Safety, Installation & Operations Precautions
TESCOM™ REGULATORS
WARNING
DO NOT ATTEMPT TO SELECT, INSTALL, USE OR MAINTAIN THIS
REGUL ATOR, VALVE OR ACCESSORY UNTIL YOU HAVE RE AD 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 SE RVICE REQUIR ES SPECIAL EX PERTISE AND K NOWLEDGE OF SY STEM
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. Inspe ct the regulat or, valve and accessories before each us e.
2. Never co nnect regulators, v alves or accesso ries to a supply source hav ing a
pressure greate r than the maximum rated pressure o f the regulator, val ve
or accessory.
3. Refer to produc t label (model specic) for max imum inlet pres sures. If this
rated pr essure cannot b e found, contac t your local TE SCOM represent ative for
the rate d pressure pri or to installation and use. Verify the design ed pressure
rating of all equipment (e.g., supp ly lines, tt ings, connections, lters, v alves,
gauges, etc.) in your sy stem. All must be capable of handling the supp ly and
operating pressure.
4. Clear ly establish ow direc tion of the uid b efore install ation of regulators,
valves and accessories. I t is the responsib ility of the user to install the
equipment in the correct direction.
5. Remove pressure from the s ystem before t ightening t tings, gauges
or components.
6. Never t urn regulator o r valve body. Instead hold re gulator or valve body and
turn t ting nut.
7. If a regulator or v alve leaks or mal functions, take it out of serv ice immediately.
8. Do not mo dify equipm ent or add atta chments not app roved by
the manufacturer.
9. Appl y pressure to the s ystem gradual ly, avoiding a sudden surge of ui d or
pressure shock to the equipment in th e system.
ER5000 — 7Safety, Installation & Operations Precautions
10. Reg ulators are not shut-of f devices. Inst all a pressure relief device downstream
of the regulator to protec t the process eq uipment from overpressure
conditions. Shu t off the supply pressur e when the regulator is not in use.
11. Periodic inspection and scheduled maintenance of your equipment is required
for continued safe operation.
12. Th e frequency of serv icing is the resp onsibility of the user based on
the application.
13. Ne ver allow problems or lack of maintenance to go unr eported.
14. Read and follow precautions on compressed gas cylinder labels.
15. It is impor tant that you analyze all aspects of your application and review
all available information concer ning the product or system. Obt ain, read
and understand the Material Safety Dat a Sheet (MSDS) for each uid used in
your system.
16. Ne ver use materials for regulators, valves or a ccessories that are not
compatible wit h the uids being used.
17. User s must test components for mater ial compatibili ty with the system
operat ing conditions prior to use in the system.
18. Vent u ids to a safe environment an d in an area away from employe es. Be sure
that vent ing and disposal m ethods are in acco rdance with Fed eral, State and
Local requirements. L ocate and const ruct vent line s to prevent condensation
or gas accumulatio n. Make sure the vent o utlet is not obst ructed by rain, snow,
ice, vegetation, insects, birds, etc. Do not interconnect vent lines; use separate
lines if m ore than one vent is n eeded.
19. Do not locate reg ulators, valves or acces sories contro lling ammable uids near
open am es or any other sour ce of ignition. Use of Hazard ous Location co ntrollers
may be necessar y to be in accordance with lo cal electri c
codes.
20. So me uids when bur ning do not exhibit a visib le ame. Use ext reme caution
when inspecting and/or ser vicing sys tems using ammab le uids to avoid
death or serious injury t o employees. Provide a device to warn employ ees of
these dangerous conditions.
21. Many gases can cause suf focation. M ake certain the area is well ventilat ed.
Provide a device to warn employees of lack of Ox ygen.
22. Ne ver use oil or grease on these r egulators, valves or ac cessories. Oil and greas e
are easil y ignited and may co mbine violent ly with some uids under pressure.
