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ER3000 Electronic Pressure Controller User Manual

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1. 4 20mA Ne JK DN VIDLET YELLOW N ve i BLACK E i 63 ttn Tin a a 1 i I lt RANSDUCER ii Figure 11 Monitor 4 20mA External Feedback Ground Referenced Input NOTE Wire power as shown in figures 2 amp 3 4 Installation 21 In order to avoid producing ground loops it may be necessary in some systems to monitor the voltage produced across the ER3000 s internal 250 Q resistor rather than breaking into the 4 20 mAmp loop TAN A YELLOW lt 4 20mA N 4 20mA I VIOLET x ORANGE td U iil II COMPUTER 1 im li ala Se GS 6 19 E V in P J I O O Es TRANSDUCER Figure 12 Monitor voltage produced by 4 20 mAmp External Feedback NOTE Wire power as shown in figures 2 amp 3 H KR li sm E un a gt E Win H OI Figure 13 Monitor 1 5V 0 10V External Feedback NOTE Wire power as shown in figures 2 amp 3 The wiring from the transducer is dependant on whether it is a 3 wire or 4 wire transducer Refer to Figure 4 and Figure 5 for 3 wire and 4 wire transducer wiring schemes 22 ER3000 User Manual 4 5 4 Profile Control Digital Inputs This feature is only available on models that have the extra analog inputs as referenced in section 3 ER300
2. 9 2 9 RESPONSE TIME 9 2 10 PORTS 9 2 11 WEIGHT 9 2 12 EXTERNAL ANALOG INPUT IMPEDANCE 9 2 13 DIGITAL OUTPUTS 9 2 14 DIGITAL INPUTS 9 2 15 ANALOG OUTPUT 9 2 16 SENSOR UPDATE RATE 9 3 ER3000 PART NUMBERING SYSTEM 10 4 INSTALLATION 0 2 0 2002 Q Q QQ 11 4 1 INTERFACE CABLE ASSEMBLIES TI 4 2 VOLTAGE CURRENT SELECT JUMPERS 12 4 3 BASIC ER3000 TO PC WIRING 13 4 4 SETTING UP A TYPICAL ER3000 PRESSURE CONTROL SYSTEM 14 44 1 Plumb the External Regulator and Transducer 14 44 2 Mount the ER3000 15 4 4 3 Connect the Power Supply 15 4 4 4 Connect RS485 Interface Connections
3. There are some features of the ER3000 that are unique when compared to other PID controllers that allow the system to be optimized In particular the use of four different modes of operation the setting of minimum values for inlet and exhaust valves deadband adjust and the setting of maximum and minimum values for the integral sum allow for greater flexibility in the ER3000 system To begin three windows should be opened Tuning Advanced Select Gains in Format Menu Signal Generator Plot Each system has unigue reguirements Since tuning will always be a compromise between various tradeoffs it is necessary to decide what are the most important parameters for the given application Typical goals include the following e Maximize speed of response Minimize peak overshoot e Minimize offset Minimize settling time In addition the region of operation will affect how the unit is tuned This application will be operating primarily in the 0 to 2500 psi region Thus tuning should be performed over this entire range However the final setup should be tested in intermediate pressure ranges as well to verify maximum performance throughout the system s range In the Tuning Window make sure the Control Mode is set to External Feedback and the Sensor Range Minimum and Maximum are 0 and 2500 respectively The ER3000 is shipped with outer loop PID parameters that have been established at the factory to work well
4. 15 4 4 5 Install the ER3000 CVI Windows Program 15 4 4 6 Communicate to the ER3000 using the ER3000 CVI Windows Program 15 4 4 7 Connect Transducer Wiring 16 44 8 Connect Pressure to the System 16 4 4 9 Tune the System 16 4 5 ADDITIONS AND VARIATIONS TO THE TYPICAL SYSTEM 17 4 5 1 Transducer Wiring Configurations 17 4 5 2 Analog Setpoint Source 19 4 5 3 Monitor the Feedback Signal 21 454 Profile Control Digital Inputs 23 4 55 Switch Feedback Control to a Second Feedback Source 24 4 5 6 Monitor Analog Signals 24 4 5 7 Networking ER3000 s 25 4 5 8 Digital Outputs 26 4 5 9 Monitor Internal Sensor using the Analog Output 27 5 OPERATION 2 28 5 1 THEORY OF OPERATION 28 5 1 1 PID Control 28 9 2 C
5. 36 ER3000 User Manual Now some Derivative is introduced Note the decrease in overshoot Tuning ME El File Format Simple Eile Axis Labels PlotStart Control Mode External Feedback nd Sensor Range Minimum 0 00 Urits Maximum 2500 00 PSI Outer Loop Proportional Term 1000 Integral Term 0 Den i 50 Integral Minimum 0 Integral Maximum 0 00 Integral Deadband ExtFBSource Extemal Feedback w Minimum Pulse Width Inlet 10 Exhaust 10 However if we zoom in on the horizontal axis between 1750 and 2000 psi we notice that a small offset remains Tuning AH E Eile Format Simple File Axis Labels PlotStart Control Mode Extemal Feedback lt Y Sensor Range Minimum 0 00 Units Maximum 2500 00 PSI Outer Loop Proportional Term 1000 5 Integral Term 0 SS 50 E J Integral Minimum Integral Maximum Integral Deadband 0 00 ExtFBSource Extemal Feedback w Minimum Pulse Width Inlet 10 Exhaust 10 Time sec 6 Tuning Procedure 37 What can be done to eliminate the offset is the addition of integral term The resulting response follows Turing AGE File Format Simple file Axis Labels PIBER Axis Labels PlotStart ControlMade External Feedback w ZOO 19754 Sensor Range Minimum 10 00 Units Maximum 2500 00 PSI 1950 DAREA Proportional Term 1000 Integral Term 200 Derivative Term 50 Integral Minimum 12 i 64 Integral Deadband 0 00 ExtFBSo
6. The program ERTALK C is a simple program illustrating the use of four of the library functions It can be used to read or write any of the controller s programmable variables as outlined in Section 9 ER3000 Internal Variables 8 4 3 Profile The Profile directory contains a set of programs that will allow users to construct complete pressure profiles by writing a DOS batch file Each program will perform a different profile function start ramp soak or step and store the setpoint feedback and time in a file called data txt This file can be imported to a program such as Excel to plot the profile The programs and their descriptions are documented in README DOC residing in TESCOM2 PROFILE directory It should be noted that this method of profiling writes to the ER3000 setpoint variable which is different then the embedded profiling capability of the ER3000 The PROFILE2 program actually downloads pressure profiles into the ER3000 for embedded pressure profiling 8 4 4 Profile2 The user may use functions such as ramp dwell step change variable loop digital in and digital out to construct the desired profile refer to Section 3 ER3000 Model Description for models with digital in and digital out The 42 ER3000 User Manual profile may then be downloaded into the controller After profile download it may be started by software writing variable ID PROFILE STATE a toggle switch or by the UI3000 UI4000 See the Readme do
7. 2 16 Sensor Update Rate 25ms Rate of sensor reading and processing task 2 Specifications 9 3 ER3000 PART NUMBERING SYSTEM Standard features RS485 communications included 1 8 inlet and exhaust ports 1 4 controlled output port Maximum inlet pressure 120 psig 0 to 100 psig internal sensor Windows DOS software package included 24 VDC power required As the table below indicates other sensor ranges are available Please consult the factory for special modifications or requirements Cv Configuration 1 Standard Cv 0 01 Current Voltage 2 Low flow 1 4 20 mA 1 5 VDC Cy 0 001 V 0 10 VDC 4 High flow Cv 0 1 Base Style 00 Standard Internal Sensor Configuration Board Configuration 02 Integrated with 0 0 100 psig 0 1 accuracy S Standard 26 1000 and 269 529 2 0 50 psia 0 1 accuracy setpoint feedback 04 OEM style no 3 0 150 psia 0 1 accuracy F 2 extra analog cover 4 0 5 psig 0 25 accuracy inputs outputs 10 Integrated with E Explosion proof 44 4000 G Combines F amp E 11 Integrated with M KEMA explosion proof 44 5200 N Combines F amp M 10 ER3000 User Manual 4 INSTALLATION The ER3000 has a number of variations and wiring options The following pages of the installation section detail a typical installation and many of those options Note Installation of explosion proof models shall be in accordance with the specifications of the sta
8. 4095 0 OFFF Signed oa oa 0 250 1 250 0 1 nsigned nsigned Denotes Read Only all other variables are Read Write 9 ER3000 Internal Variables 51 Table 3 continued ER3000 Internal Variables Variable Name and Number Type Range Decimal Range Hex SSID MAX AD SETPOINT signer 0 4095 oom 36 D_MIIN_COMPENSATED INTERNAT_SENSOR Unsigned 0 4095 orom 57D MAX COMPENSATED INTERNAT SENSOR Unsigned 0 4095 o om S5 ID_MIN COMPENSATED EXTERNAL SENSOR Unsigned 0 4095 ocom SSID MAX COMPENSATED EXTERNAL SENSOR Unsigned 0 4095 ocom G0 ID MIN INNER ACTUAL ERROR Signed 32 768 32 767 8000 7 61 ID MAX INNER ACTUAL ERROR Signed 32 768 32 767 8000 7fff 62 ID_MIN_OUTER_ACTUAL_ERROR Signed 32 768 32 767 8000 7fff 63 ID MAX OUTER ACTUAL ERROR Signed 32 768 32 767 8000 7fff 64 ID_PWM_FAILSAFE 65 ID PWM VALUE 66 ID INNER INTEGRAL DEADBAND 67 ID OUTER INTEGRAL DEADBAND 68 ID FEEDBACK FILTER 69 ID PROFILE TYPE m 70 ID PROFILE STATE 71 ID PROFILE STEP 72 ID ESTOP FLAG 73 ID PULSE 74 ID EXTRA ADI 75 ID EXTRA AD2 76 ID DAC 77 ID COMPENSATED EXTRA ADI 78 ID COMPENSATED EXTRA AD2 79 ID RANGE MIN INLET 80 ID RANGE MIN EXHAUST 81 ID PULSE PERIOD 82 ID PULSE WIDTH 83 ID PULSE DEADBAND 84 ID PULSE ENABL
9. and senses pressure from a transducer mounted downstream in the process as shown in Figure 3 The ER3000 compares the feedback signal to the setpoint every 25 milliseconds If the feedback is lower than the setpoint the ER opens its inlet valve allowing pressure to flow onto the dome of a pressure reducing regulator This opens the main valve of the regulator increasing pressure downstream The ER3000 will continue to increase pressure on the dome of the regulator increasing downstream pressure until the feedback signal is equal to the setpoint If the setpoint is lowered so that the feedback is now higher than the setpoint the ER3000 will open its exhaust valve reducing pressure on the dome of the regulator This will cause the regulator to self vent thus lowering downstream pressure The ER3000 will continue to reduce pressure on the dome of the regulator until the feedback signal is equal to the setpoint 5 1 1 PID Control PID Proportional Integral Derivative control algorithm is widely used in the process industry The most common example of a PID controller is a temperature controller for an industrial oven The basic control algorithm can best be described through use of Figure 20 ONTROLLER ee a eee er ee ee Setpoint r Feedback y Figure 20 PID Control 28 ER3000 User Manual In this drawing the dashed line represents the controller The setpoint signal which is input to the controller represents the desired
