ER5K Kits - Welcome to Emerson Process Management
Contents
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3. JA Terminal Pins J3 Terminal Pins F models only cu 5 ar zu 3 Figure 9 General Wiring Section 6 Wiring 14 Section 6 Wiring September 2015 6 2 15 Junction Box Wiring ER5K Kits DOPSM2095X012 Table 4 Prewired Power Connectioi ns Junction Box Terminal Wire ER5000 Transducer Function 3 114A braided transducer power ground from transducer 100C red transducer 100C violet 24V DC power to transducer 24V DC power to ER5000 5 5 6 101A gray 24V return power ground from ER5000 Table 5 Prewired Feedback Connections Junction Box Terminal Wire ER5000 Transducer Function 9 114 black transducer feedback input from transducer 9 1148 orange feedback input to ER5000 10 114C yellow 15 116 tan 5000 Table 6 Power Connections Required for Operation Junction Box Terminal Wire from 120V Source 1 line feed neutral feed ground Table 7 Connections to Access Additional Functions Junction Box Terminal Wire ER5000 Function 7 113 brown setpoint input 8 113A red setpoint input 11 118 blue RS485 network connection 12 117 RS485 network connection 13 118A pink analog signal output 14 115 black analog signal board ground 16 117A white 5V output 5 mA max
4. Always wear protective clothing gloves and eyewear to prevent personal injury or property damage Donotremove the ER5000 or any other component of the system while the system is pressurized Disconnect any operating lines providing air pressure electric power or a control signal to the ER5000 prior to installation or maintenance A Usebypass valves or completely shut off the process to isolate the ER5000 and associated equipment from process pressure prior to installation or maintenance Relieve process pressure on both sides of the controller and associated equipment Uselock out procedures to sure that the above measures stay effect while you work on the equipment Check with your process or safety engineer for any additional measures that must be taken to protect against process media dangers Do not install operate or maintain ER5000 controller or any associated equipment without reading and fully understanding the installation guidelines and operating instructions for every component of your application To avoid personal injury or property damage it is important to carefully read understand and follow all contents of this Getting Started guide including all safety cautions and warnings If you have any questions about these instructions contact your TESCOM sales office before proceeding Safety Installation and Operations Precautions TESCOM Electronic Controllers AWARNING D
5. ML 3215 Le 04 131110 JIE N NOLIV 014100 TviM3ivi4 50009 1405 III 11571 II 31891 j 531435 Tem DNJA 5 SWIC Figure 16 54 2100 Series Regulator Section 8 Drawings 25 Drawings Section 8 ER5K Kits September 2015 DOPSM2095X012 Back Pressure Regulator 26 1700 Series 6 3 5 155 51445 00 318 1 21891 3715 140d 191100 LIN 140d 131100 SIGANN NOI IHIGOW v 0 dil NUN 340 Sl vd 315 NOTI dN JT vl 33 5 m ON 5 E zm 5 0 531035 JON3U333H TAEA Figure 17 26 1700 Series Regulator 26 Section 8 Drawings ER5K Kits DOPSM2095X012 Drawings Section 8 September 2015 Control Air Regulator 44 5200 Series 8 3 6
6. 17 120 brown white aux input 1 18 120A red black aux input 1 19 121 orange black aux input 2 20 121A yellow black aux input 2 21 122A green white suspend control 22 123A black white digital output board ground 23 122 blue white digital output 1 24 123 gray black digital output 2 Section 6 Wiring ER5K Kits DOPSM2095X01 Section 7 Maintenance 2 September 2015 Section 7 Maintenance Section 7 Maintenance The maintenance and repair of pressure equipment must only be performed by trained personnel Since every application exists under different conditions the user is responsible for establishing a maintenance program based on their unique situation Until enough data is collected to set up a schedule we recommend a 6 to 12 month check of the following however more frequent inspection and or maintenance may be necessary 1 Visual check for damages especial of the tubing electrical components and cables 2 Functional check 3 Check for leaks A periodic calibration of the feedback pressure transducer depends on the user s requirements Tescom recommends a yearly calibration 16 Section 8 Drawings September 2015 ER5K Kits DOPSM2095X012 Section 8 Drawings The drawings in this manual are for reference only For most up to date drawings please contact your local TESCOM representative 8 1 100 101 102 103 104 105 106 107 108 109 110 111 112 17