23. Have emergency equ ipment in the area if toxic or ammable uids are used.
24. Up stream lters are reco mmended for use w ith all uids.
25. Do n ot bleed system by loose ning ttings.
26. Pr event icing of the e quipment by removing excess mois ture from the gas.
27. Always use proper t hread lubrica nts and sealant s on tapered pipe threads.
ER5000 — 8Safety, 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 e lectrical codes and f ire and
safet y standards, t o determine if you r application w ill require a Hazardou s
Location model.
CAUTION
Do not open packaging until ready for installation or in a clean environment. Product
is clean ed in accordan ce with CGA 4.1 and AST M G93, Verificat ion Type 1, Test 1 and
Test 2. With p eriodic veri fication of c leaning pro cess to MIL-STD-1330D.
WARNING
Make sure t hat the compone nts and materia ls used in the fluid handl ing
system a re compatible w ith the fluid an d have the proper pr essure rating .
Failure to d o so can result in death, serious inj ury and/or prope rty damage.
Inspect the regulator, valve and accessories for physical damage and contamination.
Do not con nect the regu lator, valve or acces sory if you de tect oil, grea se or damaged
part s. If the regul ator, valve or access ory is damage d, contact yo ur local TESCO M™
representative to have the regulator cleaned or repaired.
REPAIR SERVICE
If a regulator or va lve leaks or malf unctions, t ake it out of serv ice immediately.
You must have instruc tions before doing any maintenance. Do not make any
repair s you do not under stand. Have qual ied personnel make repairs. Re turn any
equipm ent in need of ser vice to your equipment supplier for evaluat ion and prompt
serv ice. Equipment is r estored to the original f actory performance spe cications,
if repai rable. There are at fee repair charg es for each standard mode l. The original
equipment warranty applies after a complete overhaul.
CAUTION
PROPER COMPONENT SELECTION
1. Consid er the total sys tem design when select ing a component fo r use in
a system.
2. The use r is responsible for assuri ng all safety and warning requirement s of the
application are met through his/her own analysis and testing.
3. TESCO M may suggest material for us e with specic m edia upon request.
Suggestions are based on technical compatibility resources through
associations an d manufactur ers. TESCOM do es NOT guarantee materials to be
compatible wit h specic media - - THIS IS THE RESPONSIBILIT Y OF THE USER!
4. Component function, adequate ratings, proper installation, operation and
maintenance are the responsibilities of the system user.
WARNING
Do not mod ify equipme nt or add attachments n ot approved by the
manufacture r. Fai lure to do so can re sult in death, serious inj ury and/or
property damage.
table of contentS
9
ER5000 — 10Table of Contents
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
Install the ERTune
Connect pressure to the system . . . . . . . . 73
Start up and tune the system . . . . . . . . . 75
(not supplied with ER5050) 71
™
program . . . . . . . . . 72
Installation Variations 76
Before You Begin . . . . . . . . . . . . . . . 77
ER5000 Installation Variations —
Wiring Diagrams . . . . . . . . . . . . . . . 78
Terminal Blocks and Wires . . . . . . . . . . 79
ER5000 — 11Table of Contents
Voltage/Current Select Jumpers . . . . . . . 80
LED Indicators . . . . . . . . . . . . . . . . 81
Power Supply Wiring — All Applications . . . 82
Setpoint Wiring Variations . . . . . . . . . . 83
Analog Setpoint Source — Potentiometer 83
Analog Setpoint Source — Current/Voltage 84
Analog Setpoint Source —
Passive PC or PLC D/A Card 85
Analog Setpoint Source —
Active PC or PLC D/A Card 86
Prole with External Control/Digital Inputs 87
Digital Setpoint Source — RS485 Connection,
RS232 to RS485 Converter
(TESCOM™ Model #85061) 89
Digital Setpoint Source — RS485 Connection,
USB to RS485 Converter
(TESCOM Model #82948) 90
