Tescom ER3000 User Manual
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Tescom ER3000 User Manual

Electronic pressure controller
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ER3000 Electronic
Pressure Controller
User Manual

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Summary of Contents for Tescom ER3000

  • Page 1 ER3000 Electronic Pressure Controller User Manual...
  • Page 2 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.
  • Page 3 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.

  • Page 4: Table Of Contents

    4.4.4 Connect RS485 Interface Connections -------------------------------- 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 4.4.8 Connect Pressure to the System ---------------------------------------- 16 4.4.9...
  • Page 5 Tune ------------------------------------------------------------------------ 42 8.4.2 Ertalk----------------------------------------------------------------------- 42 8.4.3 Profile---------------------------------------------------------------------- 42 8.4.4 Profile2 -------------------------------------------------------------------- 42 8.4.5 Data_log------------------------------------------------------------------- 43 8.4.6 Test_pr --------------------------------------------------------------------- 43 ER3000 INTERNAL VARIABLES ------------------------------------------ 44 --------------------------------------- 44 ETPOINT AND EEDBACK ARIABLES ------------------------------------------------- 44 ONFIGURATION ARIABLES --------------------------------------------- 45 NNER UNING ARIABLES...
  • Page 6 10.6 ------------------------------------------ 57 CCEPTABLE ESISTANCE ALUES 10.6.1 ER3000 RS485 Interface--------------------------------------------- 57 10.6.2 Converter RS485 Interface ------------------------------------------ 57 10.7 --------------------------------------------------------------------- 58 10.7.1 Windows ER3000 Program------------------------------------------ 58 10.7.2 DOS Tune Program -------------------------------------------------- 58 ER3000 ACCESSORIES --------------------------------------------------- 60 MECHANICAL DIMENSIONS OF ER3000--------------------------- 61...
  • Page 7 Figure 1: Voltage/Current Select Jumpers ............12 Figure 2: ER3000 Basic Wiring Diagram ............13 Figure 3: ER3000 Typical System Wiring Diagram ......... 14 Figure 4: Three-Wire External Feedback Cabling ........... 17 Figure 5: Four-Wire External Feedback Cabling ..........18 Figure 6: Passive PC or PLC D/A Card Analog Setpoint (4-20mA)....

  • Page 8: Introduction

    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.

  • Page 9: Specifications

    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. 2.2 Media The preferred media is clean, dry instrument grade air or nitrogen.

  • Page 10: Accuracy

    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”...

  • Page 11: Er3000 Part Numbering System

    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.

  • Page 12: Installation

    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 standards shown on the metal tag.

  • Page 13: Voltage/Current Select Jumpers

    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.

  • Page 14: Basic Er3000 To Pc Wiring

    4.3 Basic ER3000 to PC Wiring The necessary wiring for the ER3000 communicating to a PC is shown in Figure 2. A PC is typically used to communicate to the ER3000 digitally, but any device capable of the interface protocol could be used, such as a PLC.

  • Page 15: Setting Up A Typical Er3000 Pressure Control System

    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.

  • Page 16: Mount The Er3000

    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.

  • Page 17: Connect Transducer Wiring

    4.4.8 Connect Pressure to the System Figure 3 illustrates the typical pressure connections for the ER3000. 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.

  • Page 18: Additions And Variations To The Typical System

    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.

  • Page 19: Figure 5: Four-Wire External Feedback Cabling

    Figure 5: Four-Wire External Feedback Cabling NOTE: Wire power as shown in figures 2 & 3 18 ER3000 User Manual...

  • Page 20: Analog Setpoint Source

    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 how to provide a 4-20mA analog setpoint from a PC D/A card or a PLC D/A module.

  • Page 21: Figure 8: Potentiometer Analog Setpoint

    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. Figure 8: Potentiometer Analog Setpoint NOTE: Wire power as shown in figures 2 &...

  • Page 22: Monitor The Feedback Signal

    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 acquisition, etc.

  • Page 23: Figure 12: Monitor Voltage Produced By 4-20 Mamp External Feedback

    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 Ω resistor rather than breaking into the 4-20 mAmp loop. Figure 12: Monitor voltage produced by 4-20 mAmp External Feedback NOTE: Wire power as shown in figures 2 &...

  • Page 24: Profile Control / Digital Inputs

    Figure 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”...

  • Page 25: Switch Feedback Control To A Second Feedback Source

    NOTE: Wire power as shown in figures 2 & 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.

  • Page 27: Digital Outputs

    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.

  • Page 28: Monitor Internal Sensor Using The Analog Output

    4.5.9 Monitor Internal Sensor using the Analog Output The ER3000 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).

  • Page 29: Operation

    (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) and senses pressure from a transducer mounted downstream in the process, as shown in Figure 3.

  • Page 30: Control Modes

    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...

  • Page 31: Cascade Loop Mode

    ER3000. External feedback can also be useful when using the ER3000 as a standalone unit.

  • Page 32: Failsafe Limits

    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.

  • Page 33: Tuning Procedure

    6. TUNING PROCEDURE 6.1 Typical Application to Tune Figure 20: Regulator and ER3000 Internal Operation 32 ER3000 User Manual...

  • Page 35: Tune The Typical Application

    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.
  • Page 36 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.
  • Page 37 The following is an example sequence of tuning steps. First a very undertuned response is shown (note size of proportional term). Next the proportional term is increased, however, overshoot and ringing results: 36 ER3000 User Manual...
  • Page 38 Now, some Derivative is introduced. Note the decrease in overshoot. However, if we zoom in on the horizontal axis between 1750 and 2000 psi, we notice that a small offset remains. 6. Tuning Procedure 37...
  • Page 39 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...