7. Junction Box Supply Voltage AC 100 250V 3 Junction Box Communication USB and RS 485 4 Regulator for ER Supply 44 5212 241V 003 5 Pressure can be transformed according to the equition 1 MPa 10 bar 145 psig 19 Section 8 Drawings ER5K Kits Section 8 Drawings DOPSM2095X012 September 2015 All dimensions are reference amp nominal Metric millimeter equivalents are in brackets ER5000FI 1 JUNCTION BOX WIRING PANEL GAUGE 3 REGULATOR M FOR SUPPLY TESCOM 44 5212 241V 003 9 8 8 RELIEF VALVE REGULATOR Pressure Reducing or Back Pressure 26 2000 Series shown 5 TRANSDUCER 23 2 589 3 0 Section 8 Drawings L p 9 O E BOTTOM VIEW Figure 11 ER5K Series Kit Assembled on Plate 20 Section 8 Drawings ER5K Kits September 2015 DOPSM2095X012 All dimensions are reference amp nominal Metric millimeter equivalents are in brackets ER5000FI 1 ENCLOSURE GAUGE JUNCTION BOX WIRING Z 2 REGULATOR X lo FOR ER SUPPLY 44 5212 241V 003 5 RE
8. NNVAHOSHIH SNOIIOSNNOO TVOINIOWTS um UIVNOIS 104100 5 TINA 1 0 1 1458 XOWHDOOV 3n 33 9 MDD 1 39NVd aufisSdud IAdLNO NADIE 681 AlddNS 2 NOILO3NNOO9 390Hd 5 8 1 6 819 318VL WOH4 5 0108 35 1 4 JIWW LdN 2 1 8 OONIWV 81 91 6 9 31VN 1dN a t SNOII93NNOD 55392094 3unssaud 3111089 vISd JYNSSAYd 35vn9 9189 0009 9154 0009 0 00009 9154 00009 0 0009 9154 0009 0 009 9ISd 009 0 SL 9ISd 91 0 VOOE VISdOOE 0 00008 9154 00009 0 0006 9154 0007 0 00 9154 006 0 01 54 01 0 17000 154000 0 0000 9ISd 00007 0 0006 9154 0006 0 006 9154 006 0 s 91 9 0 06 06 DISd 051 06 VOSL VISdOSI O 00006 9ISd 00006 0 0006 9ISd 0008 0 00 9ISd 002 0 154 6 0 001 0 9ISd 001 0 VOOL VISd00L 0 00002 9154 00002 0 0001 9159 0001 0 051 9154 05 0 918 2 0 09 0 9159 09 06 09 VISd09 0 00091 9154 00091 0 008 9154 008 04 001 9154 001 0 00 0 9159 00 06 06 06 51 06 0 vOe VISdOE 0 00001 5159 00001 0 0S4 9ISd 094 0 09 9OISd 09 0 006 06 9154 006 08 61 06 9189 61 06 S39NVH VSL VISdSI O 0092 9OISd 005 0 009 9ISd 009 0 0 OISd 06 0 002 06 9 ISd 002 06 AOE 9VA OE O 39155394 SNOILdO SL9 S3IH3S 318V1 619 Figure 20 615 Series Transducer Drawings Section 8 29 ER5K Kits Section 8 Drawings DOPSM2095X012 September 2015 8 4 2 Transducer D51656 NB XXX Metric V
9. 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 Neveruse anything but clean dry inert gases or air into the electropneumatic controller 8 Startup sequence for electropneumatic controllers is a Feedbackloop 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 Referto product label modification specific 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 fittings connections filters valves gauges etc in your system All must be capable of handling the supply and operating pressure 10 Clearly establish flow direction of the fluid 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 fittings gauges or components 12 Neverturn controller regulator or valve body Instead hold the controller body and turn fitting nut 13 Ifacontroller regula
10. 06 27 4 oj 0 79 20 0 12 3 012 A del 00 24 6 1 12 28 5 All dimensions are reference amp nominal Metric millimeter equivalents are in brackets G1 2B Electrical Connection L connector DIN 175301 803 A 2 wire 0 1 U 2 3 wire U 1 U 2 5 3 Cable screen Wire gauge up to max 1 5 mm2 Diameter of cable 6 to 8 mm ship approval 10 to 14 mm Ingress protection per IEC 60 529 IP65 Figure 21 D51656 NB XXX Transducer 31 Section 8 Drawings ER5K Kits Notes DOPSM2095X012 September 2015 For Your Own Notes Notes 32 Emerson Process Management Regulator Technologies Inc TESCOM AMERICAS 12616 Industrial Blvd Elk River MN 55330 USA T 1800447 1250 1 763 241 3238 F 1 763 241 3224 na tescom emerson com www tescom com EUROPE An der Trave 23 25 23923 Selmsdorf Germany T 49 0 388 23 31 287 F 49 0 3 88 23 31 140 eu tescom emerson com www tescom europe com Brandon House 23 25 Brandon Street Hamilton ML3 6DA South Lanarkshire UK 44 1698 424 254 F 44 1698 459 299 uk tescom emerson com www tescom com TESCOM ASIA PACIFIC 3 F Building 2 No 1277 Xin Jin Qiao Road Jingiao E P Z Pudong Shanghai 201206 China T 86 21 2892 9970 F 86 21 2892 9001 ap tescom emerson com www tescom com MIDDLE EAST amp AFRICA PO Box 17033 Jebel Ali Free Zone South Zone 2 Duba
11. 26 2100 1500 0 08 SST 15to 165 713 2 100 26 to 74 C L 26 2100 3000 0 08 SST 15 0 165 F 7 3 2 160 26to 74 26 2100 6000 0 08 SST 15to 165 713 2 400 26 to 74 C N 26 2100 10 000 0 08 SST 15to 165 F NA 713 2 600 10 000 690 26 to 74 C 26 1700 1500 0 14 SST 40to 165 F NA 7 3 2 100 40 to 74 C R 26 1700 3000 Cv 0 10 SST 40 to 165 F NA 7 3 2 160 40 to 74 C 5 26 1700 6000 0 10 SST 40to 165 F NA 7 3 2 400 40 to 74 C T 26 1700 10 000 Cv 0 10 SST 40to 165 F 7 3 2 690 40to 74 C Operating Parameters Process Pressure Electrical See specifications for Kit Regulator Type Power Requirrement Input Signals 90 264 VAC Setpoint USB 5485 4 20 mA 1 5 VDC 0 10 VDC for Supply Requirement ER5XX0XV 1 downloaded Profile Maximum Inlet Pressures ER5000 Maximum Supply Pressure Feedback external 120 psig 8 3 bar 4 20 mA or 1 5 VDC 0 10 VDC for 5 1 ER Supply Regulator Communication Protocol 3500 psig 241 bar USB and RS485 Section 4 Technical Data 10 Section 5 Installation ER5K Kits September 2015 DOPSM2095X012 Section 5 Installation 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 person