Digital Setpoint Source — RS485 Network,
RS232 to RS485 Converter
(TESCOM Model #85061) 91
Digital Setpoint Source — RS485 Network,
USB to RS485 Converter
(TESCOM Model #82948) 93
Feedback Wiring Variations . . . . . . . . . . 95
Two Wire Transducer 95
Three Wire Transducer 96
Four Wire Transducer 97
4–20 mA External Feedback, Floating Input,
Feedback Signal Monitored by PC or PLC A/D Card 98
4–20 mA External Feedback, Ground
Referenced Input, Feedback Signal Monitored
by PC or PLC A/D Card 99
Two Wire Transducer, PC or PLC A/D Card
Used to Monitor Voltage Produced by the
4–20 mA External Feedback 100
Three Wire Transducer, PC or PLC A/D Card
Used to Monitor Voltage Produced by the
4–20 mA External Feedback 101
Four
Wire Transducer, PC or PLC A/D Card Used
to Monitor Voltage Produced by the 4–20 mA
External Feedback 102
Switch Feedback Control to a Second
Feedback Source 103
Wiring Variations for
Additional Functions . . . . . . . . . . . . . 104
Monitoring Additional Analog Inputs 104
Monitoring the ER5000’s Internal Sensor
Using the Analog Output, 4–20 mA Wiring 105
Monitoring the ER5000’s Internal Sensor
Using the Analog Output, 0–10V Wiring 106
Digital Outputs 107
Suspend Mode 109
Installing a Hazardous Location
Model (ER5050) . . . . . . . . . . . . . . . 110
The ERTune™ Program 111
ER5000 Software
Development Support 196
ER5000 Communication Requirements . . . . 197
ER5000 Software Development Support . . .197
Windows Programming Examples . . . . . .198
Accessing the Windows DLL File . . . . . . .199
The TESCOM Protocol . . . . . . . . . . . . . 200
Troubleshooting 202
Installation . . . . . . . . . . . . . . . . . . 203
Operation . . . . . . . . . . . . . . . . . .206
RS485 Communication . . . . . . . . . . . . 216
Using Profiles to Control the ER5000 . . . . . 217
Internal Variables 221
Table of ER5000 Internal Variables . . . . . .222
ER5000 Internal Variables . . . . . . . . . . 225
ER5000 Setpoint and Feedback Variables 225
ER5000 Conguration Variables 226
ER5000 Inner Loop Tuning Var iables 227
ER5000 Outer Loop Tuning Variables 228
ER5000 Analog Input Variables 229
ER5000 Pressure Prole Variables 230
ER5000 — 12Table of Contents
ER5000 Single “Puff” Solenoid
Control Variable 231
ER5000 Pulse Mode Variables 231
ER5000 Analog and Digital Output Variables 232
ER5000 Pulse Width Modulation (PWM)
Control Variables 233
ER5000 Gain/Offset Variables 234
ER5000 Control Limit Variables 235
Control Limits for Specied Signals 235
Certifications and Warranty 236
Certifications . . . . . . . . . . . . . . . . . 237
Hazardous Locations Special Requirements
and Certifications for the ER5050 . . . . . . . 238
LIMITED WARRANTY . . . . . . . . . . . . . 240
Appendix A: Setting up the
ERTune
™
Program on
Windows 8 PCs 241
Installing the .NET Framework 3.5 . . . . . .242
Installing the ER5000 Device Driver . . . . . . 244
ER5000 — 13Table of Contents
NOTENOTE
IMPORTANT
!
IMPORTANT
!
Conventions of This Manual
refer to
page 41
Click the Add
Variable button
CAUTION
WARNING
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reference. Clicking this text moves you to the referenced page
in the manual. After reading the referenced material, you can
return to your original page by clicking the BACK button at the
bottom of the page.
Cross references link to gures, tables and section headings.
Also, words which are described in the Glossary are cross
referenced to their Glossary description the rst time they
appear in the body text.
Text formatted as gray and narrow denotes a part of the
user interface, either of the Windows operating system or
the ERTune™ program. This includes menu items, buttons,
windows, screens, commands and onscreen instructions.
Paragraphs highlighted by the NOTE icon contain information
that should be given particular attention.
Paragraphs highlighted by the IMPORTANT! icon contain
information that references specic requirements of your
operating system.
