1960 ER30 Exp Manual.indd
Contents
1. Seal conduit within 18 inches Canadian Standards Association CSA Explosion proof Certification No LR 85614 4 Class Groups B C and D Enclosure Type 4X SPECIAL CONDITIONS FOR SAFE USE 20 C lt Tamb lt 60 C Do not remove cover while circuits are live Installation to be in accordance with the latest edition of Canadian Electrical Code Rated 24 VDC 350 mAmps Maximum working pressure 110 PSIG KEMA Cenelec Flameproof Certification Certificate No KEMA 03ATEX2365 ATEX Marking EEx d IIB H T4 Category Il 2 G Enclosure type IP65 SPECIAL CONDITIONS FOR SAFE USE 20 C lt T mb lt 60 C Do not remove cover while circuits are live Installation to be in accordance with the applicable local requirements The cable and conduit entry devices shall be of certified flameproof types suitable for the conditions of use and correctly installed Unused apertures shall be closed with certified flameproof blanking elements SPECIFICATIONS Enclosure NEMA 4X IP65 To prevent any interference from electromagnetic radiation use rigid metal conduit to enclose the wiring entering the ER3000 Two 1 2 NPT wire ports have been provided for this purpose If unused properly seal with a metal plug Media The preferred media is clean dry instrument grade air or nitrogen Use of an in line 40 micron filter is highly recommended to prevent damage to the solenoid valves Inlet Pressure2. Minimum Outlet pressure 1 PSIG Maximum 120 PSIG Typical 110 PSIG Note Response time is affected by inlet pressure Environment Temperature 20 C to 60 C dry nitrogen supply gas 5 C to 60 C shop air Pressure 28 32 inches Hg Humidity To 100 R H non condensing 0 C to 60 C Flow Rate Cv 0 01 Note The flow rate can be increased through the use of a booster regulator Power Requirement Voltage 24 VDC 22 VDC to 28 VDC Current 340mA maximum 180mA nominal RS485 Communication Interface Networking Up to 32 controllers on one network Cable length 4000 ft maximum Baud rate 9600 Accuracy Room temp 0 1 of span maximum Temperature effects 0 002 F of span maximum Note Accuracy is based on the user provided external transducer when used in external feedback mode Response Time Rise Time 257ms 10 PSIG to 90 PSIG Fall Time 552ms 90 PSIG to 10 PSIG Note Step response into dead end system 1 cubic inch volume Ports Conduit 1 2 NPT Pneumatic 1 8 NPT Inlet exhaust and gauge ports 1 4 NPT Controlled outlet port Weight 40 6 oz 1 15 kg External Analog Input Impedance 4 20mA 2500 1 5V 220KQ Single input pin to ground 1 7MO Differential input 0 10V 100KO Digital Outputs Current 50 mA Continuous 100 mA Instantaneous Voltage 5V 28V Type Open collector grounded emitter Digital Inputs Voltage Range Input Impedance 4 20 mA 2500 1 5V 220KQ
3. Single input pin to ground 1 7MO Differential input 0 10V 100KQ Type Level sensitive Analog Output 4 20mA 0 5 Accuracy Sensor Update Rate 25ms Rate of sensor reading and processing task ER3000 INSTALLATION FLOW CHART Step 1 Select Voltage Current Jumper J5 top board see below right for Figure 1 Select Jumper position for 1 Analog Setpoint 2 External Feedback 3 Auxiliary input 1 4 Auxiliary input 2 For all the above jumper positions e Jumper not installed configured for 1 5V e Jumper installed configured for 4 20mA Not on 0 10V models Step 2 Plumb the external regulator and transducer Use safety information on pages 4 6 amp 8 10 prior to pressurization and operation of all equipment Step 3 Mount the ER3000 Four 8 32 UNC screw holes are provided Step 4 Electrical wiring Connect ER3000 to a power supply transducer and computer if needed using the tables on this page Note All electrical wiring must be in accordance with applicable local standards see pages 4 6 amp 8 10 Step 5 Tune program if using a computer Download the Tune program onto your computer Step 6 Read and follow the safety sections on page 4 6 amp 8 10 carefully prior to pressurization and operation of the system ER3000 WIRING DIAGRAM The following tables give the complete wiring layout of the ER3000 wiring assemblies which are connected to the J3 and J4 term
4. AINTAIN THIS CONTROLLER OR ACCESSORY MAINTENANCE MISUSE OR ABUSE OF THIS CONTROLLER OR RELATED ACCESSORIES CAN CAUSE DEATH SERIOUS INJURY WARNING AND OR PROPERTY DAMAGE 1 IMPROPER SELECTION IMPROPER INSTALLATION IMPROPER Possible consequences include but are not limited to e High velocity fluid gas or liquid discharge e Electrocution e Parts ejected at high speed e Contact with fluids that may be hot cold toxic or otherwise injurious e Explosion or burning of the fluid e Lines hoses whipping dangerously e Damage or destruction to other components or equipment in the system 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 specified environmental conditions 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 setp