12. Electrical Drawing 24 VDC POWER SUPPLY PS100 FU100 100 1 2 101 NEUTRAL 3 102 D PE 100C from 100 24V 100C to 113 24V 100A 4 5 1008 Fut 100C 100C E to 104 24 VDC 24V 101A 101A to 104 COMMON COM 101A from 101 ICOM 101A to 113 COM Figure 10 Electrical Drawing Section 8 Drawings ER5K Kits DOPSM2095X012 113 114 115 116 117 118 119 120 121 122 123 124 125 Section 8 Drawings I 1 FOR P 7 D SETPOINT INPUT AUX N 21 23 D 06 OUT fii 1 06 OUT 2 113yBRN NI Ed ER 5 Section 8 Drawings Figure 10 Electrical Drawing continued September 2015 4 101A ULATOR from 112 0 8 COM RE 13M c SETPOINT INPUT L ANALOG SIGNAL BOARD GROUND 5 D ANALOG SIGNAL BOARD GROUND i 16 WHEN 117A 5V DC OUTPUT i 1 i 13 118A ANALOG SIGNAL OUTPUT i I 1 i 6 GRYN 101A p 24V RETURN POWER GROUND i I i 18 AUX IN fi i I i 20 121A AUX IN 2 I 1 i n 1 L SUSPEND I 1 i 2 1 DIGITAL OUTPUT BOARD GROUND Section 8 Drawings ER5K Kits September 2015 DOPSM2095X012 8 2 ER5K Kit Dr
13. General WINN u RE 14 Section 7 ci usapu 16 Section on DraWinNgS PERMET 17 8 1 Electrical Drawing 17 8 2 ER5K Kit Drawing 19 8 3 Regulator Drawings 22 8 3 1 Regulator Flow 22 8 3 2 Pressure Reducing Regulator DK 5 5 23 8 3 3 Pressure Reducing Regulator 26 2000 24 8 3 4 Hydraulic Back Pressure Regulator 54 2100 5 25 8 3 5 Back Pressure Regulator 26 1700 5 5 26 8 3 6 Control Air Regulator 44 5200 27 8 4 Pressure 28 Table of Contents i Section 1 Introduction ER5K Kits September 2015 DOPSM2095X012 Section 1 Introduction This manualis valid only for ER5K kits ER5K XXXX The instructions for individual components must also be read and followed and are either attached in the appendix or supplied separately Section 2 Before You Begin 2 1 2 1 1 This device is not intended for or rated for use in hazardous locations 1 Please contact your TESCOM representative for Explosion Proof options 2 Avoid personalinjury or property damage from sudden release of pressure or bursting parts Before proceeding with any installation procedures
14. Inn384 54 Figure 14 DK Series Regulator Section 8 Drawings 23 Drawings September 2015 Section 8 Oud AdAL AZIS 1804 ONY 3011094348 1 40 ONHV2 JENY 38 1SNW 03 1 HDIHA 1v 1935 211191 345 3511 possesses h 140d LN 23 43 7 3 1 1071531 m D tu A Diod 191000 LINI MD ON 300 AJ ALDvevO MOH usva EU sss z 13453 5 ti Waly vas 1 mam 1835 JATA 300 L 155 96 E d Wav agoel m ind SS TANK B ut Pressure Reducing Regulator 26 2000 Series ER5K Kits DOPSM2095X012 8 3 3 00 LLA 22 453 15 AIC TIN 24 Figure 15 26 200 Series Regulator Section 8 Drawings ER5K Kits DOPSM2095X012 Drawings Section 8 September 2015 ic Back Pressure Regulator 54 2100 Series Hydraul 8 3 4 ino N vL Ft
15. Instruction Manual DOPSM2095X012 September 2015 ER5K Kits TESCOM Product Manual A TESCOM EMERSON Process Management ER5K Kits Table of Contents DOPSM2095X012 September 2015 Contents Section Iz ita RR 1 Section 2 Before You Begin 1 2 1 Safety Installation and Operations Precautions 1 2 1 1 TESCOM Electronic Controllers 1 2 1 2 Installation 3 2 13 MESCOM Regulators 4 Section 3 Product Description 7 3 1 Kit Benefits kb ev ee rk REDDE RAS M E YER X KR RE kana 7 3 1 1 Very high pressure stability 7 34 2 Automation E erri nb SOS M 7 3 1 3 ERTune V a es 7 3 1 4 7 3 2 Regulator ERES YI 7 313 Controlling System 8 xr rer aeris Data MN 10 na 11 5 1 Two Mounting Types 11 5 2 System Leak 14 5 3 ER5000 Tuning 14 Section OF WING eer 14 6 1
16. LIEF VALVE 15 8 401 5 lt REGULATOR Pressure Reducing 8 8 or Back Pressure DK shown lc i TRANSDUCER 25 92 658 4 8 04 204 4 eO Figure 11 ER5K Series Kit Assembled on Plate continued BOTTOM VIEW Junction Box The Junction box is internally wired and includes an AC DC power converter fuses and wire terminal blocks mounted Power Unit 90 to 264 VAC ona DIN rail Footprint 7 9 x 7 9 200 x 200 Height 4 7 120 gt Analog Setpoint Q ER5000FI 1 Customer Supplied Transducer Digital Communication RS485 Figure 12 Junction Box 21 Section 8 Drawings ER5K Kits Section 8 Drawings September 2015 DOPSM2095X012 8 3 Regulator Drawings 8 3 1 Regulator Flow Booster Table 9 Pilot Operated Diaphragm Style Regulator Dimensions NUMBER INSTALLATION DIMENSIONS 269 529 04 269 529 06 INLET AND OUTLET PORT SIZE 1 4 NPT 3 8 NPT CE PILOT WEIGHT PORT SIZE PORT SIZE LBS 1 4 NPT 1 8 NPT 1 6 2 2 Pilot Operated Diaphragm Style Regulator Max Inlet Pressure 300 psig 20 4 bar Max Outlet Pressure 290 psig 19 7 bar 100 psig 6 9 bar when used with ER5000 Temperature Range 40 to 120 F 4 4 to 48 9 C Cast Zinc Body Constant bleed from pilot pressure to vent for improved control PILOT PORT INLET POR