Paragraphs highlighted by the CAUTION icon contain
information that must be followed to maintain a safe and
successful operating environment.
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.
Navigating This Manual
Clicking any item in the Table of Contents moves you to that page
in the manual.
You can also open the Bookmarks panel at any time to access an
interactive set of links based on the Table of Contents.
Clicking the PREVIOUS button moves you to the previous
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featureS and
pecIfIcatIonS
S
14
ER5000 Series — 15Features and Specications
IMPORTANT
!
IMPORTANT
!
ER5000 Series Part Numbering System
As Figure 1 indicates, several base styles are available, including a
compact OEM model for tight spaces where the NEMA 4 enclosure
isn’t needed. Please consult with your TESCOM™ representative
for special modications or requirements.
ER5 XX X X X – X
Base Style
00 Standard NEMA 4X
02 Integrated Double Piston*
04 OEM Style (No Cover)*
05 Hazardous Location Enclosure**
10 Integrated with 44-4000*
11 Integrated with 44-5200*
Internal Sensor Configuration
0 0–100 psig, 0.1% Accuracy
* Contac t the fac tory for dimensions and spe cications of these ER50 00 Series models.
** Click this link to view all Hazardous Location certications for ER5050 model.
Figure 1: Breakdown of the ER5000 Part Number
Feature s
S Standard Features
F Enhanced Features
Cv Configuration
1 Standard Valves, Cv = 0.01
Analog Signal Type
I 4–20 mA / 1–5V DC
V 0–10V DC
ER5000 Standard Features
• USB and RS485 communications
• USB cable with integrated strain relief***
• 1/8" NPTF Inlet and Exhaust Ports
• 1/2" SAE controlled Outlet Port
• Adaptor tting 1/2" SAE x 1/8" NPTF
• Maximum inlet pressure = 120 psig / 8.2 bar***
• 0–100 psig / 0–6.9 bar internal sensor
™
• ERTune
Windows 8
with previous Windows operating systems, the ERTune™ program uses
the .NET Framework 3.5, which is not installed by default in Windows
8. If you are using Windows 8, you will need to download and install
.NET Framework 3.5 before installing the ERTune™ program. You may
also need to disable Driver Signature Enforcement to install the ER5000
driver. We have provided step-by-step instructions for both these task s
in Appendix A: Setting up the ERTune™ Program on Windows 8 PCs.
*** These fe atures do not app ly to ER5050 Haza rdous Locati on model.
program for Windows XP, VISTA, Windows 7 and
Windows 8 users: In order to maintain compatibility
ER5000 Series — 16Features and Specications
ER5000
Dimensions – Side Views
3.90
[99.0]
.98
[24.9]
1/2-14 NPTF
Conduit
Connection for
USB Wiring
.54
[13.77]
Gauge Port
1/8–27 NPTF
.63
[16.0]
[13.77]
Contact the fac tory for dimensions and specications
of model s ER5020, ER5040, ER5100 and ER5110.
Refer to th e ER5000 Series Part Numbering System.
All dimensions are called out in
inches [millimeters]
1/2-14 NPTF
Conduit
Connection for
Internal Wiring
.54
Inlet Port
1/8–27 NPTF
Atmospheric
Reference for
Internal Sensor
.75
[19.0]
.93
[23.7]
.93
[23.7]
.75
[19.0]
4x
Exhaust Port
1/8–27 NPTF
Not Used
.87
[22.1]
Mounting
Holes
#10-32 UNF
.50 FULL THREAD
[M5 X 0.8
12.7 FULL THREAD]
(4 Places)
Not Used
.20
[5.1]
ER5000 Series — 17Features and Specications
ER5000
Dimensions – Top and Bottom View
3.72
[94.5]
ER5000 Series
Electropneumatic Controller
3.72
[94.5]
Bottom View
Top View
Contact the fac tory for dimensions and specications
of model s ER5020, ER5040, ER5100 and ER5110.
Refer to th e ER5000 Series Part Numbering System.