5. ER3000 Explosion Proof Manual www tescom com TESCIHM EMERSON ER3000 EXPLOSION PROOF MANUAL This manual provides basic installation information and safety precautions for the following Tescom ER3000 Pressure Controllers MODEL NO ER3OOOEI 1 ER3000EV 1 ER3000MI 1 ER3000MV 1 ER3000GI 1 ER3000GV 1 ERSOOONI 1 ER3000NV 1 ER3000P ER3000H TESCOM DESCRIPTION 4 20 mAmp 1 5 VDC analog setpoint and feedback FM Explosion Proof Packaging Class I Division I Groups B C D CSA Explosion Proof Packaging Class l Groups B C D Type 4X O 10 VDC analog setpoint and feedback FM Explosion Proof Packaging Class I Division I Groups B C amp D CSA Explosion Proof Packaging Class l Groups B C amp D Type 4X 4 20 mAmp 1 5 VDC analog setpoint and feedback KEMA ATEX Explosion Proof Packaging Eex d IIB H T4 Hazardous Locations Category Il 2 G 0 10 VDC analog setpoint and feedback KEMA ATEX Explosion Proof Packaging Eex d IIB H T4 Hazardous Locations Category Il 2 G Same as ER3000El 1 with the addition of 2 analog digital inputs 2 digital outputs and 1 analog sensor output Same as ER3000EV 1 with the addition of 2 analog digital inputs 2 digital outputs and 1 analog sensor output Same as ER3000MI 1 with the addition of 2 analog digital inputs 2 digital outputs and 1 analog sensor output Same as ER3000MV 1 with the addition of 2 analog digital inputs 2 digital outputs and 1 anal
6. 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 WARNING 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 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 10 Safe Component Selection 1 Consider the total system design when selecting a component to WARNING ensure safe trouble free performance 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 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 ra
7. e vent is needed 25 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 26 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 27 Many gases can cause suffocation Make certain the area is well ventilated Provide a device to warn employees of lack of oxygen 28 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 29 Have emergency equipment in the area if toxic or flammable fluids are used 30 Upstream filters are recommended for use with all fluids and gases 31 Do not bleed system by loosening fittings 32 Prevent icing of the equipment by removing excess moisture from the gas 33 Always use proper thread lubricants and sealants on tapered pipe threads Installations 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
8. inal blocks Refer to the tables to ensure proper wiring of external devices Note The and the refer to the differential inputs Both must be connected for the system to work properly Table 1 Main Cable Assembly J3 Pins Description Color 1 Setpoint Input Brown 2 Setpoint Input Red 3 Feedback Input Orange 4 Feedback Input Yellow 5 RS485 Network connection Green 6 7 8 RS485 Network connection Blue 24 Volt DC Power Violet 24 Volt Return Power Ground Gray 9 5 Volt output 5mA max White 10 Analog Signal Ground Black 11 Analog Signal Output Pink 12 Analog Signal Ground Tan The tan wire should be connected to the yellow wire in systems with 4 20mA feedback Table 2 Auxiliary Cable Assembly ER3000F ER3000G J4 Pins Description Color Auxiliary Input 1 Brown Auxiliary Input 1 Red Auxiliary Input 2 Orange Auxiliary Input 2 Yellow Analog Signal Ground Green Analog Output Ground Black Digital Output 1 Blue Digital Output 2 White CO N OD Om B amp B OG hm gt Figure 1 Top Board J3 8 J4 Terminal Blocks J5 Jumpers SAFETY INSTALLATION 8 OPERATION PRECAUTIONS 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 M
9. og sensor output Same as ER3000MI 1 with screw terminal strip style and 2 additional analog inputs Same as ER3000El 1 with screw terminal strip style and 2 additional analog inputs S EMERSON TABLE OF CONTENTS INTroductiON Hazardous Locations CertificationS SDECCHICATIONS isis Ree EOS eee eS ENCIOSUTO c acu mms rr a de ace Sew a OE ae be eek Power Requirement se owe wee Cae ew wh eee ee RS485 Communication Interface 0 0 cee es ACCUTACY 2565 dus Gea a eee ee eee pee eee Sees ee RESPOnse TINO coco cos eae is eae Cae ee do ico ee Digital NOUNS s re ae eee A paca Reba ete ewes A eee ee A AA A ee es ee eee ee ee Sensor Update Rate os dakccmide nde oda ieee eee eee kee ew aR Y OOD O O O O O O 0 0 0 00000 A OW ER3000 Installation Flow Chart amp ER3000 Wiring Diagram Safety Installation amp Operation Precautions 8 10 Sale PrecaullOMS embestida 8 10 stalas ss sime a i akin a kth A te ar ne A 10 is 6 au anne ree hee ee ee eee oe wee 10 Safe Component Selection 0 0 cee ees 11 Assembly Installation Wiring Drawings amp Bills of Materials 11 INTRODUCTION The ER3000 Series Electronic Regulator is a versatile O to 100 PSIG pressure controller It can be used in conjunction with any pneumatically actuated regulator or valve to control pressure Setpoints can be provided via an analog inp