17. Mean TC of zero of span lt 0 2 10 K 0 4 for pressure range lt 0 25 bar Mean TC of range of span lt 0 2 10K CE conformity Pressure equipment directive 97 23 EC EMC directive 2004 108 EEC EN 61 326 Emission Group 1 Class B and Immunity Industrial locations Shock resistance g 1000 according to IEC 60068 2 27 mechanical shock Vibration resistance g 20 according to IEC 60068 2 6 vibration under resonance 1 Vacuum gauge pressure compound range absolute pressure other pressure ranges and units are available 2 Not for Model S 10 with pressure ranges gt 25 bar 3 NEC Class 02 power supply low voltage and low current maximum 100 VA even under fault conditions 4 Including non linearity hysteresis zero point and full scale error corresponds to error of measurement per IEC 61298 2 Adjusted in vertical mounting with lower pressure connection 5 Accuracy for pressure ranges gt 0 25 bar 6 Also complies with EN 50178 Tab 7 Operation 4K4H Storage D 1 4 Transport E 2K3 Section 8 Drawings 30 Section 8 Drawings ER5K Kits September 2015 DOPSM2095X012 8 4 3 Transducer D51656 NB XXX Europe Only Dimensions Connection NB DIN 175301 803 114 L connector per Nominal size for US standard tapered pipe thread NPT 4 27 lt 1 89 48 alo g 0 85 z are A 1 4 jas 1 79 45 5 1
18. NVHL 5597 20 5 aovauns IPE 1010 d LINOYIO LHOHS oe 3 SOVITOAHHAO ALINVIOd NOILOSIOHd TVOIHLOWIS ae snow 1 Z TSAST 05 S d LSUNd Z800S T800S Na NJAID Ol 350725 OL PERLES EE BERT 0 8 9 2 THAWT 144 5 7 0001 4 Su NO CaNNINOD NOUSASOHNI 0 2 80 01 21 H THANT USH 2 7 SILSNOVWONLDSIM 605 694 XF WWAN 258011042084 TIVINSWNOHIANS wow 8082402 I NVdS OHSZ 40 XIVOS TINA 6 TINAWLSOCIY sy ed 531212 NOITIIN 001 ONILVHHdO WO2OSiL E 1 31VOS TINA 06 0 NWEMISNgH SUI NVHL 5941 SWIL NSNOdSHH 2 08 OL 0I 3 GLl OL ST LNSIGAV 2 001 OL 06 4 212 OL 0c W nIGSW 9 001 OL 07 4 212 OL 0b 39VHOLS EONVH SHDSSHd LNIOd OHSZ OL 4 510 07 LO844H 90 T 2 08 OL 0 4 9 1 OL ZE 9HDNVH SH LVHHdWHUl 08 01 NOILV m usd AIVOS TINA 204 IgVLS 1 25 TINA SI O TSISIHSLSAH divos TINA 50 0 DALITISVIVSdHH ec I HONVH SSNIL 2 4154 00009 0 HONOYHL ISd 00001 0 S5NVH SHWIL ISd 005 0 HONOWHL ISd 2 0 55 LSuna orz EONVH SHWIL Z L 7154 00009 0 HOnOHHL ISd 00001 0 HONWY SSWIL 67 5 00001 0 HONVH SHWIL Z 15 00S 0 HONOWHL ISd 2 0 Hgu sSsuHd 43OOHd 22 02 QGIOLOZNNOO SNILVW M
19. OIIVOIJIO34S5 VH3N39 801 1093 4 9 120834 38055544 9NIIN3A 4135 035836 NOLSId d31vu3d0 GNVH 030 01 9NIUdS golvin93H 531435 0045 v9 110 3Sv3u930 131N1 131100 3SV3uNI v9 1010 Figure 18 44 5200 Series Regulator Drawings Section 8 27 ER5K Kits Section 8 Drawings DOPSM2095X012 September 2015 8 4 Pressure Transducer Table 10 Transducer Pressure Ranges AVAILABLE PRESSURE RANGE 615 D51656 psig bar 100 6 600 40 1500 100 3000 160 6000 400 10 000 690 Figure 19 Pressure Transducer Section 8 Drawings 28 ER5K Kits DOPSM2095X012 Drawings Section 8 September 2015 Transducer 615 Series Imperial Versions 8 4 1 56 9 40 506 z 30 L Hs O 89951 ow 300 onimvaia 10N 5 9 3ON3H3 34 519 m NoL23ros4 aaen 3715 NI d 5 SIXV ANV NO ZH 0002 0 8 S bGI 330ss33d H3On SNVHL n d 7 Ei 1 ATVOS TINA 10 0x NVEL SSHT NOILVHSIA wc uer ee ee cmt SIXV ANY NO SWOZ 8 S 500T AB Nw oro eoo wi LIT 7 anaoa 00 97 00 2 HO 105541 STIVOS TINA 6070
20. PROCESS INLET Figure 7 ER5K Piping Installation Connect power to terminals 1 2 and 3 See Section 6 Wiring for details Note Power cord is customer supplied Plug USB Cable into device which has ERTune software installed software supplied kit Figure 8 ERTune Software Installation 13 Section 5 Installation ER5K Kits Section 6 Wiring DOPSM2095X012 September 2015 5 2 System Leak Check After installation of all components and wiring Switch on the ER5000 s power supply Slowly apply ER supply pressure and then process pressure Set the output pressure to a safe value e Check all fittings for tightness using leak test fluid No bubbles should be seen 5 3 EE Tuning In many applications the standard factory settings will work satisfactorily but to get the best performance tuning of the control loop parameters may be required When tuning use conditions similar to the final application i e similar pressures flow and medium A tuning procedure is provided in the ER5000 User Manual There is also Help available in the ERTune program itself available on the Diagnostic Tools tab in the ERTune program by clicking the Tuning Tips button Section 6 Wiring 6 1 General Wiring prewired terminal connection Kise open terminal connection
21. T N a lt NN NN N NS VENT PORT Ww OUTLET PORT GAUGE PORT Figure 13 Pilot Operated Diaphragm Style Regulator Section 8 Drawings 22 ER5K Kits DOPSM2095X012 ings Draw September 2015 Section 8 Ies Pressure Reducing Regulator DK Ser 5 3 2 1 n n la 1804 Q3HOldYO INIA 0317934035 7 2 m DNILN3A TIBIA no INON m i ON 1 esse m SA31I TVNOILdO usva i BD d Do WRN 1935 2 17 7 01 300 15 P ISd E 3enss3ud LINO 2 m ON m av cog Hsv E Nim a HSv I NLET Liv JIdIGOIA d A 31971 335 T 3IEVI 45 ve 13 33 3191 335 VOIN INIT D ILDVIN02 51 1831 qv0T 597 SE D V 10538 DND00343 55244 195 C31v93e