All dimensions are called out in
inches [millimeters]
Outlet Port
1/2 SAE (3/4-16 UNF)
1.86
[47.2]
ER5000 Series — 18Features and Specications
DO NOT REMOVE
4.09
[103.8]
1/8" NPTF Plug
Not Used
.98
[24.9]
1/2-14 NPTF
Conduit
Connection for
USB Wiring
ER5050 Hazardous Location Model
Contact the fac tory for dimensions and specications
of model s ER5020, ER5040, ER5100 and ER5110.
Refer to th e ER5000 Series Part Numbering System.
Gauge Port
1/8–27 NPTF
.43
[11.0]
.54 [13.77] .54 [13.77]
Dimensions – Side Views
External Ground
Atmospheric Reference
for Internal Sensor
CAUTION
Removal of ANY of the 1/8" NPTF
plugs called out on this page, other
than the Gauge Port plug, will
invalidate the Hazardous Location
certification for the ER5050.
1/2-14 NPTF
Conduit
Connection for
Internal Wiring
All dimensions are called out in
inches [millimeters]
Inlet Port
1/8–27 NPTF
.75
[19.0]
.93
[23.7]
.75 [19.0] (4x)
.93
[23.7]
Exhaust Port
1/8–27 NPTF
.83
1/8" NPTF Plug – Not Used
DO NOT REMOVE
[22.0]
Mounting
#10-32 UNF
.50 FULL THREAD
[M5 X 0.8
12.7 FULL THREAD]
(4 Places)
1/8" NPTF Plug
Not Used
DO NOT REMOVE
Holes
.20
[5.1]
ER5000 Series — 19Features and Specications
ER5050 Hazardous Location Model
Dimensions – Top and Bottom View
3.72
[94.5]
3.72
[94.5]
Bottom View
Top View
Cover Lock Screw
1.86
[47.2]
Contact the fac tory for dimensions and specications
of model s ER5020, ER5040, ER5100 and ER5110.
Refer to th e ER5000 Series Part Numbering System.
All dimensions are called out in
inches [millimeters]
Outlet Port
1/2 SAE (3/4-16 UNF)
ER5000 Series — 20Features and Specications
NOTENOTE
ER 5000 Specifications
Contact the factor y for dimensions and specications of models ER5020, ER5040, ER5100 and ER5110. Refer to the ER5000 Series Par t Numbering System.
Enclosure
Type 4X, IP66. If the two 1/2-14 NPTF ports are unused, properly
seal with a plug.
CE Approved Wiring Instructions
Use shielded, twisted pair cable.
Weight
3.1 lbs / 1.4 kg
Media
Supply pressure must be clean, dry inert gas or instrument grade
air that meets the requirements of ISA Standard 7.0.01. Use of an
in-line lter that meets the requirements of ISA standard 7.0.01
and is less than 40 microns and as small as 10 microns, is highly
recommended to prevent damage to the solenoid valves. Moisture
should be kept to a minimum.
Ports
Conduit: 1/2" NPTF
Pneumatic: 1/8" NPTF — Inlet, Exhaust and Gauge Ports
1/2" SAE — Controlled Outlet Port
Power Requirement
Voltage: 24V DC (22V DC to 28V DC)
Current: 340 mA max, 180 mA nominal
Environment
Temperature: -30°C to 75°C (dry Nitrogen supply gas)
Pressure: 28" to 32
Humidity: To 100% R.H. (non-condensing) @ 0°C to 75°C.
Inlet Pressure
Minimum: Outlet pressure + 1 psig
Maximum: 120 psig / 8.2 bar
Typical: 110 psig / 7.5 bar
Sensor Update Rate
25ms (rate of sensor reading and processing task)
USB Communication Interface
USB: 2.0
Maximum cable length: 15 ft / 4.5 m
Connector: Mini-B
5°C to 75°C (shop air)
" Hg / 71 mm to 762 mm Hg
Response time is affected by input pressure.
ER5000 Series — 21Features and Specications
NOTENOTE
NOTENOTE
ER 5000 Specifications (cont.)