10. oint reduced to its lowest pressure output before turning on the pneumatic supply to the controller WARNING 10 11 12 13 14 15 16 ive 18 19 20 21 22 23 24 Refer to 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 Clearly establish flow direction of the fluid before installation of controllers regulators valves and accessories lt is the responsibility of the user to install the equipment in the correct direction Do not tighten fittings gauges or components in pressurized systems Never turn controller regulator or valve body Instead hold the controller body and turn fitting nut If a controller 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 Regulators are not shut off valves Install a pressure relief device downstream of the regulator to protect the process equipment from operating pressu
11. re increases Shut off the supply pressure when the regulator is not in use Periodic inspection and scheduled maintenance of your equipment is required for continued safe operation The frequency of servicing is the responsibility of the user based on the application Never allow problems or lack of maintenance to go unreported Read and follow precautions on compressed gas cylinder labels It is important that you analyze all aspects of your application and review all available information concerning the product or system Obtain read and understand the Material Safety Data Sheet MSDS for each fluid used in your system 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 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 determine 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 on
12. tings 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 not limited to all explosion proof 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 Do not modify equipment or add attachments not approved by the manufacturer WARNING ASSEMBLY INSTALLATION WIRING DRAWINGS amp BILLS OF MATERIALS Drawings and parts lists for your product may be obtained by calling the number below Tescom will provide these by fax or mail Your local Tescom representative can provide additional assistance Call 800 447 1250 or email to systems tescom com for assembly installation wiring drawings amp bills of materials Be sure to have your complete model number ready 11 Tescom Industrial Controls Systems Group 12616 Industrial Boulevard Elk River Minnesota 55330 2491 Toll Free 800 447 1250 Tel 763 241 3238 Fax 763 241 3224 e mail systems tescom com www TESCOM com TESCOM Form No 1960 Rev 4 06 Printed 4 06 150 Printed in U S A EMERSON
13. ut 4 20mA 1 5V or 0 10V the digital RS485 interface or a downloaded profile The controller can be wired through a standard serial communication port using an RS232 to RS485 adapter This communication channel also provides for the programming of a number of internal parameters including PID tuning variables zero and span mode of operation limits etc Feedback can be derived either from the ER3000 s internal temperature compensated sensor or an external transducer 4 20mA 1 5V or 0 10V Four modes of operation are available 1 Internal feedback mode makes the controller an I P when analog setpoints are used and uses the internal sensor as the source of feedback External feedback mode uses an external sensor as the feedback Cascade mode creates a loop within a loop the inner loop uses the internal sensor for feedback and the outer loop uses the external transducer for feedback 4 Manual mode allows for direct control of the solenoid valves used for troubleshooting the system only HAZARDOUS LOCATIONS CERTIFICATIONS Factory Mutual FM Approval Explosion Proof Identification No 220A0 AE Class Division Groups B C and D Enclosure type 4X SPECIAL CONDITIONS FOR SAFE USE 20 C lt Tmp S 60 C Do not remove cover while circuits are live Installation to be in accordance with the latest edition of National Electrical Code Unused conduit entry must be closed with suitable blanking element
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