22. awing ER5K EFTA Table 8d DASH PORTING FITTING SIZE NO FOR INLET AND OUTLET TUBING SIZE Table 8a A Metric System KIT B Imperial System L Parts Assembled on Plate Table 8c E Parts in Assemled Enclosure DASH EE NO D Buna NBR T Viton FKM U Urethane PUR 2 Table 8b DASH PORTING FITING SIZE No REGULATOR TYPE MATERIAL SEAT bar psi Metric Imperial A Flow Booster Pressure Reducing Zinc 6 100 Buna 1 5 12 1 2 B Flow Booster Pressure Reducing Zinc 6 100 Buna 2 2 12 1 2 DK Dome Load Pressure Reducing ss 6 100 PCTFE 0 35 12 1 2 D DK Air Load Pressure Reducing SST 40 600 PCTFE 0 35 12 1 2 F 26 20 Air Load Pressure Reducing SST 00 1500 Vespel 0 06 6 1 4 G 26 20 Air Load Pressure Reducing ss 60 3000 Vespel 0 06 1 4 H 26 20 Air Load Pressure Reducing SST 400 6000 Vespel 0 06 6 1 4 J 26 20 Air Load Pressure Reducing SST 690 10000 Vespel 0 06 6 1 4 K 54 21 Air Load Back Pressure ss 00 1500 17 4 SST 0 08 6 1 4 L 54 21 Air Load Back Pressure SST 60 3000 17 4 SST 0 08 6 1 4 M 54 21 Air Load Back Pressure SST 400 6000 17 4 SST 0 08 6 1 4 N 54 21 Air Load Back Pressure ss 690 10000 17 4 SST 0 08 6 1 4 P 26 17 Air Load Back Pressure SST 00 1500 Teflon PTFE 0 14 6 1 4 R 26 17 Air Load Back Pressure ss 60 3000 PCTFE 0 1 6 1 4 5 26 17 Air Load Back Pressure ss 400 6000 PCTFE 0 1 6 1 4 1 26 17 Air Load Back Pressure ss 690 10000 PCTFE 0 1 6 1 4 Notes 1 Outlet transducer 0 1 accuracy 2
23. e trouble free performance 2 Theuser 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 specific media upon request Suggestions are based on technical compatibility resources through associations and manufacturers Tescom does NOT guarantee materials to be compatible with specific 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 Theuser 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 explosion proof controllers 6 Theuser is responsible for the selection of the proper model number of the controller that would meet the application s possible hazardous environment or conditions Do not modify equipment or add attachments not approved by the manufacturer 2 1 3 TESCOM Regulators AWARNING r rr L U U UT 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 personnel to install use or maintain this regulator va
24. ersions Table 11 D51656 NB XXX Technical Data Specifications Model S 10 Pressure ranges bar 6 Over pressure safety bar 35 Burst pressure bar 42 Pressure ranges bar 40 100 160 400 690 Over pressure safety bar 80 200 320 800 1500 Burst pressure bar 400 800 1000 1700 3000 Materials Wetted parts Model S 10 Stainless steel Case Stainless steel Internal transmission fluid Synthetic oil Halocarbon oil for oxygen applications Power supply U U in VDC 10 to 30 14 to 30 with signal output 0 to 10 V Signal output and 4to 20 mA 2 wire Ra lt 0 10 0 02 maximum ohmic load Ra 0 to 20 mA 3 wire Ra lt U 3V 0 02A Oto 5 V 3 wire Ra gt 5k Oto 10 V 3 wire Ra gt 10k other signal outputs on request Adjustability zero span 5 using potentiometers inside the instrument Response time 10 to 90 fag at medium temperatures below lt 30 for pressure ranges to 25 or with flush Insulation voltage VDC 500 Accuracy of span lt 0 5 0 25 Non linearity of span lt 0 2 BFSL according to IEC 61298 2 Non repeatability of span lt 0 1 1 year stability of span lt 0 2 at reference conditions Permissible temperature of Medium 30 to 100 C 4 to 125 C 22 to 212 F 40 to 257 F Ambience 20 to 80 C 4to 176 F Storage 40 to 100 C 40 to 212 F Rated temperature range 0 to 80 C 32 to 176 F Temperature coefficients within rated temperature range
25. he force generated by the ER5000 allowing the pilot pressure to modulate system pressure that may be many times greater up to 30 000 psig 2068 bar 9 Section 3 Product Description ER5K Kits Section 4 Technical Data DOPSM2095X012 September 2015 Section 4 Technical Data Table 3 ER5K Pressure Reducing and Back Pressure Regulators Technical Data Dash Regulator Transducer Max Regulator Flow Body Temperature Venting Weight Code Series pressure Input Pressure Coefficient Material approx range psi bar Gy Ibs kg psig bar ER5K X Pressure Reducing Regulators A Flow 0 100 1 5 Zinc 40 to 120 F Yes 1 6 0 75 Booster 0 6 4to 48 C 300 20 7 B Flow 0 100 2 2 Zinc 40 to 120 F Yes 1 6 0 75 Booster 0 6 4 to 48 C DK 0 100 Cv 0 35 SST 15 0 165 F Yes 3 9 1 8 dome loaded 0 6 20 to 73 C Captured 1000 69 D DK 0 600 Cv 0 35 SST 4 to 163 F Yes 6 2 2 8 air loaded 0 40 26 to 74 C Captured F 26 2000 0 1500 Cy 0 06 SST 15 0 165 F Yes 7 7 3 5 0 100 26 to 74 C Captured G 26 2000 0 3000 0 06 SST 15to 165 F Yes 7 7 3 5 0 160 SST 26 to 74 C Captured H 26 2000 0 6000 10 000 690 0 06 55 15to165 Yes 7 7 13 5 0 400 26 to 74 C Captured J 26 2000 0 10 000 Cy 0 06 SST 15 0 165 F Yes 7 7 3 5 0 690 26 to 74 C Captured ER5K X Back Pressure Regulators K
26. i UAE 97148118443 F 9714 886 5465 mea tescom emerson com www tescom com DOPSM2095X012 OTESCOM Corporation 2015 All Rights Reserved TESCOM is a business unit of Emerson Proces 5 Management Regulator Technologies Inc Trademarks are property of divisions of Emerson Process Management The contents of this publication are presented for information purposes only and while effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or t All sales are governed by our terms and condi heir use or applicability tions which are available on request We reserve the right to modify or improve the designs or specifications of our products at any time witl hout notice es EMERSON Process Management