10. controller For example if the controller s output passes through a length of pipe to a vessel and it is expected that there will be pressure drops in the pipe then it may be beneficial to install a pressure transducer at the vessel to provide the feedback signal 5 2 3 Cascade Loop Mode Cascade loop mode implements one PID loop within another PID loop The inner loop uses the controller s internal sensor and the outer loop uses an external sensor This mode of operation creates more stability but slows down the response of the system Note For cascade control it is best to set the Integral Minimum 0 and Integral Maximum 32767 This is because it is necessary to maintain a positive pressure on the dome of the regulator to maintain output pressure from the system 5 2 4 Manual Mode In manual mode no control algorithm is implemented The setpoint is used to directly control the unit s pulse width modulators This mode can be useful for system testing In Windows ER3000 Signal Generator Screen or DOS Tune a setpoint value of 0 Fully opens the exhaust solenoid valve 50 Closes both solenoid valves 100 Fully opens the inlet solenoid valve In Windows ER3000 Read Write Screen or DOS ERTALK a setpoint value of 0x0706 Fully opens the exhaust solenoid valve 0x0800 Closes both solenoid valves 0x08fa Fully opens the inlet solenoid valve 5 3 Setpoint sources The setpoint for the unit can be derived from one of thre
11. for systems without an external transducer 4 5 1 Transducer Wiring Configurations The wiring for the two wire transducer is shown in Figure 3 The wiring for the three wire and four wire transducers are shown in Figure 4 and Figure 5 respectively Connect the ER3000 to the transducer or other feedback source as shown in the respective diagrams Check to ensure that the external feedback voltage current select jumper J5 2 is installed for 4 20mAmp or removed for 1 5 Volt operation There is no jumper on the 0 10 Volt ER3000 models BLACK T AN A YELLOW OUTPUT GROUND J N lt CH TRANSDUCER Figure 4 Three Wire External Feedback Cabling NOTE Wire power as shown in figures 2 amp 3 4 Installation 17 DUTPUT sack Sen PON OUTPUT IU r 1 L m IX l GROUND EH N POWER VIOLET fin ji TTT TO H O O TRANSDUCER Figure 5 Four Wire External Feedback Cabling NOTE Wire power as shown in figures 2 amp 3 18 ER3000 User Manual 4 5 2 Analog Setpoint Source Check to ensure that the analog setpoint voltage current select jumper J5 1 is installed for 4 20mA or removed for 1 5V operation There is no jumper on the 0 10V external feedback models Figure 6 and Figure 7 show h
12. on the ER3000 Table 7 LED s Data Transfer Terminal Top Board LED1 red ON LED2 green BLINKING LED3 amber BLINKING Micro Bottom Board LED1 red BLINKING If the LED indicators are not as specified in Table 7 refer to Figure 2 to ensure proper wiring If the amber LED LED3 is OFF suspect the wrong COM port setting If the amber LED LED3 is BLINKING and the green LED LED2 is OFF suspect the wrong node address e If the error message Tescom Startup failed DLL may be in use by another application click OK and use the Channel Selection box to change the comm port Repeat the above step e If you try all 4 comm ports without success then try the following 1 Go to Device Manager Depending on your operating system it may be in MyComputer Control Panel System Hardware Device Manager 2 Click on Ports this will list all the comm ports on your computer 3 If your communications port is higher than 4 you will need to go to the Tescom ini file and change it there This file is installed automatically during the Windows Tune installation It is found in the windows directory on your computer hard drive 4 After changing the comm port in the file save the file and run Windows Tune If after trying the comm port found in the Device driver you are still unable to establish communications run Hyperterminal typically found in Programs Accessories Communications 1 A C
13. to translate between counts and percent This variable is written to Digital Output 2 shown in Table 2 Auxiliary Cable Assembly ID DIGITAL OUT1 INIT Power up state of ID DIGITAL OUT1 ID DIGITAL OUT2 INIT Power up state of ID DIGITAL OUT2 ID DA ANALOG OUT This is the value written to the D A converter to generate the 0 10V or 4 20mA output signal ID TTL ERRO Maximum error allowed at 0 counts see variable 89 ID TTL ERR4095 Maximun error allowed at 4095 counts see variable 89 ID TTL FLAG This variable enables 1 or disables 0 the usage of ID DIGITAL OUTPUT2 as a within tolerance indicator 9 11 PWM Control Variables 12 13 19 20 ID PWM SHUTOFF FLAG This flag is only active if ID RTTASK DELAY variable 13 is not a 0 or 1 and designates what the ER3000 will send to the PWM every 25ms while it is delaying 0 gt Write the previously computed value to the PWM 1 gt Write a 0 to the PWM ID_RTTASK_DELAY This variable is set to 0 typically allowing the control algorithm to generate a new value for the PWM every 25ms Certain systems need a slower acting control system which is allowed by with this variable for example writing a 4 to this variable will allow the control algorithm to compute a new PWM value every 100ms ID_INNER_SENSOR_MIN This variable operation is typically disabled by writing a 0 to it If not disabled it allows for a minimum internal pressure If the internal pressure is below t
14. with the regulator in that system however in this example we will begin tuning by setting the parameters as follows Proportional 200 Integral 0 Derivative 0 Integral Minimum 0 Integral Maximum 0 34 ER3000 User Manual Note For cascade control it is best to set the Integral Minimum 0 and Integral Maximum 32767 This is because it is necessary to maintain a positive pressure on the dome of the regulator to maintain output pressure from the system In the Signal Generator set Setpoint 1 amp Setpoint 2 to 625 and 1875 which is 25 and 75 Make sure that the plot screen is set up to show the entire tuning range For example with the above setpoints the display should be set up for 0 to 2500 Since tuning is generally done using step changes set up Wave Type for option TOGGLE Now click on the Setpoint 1 Setpoint 2 in the Signal Generator to toggle between the two setpoints With the proportional term set to 200 the response will be relatively slow The first step in tuning is to see how far the proportional term can be increased In general increasing the proportional term will decrease the response time i e make the response wave more square however a point will be reached at which the effect becomes detrimental That is too much proportional term will result in overshoot and possibly ringing of the response Also it should be noted that the effect of the tuning para
15. 0 Model Descriptions Figure 14 shows a simple wiring method of controlling a profile without the need for a computer Once the profile is downloaded into the ER3000 it can be started or stopped with a toggle switch The Digital Input pushbutton may be used if the Digital Input function has been used within the profile This allows an operator the flexibility to wait until an event has occurred like changing to the next device An additional feature necessary for some demanding applications is provided for by the Profile Start Stop and Digital Input signals which are the Extra Analog Input 1 and Extra Analog Input 2 inputs of the ER3000 This feature is the ability to adjust the toggle level or trip point of the analog input where it switches between a logical 0 and a logical 1 The ER3000 toggle variables enable this feature and are described in section 9 5 Analog Input Variables For example this feature allows connecting a pressure transducer to the Digital Input and waiting for a specific pressure before continuing on in the pressure profile l Pk pot ORANGE ZS Xe PROFILE START STOP DN BROWN F NH TH A DIGITAL AN INPUT A I WHITE Figure 14 External Profile Control NOTE Wire power as shown in figures 2 amp 3 J5 jumpers 3 and 4 must be removed refer to Figure 1 4 Instal
16. 0 provides the capability of monitoring the internal sensor Figure 18 shows the 4 20 mA wiring option This feature is only available on models that supply the analog output of the internal sensor as referenced in Section 3 ER3000 Model Description A r BAVDC MIDLET POWER SUPPLY GROUND Figure 18 Monitor Internal Sensor 4 20mA wiring i n Sm LEEK Ol O Q V in INPUT PC PLC DIFFERENTIAL INPUT CARD s BY INPUT COMPUTER V in Figure 19 Monitor Internal Sensor 0 10V wiring NOTE Wire power as shown in figures 2 amp 3 4 Installation 27 5 OPERATION 5 1 Theory of operation The ER3000 is a microcontroller based device that implements a digital control algorithm to regulate pressure Supply pressure is allowed into the ER3000 via a pulse width modulated solenoid valve at the inlet port and pressure is reduced via a similar valve at the exhaust port normally the exhaust vents to ambient In a typical application the ER3000 loads the dome of a dome loaded regulator air to open and a venting type regulator for the purpose of this example
17. 0 series models as referenced in Section 3 ER3000 Model Description can monitor two additional analog signals the extra input 1 and extra input 2 signals Monitoring Extra Input 2 does necessitate the knowledge that this input doubles as the Profile Start Stop input The toggle level of Extra Input 2 should be set to its maximum value 4095 if you do not want the pressure profile to start running This is simply done by adjusting variable 86 ID_AD_EXTRA2_TOGGLE described in section 9 5 Analog Input Variables 24 ER3000 User Manual ST WOHELI EJSUT y OOOSNA Sw1UIDYIKSIDG SUDJ4OMION 9 24n917 ANNDAI MAMA A idens asaca je 3Ar ama LOSS ace OmU JU Ul QOOE AA YW 03 VWQQE praod 03 afqe aq Isnuu Ajddns Jamog 9JON s pou e 107 ssaooid sty jeadoy SSAIPPL apou PAIISAP AY 01 GT WIOIJ AopurAA Sno up SI A OU UL pory JAGUNN PON oy 230843 OOLENA oy 0 SUHLITUNUIUIO9 ouO WeIs0Id OOLYA SMOPUTAA oY Suruuni pue 7 mJy ut UMOYS se QOOE MA ue Summ Ag poyst durosor st SSAIPPL pou AY SuIsSULYD YOM JOU u UO eorunututoo Te 0 WY MOJJE o PISULYI oq ysn SSAIPPL Y BOJoIOY OST SSAIPPL pou o 39S 410JIBJ T S COOSAA IV dn posomod pue 191330 po
18. CTION Ae ff 2 PLACES 1 20 OUTLET PORT 1 4 18 NPT MOUNTING H 8 32 UNC E ls 4 PLACES l t 4 2X 74 2X 83 LTL Le 4X 1 46 ES NOTE DIMENSIONS ARE IN INCHES AND ARE FOR REFERENCE ONLY 62 ER3000 User Manual CE Declaration of Conformity Manufacturer s Name Manufacturer s Address European Contact declares that the product Product Name Model Number Tescom Corporation 12616 Industrial Boulevard Elk River Minnesota 55330 2491 United States of America Marc Lembcke TESCOM EUROPE GMBH amp CO KG An der Trave 23 25 23923 Selmsdorf Germany 49 38823 31 0 Electronic Pressure Controller ER3000 to which this declaration relates is in conformity with the relevant EU Directives listed below EU EMC Directive 89 336 EEC using the relevant section of the following EU standards and other normative documents EN55011 Limits and measurements of RFI for Industrial Scientific and Medical ISM Equipment EN50082 2 Generic Immunity for Heavy Industrial Environment Approval Jim Tomczak Title Vice President amp Chief Financial Officer INDUSTRIAL CONTROLS 12616 Industrial Boulevard Elk River Minnesota 55330 2491 TEL 1 800 447 1250 763 241 3238 FAX 763 241 3224 E mail ic tescom com www TESCOM com TESCOM Form No 1893 Rev 1 07 Printed 1 07 2M P Hii EMERSON