RS485 Communication Interface
Networking: Up to 32 controllers on one network
Maximum cable length: 4000 ft / 1219 m
Baud rate: 9600
Flow Rate
Cv: 0.01
The ow rate can be increased using a booster regulator.
Accuracy
Room temp: 0.1% of span maximum
Response Time
Rise Time: 257ms — 10 psig to 90 psig / 0.7 bar to 6.2 bar
Fall Time: 552ms — 90 psig to 10 psig / 6.2 bar to 0.7 bar
Step response into dead-end system (1 cubic inch volume).
External Analog Input Impedance
4–20 mA: 250Ω
1–5V: 220KΩ — single input pin to ground
1.7MΩ — differential input
0–10V: 100K Ω
Digital Inputs
Voltage Range/Input Impedance:
4–20 mA: 250Ω
1–5V: 220KΩ — single input pin to ground
1.7MΩ — differential input
0–10V: 100KΩ
Digital Outputs
Current: 50 mA continuous, 100 mA instantaneous
Voltage: 5V to 28V
Type: Open collector, grounded emitter
Analog Output
4–20 mA: Better than 0.5% accuracy;
loads from 50Ω to 1000Ω
0–10V DC: Better than 0.5% accuracy;
loads no less than 5000Ω
ER5000 Series — 22Features and Specications
NOTENOTE
Hazardous Location Model (ER5050) Specifications
Certifications
Refer to Hazardous Locations Special Requirements and Certication
for the ER5050 for a complete list of hazardous location certications.
Enclosure
Type 4X/IP66. If the two 1/2-14 NPTF ports are unused, properly
seal with a metal plug.
CE Approved Wiring Instructions
Use shielded, twisted pair cable. Use rigid metal conduit to
enclose the wiring entering the ER5050 when required per local
electrical code.
Weight
2.6 lbs / 1.2 kg
Media
Supply pressure must be clean, dry inert gas or instrument grade
air that meets the requirements of ISA Standard 7.0.01. Use of
an in-line lter that meets the requirements of ISA standard
7.0.01 and is less than 40 microns and as small as 10 microns, is
highly recommended to prevent damage to the solenoid valves.
Moisture should be kept to a minimum.
Ports
Conduit: 1/2" NPTF
Pneumatic: 1/8" NPTF — Inlet, Exhaust and Gauge Ports
Power Requirement
Voltage: 24V DC (22V DC to 28V DC)
Current: 340 mA max, 180 mA nominal
Environment
Temperature: -20°C to 60°C (dry Nitrogen supply gas)
Pressure: 28" to 32
Humidity: To 100% R.H. (non-condensing) @ 0°C to 60°C.
Inlet Pressure
Minimum: Outlet pressure + 1 psig
Maximum: 110 psig / 7.5 bar
Typical: 110 psig / 7.5 bar
Sensor Update Rate
25ms (rate of sensor reading and processing task)
1/2" SAE — Controlled Outlet Port
5°C to 60°C (shop air)
" Hg / 71 mm to 762 mm Hg
Response time is affected by input pressure.
ER5000 Series — 23Features and Specications
NOTENOTE
NOTENOTE
NOTENOTE
Hazardous Location Model (ER5050) Specifications (cont.)
USB Communication Interface
USB: 2.0
Maximum cable length: 15 ft / 4.5 m
Connector: Mini-B
Due to var ying hazardous location wiring requirements, a USB
cable is not included with the ER5050.
RS485 Communication Interface
Networking: Up to 32 controllers on one network
Maximum cable length: 4000 ft / 1219 m
Baud rate: 9600
Flow Rate
Cv: 0.01
The ow rate can be increased using a booster regulator.
Accuracy
Room temp: 0.1% of span maximum
Response Time
Rise Time: 257ms — 10 psig to 90 psig / 0.7 bar to 6.2 bar
Fall Time: 552ms — 90 psig to 10 psig / 6.2 bar to 0.7 bar
Step response into dead-end system (1 cubic inch volume).