27. icing of the equipment by removing excess moisture from the gas Always use proper thread lubricants and sealants on tapered pipe threads 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 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 Section 2 Before You Begin ER5K Kits Section 2 Before You Begin DOPSM2095X012 September 2015 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 qualified 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 specifications if repairable There are flat fee repair charges for each standard model The original equipment warranty applies after a complete overhaul Safe Component Selection 1 Consider the total system design when selecting a component to ensure saf
28. ine suitability of materials in an application Vent fluids 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 Do not locate controllers regulators valves or accessories using flammable fluids near open flames or any other source of ignition Use of Explosion Proof controllers may be necessary to be in accordance with local electric codes Some fluids when burning do not exhibit a visible flame Use extreme caution when inspecting and or servicing systems using flammable fluids to avoid death or serious injury to employees Provide a device to warn employees of these dangerous conditions Many gases can cause suffocation Make certain the area is well ventilated Provide a device to warn employees of lack of Oxygen Never use oil or grease on these controllers regulators valves or accessories Oil and grease are easily ignited and may combine violently with some fluids under pressure Have emergency equipment in the area if toxic or flammable fluids are used Upstream filters are recommended for use with all fluids Do not bleed system by loosening fittings Prevent
29. lve 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 fluid gas or liquid discharge Parts ejected at high speed Contact with fluids that may be hot cold toxic or otherwise injurious Explosion or burning of the fluid Lines hoses whipping dangerously Damage or destruction to other components or equipment in the system Section 2 Before You Begin Section 2 Before You Begin ER5K Kits September 2015 DOPSM2095X012 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 specific 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 fittings connections filters valves gauges etc in your system All must be capable of handling the su
30. nel to install use or maintain this regulator valve or accessory 5 1 Two Mounting Types Kits are supplied with one of two mounting configurations 1 Panel Version Open Wall Mount Figure 4 Open Wall Mount Panel 2 Enclosure Version Enclosed Wall Mount 11 Section 5 Installation ER5K Kits Section 5 Installation DOPSM2095X012 September 2015 Kits are mounted using 4 bolting locations in each corner MOUNTING SURFACE RE ae n ee BOLT LOCATIONS Note Mounting hardware not included 4x MOUNTING LOCATIONS 4x MOUNTING LOCATIONS 14 224 mm 0 56 8 7 mm 0 3425 Note maximum diameter available for mounting fasteners Figure 6 Wall Mount Installation Section 5 Installation 12 Section 5 Installation ER5K Kits September 2015 DOPSM2095X012 Attach up to 3500 psig 241 bar clean dry inert gas to the ER Supply Regulator Inlet port Pressure supplied by the ER Supply Regulator to the ER5000 Inlet Port should not exceed 120psig 8 3 Attach Process supply pressure to the Process Inlet port See specifications for your Kit Regulator Type Attach Kit outlet to downstream process piping If desired attach piping to Kit vent port Note Piping not included beyond what is already present in the kit a ER SUPPLY REGULATOR INLET zu VENT G j H rsf rts u LT s
31. o not attempt to select install use or maintain this controller or accessory until you have readand fully understood these instructions Be sure this information reaches the operator and stays with the product after installation Do not permit untrained personnel to install use or maintain this controller or accessory Improper selection installation 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 Section 1 Introduction ER5K Kits Section 2 Before You Begin DOPSM2095X012 September 2015 Possible consequence include but are not limited to High velocity fluid gas or liquid discharge AAElectrocution Parts ejected at high speed Contact with fluids that may be hot cold toxic or otherwise injurious Explosion or burning of the fluid Lines hoses whipping dangerously Damage or destruction to other components or equipment in the system Read and understand the user s manual before operating the controller Inspect the controller and accessories before each use 1 2 3 Operate the unit only under specified environmental conditions 4 Follow instructions in the manuals for proper wiring 5 Never connect the controller or accessories to a supply