19. E 85 ID AD EXTRAL TOGGLE ci e alalalalale ljalalalalala _ ajajajaja ele ale ajajaja Signed Signed nsigned nsigned nsigne nsigne nsigne 0 nsigne nsigne nsigned a A nsigne 0 4095 0 Offf 0 4095 0 Offf A nsigne eN nsigne 0 65 535 0 ffff nsigne 0 4095 0 Offf e nsigne nsigned nsigne nsigne nsigned 0 4095 0 Offf nsigne 0 330 ane 86 ID AD EXTRA2 TOGGLE 87 ID EXT FEEDBACK SOURCE 89 ID DIGITAL OUTPUT2 90 ID DIGITAL OUT1 INIT 91 ID DIGITAL OUT2 INIT 92 ID DA ANALOG OUT 93 ID TTL ERRO 94 ID TTL ERR4095 95 ID DA ANALOG WRITE FLAG 96 ID TTL FLAG e el f l f l le f lle f l f l l ajajajaja A A nsigned 0 Offf nsigned 0 4095 0 Offf ona onu nsigned on ou nsigned oo 1 on nsigned o ou nsigne 0 255 0 4095 0 4095 e nsigne A 1 nsigne ojojojo m a a o nsigne nsigne nsigne nsigne nsigned ojo ojo E lt E 88 ID DIGITAL OUTPUTI mM E 98 ID_SENSOR_FLAG Denotes Read Only all other variables are Read Write 52 ER3000 User Manual ji ji uni ui nsigned Most of the following variables are used exclusively by the UI3000 UI4000 The exceptions are the sensor range variables 108 111 and 114 117 and the profile restart variable 119 The profile restart variable is the only one
20. ER3000 Electronic Pressure Controller User Manual TESCADM EMERSON Process Management PRODUCT WARRANTY Tescom Tescom warrants to the party who purchases products for initial use directly from Tescom its affiliates or authorized distributors or representatives Initial Purchaser that products manufactured and sold by its Industrial Controls Group TC are free from defects in materials and workmanship under normal use and service for a period of 365 days from the date of delivery of the products Warranty Period This warranty applies only to the Initial Purchaser This warranty is not transferable to subsequent purchasers or users of the products During the Warranty Period Tescom will in its sole discretion repair or replace free of charge at its factory in Minnesota any product or part thereof that is found by Tescom after reasonable notification by the Initial Purchaser to have been defective in materials or workmanship The Initial Purchaser must pay all shipping costs for warranty service and is responsible for risk of loss or damage of products during shipment Tescom does not warrant and will not pay for any repairs or replacement made during the Warranty Period by anyone other than personnel authorized by Tescom or its IC Group to make such repairs or replacement THE ABOVE WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES TESCOM AND ITS IC GROUP MAKE NO OTHER EXPRESS OR IMPLIED WARRANTY AND IN PARTICULA
21. ESS Xy Figure 3 ER3000 Typical System Wiring Diagram 4 4 1 Plumb the External Regulator and Transducer If higher pressures or flows are required by the application or it is necessary to isolate the controller from the process media an air actuated mechanical regulator can be used to boost the output and or provide isolation Additionally an external transducer may be used to sense the process pressure supplied by the external regulator 14 ER3000 User Manual 4 4 2 Mount the ER3000 Four 8 32 UNC screw holes are provided for the physical mounting of the ER3000 For details reference mechanical drawings at the back of the manual 4 4 3 Connect the Power Supply Connect a 24 Volt power supply to the ER3000 as shown in Figure 2 Power up the ER3000 Visually check the LED indicators to ensure that power is supplied to the ER3000 The red LED LED1 on the top board should be ON indicating power applied and the red LED LED1 on the bottom board should be blinking indicating the embedded software is running Power down the ER3000 4 4 4 Connect RS485 Interface Connections Connect the ER3000 to the Tescom RS232 RS485 converter as shown in Figure 2 Consult our Troubleshooting section if using a third party converter not all converters are capable of the mode of operation expected by our software Connect the RS485 converter directly to a COMM port default COM2 of the computer if necessary include the 25 to 9 p
22. INGLE PUFF SOLENOID CONTROL VARIABLE 47 9 8 PULSE MODE VARIABLES 47 9 9 SCALING VARIABLES 47 9 10 ANALOG AND DIGITAL OUTPUT VARIABLES 48 9 11 PWM CONTROL VARIABLES 48 9 12 GAIN OFFSET VARIABLES 49 9 13 FAILSAFE VARIABLES 49 9 14 TABLE OF ALL ER3000 INTERNAL VARIABLES 51 10 TROUBLESHOOTING 54 10 1 LED INDICATORS 54 10 2 THIRD PARTY RS232 RS485 CONVERTERS 55 10 3 ER3000 POWER UP TEST USING LED INDICATORS 55 10 4 ER3000 DATA COMMUNICATIONS TEST USING LED INDICATORS 55 10 5 PRESSURE CONTROL PROBLEMS 57 10 6 ACCEPTABLE RESISTANCE VALUES 57 10 6 1 ER3000 RS485 Interface 57 10 6 2 Converter RS485 Interface 57 10 7 LEAK TEST 58 10 7 1 Windows ER3000 P
23. IN_EXHAUST This is the minimum value for the exhaust pulse width modulator The pulse width modulator s value ranges from 0 to 250 This variable along with variable 47 sets the deadband for the system This variable is solenoid dependant and typically a value close to 10 Larger values can give tighter regulation but at a cost of more gas being exhausted ID PWM VALUE This is the value which is controlling the Pulse Width Modulators for the solenoids Positive values represent the inlet solenoid opening and negative values are for the exhaust solenoid A value of 250 represents a 100 duty cycle full on 9 12 Gain Offset Variables 39 40 ID_GAIN This is the gain value This value in conjunction with the offset variable 40 is used to form the feedback signal see variable 44 feedback gain compensated_reading offset 0x0200 gt 1 8 2 adjustability 0x1000 gt 1 025 adjustability 0x8000 gt 8 003 adjustability ID_OSET This is the offset value This value in conjunction with the gain variable 39 is used to form the feedback signal see variable 44 feedback gain compensated_reading offset 0x0000 gt 1 2 FS OxOfff gt 1 2 FS 9 13 Failsafe Variables 64 ID _PWM_FAILSAFE This variable establishes the failsafe state of the unit which is established if any of the programmed limits is 9 ER3000 Internal Variables 49 exceeded Normally the unit will be set up to open t
24. Jomyjos unj pepinoid y Buisn 0315 0 p Bupuo ag uoo aounos julodjes ul ulodjes vWQZ olouo uo 3da990 0 p Jjn uuoo k10390 By Wos s woo jun ay HJOMJSU SUOJOIIUNWUOI GBYSY ul JaA0 papinoid jou 6ip 10 joubis Bojouo uo sayye aq uoy nuiod es p pu po p 0 olu bisdgogz puo O Waamjag UaBoNIN Jo ainssaud posinbes si Bisdgggtz 0 wnwuw D uonpoiddo 104 I Bisdgoo o Wwnwixon 7 ainssalg l lul Joyojnbay L 1S000 43 Jojojnfa1 p on oo ao y War jajrno BISAOOGT In y u iolqo o pasinbas si Bisdog Jo wnwiuiu D uo1npoiddopo siy 104 Bisdoz jo wnwixow D 0 payojnbay JNSS Jd jajul 000843 JAH IUSUDIL ainssaig YWZ zozyoinbay bunuen p s buionpsy einsssig 0 7Vr707907 97 J9 O4JUOD jnss jq Snpuin udodqo l3 L IS000 43 jnu uudinb3 seyou Siqno O uun oA ows volooyddy jooidAy v 011409 0 pa3N sSuonpoui sds 6 2 Tune the Typical Application This tuning procedure utilizes the Windows Tuning program ER3000 CVI and is taken from the ER3000 CVI On Line Help It applies to the above typical application using external feedback To begin it should be realized that the tuning of PID controllers is learned with experience However the following basic concepts should allow the inexperienced user to tune their loops sufficiently for use on a majority of applications
25. ONTROL MODES 29 52 1 Internal Feedback Mode 29 522 External Feedback Mode 29 5 2 3 Cascade Loop Mode 30 5 2 4 Manual Mode 30 3 3 SETPOINT SOURCES 30 5 4 FAILSAFE LIMITS 3 359 LEDS 31 5 6 RS485 COMMUNICATION 31 5 6 1 Protocol 31 6 TUNING PROCEDURE 32 6 1 TYPICAL APPLICATION TO TUNE 32 6 2 TUNE THE TYPICAL APPLICATION 34 7 CALIBRATION 39 7 1 ZERO SPAN 39 8 SOFTWARE PROGRAMS 40 8 1 WINDOWS TUNE PROGRAM 40 8 2 WINDOWS EXAMPLE PROGRAMS 40 8 3 TESCOM PROTOCOL PROVIDE
26. R AND WITHOUT LIMITATION MAKE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE The Initial Purchaser s only remedy under this warranty is repair or replacement of the products during the Warranty Period This warranty does not apply to any product which has been damaged by accident abuse misuse modification or lack of proper maintenance NEITHER TESCOM NOR ITS IC GROUP WILL BE LIABLE FOR ANY CONSEQUENTIAL SPECIAL INCIDENTAL OR INDIRECT DAMAGES INCLUDING WITHOUT LIMITATION LOST PROFITS TESCOM INDUSTRIAL CONTROLS 12616 Industrial Boulevard Elk River Minnesota 55330 2491 1 800 447 1250 763 241 3238 FAX 763 241 3224 e mail icd Otescom com www tescom com EMERSON Windows 3 1 Windows 95 Windows NT DOS and Visual Basic are trademarks of Microsoft Corporation LabVIEW and LabWindows CVI are trademarks of National Instruments Installation amp Operation Precautions TESCOM Industrial Controls INTRODUCTION Prior to installing or operating any equipment read and follow all the information listed Improper application and operation can result in damage to equipment or severe personal injury All possible hazards and precautionary measures cannot be covered here It is recommended that prior to using this equipment you fully understand and comply with existing safety regulations OXYGEN SERVICE Specification of the materials in regulators used for oxygen service is the USER S RE
27. S CUSTOM SOFTWARE SUPPORT 40 8 3 1 DOS Library 4 8 3 2 Windows DLL 4 8 3 3 Macintosh Custom Software 42 6 4 DOS PROGRAMS 42 8 4 1 Tune 42 84 2 Ertalk 42 8 4 3 Profile 42 8 4 4 Profile2 42 8 4 5 Data l g 43 8 4 6 Test _pr 43 9 ER3000 INTERNAL VARIABLES 44 9 1 SETPOINT AND FEEDBACK VARIABLES 44 9 2 CONFIGURATION VARIABLES 44 9 3 INNER LOOP TUNING VARIABLES 45 9 4 OUTER LOOP TUNING VARIABLES 45 9 5 ANALOG INPUT VARIABLES 46 9 6 PRESSURE PROFILE CONTROL VARIABLES 46 9 7 S
28. SENSOR 9 ID CONTROL MODE 10 ID INNER DERIVATIVE 11 ID INNER EFFECTIVE ERROR 12 ID PWM SHUTOFF FLAG 13 ID RTTASK DELAY 14 ID OUTER ACTUAL ERROR 16 ID OUTER D COEFI1 17 ID OUTER D COEF2 signed 4095 4095 Offf OFFF 2 768 32 767 8000 7fff 18 ID_OUTER_EFFECTIVE_ERROR 19 ID_INNER_SENSOR_MIN 20 ID_INNER_SENSOR_MAX 21 ID OUTER INTEGRAL CONSTANT 22 ID OUTER INTEGRAL MAXIMUM 23 ID OUTER INTEGRAL SUM 25 ID OUTER PROPORTIONAL CONSTANT 26 ID FACTORY MIN INLET 27 ID FACTORY MIN EXHAUST 28 ID INNER INTEGRAL CONSTANT 29 ID INNER INTEGRAL MAXIMUM nused di igned 32 768 32 767 8000 7fff U 0 65535 0 ffff U U 0 4095 0 Offf 0 4095 0 OFFF 2 768 32 767 8000 7fff 30 ID_LINNER_INTEGRAL_SUM 34 ID OUTPUT 35 ID INNER PROPORTIONAL CONSTANT 37 ID SETPOINT 38 ID RAW TEMP SENSOR 39 ID GAIN 40 ID OSET 41 ID_ARDG 42 ID_NODE 43 ID_SETPOINT_FLAG 44 ID_FEEDBACK 46 ID_SOLENOID_DIRECTION 47 ID_MIN_INLET 48 ID_MIN_EXHAUST 49 ID_OUTER_INTEGRAL_MINIMUM 50 ID_INNER_INTEGRAL_MINIMUM 51 ID_RAW_AD_SETPOINT 52 ID_SERIAL_NUMBER 53 ID VERSION NUMBER 54 ID MIN AD SETPOINT Signed 3 7 d d Signed 3 167 Signed 3 7 d d Signed 3 7 d 7 2 768 32 767 8000 7fff igned 32 768 32 767 8000 7fff Signed nsigned nsigned nsigned nsigned 0