External Analog Input Impedance
4–20 mA: 250Ω
1–5V: 220KΩ — single input pin to ground
1.7MΩ — differential input
0–10V: 100KΩ
Digital Inputs
Voltage Range/Input Impedance:
4–20 mA: 250Ω
1–5V: 220KΩ — single input pin to ground
1.7MΩ — differential input
0–10V: 100KΩ
Digital Outputs
Current: 50 mA continuous, 100 mA instantaneous
Voltage: 5V to 28V
Type: Open collector, grounded emitter
Analog Output
4–20 mA: Better than 0.5% accuracy;
loads from 50Ω to 1000Ω
0–10V DC: Better than 0.5% accuracy;
loads no less than 5000Ω
ER5000 Series — 24Features and Specications
Accessories
Part # Description
80129 1/8" NPTF male tube connector
82575-25
82575-50
82919
82948
85061
85121
ERSA04539 20-wire, shielded, twisted pair cable assembly — 24" / 61 cm Included with “F” model ER5000s
85138-X 12-wire, shielded, twisted pair cable assembly — 5, 10, 20, 50 and 100 ft / 1.5, 3, 6, 15 and 30 m options
ERSA04539-X 20-wire, shielded, twisted pair cable assembly — 5, 10 and 20 ft / 1.5, 3 and 6 m options
85145 Filter kit
ERAA03458-02 Adaptor tting 1/2" SAE x 1/8" NPTF — mates ER5000 to most TESCOM™ air actuated regulators Included with all standard ER5000s
ERAA03458-04 1/2" SAE X 1/4" NPTF
ERAA03409 USB Cable with Mini-B connector Included with all standard ER5000s NOT for use with ER5050s
ERAA05146 MTA Connector Replacement Kit
250 mA / 24V DC power supply — input voltage 120V AC, 60 Hz
500 mA / 24V DC power supply — input voltage 120V AC, 60 Hz
Potentiometer with digital display
USB to RS485 converter
RS232 to RS485 converter
12-wire, shielded, twisted pair cable assembly — 24" / 61 cm Included with all standard ER5000s
What’S neW
25
ER5000 — 26What’s New
New Features
• Built-in USB connectivity
• Improved resolution for data acquisition with 16-bit A/D
converter
• For “F” model ER5000s, single 20-wire cable replaces separate
12-wire and 8-wire cables
• Suspend Control, a new operational mode available on
“F” models, gives you the ability to lock output at a stable
pressure over an extended period of time for operations, such
as sensor calibration, where system stability is critical.
• The
ERTune™
advantage of the Windows graphic user interface, with a
single, unied operating environment and quick, tab-based
access to all functions. Other enhancements include:
> Setup Wizard and COM Port Search speed up installation.
> The Tuning Tab now features highly responsive sliders,
with optimal ranges for all congurable parameters clearly
displayed in the interface.
> Data acquisition can now be triggered automatically
by system events such as digital input detection or a
monitored variable reaching a target value.
program has been upgraded to take full
> Proles can now include up to 100 command segments. Loop
counts are now displayed in real time.
> For “F” model ER5000s, Proles can now include these new
commands:
Soak, which waits until feedback indicates a new setpoint
has been reached before initiating a Dwell.
If and Goto, which allow you to create complex branching
command sequences that respond to real-time operating
conditions and inputs.
> The Diagnostic Tools Tab now gives you one-click access to
tuning and troubleshooting recommendations.
> The Automated Solenoid Leak Test gives you a quick,
intuitive and accurate assessment of the controller’s
solenoid valves.
> Regulator Diaphragm Protection is a new feature that gives
an added layer of protection for applications where rapidly
changing ow demands put undue stress on the sensing
element of diaphragm sensed regulators, particularly those
with metal diaphragms.
ER5000 — 27What’s New
!
!
Replacing an ER3000 with an ER5000
IMPORTANT
IMPORTANT
WARNING
Safety standards are subject to continual revision. 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, before replacing a controller in a hazardous location.