32. pply and operating pressure 4 Clearly establish flow direction of the fluid 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 fittings gauges or components 6 Never turn regulator or valve body Instead hold regulator or valve body and turn fitting nut 7 Ifa regulator or valve leaks or malfunctions take it out of service immediately Do not modify equipment or add attachments not approved by the manufacturer Apply pressure to the system gradually avoiding a sudden surge of fluid or pressure shock to the equipment in the system 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 Readand follow precautions on compressed gas cylinder labels 15 Itis 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 fo
33. r each fluid used in your system 16 Never use materials for regulators valves or accessories that are not compatible with the fluids being used 17 Users must test components for material compatibility with the system operating conditions prior to use in the system 18 Ventfluids 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 Donotlocate regulators valves or accessories controlling flammable fluids near open flames or any other source of ignition 20 Somefluids when burning do not exhibit a visible flame Use extreme caution when inspecting and or servicing systems using flammable fluids to avoid death or serious injury to employees Provide a device to warn employees of these dangerous conditions 5 Section 2 Before You Begin ER5K Kits Section 2 Before You Begin DOPSM2095X012 September 2015 21 Many gases can cause suffocation Make certain the area is well ventilated Provide a device to warn employees oflack of Oxygen 22 Never use oil or grease on these regulators valves or accessories Oil and grease easily ignited and may combine violentl
34. r for evaluation and prompt service Equipment is restored to the original factory performance specifications if repairable There are flat fee repair charges for each standard model The original equipment warranty applies after a complete overhaul Proper Component Selection 1 Considerthe total system design when selecting a component for use in a system 2 Theuseris 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 specific media upon request Suggestions are based on technical compatibility resources through associations and manufacturers TESCOM does NOT guarantee materials to be compatible with specific media THIS IS THE RESPONSIBILITY OF THE USER 4 Componentfunction adequate ratings proper installation operation and maintenance are the responsibilities of the system user 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 Section 2 Before You Begin Section3 Product Description ER5K Kits September 2015 DOPSM2095X012 Section 3 Product Description 3 1 221 2 3 1 3 3 1 4 3 2 The ER5K Kits are designed to provide a complete pressure control system for the most common pressure reducing and back pressure control applications All the components are completely assembled profe
35. rformance an accuracy of 0 1 or better is required Alless accurate transducer can be used but doing so will degrade the accuracy of Main Valve the overall system Vent Valve Regulator Regulator Inlet Inlet Pressure Pressure Captured Vent exhausts excess pressure Figure 3 Typical Pressure Reducing Application continued Iffeedback is lower than setpoint the ER5000 activates the inlet valve allowing Pilot Pressure to flow into the actuator of the regulator This causes the main valve ofthe regulator to open up resulting in an increase in downstream System Pressure The ER5000 will continue to send pilot pressure into the air actuator of the regulator until feedback and setpoint are equal At that point the inlet valve closes stabilizing the system at that pressure Iffeedback is higher than setpoint the ER5000 activates the exhaust valve releasing pilot pressure from the regulator The decrease in pilot pressure causes the main valve of the regulator to close up and also causes the regulator vent to open exhausting excess system pressure if your application uses a non venting regulator refer to page 36 The result is a decrease in downstream system pressure The ER5000 will continue to exhaust pilot pressure until the feedback signal is equal to the setpoint At that point the exhaust valve closes stabilizing the system at that pressure The air actuator also known as the Ratio Actuator amplifies t