29. SPONSIBILITY Cleaning for oxygen service to 3000 PSIG is supplied standard by Tescom at no additional cost for mechanical regulators Cleaning for service above 3000 PSIG may be contracted through an outside source COMPATIBILITY 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 Users must test under operating conditions to determine suitability of materials in an application PRESSURE RATING Verify the designed pressure rating of the equipment Check supply lines fittings connections filters valves and gauges All must be adequate for the supply and operating pressure RELIEF PROTECTION A regulator is not intended to be used as a shut off device A pressure relief device should be installed downstream of the regulator to protect the process equipment in the case of a rise in operating pressure When the regulator is not in use the supply pressure should be closed FILTRATION An auxiliary upstream filter is recommended for use in all media Gaseous media should be free of excessive moisture to prevent icing of the equipment MAINTENANCE Periodic inspection and scheduled maintenance of your equipment is essential for continued safe and satisfactory operation The frequency of servicing will depend on t
30. able determines the source of the setpoint variable 37 ID SETPOINT 0 gt setpoint from A D analog setpoint input 1 gt setpoint from RS485 network typically a PC 2 gt setpoint from internal pressure profile ID_FEEDBACK This is the controller s overall feedback signal For internal sensor mode it is the same as inner feedback For external sensor mode or cascade mode it equals the outer loop feedback ID EXT FEEDBACK SOURCE This variable determines the source of the external feedback 0 gt feedback from the compensated external sensor see variable 5 1 gt feedback from extra analog input 1 see variable 77 Note For both setpoint and feedback a value of 400 counts is 0 and 3700 counts is 100 To convert between counts and percent use the following formulas value_percent value_counts 400 100 3300 value_counts value_percent 3300 100 400 9 2 Configuration Variables 9 ID CONTROL MODE This variable establishes the control mode for the controller A value of four only occurs when a failsafe condition exists due to a failsafe limit being exceeded see variables 54 to 64 A value of five only occurs if the controller is in ESTOP emergency stop mode 0 gt internal feedback mode 1 gt external feedback mode 2 gt cascade mode 3 gt manual mode setpoint 0x08fa gt inlet open setpoint 0x0800 gt solenoids closed setpoint 0x0706 gt exhaust open 4 gt failsafe mod
31. and the minimum and maximum reduced until flow is no longer maintained then slightly increase these values Often for closed ended systems a value of one or two is sufficient After performing the steps mentioned above tuning can often be improved by iterating between the various parameters Although performing basic tuning can be simple learning to fully optimize the tuning requires experience so experiment 6 Tuning Procedure 35 The following is an example seguence of tuning steps First a very undertuned response is shown note size of proportional term Tuning BEI Plot 5 x Eile Format Simple File Axis Labels PlotStart Control Mode External Feedback lt w Sensor Range Minimum 0 00 Units Maximum 2500 00 PSI Outer Loop Proportional Term 200 ra Integral Perm 0 6 i 3 Integral Minimum 0 Integral Maximum 0 Integral Deadband 0 00 ExtFBSource External Feedback v Minimum Pulse Width Inlet 10 Exhaust 10 Next the proportional term is increased however overshoot and ringing results Tuning BEE File Format Simpe W Fie Axis Labels PlotStart ControlMode External Feedback lt w 2500 2250 Sensor Range Minimum 10 00 Units Maximum 2500 00 PSI 2000 Outer Loop 1750 i 1 1000 Integral Term 0 Derivative Term Integral Minimum 0 Integral Maximum Integral Deadband 0 00 ExtFBSowce External Feedback lt w Minimum Pulse Width Inlet 10 Exhaust 10 Time sec
32. c in the profile2 directory for a detailed description of the software 8 4 5 Data log This sample data acguisition program provides basic data collection for the user The program can be used to read up any of the ER variables and store the information into an output file Data log cfg is used to configure the data collection variables including sample time number of samples variables to collect and output file name See readme doc in Data log directory for more information 8 4 6 Test pr Test pr exe resides in the Debug directory This program can be used as a simple test for the user to check for node and serial numbers version of software and communication port This program should be used as part of the troubleshooting steps described in Section 10 Troubleshooting 9 ER3000 Internal Variables 43 9 ER3000 INTERNAL VARIABLES The ER3000 has a number of internal variables which can be accessed via the RS485 interface The most commonly used variables are listed below The variable index number name and description are shown The index number is the value that is entered in the DOS based ERTALK program or the Read Write Screen of the Windows based ER3000 CVI program to access the specified variable A complete list of internal variables is shown in the table at the end of this section 9 1 Setpoint and Feedback Variables 37 43 44 87 ID SETPOINT This is the controller s setpoint ID SETPOINT FLAG This vari
33. ck on Setpoint 1 wait until feedback reaches 0 Click on Setpoint 2 e Watch the feedback signal for 25 seconds it should remain constant If feedback increases the inlet solenoid is leaking e Change Setpoint 1 to 100 Click on Setpoint 1 Wait for feedback to stabilize which takes approximately 5 seconds e Click on Setpoint 5 e Watch feedback signal for 25 seconds it should remain constant If feedback decreases the unit is leaking If leaking plug exhaust port with finger and release If pressure buildup at exhaust then exhaust solenoid is leaking 10 7 2 DOS Tune Program Main Screen Settings Setup Screen Settings Setpoint 1 Display Upper a 100 approx Span Setpoint 2 Timebase b 0 approx Zero Wave Type Sensor Range Low c Manual Mode Display Lower Sensor Range High d Digital Setpoint Source Procedure From the TUNE Main Screen select b to run plot Press spacebar to toggle Setpoint to 0 Wait until Feedback reaches 0 Press spacebar to toggle Setpoint to 50 e Watch the Feedback FB signal for 25 seconds If feedback increases the inlet solenoid is leaking Change j Setpoint 2 to 100 Press spacebar to toggle Setpoint to 100 58 ER3000 User Manual e Wait for Feedback to stabilize which takes approximately 5 seconds Press spacebar to toggle Setpoint to 50 e Watch Feedback signal for 25 seconds If feedback decreases the unit
34. e Check for pneumatic connections the inlet pressure max 120 psig must go into the inlet port marked IN on the unit The gauge port must be plugged if gauge not installed Check the control mode and setpoint source using the provided software Check the values of the PID parameters using the provided software Check the unit s calibration see the Calibration Section for details 10 6 Acceptable Resistance Values The resistance values must be measured with all external wiring disconnected including the power Ensure converter screw terminals are tight 10 6 1 ER3000 RS485 Interface e RS485 to GND 10KQ to 50KQ e RS485 to GND 10KQ to 50KQ 10 6 2 Converter RS485 Interface e RS485 to GND 3K to 5KQ e RS485 to GND 9009 to 1 2KQ 10 Troubleshooting 57 10 7 Leak Test The ER3000 can be leak tested using the DOS Tune program or the Windows ER3000 CVI program Prior to running the leak test ensure the following items are done ER3000 wired up and communicating to the computer 100psi is applied to the inlet of the ER3000 The outlet port of the ER3000 is plugged 10 7 1 Windows ER3000 Program Setup Screens as Shown in Table Signal Gen Control Mode Manual Signal Type Toggle Axis Vertical 5 105 Span 100 Sensor Range 0 100 Setpoint 1 0 Min Max Zero 0 Min Max Setpoint 2 50 Axis Time 5 Need not be exact Procedure Open PLOT and SIGNAL GENERATOR Screens Cli
35. e read only 5 gt emergency stop read only 44 ER3000 User Manual 42 52 53 ID NODE This is the unit s network node address Note that if this variable is changed then all future communication must be addressed to the new node address ID SERIAL NUMBER This is the serial number for the unit It is programmed at the factory and should not be changed by the user ID VERSION NUMBER This is the version number of the embedded software 9 3 Inner Loop Tuning Variables 35 28 3 50 29 30 66 ID INNER PROPORTIONAL CONSTANT This is the P term proportional constant for the inner loop ID INNER INTEGRAL CONSTANT This is the I term integral constant for the inner loop ID INNER D COEFI1 This is the D term derivative constant for the inner loop ID INNER INTEGRAL MINIMUM This is the minimum value allowed for the integral sum on the inner loop ID INNER INTEGRAL MAXIMUM This is the maximum value allowed for the integral sum on the inner loop ID INNER INTEGRAL SUM This is the value of the integral sum for the inner loop It is formed by multiplying the integral constant time the error and summing the result with the previous value for the integral sum ID INNER INTEGRAL DEADBAND This is the inner loop minimum error reguired for the integral sum to be changing in value Often it is set to zero and has no effect However if it is desirable to stop integrating once the error is reduced bel
36. e sources It can be Transmitted over the RS485 interface Input from an analog signal 4 20mA 1 5V or 0 10V Supplied by an embedded profile 30 ER3000 User Manual 5 4 Failsafe Limits Another function of the ER3000 is to detect when programmable limits are exceeded Limits can be set on the following variables Analog setpoint Internal feedback External feedback Inner loop error signal Outer loop error signal Associated with the limits is a failsafe state that is user defined to set the inlet and exhaust valves in any desirable combination of open and or closed states The default failsafe state is to close the inlet valve and open the exhaust valve so that the system will be vented if a limit is exceeded Limits can be useful for providing added security in the event of a system failure such as broken transducer wiring lack of supply pressure etc When limits are not desired the failsafe modes should be disabled they are disabled when shipped from the factory 5 5 LEDs There are four LEDs light emitting diodes on the boards to indicate the status of the unit The LEDs indicate the ER3000 is fundamentally operating correctly Refer to the Troubleshooting Section for more details on LED indicators 5 6 RS485 Communication RS485 communication provides a low cost yet efficient means of communicating between a computer and a network of ER3000 controllers 5 6 1 Protocol In the ne