  • Page 40: Calibration

    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.

  • Page 41: Software Programs

    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...

  • Page 42: Dos Library

    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.

  • Page 43: Macintosh Custom Software

    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.

  • Page 44: Data_Log

    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...

  • Page 45: Er3000 Internal Variables

    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...

  • Page 46: Inner Loop Tuning Variables

    16 ID_OUTER_D_COEF1 - This is the D-term, derivative constant, for the outer loop. 49 ID_OUTER_INTEGRAL_MINIMUM - This is the minimum value allowed for the integral sum on the outer loop. 9. ER3000 Internal Variables 45...

  • Page 47: Analog Input Variables

    - after linearization has been applied to the raw signal. 85 ID_AD_EXTRA1_TOGGLE - This variable is used to adjust the level that the ER3000 interprets the ID_COMPENSATED_EXTRA_AD1 variable as a logical 0 or a logical 1. 86 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.

  • Page 48: Pulse Modev

    111 ID_UI_UNITS_CHAR4 range units (i.e. psi.). 114 ID_UI_SCALE_MIN_LO The scale minimum and scale maximum 115 ID_UI_SCALE_MIN_HI variables are used by supplied software to 116 ID_UI_SCALE_MAX_LO show minimum and maximum ranges. 117 ID_UI_SCALE_MAX_HI 9. ER3000 Internal Variables 47...

  • Page 49: Pwm Controlv

    12 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 => Write the previously computed value to the PWM 1 =>...

  • Page 50: Gain /Offsetv

    34 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.

  • Page 51: Failsafe Variables

    Minimum/Maximum Limited Signal 54 ID_MIN_AD_SETPOINT 55 ID_MAX_AD_SETPOINT ID_MIN_COMPENSATED_INTERNAL_SENSOR ID_COMPENSATED_INTERNAL_SENS ID_MAX_COMPENSATED_INTERNAL_SENSOR ID_MIN_COMPENSATED_EXTERNAL_SENSOR ID_COMPENSATED_EXTERNAL_SEN ID_MAX_COMPENSATED_EXTERNAL_SENSOR 60 ID_MIN_INNER_ACTUAL_ERROR 0 ID_INNER_ACTUAL_ERROR 61 ID_MAX_INNER_ACTUAL_ERROR 62 ID_MIN_OUTER_ACTUAL_ERROR 14 ID_OUTER_ACTUAL_ERROR 63 ID_MAX_OUTER_ACTUAL_ERROR 50 ER3000 User Manual...

  • Page 52: Table Of All

    9.14 Table of all ER3000 Internal Variables Table 3: ER3000 Internal Variables Variable Name and Number Type Range:Decimal Range:Hex 0 - ID_INNER_ACTUAL_ERROR Signed -4095 : 4095 -0fff : 0fff 1 - ID_AD_SETPOINT * Unsigned 0 : 4095 0 : 0fff...
  • Page 53 Table 3 (continued): ER3000 Internal Variables Variable Name and Number Type Range:Decimal Range:Hex 55 - ID_MAX_AD_SETPOINT Unsigned 0 : 4095 0 : 0fff 56 - ID_MIN_COMPENSATED_INTERNAL_SENSOR Unsigned 0 : 4095 0 : 0fff 57 -ID_MAX_COMPENSATED_INTERNAL_SENSOR Unsigned 0 : 4095 0 : 0fff...
  • Page 54 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 that is used by the embedded software. Table 3 (continued): ER3000 Internal Variables Variable Name and Number Type...

  • Page 55: Troubleshooting

    Table 4: LED Indicators Terminal (Top) Board LED1, red = On continuously, if power is 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.

  • Page 56: Rs232/Rs485 Converters

    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.
  • Page 57 LED, LED2, is OFF, suspect the wrong node address. • 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.

  • Page 58: Acceptable R

    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 pressure: •...

  • Page 59: Leak Test

    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.
  • Page 60 • Press “spacebar” to toggle Setpoint to 100. • Wait for Feedback to stabilize, which takes approximately 5 seconds. • Press “spacebar” to toggle Setpoint to 50. • Watch Feedback signal for 25 seconds. If feedback decreases, the unit is leaking •...

  • Page 61: Er3000 Accessories

    Fitting Kit (includes ¼”x 1/8” NPT, ¼”x ¼” 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...

  • Page 62: Mechanical Dimensions Of Er3000

    12. MECHANICAL DIMENSIONS OF ER3000 NOTE: DIMENSIONS ARE IN INCHES AND ARE FOR REFERENCE ONLY 12. Mechanical Dimensions of ER3000 61...
  • Page 63 NOTE: DIMENSIONS ARE IN INCHES AND ARE FOR REFERENCE ONLY 62 ER3000 User Manual...
  • Page 64 Tescom Corporation Manufacturer’s Address: 12616 Industrial Boulevard Elk River, Minnesota 55330-2491 United States of America European Contact: Marc Lembcke TESCOM EUROPE GMBH & CO. KG An der Trave 23-25 23923 Selmsdorf Germany +49/38823/31-0 declares that the product: Product Name: Electronic Pressure Controller...
  • Page 65 Emerson Process Management TESCOM 12616 Industrial Boulevard Elk River, Minnesota 55330 USA T +1 800 447 1250 +1 763 241 3238 F +1 763 241 3224 E na.tescom@emerson.com www.TESCOM.com DOPSM1893X012 Rev. 11/09...

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