36. ssionally plumbed together and tested for proper operation to save the user time and the inconvenience of not having all the accessories and interconnections needed to get the system up and running Kits are available with the components mounted on a SST plate or mounted inside an enclosure The ER5000 is a unique and flexible electropneumatic closed loop PID controller When combined with a mechanical regulator and pressure transmitter in these kits the system provides precise control of pressures up to 10 000 psig 690 bar The included ERTune software program provides an easy means of setup tuning and data acquisition Kit Benefits Very high pressure stability Pressure is independent of the flow eliminates droop Pressure is independent of the input pressure eliminates decaying inlet effect Automation Pressure can be controlled by a signal from a PC or PLC Easy integration into automated test cycles ERTune Program Included with every ER5000 provides data acquisition routine Setup Wizard loads PID parameters for your regulator series Items Included All ER5K kits includes 5000 1 w ERtune program and Complete User Manual Mechanical Regulator see Regulator Families below 4 20 mAmp Feedback Transducer 0 12575 accuracy ER Supply Regulator with relief valve and gauge Prewired Electrical Junction Box All connections and fittings Regulator Families With ER5K ki
37. tem Pressure In a typical application the Outlet Port of the ER5000 connects to the top of a Dome Loaded or Air Actuated pressure reducing Regulator usually through the included 1 2 SAE x 1 8 NPTF adaptor This is shown in Figure 4 Supply Pressure of up to 120 psig 8 2 bar with 110 psig 7 5 bar being typical is provided to the ER5000 by an external source The ER5000 increases Pilot Pressure to the air actuator of the regulator by opening the Pulse Width Modulation PWM solenoid valve at the Inlet Port and reduces pilot pressure by opening the PWM solenoid valve at the Exhaust Port Normally the exhaust vents to atmosphere The controller configured in External Feedback mode senses System Pressure through input from a transducer mounted downstream in the Process Line Every 25 milliseconds the controller reads the feedback and compares it to the setpoint which it receives from an external source or from a Profile in its onboard memory Section 3 Product Description 8 Section3 Product Description ER5K Kits September 2015 DOPSM2095X012 USB Connection ER5000 ER5000 Inlet Port 2 1 Exhaust Supply Pressure 110psi 75 psig Setpoint Source can be either 3000 Outlet Port digital signal provided over and Adaptor USB or R5485 analo signal or a Profile stored in Pressure To Air Actuator Air Actuator onboard memory Feedback For optimal system pe
38. tor 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 fluid 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 Section 2 Before You Begin 2 Section 2 Before You Begin ER5K Kits September 2015 4 1 4 19 20 21 22 23 24 25 26 27 28 29 30 31 32 DOPSM2095X012 Read and follow precautions on compressed gas cylinder labels Itis 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 fluid used in your system Never use materials for controllers regulators valves or accessories that are not compatible with the fluids being used Users must test under normal operating conditions to determ
39. ts the customer has a choice of the most versatile mechanical regulators to cover a wide range of applications both pressure reducing and back pressure Table 1 Pressure Reducing Regulators 26 2000 High pressure regulator to control various output ranges up to 10 000 psig 690 bar segregated captured vent DK Hig hly accurate and sensitive regulator with captu red vent for low pressure 90 psig 6 bar or mid range applications 600 psig 40 bar requiring significant flow capabilities 44 5200 Piston sensed venting regulator for mid pressure range low flow applications 600 psig 40 bar Flow booster Low pressure 90 psig 6 bar high flow diaphragm regulator for air or nitrogen service Zinc body Table 2 Back Pressure Regulators 26 1700 High pressure regulator to control various back pressure ranges up to 10 000 psig 690 bar High pressure regulator to control various back pressure ranges up to 10 000 psig 690 bar Specially designed for 54 2100 n hydraulic applications metal seat Section 3 Product Description ER5K Kits Section3 Product Description DOPSM2095X012 September 2015 USB Connection ER5000 Supply Pressure 110 psig 7 5 bar Regulator External Transducer Outlet Pressure To Process Inlet Pressure Figure 3 Typical Pressure Reducing Application 3 3 Controlling Sys
40. y with some fluids under pressure 23 Have emergency equipment in the area if toxic or flammable fluids are used 24 Upstream filters are recommended for use with all fluids 25 Donot bleed system by loosening fittings 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 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 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 qualified personnel make repairs Return any equipment in need of service to your equipment supplie
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