37. ed by input pressure Environment Temperature 30 C to 75 C Dry nitrogen supply gas 20 C to 60 C KEMA Explosion Proof Versions M amp N 5 C to 75 C Shop air Pressure 28 32 inches Hg Humidity To 100 R H non condensing 0 C to 75 C Flow Rate Cv 0 01 Note The flow rate can be increased using a booster regulator Power Requirement Voltage 24V 22V to 28V Current 340mA Max 180mA Nominal RS485 Communication Interface Networking Up to 32 controllers on one network Cable length 4000 ft Max Baud rate 9600 8 ER3000 User Manual 2 8 Accuracy Room temp 0 1 of span max Temp effects 0 002 F of span max 2 9 Response Time Rise Time 257ms 10 psi to 90 psi Fall Time 552ms 90 psi to 10 psi Note Step response into dead end system 1 cubic inch volume 2 10 Ports Conduit 1 2 NPT Pneumatic 1 8 NPT Inlet exhaust and gauge ports 1 4 NPT Controlled outlet port 2 11 Weight 34 8 oz 1 0 kg 2 12 External Analog Input Impedance 4 20mA 250Q 1 5V 220KQ Single Input Pin to Gnd 1 7MQ Differential Input 0 10V 100KQ 2 13 Digital Outputs Current 50 mA Continuous 100 mA Instantaneous Voltage SV 28V Type Open collector grounded emitter 2 14 Digital Inputs Voltage Range Input Impedance 4 20 mA 2509 1 5V 220KQ Single Input Pin to Gnd 1 7MQ Differential Input 0 10V 100KQ Type Level Sensitive 2 15 Analog Output 4 20mA 0 5 Accuracy
38. een OFF LED3 amber OFF Micro Bottom Board LED1 red BLINKING If the LED indicators are not as specified in Table 6 refer to Figure 2 to ensure proper wiring Check power wiring if the red LED s are off Check the RS485 wiring if the amber LED is on Check to ensure no jumper is on J3 of the micro bottom board if the green LED is on If not using a Tescom RS485 RS232 converter refer to Table 5 for proper mode of operation If unable to resolve the problem contact your local distributor A list of Tescom distributors may be found on our website www tescom com or by contacting the factory 10 4 ER3000 Data Communications Test using LED Indicators For Windows These procedures assume You have followed the instructions in Sections 4 4 3 thru 4 4 6 to run the Windows Tune program You are using a Tescom converter or some other converter that has TxD amp RxD indicator lights If you are not using a Tescom converter refer to Table 5 for proper setup The test above Power up Test of the ER3000 using LED Indicators works 10 Troubleshooting 55 Ifthe Comm Error window pops up click on Search Network As the program scrolls through the nodes check the TxD light on the converter o Tfitis not blinking you are not connected to that comm port When the search is completed change the comm port and repeat until you find the correct comm port o If it is blinking Check the LED indicators
39. erating under nonstandard temperature conditions and it is desired to optimize the calibration for this environment There has been some long term drift in the calibration An external transducer is being used to provide feedback The procedure is as follows 1 Connect a reference pressure gauge to the output of the ER3000 or the output of the booster regulator if one is being used 2 Set the setpoint via the analog setpoint input or the RS485 interface as appropriate to a value close to zero 4 16 mA for analog input or 1 for RS485 interface are recommended 3 If the reference pressure meter does not indicate 1 psi then increase the zero value to raise the reading or decrease to lower it as required 4 Next set the setpoint to a value close to 100 19 2 mA for the analog setpoint or 95 for RS485 interface are good values 5 If the reference pressure meter does not indicate 95 psi then increase the span value to raise the reading or decrease to lower it as required 6 Set the setpoint via the analog setpoint input or the RS485 interface as appropriate to a value close to zero 4 16 mA for analog input or 1 for RS485 interface are recommended 7 Verify that the pressure meter indicates 1 psi If not then repeat above procedure A couple of points should be noted for proper calibration First the controller should be properly tuned before performing calibration if possible Second proper time for the pressure to set
40. ernal dome loaded regulator which has hysteresis then this parameter should be set to the minimum acceptable error 9 5 Analog Input Variables 1 77 78 85 86 ID_AD_SETPOINT This is the value of the analog setpoint A value of 400 is 0 and 3700 is 100 Note that the analog setpoint is not used unless the controller is programmed to use it see variable 43 ID COMPENSATED EXTERNAL SENSOR This is the compensated external sensor value i e after linearization zero and span have been applied to the raw signal A value of 400 is 0 and 3700 is 100 ID COMPENSATED EXTRA ADI This input is available only on certain models refer to section 3 This is the compensated external analog input value 1 e after linearization has been applied to the raw signal ID COMPENSATED EXTRA AD This input is available only on certain models refer to section 3 This is the compensated external analog input value 1 e after linearization has been applied to the raw signal ID AD EXTRA1 TOGGLE This variable is used to adjust the level that the ER3000 interprets the ID COMPENSATED EXTRA ADI variable as a logical 0 or a logical 1 ID_AD_EXTRA2_TOGGLE This variable is used to adjust the level that the ER3000 interprets the ID COMPENSATED EXTRA AD2 variable as a logical 0 or a logical 1 9 6 Pressure Profile Control Variables 69 ID PROFILE TYPE This is the type of the profile step currently active 0 gt STOP 1
41. gromu Suroq 210729 SISSAIPPL pou JUHTIJJIP 07 dn jas aq snu S QOOSAA UL II mr ur UMOYs se PIUTLYJASTEP 1943330 PIJTIOMJIU aq WeI S COOSAA TE 01 AN S 000EAA SUBJIOMJIN S P 4 5 8 Digital Outputs The ER3000 s can provide digital outputs to the rest of the system The outputs can be toggled using a PC computer program or as part of a pressure profile This can be used to trigger a process in another part of the system or simply turn on a light bulb or sound an alarm This feature is only available on ER3000 models that have the digital outputs as referenced in Section 3 ER3000 Model Description J m POWER SUPPLY ad b Ns 12 VDC lt 120 VAC ail DAD 1 w P ee ee ID A J ES RELAY y LOAD 2 iat m Ll N T 24VDC 271 E VIOLET Sl J eo EN CT WHITE GRAY N g GROUND MECHANICAL RELAY MW kk f ait ii l l l 1 O O Figure 17 ER3000 Digital Outputs Output load 1 is shown in Figure 17 using an external supply to switch a 12VDC solid state relay which controls the load Output load 2 is shown in Figure 17 using the ER3000 s power supply to switch a 24VDC relay which controls the load 26 ER3000 User Manual 4 5 9 Monitor Internal Sensor using the Analog Output The ER300
42. gt RAMP 2 gt STEP 3 gt DWELL 4 gt DIGITAL OUTPUT 5 gt DIGITAL INPUT 6 gt LOOP 7 gt CHANGE VARIABLE 46 ER3000 User Manual 70 ID PROFILE STATE This is the run state of the profile 0 gt STOP 1 gt START 2 gt RUN 71 ID PROFILE STEP This is the step in the profile which is currently being run 119 ID UI PROFILE STARTRUN This is the restarting mode of the profile 0 gt Restart profile at the beginning 1 gt Resume profile at current profile step 9 7 Single Puff Solenoid Control Variable 73 ID PULSE This variable allows opening the inlet or exhaust for the specified duration for one pulse period After one pulse duration the variable is returned to a value of 0 0x08fa gt Inlet full open 0x0800 gt Both valves closed 0x0706 gt Exhaust full open 9 8 Pulse Mode Variables 81 ID_PULSE_PERIOD This controls the rate of the pulse while pulse mode is active The value represents how many passes through the control algorithm 25ms per pass before sending a pulse to one of the solenoids 82 ID PULSE WIDTH This controls how long the solenoid is held open while pulse mode is active Part of this number compensates for allowed system fluctuations or noise so too small a number will not open the solenoid valve 83 ID_PULSE_DEADBAND This is the error from the setpoint allowed for the pulse function to stop pulsing This value is in counts read up from the sensor One count of e
43. gured for 1 5V input Jumper installed configured for 4 20mA input LED s Refer to Section 10 1 LED Indicators for an explanation of the LED indicators 12 ER3000 User Manual 4 3 Basic ER3000 to PC Wiring The necessary wiring for the ER3000 communicating to a PC is shown in Figure 2 A PCis typically used to communicate to the ER3000 digitally but any device capable of the interface protocol could be used such as a PLC BLUE D A al IIB NI OS III U JM GREEN lesel Figure 2 ER3000 Basic Wiring Diagram 4 Installation 13 4 4 Setting up a Typical ER3000 Pressure Control System One of the most commonly used modes of operation is shown in Figure 3 The configuration shows the ER3000 with a 24 Volt power supply pressure regulator 4 20mA transducer RS232 RS485 converter and an optional 25 9 pin adapter cable BLUE GREEN 4 20m A nn d TRANSDUCER I e ER3000 SUPPLY PRESSURE 110 PSD F Se gt SUPPLY PRESSURE TO PROC
44. hanging signals Its primary function in the control algorithm is to suppress oscillations Tuning a controller is the process of selecting the optimal Kp Ki and Kd constants to yield the best response The best response depends on what is most important for a given application and often becomes a compromise between response time and stability 5 2 Control Modes The ER3000 provides four modes of operation These modes depend on whether the feedback signal is derived from the controller s internal pressure sensor a user supplied external sensor such as a 4 20 mA pressure transducer or a combination of the two The four modes are described in the following sections 5 2 1 Internal Feedback Mode The internal feedback mode uses the ER3000 s temperature compensated internal sensor to control the output pressure in the 0 100 psig range 5 2 2 External Feedback Mode The external feedback mode uses a user supplied external transducer to control the process pressure This mode is typically used when using the ER3000 to load the dome of a mechanical air actuated regulator or control valve Control of the 5 Operation 29 actual process pressure is obtained by installing a pressure transducer at the output of the regulator or valve to provide the feedback signal to the ER3000 External feedback can also be useful when using the ER3000 as a standalone unit It may be desirable to measure the pressure downstream from the