Click this link to view all Hazardous Location certifications and
specifications.
Wiring for the Standard Model ER5000
The wiring for the 12-pin MTA connector is the same for the
ER5000SI-1 as it was for the ER3000SI-1. An MTA connector
replacement kit is available to allow use of the existing installation
cable with the new ER5000.
Reference current Hazardous Location
standards when replacing a Hazardous Location
ER3000 with an ER5050.
Wiring for the “F” Model ER5000
For “F” model ER5000s, the 12-pin MTA connector and 8-pin
auxiliary MTA connector, which were previously fed by separate
cables, are now fed by a single 20-wire cable. All wires feeding the
8-pin connector are color striped to distinguish them visually from
the solid color wires feeding the 12-pin connector. Refer to
Figure 18 to see all wire colors and pin terminations.
The function of the green/white wire (J4 Pin 5), which was
previously the Analog Signal Ground, has changed: it now
activates the Suspend Control function, which closes both valves
and locks the controller at the current pressure. If your current
application makes use of this wire, refer to the Installation
Variations section for recommended wiring congurations.
For standard model ER5000s, there are two wires which act
as signal/board grounds: the black wire (J3 Pin 10) and the tan
wire (J3 Pin 12).
For “F” model ER5000s, the black/white wire (J4 Pin 6) also acts as
signal/board ground.
ER5000 — 28What’s New
NOTENOTE
Using the ER5000 with ER3000 software
If you wish to continue using the Windows Tune or other soft ware
that controlled your ER3000, you must install Jumper J9 to put
the ER5000 into ER3000 Mode (refer to Figure 19). The ER5000
uses a 16-bit A/D converter to translate analog input signals into
the digital language the microprocessor understands, while
the ER3000 uses a 12-bit converter. In order for the ER5000 to
correctly interpret the signals generated by a program written for
the ER3000, it must use a 12-bit scale.
Installing the ER3000 Mode Jumper will also turn off the new
Suspend Control feature, as well as the new Prole commands.
UI3000 or UI4000
The ER5000 is NOT compatible with either the UI3000 or
the UI4000.
hoW It
W
orkS
29
ER5000 — 30How It Works
The ER5000: How It Works
The ER5000 (Electronic Regulator 5000) is a microprocessor-based
PID (Proportional, Integral, Derivative) controller that brings precise
algorithmic pressure control to a wide range of applications.
It can be used as a standalone unit to control the pressure of clean,
dry inert gases from 0–100 psig / 0–6.9 bar or be connected to any
pneumatically actuated regulator or valve. Used with TESCOM™
regulators, the ER5000 provides distributed pressure control of
gases and liquids from vacuum to 30,000 psig / 2068 bar, with a Cv
of up to 12.
The ER5000 can be controlled from any PC via a direct USB or
RS485 connection. The ER5000 also accepts analog setpoint
signals from 4–20 mA, 1–5V or 0–10V analog sources, such as
from a PC or PLC D/A card. The ER5000 can be wired to allow for
multiple input/output congurations and daisychaining of up to 32
controllers within the same RS485 network.
The ER5000 senses pressure using either its internal sensor or an
external transducer (4–20 mA, 1–5V or 0–10V) placed within the
actual process line. You can operate the ER5000 in one of three
control modes:
• Internal Feedback, which uses only the internal sensor
• External Feedback, which uses only the external source;
• Cascade, which uses both internal and external sources in a
“loop within a loop” conguration.
During setup, you can download PID settings that have been
programmed by TESCOM to meet the needs of most commercial
applications. The included ERTune™ program provides an intuitive
interface to customize the performance parameters of the ER5000
by directly tuning the Proportional, Integral and Derivative values.
Using the ERTune™ program, you can create Proles, which guide
the ER5000 through command sequences that may include
multiple setpoint changes, precisely timed digital inputs and
outputs and modication of response characteristics and other
internal variables based on real-time operational conditions.
The ER5000 installs in just minutes, yet provides the precision,
dependability and exibility to meet the needs of the most
demanding user.
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