45. he application REPAIR SERVICE Any equipment in need of service should be returned to your equipment supplier for evaluation and prompt service If repairable your equipment will be restored to the original factory performance specifications A flat fee repair charge has been established for each standard model and the original equipment warranty will be reinstated after a complete overhaul ASSEMBLY INSTALLATION DRAWINGS amp BILLS OF MATERIAL Drawings and parts lists for your product may be obtained by calling 1 800 447 1204 Tescom will provide these by fax or mail Your local distributor can provide additional assistance TABLE OF CONTENTS 1 INTRODUCTION 0000 nnn nnn nnn nnnnnnnnnennennenennnnn 7 2 SPECIFICATIONS 22 22 2220 200 2220002 n nen neem mmm 8 2 1 ENCLOSURE 8 2 2 MEDIA 8 2 3 INLET PRESSURE 8 2 4 ENVIRONMENT 8 25 FLOW RATE 8 2 6 POWER REQUIREMENT 8 2 1 RS485 COMMUNICATION INTERFACE 8 2 8 ACCURACY
46. he exhaust and close the inlet valve if a limit is exceeded Also note when shipped from the factory the limits are set to their limits i e disabled The unit will automatically remove itself from failsafe if the failsafe limit is no longer exceeded 0 gt IN CLOSED EX CLOSED 1 gt IN OPEN EX CLOSED 2 gt IN CLOSED EX OPEN 3 gt IN OPEN EX OPEN Failsafe Limits for Specified Signals These variables are the minimum and maximum values allowed for a given signal that is permissible before tripping a limit and causing the unit to go into failsafe Limited Signal 54 ID MIN AD SETPOINT 1 ID AD SETPOINT 55 ID MAX AD SETPOINT 56 6 ID MIN COMPENSATED INTERNAL SENSOR ID COMPENSATED INTERNAL SENS 57 OR ID MAX COMPENSATED INTERNAL SENSOR 58 T ID MIN COMPENSATED EXTERNAL SENSOR ID COMPENSATED EXTERNAL SENS 59 OR ID MAX COMPENSATED EXTERNAL SENSOR 60 ID MIN INNER ACTUAL ERROR 0 ID INNER ACTUAL ERROR 61 ID MAX INNER ACTUAL ERROR 63 ID MAX OUTER ACTUAL ERROR 50 ER3000 User Manual 9 14 Table of all ER3000 Internal Variables Table 3 ER3000 Internal Variables Variable Name and Number Type Range Decimal Range Hex 4 ID INNER D COEF2 Unused 3 ID INNER D COEF1 Signed 32 768 32 767 8000 7fff 5 ID COMPENSATED EXTERNAL SENSOR 0 4095 0 Offf 6 ID COMPENSATED INTERNAL SENSOR 0 4095 0 OFFF 7 ID RAW EXTERNAL SENSOR 0 4095 0 Offf 8 ID RAW INTERNAL
47. he specified value the exhaust valve will not be opened to decrease the pressure ID INNER SENSOR MAX This variable operation is typically disabled by writing a 4095 to it If not disabled it allows for a maximum internal pressure If the internal pressure is above the specified value the inlet valve will not be opened to increase the pressure 48 ER3000 User Manual 34 46 47 48 65 ID OUTPUT This is the value of the output from the controller It is this value which controls the ER3000 s valves A positive number will open the inlet valve and a negative number will open the outlet valve ID SOLENOID This variable determines which valve is open when the output is positive or negative In normal mode 0 gt Normal positive outputs open the inlet solenoid and negative outputs open the exhaust solenoid In reversed mode 1 gt Reversed positive outputs open the exhaust solenoid and negative outputs open the inlet solenoid This is useful in reverse acting systems i e in systems where increasing the pressure causes the process variable to decrease ID MIN INLET This is the minimum value for the inlet pulse width modulator The pulse width modulator s value ranges from 0 to 250 This variable along with variable 48 sets the deadband for the system This variable is solenoid dependant and typically a value close to 10 Larger values can give tighter regulation but at a cost of more gas being exhausted ID_M
48. in adapter cable 4 4 5 Install the ER3000 CVI Windows Program Insert the ER3000 User Software CD into your PC and the install program should start automatically If it does not choose and run the autorun executable on the CD Click on the INSTALL button in the CD Menuing System menu to get to the Installation Menu From the Installation Menu chick on the Windows Tune 32 BIT button Follow the on screen instructions during the installation process The installation will automatically create the directory ER3000 and install the Windows Tune program including support files e g TESCOM DLL The Windows program contains a complete online help manual and a manual rtf file of all the online help pages that may be easily printed out 4 4 6 Communicate to the ER3000 using the ER3000 CVI Windows Program Power up the ER3000 Execute the ER3000 CVI program The program is executed by pressing the Start button choosing the Programs menu choosing the ER3000 CVI folder and then selecting the ER3000 CVI program If an error occurs go to the Troubleshooting section Power down the ER3000 4 Installation 15 4 4 7 Connect Transducer Wiring If the downstream process pressure regulation is required by the application a pressure transducer can be used to provide a 4 20mA 1 5V or 0 10V feedback signal Figure 3 shows wiring for a 2 wire 4 20mA transducer The wiring of three and four wire tra
49. is leaking If leaking plug exhaust port with finger and release If pressure buildup at exhaust then exhaust solenoid is leaking 10 Troubleshooting 59 11 ER3000 Accessories Part Description 82699 12 pin MTA connector only 85138 X 12 wire cable assembly 5 10 20 50 and 100 foot options 85121 12 wire cable assembly 24 85139 X 8 wire cable assemble 5 10 and 20 foot options 85122 8 wire cable assembly 24 85137 Fitting Kit includes 14 x 1 8 NPT 14 x 14 NPT and a male tube connector 80279 Filter 85145 Filter Kit 82575 25 250 mA 24VDC Power Supply 82575 50 500 mA 24VDC Power Supply 85061 RS232 to RS485 converter 82948 USB to RS485 converter 82919 Potentiometer with digital display 60 ER3000 User Manual 12 MECHANICAL DIMENSIONS OF ER3000 3 83 97 28 AN ATMOSPHERIC REFERENCE FOR INTERNAL SENSOR i EXHAUST PORT 1 8 27 NPT 4 20 BK le 94 j L P97 86 N GAUGE PORT 1 8 27 NPT INLET PORT 178 27 NPT NOTE DIMENSIONS ARE IN INCHES AND ARE FOR REFERENCE ONLY 12 Mechanical Dimensions of ER3000 61 172 14 NPT CONDUIT CONNE
50. lation 23 4 5 5 Switch Feedback Control to a Second Feedback Source The feedback source can be easily switched between two feedback sources by writing to variable 87 ID EXT FEEDBACK SOURCE in the ER3000 This may be guite beneficial if trying to control at two very different pressures e g 80 psi and 8000 psi Transducer 1 could be a 10 000 psi transducer and Transducer 2 could be a 100 psi transducer This feature is only available on ER3000 models that have the extra analog inputs as referenced in Section 3 ER3000 Model Description m I AI W l JIN L YELLOW EN M l TV ORANGE A C 4 20mA Ww 4 20mA 4 20mA J NN 4 20mA gt gt VIOLET AAA A at E z TRANSDUCER 1 TRANSDUCER 2 Figure 15 Switch between two External Feedback Sources NOTE Wire power as shown in figures 2 amp 3 4 5 6 Monitor Analog Signals The ER3000 can monitor a number of analog signals This is quite useful in data acquisition systems to perform trend analysis on the system Figure 15 shows two transducers e g with outputs P1 and P2 that can be continuously monitored by a PC program All of the ER3000 models can monitor two analog signals the analog setpoint and external feedback Some ER300
51. level of response the desired pressure in this case The output which goes to the system under control is the actuating signal to the process the amount that each valve is opened in this case The feedback signal represents the measured response of the system using for example a 4 20 mA pressure sensor Thus the function of the controller is to analyze the setpoint and the feedback to produce the output signal This is done in the following manner Refer to the Figure 20 ignoring for the moment the lower block containing the term Kd We see that the feedback signal is subtracted from the setpoint signal to form the error signal The error thus represents the deviation of the actual system response from the desired response The output is then produced by summing two terms The first term is the product of the error and the constant Kp the proportional constant Thus the larger the error the greater the output is The second term is formed by multiplying the integral of the error times the constant Ki the integral constant The effect of the integral is to accumulate the error over time The effect of even small errors will eventually cause the output to increase over time until the system responds and the error is eliminated We return now to the effect of the Kd block in the feedback path This block multiplies the derivative of the feedback times the constant Kd the derivative constant The derivative is sensitive to rapidly c
52. meters PID tends to be logarithmic Thus a possible sequence of values to try for the proportional term might be 200 400 800 1600 until ringing and or overshoot occurs and then narrow down to an optimal value one which gives just a slight amount of overshoot and ringing Next the derivative term should be increased so as to reduce the overshoot and ringing in the system However too much derivative term may result in a noisy output Once the optimal proportional and derivative terms are found the integral term should be adjusted The integral term has the effect of eliminating DC offsets however too much integral will lead to instability overshoot and ringing Again the effect is logarithmic so values such as 10 20 50 100 200 500 1000 can be tried until an optimal value is obtained At this point it should be noted that the ER3000 provides a unique integral limiting feature Minimum Outer Integral and Maximum Outer Integral This allows for using large integral terms without creating excessive overshoot It should be realized that the integral sum is what holds the valves open even when there is zero error For closed ended systems the minimum and maximum integrals can be very small However for systems requiring flow it is necessary to keep these values higher To determine how small they can be made remember smaller is better as long as proper flow is maintained the setpoint should be set to the maximum level
53. ndards shown on the metal tag 4 1 Interface Cable Assemblies The following tables give the complete wiring layout of the ER3000 wiring assemblies which are connected to the J3 and J4 terminal 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 Assembl Setpoint Input ed Feedback Input 7 24 Volt DC Power Violet 8 24 Volt Return Power Ground Gray 10 k n Table 2 Auxiliary Cable Assembly ER3000F and ER3000G models 2 Awp Red 5 AnalogSignal Ground Green 6 Digital Output Ground Black 8 On DigitalOutput 2 White Active in ER3000F and ER3000G Models only 4 Installation 11 4 2 Voltage Current Select Jumpers Figure 1 shows the J5 voltage current select jumpers location on the ER3000 Use them to select between 4 20mA and 1 5V The 0 10V models of the ER3000 do not have the jumpers The jumper on the bottom board is for factory installation of the embedded software only and the jumper should not be installed for normal operation Figure 1 Voltage Current Select Jumpers Jumper J5 top board Voltage Current Select not on 0 10V models 1 Analog Setpoint 2 External Feedback 3 Auxiliary input 1 4 Auxiliary input 2 For all the above jumper positions Jumper not installed confi
54. nsducers are shown in section 4 5 1 Transducer Wiring Configurations Check to ensure that the external feedback voltage current select jumper is installed for 4 20mA or removed for 1 5V operation There is no jumper on the 0 10V external feedback ER3000 models 4 4 8 Connect Pressure to the System Figure 3 illustrates the typical pressure connections for the ER3000 The ER3000 inlet pressure is the supply pressure max 120 psi The exhaust port on the ER3000 is used for venting when a pressure reduction is required The inlet pressure to the regulator depends on the capability of the regulator and the system requirements The output pressure is the regulated pressure being supplied to the process The gauge port can have a pressure gauge attached or simply plugged If desired the gauge port can be used as the output the normal output port must then be plugged 4 4 9 Tune the System The system should now be fully installed The system performance can be checked using the Windows ER3000 CVI program or the DOS Tune program provided The tuning parameters can be updated using these programs to alter the ER3000 and system performance Refer to the Tuning Procedure section for details on tuning the pressure control system 16 ER3000 User Manual 4 5 Additions and Variations to the Typical System This section shows variations and additions to the Typical ER3000 control system shown in Figure 3 Alternatively use Figure 2 as a baseline
55. ntrol eteemeemeeneenennenneeneeneeneeneee 23 Switch between two External Feedback Sources 24 Networking Daisychaining ER3000 s 29 ER3000 Digital Outputs mimeeeemeeneeneneeeenennennenneneeneee 26 Monitor Internal Sensor 4 20mA wiring 27 Monitor Internal Sensor 0 10V wiring 27 Regulator and ER3000 Internal Operation 32 EED LOCQUHONS oiaren l b an a a a a u asus 54 ER3000 USER MANUAL 1 INTRODUCTION The ER3000 Electronic Regulator is a versatile 0 to 100 psi pressure controller It can be used in conjunction with any pneumatically actuated regulator or valve to control pressure from subatmosphere to 20 000 psi with Cv s of up to 45 Setpoints can be provided via an analog input 4 20mA 1 5V or 0 10V the digital RS485 interface or a downloaded profile The RS485 interface makes pressure control by a computer easier than ever before The controller can be wired quickly into the standard serial communication port found on any PC using a low cost 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 tempera
56. o allow PC initialization including the serial port This function does not send any data to the ER3000 This function needs to be called only once WriteNetVar This function is used to write any of the ER3000 internal variables ReadNetVar This function is used to read any of the ER3000 internal variables WriteProfileSegment This function is used to write any of the ER3000 profile segments 1 32 ReadProfileSegment This function is used to read any of the ER3000 profile segments 1 32 Shutdown This function must be called before exiting the program This function does not send any data to the ER3000 This function needs to be called only once 8 3 1 DOS Library The Tescom protocol protocol lib allows easy access to the ER3000 from a PC for DOS based C language programs One thing to note is that the LIBRARY directory contains two subdirectories one for Microsoft libraries and another for Borland It is important to use the PROTOCOL LIB file from the directory corresponding to the compiler being used Custom DOS applications can be developed easily using the existing software as a baseline The ERTALK program demonstrates basic communication with the ER3000 and is a good starting point for custom software development The PROFILE2 program demonstrates the usage of the profiling functions 8 3 2 Windows DLL The Tescom protocol TESCOM DLL allows easy access to the ER3000 from a PC for Windows based programs The
57. ograms In the WIN16 and WIN32 directories there are four subdirectories of Windows programs LabVIEW Visual Basic LabWindows CVI and C In the windows directory i e WINDOWS there are two files tescom dll tescom ini which are used with any Windows program see README DOC file for more information The files in the corresponding subdirectories contain simple programs in the LabVIEW Visual Basic LabWindows CVT and C languages illustrating the use of the tescom dll Dynamic Link Library There are also two subdirectories DLL and DLL32 The files in these directories are used to create the 16 and 32 bit versions of the Tescom DLL 8 3 Tescom Protocol Provides Custom Software Support The Tescom Protocol used to interface to the ER3000 is non proprietary A description of the protocol is given in PROTOCOL DOC in the subdirectory TESCOM2 LIBRARY Typically programmers can use the DOS based library or the Windows based DLL provided to aid in communicating to the ER3000 However not all systems 40 ER3000 User Manual run on these platforms We provide all the software used in the development of the Tescom Protocol library and DLL This allows the programmer the ability to alter and recompile the Tescom Protocol in a format suitable for their system The Tescom protocol software includes the following six functions Startup This function must be called during program initialization before any other function t
58. onnection Description box will open for a new connection Enter any name such as abc and click OK 2 A Connect To box titled abc will open Use the drop down menu at Connect Using to connect to the comm port in guestion 1 e COM2 Click OK 56 ER3000 User Manual If the port is in use by another application then the error message Unable to open COM2 will appear That port will have to be freed up before it can be used by the ER3000 software Ifa connection box does appear check the LED indicators on the ER3000 For DOS This procedure assumes The Tescom ER3000 User Software CD DOS install has been installed The communications hardware is configured as shown in Figure 2 The test above Power up Test of the ER3000 using LED Indicators works e Run ERTALK by Typing tescom2 tescom 1 at a DOS prompt i e C gt Type in the node address 250 if unknown Select 1 to Read ER 3000 Type 44 for parameter index any parameter works If Node x Variable Number 44 scrolls on the screen communication to the ER3000 is working Otherwise Error is scrolling LET IT SCROLL If unable to resolve the problem contact your local distributor A list of Tescom distributors may be found on our website www tescom com or by contacting the factory 10 5 Pressure Control Problems If there is a problem with controlling the pressur
59. ow a certain value for instance when using an external dome loaded regulator which has hysteresis then this parameter should be set to the minimum acceptable error ID_COMPENSATED_INTERNAL_SENSOR This is the compensated internal sensor value 1 e after temperature compensation zero and span have been applied to the raw signal A value of 400 is 0 and 3700 is 100 9 4 Outer Loop Tuning Variables 25 21 16 49 ID OUTER PROPORTIONAL CONSTANT This is the P term proportional constant for the outer loop ID_OUTER_INTEGRAL_CONSTANT This is the I term integral constant for the outer loop ID OUTER D COEF1 This is the D term derivative constant for the outer loop ID OUTER INTEGRAL MINIMUM This is the minimum value allowed for the integral sum on the outer loop 9 ER3000 Internal Variables 45 22 23 67 ID OUTER INTEGRAL MAXIMUM This is the maximum value allowed for the integral sum on the outer loop ID OUTER INTEGRAL SUM This is the value of the integral sum for the outer loop It is formed by multiplying the integral constant time the error and summing the result with the previous value for the integral sum ID_OUTER_INTEGRAL_DEADBAND This is the outer loop minimum error required for the integral sum to be changing in value Often it is set to zero and has no effect However if it is desirable to stop integrating once the error is reduced below a certain value for instance when using an ext
60. ow to provide a 4 20mA analog setpoint from a PC D A card or a PLC D A module BLACK BROWN NI ken oma SIN RED piid IA d Figure 6 Passive PC or PLC D A Card Analog Setpoint 4 20mA NOTE Wire power as shown in figures 2 amp 3 a BROWN S i V ren Oo 1 LJ NE auteut A OUTPUT TI O O O Figure 7 Active PC or PLC D A Card Analog Setpoint 4 20mA 1 5V 0 10V NOTE Wire power as shown in figures 2 amp 3 4 Installation 19 Figure 8 shows how to provide a 0 5V signal to the analog setpoint from a potentiometer The 0 1V range can be programmed to be a failsafe condition for 1 5V ER3000 s Refer to section 5 4 Failsafe Limits for more information on failsafe Note The ER3000 cannot directly provide a 0 10 volt signal An external 10 volt supply must be used for power POWER SUPPLY WHITE 5 10 Pa 5 10 VDC SE 120 VAC Cy Pe N 2 Ce BLACK ne AW PS _ WU TAN VO LAAN i mi TSERE ag 12 A zala TTT TI FI I HIGH eg O oO WIPER 6 i LOW O O leet Figure 8 Potentiometer Analog Setpoin
61. protocol is available as a 16 bit and a 32 bit DLL The proper DLL should be placed in the Windows directory when generating custom software this is automatically done if the Tescom Windows program is installed ER3000 CVD Custom Windows applications can be developed easily using the example for the programming environment being chosen There are examples for C Visual Basic LabVIEW and LabWindows CVI 9 ER3000 Internal Variables 41 8 3 3 Macintosh Custom Software The Tescom protocol is provided and written in C The protocol software can be easily compiled with custom software for the Macintosh A demo program is also provided to ensure proper system operation and provide an example program using the Tescom protocol software 8 4 DOS Programs To run any of the DOS based programs type CATESCOM2XTESCOM at the DOS prompt and follow the instructions on the display Most subdirectories contain a README DOC file describing the files in the directory 8 4 1 Tune The program TUNE EXE provides the user with access to many of the controller s programmable variables It also includes a graphics screen for displaying the setpoint and feedback In addition it includes a function generator for creating waves square sine triangular or sawtooth that are transmitted as setpoints to the controller This program provides a powerful means of tuning the ER3000 Details on its use can be found in the file tune doc 8 4 2 Ertalk
62. rogram 58 10 7 2 DOS Tune Program 58 11 ER3000 ACCESSORIES 60 12 MECHANICAL DIMENSIONS OF ER3000 61 Table Of Figures Figure 1 Voltage Current Select Jumpers mememeeneeeeeneonennenneeneenee 12 Figure 2 ER3000 Basic Wiring Diagram imtmimeeeeeereeneeneeneenenee 13 Figure 3 ER3000 Typical System Wiring Diagram nsss 14 Figure 4 Three Wire External Feedback Cabling 17 Figure 5 Four Wire External Feedback Cab ling senere reen 18 Figure 6 Passive PC or PLC D A Card Analog Setpoint 4 20mA 19 Figure 7 Active PC or PLC D A Card Analog Setpoint 4 20mA 1 5V 0 10V 19 Figure 8 Potentiometer Analog Selpoint aa aasasssssssssssssss 20 Figure 9 Current Voltage Analog Setpoint ass 20 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Monitor 4 20mA External Feedback Floating Input 21 Monitor 4 20mA External Feedback Ground Referenced Input 21 Monitor voltage produced by 4 20 mAmp External Feedback 22 Monitor 1 5V 0 10V External Feedback 22 External Profile Co
63. rror is 03 and typically this number is in the range of 0 3 84 ID PULSE ENABLE This turns the pulse function ON 1 or OFF 0 9 9 Scaling Variables ID UI UNITS CHARI ID UI UNITS CHAR2 The units variables are used by supplied ID UI UNITS CHAR3 software to display the pressure range ID UI UNITS CHAR4 units i e psi ID UI SCALE MIN LO The scale minimum and scale maximum ID UI SCALE MIN HI variables are used by supplied software to ID UI SCALE MAX LO show minimum and maximum ranges ID UI SCALE MAX HI 9 ER3000 Internal Variables 47 9 10 Analog and Digital Output Variables 88 89 90 92 93 94 96 ID DIGITAL OUTPUT This variable can be written directly by a program or by the embedded profile using the Digital Output command This variable is written to Digital Output 1 shown in Table 2 Auxiliary Cable Assembly ID DIGITAL OUTPUT2 This variable can be written directly by a program by the embedded profile using the Digital Output command or by the embedded code The embedded code updates this output if variable ID_TTL_FLAG enables this output as a within tolerance indicator If enabled ID_TTL_ERRO and ID_TTL_ERR4095 variables are used to set the maximum error allowed in counts for a setpoint of 0 and 4095 counts respectively The embedded code interpolates between these points to find the maximum error allowed for all other setpoint values Reference ID_SETPOINT and ID FEEDBACK
64. supplied to the ER3000 LED2 green On if ER3000 is sending data out via RS485 LED3 amber On if ER3000 is receiving data in via RS485 Micro Bottom Board LED 1 red blinks heartbeat if system is functioning properly Additionally the Micro Bottom Board LED LED1 blinks once per second staying on more than off when the system is functioning properly If this LED is on or off continuously then the electronics are not functioning This LED will also blink at a different rate twice a second if the zero or span buttons have been pressed too long causing their corresponding limits to be exceeded If a failsafe limit has been exceeded the LED will also blink once per second but will be off more than on 54 ER3000 User Manual 10 2 Third Party RS232 RS485 Converters The RS232 RS485 converters range in modes of operation The provided Tescom software needs the RS232 RS485 converter to be configured in the following mode Table 5 Third Party RS232 RS485 Converter Mode Echo off Transmitted data SD is used for flow control No handshake control RTS CTS DSR DTR Additionally for 4 wire RS422 converters half duplex Connect TD to RD Connect TD to RD 10 3 ER3000 Power up Test using LED Indicators Power up the ER3000 without any Tescom provided software packages running Check the LED indicators on the ER3000 Table 6 LED s Power Up Terminal Top Board LED1 red ON LED2 gr
65. t NOTE Wire power as shown in figures 2 3 Figure 9 shows how to provide the analog setpoint from an active variable current supply veame V ia SIGNAL SOURCE 4 20 mA OR 1 5 V gt OR 0 10V gt Al JA A O Ld VI IV WY L 4 20mA 4 20mA Figure 9 Current Voltage Analog Setpoint NOTE Wire power as shown in figures 2 amp 3 Figure 9 also can represent how to provide a 1 5V 0 10V analog setpoint The negative lead of your source connects to the red wire and the positive lead connects to the brown wire 20 ER3000 User Manual 4 5 3 Monitor the Feedback Signal The feedback signal can be monitored using an A D card in the PC or a PLC Although currently available through the RS485 interface the user may find it more convenient to directly read the transducer analog output This would be beneficial when adding to existing system software which performs system control data acguisition etc PM LI LA m T4 20mA gt N CT VILET EA V 7 aon i iii ill Td COMPUTER EX 2 an O O O O O TRANSDUCER L Figure 10 Monitor 4 20mA External Feedback Floating Input NOTE Wire power as shown in figures 2 amp 3
66. that is used by the embedded software Table 3 continued ER3000 Internal Variables VariableNameandNumbr Type Range Decimal Range Hex 100 ID_UIINIT a o 101 ID UL LOCK FLAG 102 ID UL PASSWORD ENABLE Heo A 103 ID ULUSER PASSWORD i CT 104 IDULGRAPHMN CT CE y 105 ID_UI GRAPH_MAX iC TT 106 ID_ULGRAPH_TIME o Jel CE 107 IDUL GRAPH CONTINUOUS t me 108 ID ULUNITS CHARI Unsigned 0 255 ff 109 ID UL UNITS CHAR2 Unsigned 0 255 ff 110 ID UL UNITS CHAR3 Unsigned _ 0 255 m 111 ID UL UNITS CHAR4 Unsigned 0 25 Off ei o 5 s 113 ID_UI REMOTE_SP2 Jal L 114 ID ULSCALEMNIO fo 0 65535 O fr 115 ID UL SCALEMN HI float 0 65535 O ffff 116 ID UL SCALEMAXIO fo 0 65535 O fr 117 ID UL SCALE MAXHI for 0 65 535 O fr 118 ID_UI_SPIOR2_FLAG nn 119 ID ULPROFILE STARTRUN Unsigned 0 1 0n 120 ID_UI_DECIMAL_POSITION Jaj CT 121 ID_UI BACKLIGHT CTC 122 ID ULCONTRAST sr Cid it Denotes usage by the UI3000 U14000 only all other variables are Read Write Denotes 32 bit floating point numbers for the scale_min and scale_max variables 9 ER3000 Internal Variables 53 10 TROUBLESHOOTING 10 1 LED Indicators Figure 21 LED Locations Table 4 LED Indicators Terminal Top Board LED1 red On continuously if power is
67. tle to a stable value should be allowed for each step Finally if the zero is adjusted too far in the negative direction then the output will not respond until the zero is raised to within the control range i e so that the output is above zero psi 7 Calibration 39 8 SOFTWARE PROGRAMS 8 1 Windows Tune Program To run the Windows Tune program click the ER3000 CVI icon The Tune program is an all encompassing software package which allows the user to address any ER3000 Controller on the RS485 network and provides easy tuning of the ER3000 s Additionally the Tune program allows you to monitor system operation alter profiles specify failsafe limits enable password protection read write internal variables acguire data and review previously acguired data The basic screens available are Signal Generator Plot Tuning Profile Pulse Failsafe Data Acguisition Dacg View Miscellaneous Read Write and Password For more information on the Windows Tune program see section 6 Tuning Procedure which uses the Windows Tune Program to explain how to tune the ER3000 Information is also available on the Windows Tune program Help Screens The help screens are accessed by the Help Menu in the ER3000 Control Window To access help on a particular Window right click on the mouse while that Window is highlighted To get a printout of the Windows Help Screens use the file MANUAL RTF in the MANUAL subdirectory 8 2 Windows Example Pr
68. ture compensated sensor or an external transducer 4 20mA 1 5V or 0 10V This second option allows for positioning the sensor downstream in the actual process line Four modes of operation are available Internal feedback mode which 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 Manual mode allows for direct control of the solenoid valves useful for troubleshooting the system In summary the ER3000 electronic pressure regulator is easy to get up and running yet offers the flexibility required by the most demanding user 1 Introduction 7 2 1 2 2 2 3 2 4 2 5 2 6 2 7 SPECIFICATIONS Enclosure NEMA 4X To prevent any interference from electromagnetic radiation use rigid metal conduit to enclose the wiring entering the ER3000 Two 1 2NPT 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 Pressure Minimum Outlet pressure 1 PSIG Maximum 120 PSIG Typical 110 PSIG Note Response time is affect
69. twork the computer serves as a master and all of the controllers as slaves Each controller must have a unique node number between 1 and 250 Controllers have a default node number of 250 when shipped from the factory When configuring a network each controller must be individually powered up and have a unique node number assigned using Windows ER3000 CVI or DOS tune exe The computer initiates all communication and the controllers respond only to messages that are sent specifically to their node addresses The implementation of the Tescom protocol is explained fully in the Software Programs Section of the manual 5 Operation 31 6 TUNING PROCEDURE 6 1 Typical Application to Tune R3000 Inlet 23000 Exhaust 120psig Main ES Valve Regulator Regulator Outlet Pressure Inlet Pressure Captured Vent Does Not Connect With Inlet Port Figure 20 Regulator and ER3000 Internal Operation 32 ER3000 User Manual EE aanpavolg Suny 9 E paljosjuog eq 0 ainssaud Ne ad uoyvoyddy Suung jooidk7 ZZ 4n917 0 2ZYr7Z0r907 97 q wa SkS D1940 ay JO AIDINIIO y apos ap jjim os Bulop nq pasn aq upo JBONPSUDI oinoo 0 ssaj v painbas SI 127729 JO O JO AaDIN220 uo souowsop d uj l s s Ipuundo joj BisdooSZ O0 Jo Bupi aunssaud aywsuds vuu0Z 4909p294 a
70. urce Extemal Feedback wY Minimum Pulse Width Inlet 10 Exhaust 10 Time sec The application should now be tuned for the system working in the mode of toggling between 625 and 1875 psi The system can be fine tuned to optimize speed or stability by adjusting the tuning parameters The system can be further tuned by selecting different pressure settings and testing the response The final tuning should be done at pressures that are representative of how the system will be operated 38 ER3000 User Manual 7 CALIBRATION The ER3000 is fully calibrated at the factory The calibration process involves temperature compensation and pressure linearization of the internal pressure sensor and linearization of both the analog setpoint and external feedback inputs The additional inputs and outputs on some models as referenced in Section 3 ER3000 Model Description are also linearized The user is able to adjust the calibration as described in the following sections 7 1 Zero span The calibration of the unit may be changed by adjusting the zero and span settings of the ER3000 The Zero and Span settings are found on the Miscellaneous Screen of the Windows ER3000 program Normally the zero and span do not need adjustment since the unit has been factory calibrated However under the following conditions it may be advantageous to make some adjustment The application is using a reduced pressure range The unit is normally op

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