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Emerson Tescom ER5000 Series User Manual Download Page 11

ER5000

 — 

11

Table of Contents

Voltage/Current Select Jumpers       .     .     .     .     .     .     .     80
LED Indicators      .     .     .     .     .     .     .     .     .     .     .     .     .     .     .     .     81
Power Supply Wiring — All Applications       .     .     .     82
Setpoint Wiring Variations  .   .   .   .   .   .   .   .   .   .    83

Analog Setpoint Source — Potentiometer 

83

Analog Setpoint Source — Current/Voltage 

84

Analog Setpoint Source  —  
Passive PC or PLC D/A Card 

85

Analog Setpoint Source  —  
Active PC or PLC D/A Card 

86

Profile with External Control/Digital Inputs  

87

Digital Setpoint Source  — RS485 Connection,  
RS232 to RS485 Converter  
(TESCOM™ Model #85061) 

89

Digital Setpoint Source  — RS485 Connection,  
USB to RS485 Converter  
(TESCOM Model #82948) 

90

Digital Setpoint Source  — RS485 Network,  
RS232 to RS485 Converter  
(TESCOM Model #85061) 

91

Digital Setpoint Source  — RS485 Network,  
USB to RS485 Converter  
(TESCOM Model #82948)  

93

Feedback Wiring Variations .   .   .   .   .   .   .   .   .   .   95

Two Wire Transducer  

95

Three Wire Transducer  

96

Four Wire Transducer 

97

4–20 mA External Feedback, Floating Input,  
Feedback Signal Monitored by PC or PLC A/D Card 

98

4–20 mA External Feedback, Ground  
Referenced Input, Feedback Signal Monitored  
by PC or PLC A/D Card  

99

Two Wire Transducer, PC or PLC A/D Card  
Used to Monitor Voltage Produced by the  
4–20 mA External Feedback 

100

Three Wire Transducer, PC or PLC A/D Card  
Used to Monitor Voltage Produced by the  
4–20 mA External Feedback 

101

Four Wire Transducer, PC or PLC A/D Card Used  
to Monitor Voltage Produced by the 4–20 mA  
External Feedback 

102

Switch Feedback Control to a Second  
Feedback Source 

103

Wiring Variations for  

Additional Functions  .   .   .   .   .   .   .   .   .   .   .   .   . 104

Monitoring Additional Analog Inputs  

104

Monitoring the ER5000’s Internal Sensor  
Using the Analog Output, 4–20 mA Wiring 

105

Monitoring the ER5000’s Internal Sensor  
Using the Analog Output, 0–10V Wiring 

106

Digital Outputs  

107

Suspend Mode 

109

Installing a Hazardous Location  

Model (ER5050)       .     .     .     .     .     .     .     .     .     .     .     .     .     .     . 110

The ERTune

™

 Program 

111

ER5000 Software  

Development Support 

196

ER5000 Communication Requirements  .   .   .   . 197
ER5000 Software Development Support      .     .     . 197
Windows Programming Examples      .     .     .     .     .     . 198
Accessing the Windows DLL File       .     .     .     .     .     .     . 199
The TESCOM Protocol .   .   .   .   .   .   .   .   .   .   .   .   . 200

Troubleshooting 202

Installation .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   . 203
Operation       .     .     .     .     .     .     .     .     .     .     .     .     .     .     .     .     .     . 206
RS485 Communication  .   .   .   .   .   .   .   .   .   .   .   . 216
Using Profiles to Control the ER5000      .     .     .     .     . 217

Internal Variables 

221

Table of ER5000 Internal Variables       .     .     .     .     .     . 222
ER5000 Internal Variables        .     .     .     .     .     .     .     .     .     . 225

ER5000 Setpoint and Feedback Variables  

225

ER5000 Configuration Variables  

226

ER5000 Inner Loop Tuning Variables  

227

ER5000 Outer Loop Tuning Variables  

228

ER5000 Analog Input Variables 

229

ER5000 Pressure Profile Variables  

230

Summary of Contents for Tescom ER5000 Series

Page 1: ...a Hazardous Location you MUST use model ER5050 Models ER5000 ER5020 ER5040 ER5100 and ER5110 are not intended for or rated for use in Hazardous Locations Do not attempt to select install use or maintain this product until you have read and fully understood the Safety Installation Operations Precautions section of this manual ...

Page 2: ...2 Safety Installation Operations Precautions ...

Page 3: ...Y PRECAUTIONS 1 Read and understand the user s manual before operating the controller 2 Inspect the controller and accessories before each use 3 Operate the unit only under specified environmental conditions 4 Follow instructions in the manuals for proper wiring 5 Never connect the controller or accessories to a supply source having a voltage greater than the maximum rated voltage of this controll...

Page 4: ...r controllers regulators valves or accessories that are not compatible with the fluids being used 22 Users must test under normal operating conditions to determine suitability of materials in an application 23 Vent fluids to a safe environment and in an area away from employees Be sure that venting and disposal methods are in accordance with Federal State and Local requirements Locate and construc...

Page 5: ...s for each standard model The original equipment warranty applies after a complete overhaul WARNING SAFE COMPONENT SELECTION 1 Consider the total system design when selecting a component to ensure safe trouble free performance 2 The user is responsible for assuring all safety and warning requirements of the application are met through his her own analysis and testing 3 TESCOM may suggest material ...

Page 6: ...UTION SAFETY PRECAUTIONS 1 Inspect the regulator valve and accessories before each use 2 Never connect regulators valves or accessories to a supply source having a pressure greater than the maximum rated pressure of the regulator valve or accessory 3 Refer to product label model specific for maximum inlet pressures If this rated pressure cannot be found contact your local TESCOM representative for...

Page 7: ...ce with Federal State and Local requirements Locate and construct vent lines to prevent condensation or gas accumulation Make sure the vent outlet is not obstructed by rain snow ice vegetation insects birds etc Do not interconnect vent lines use separate lines if more than one vent is needed 19 Do not locate regulators valves or accessories controlling flammable fluids near open flames or any othe...

Page 8: ...ions take it out of service immediately You must have instructions before doing any maintenance Do not make any repairs you do not understand Have qualified personnel make repairs Return any equipment in need of service to your equipment supplier for evaluation and prompt service Equipment is restored to the original factory performance specifications if repairable There are flat fee repair charge...

Page 9: ...9 Table of Contents ...

Page 10: ...trolling System Pressure 39 A Note Concerning Non Venting Regulators in Closed Loop Applications 41 Monitoring System Control Limits 42 The ER5000 Control Modes 43 Internal Feedback Mode 43 External Feedback Mode 43 Cascade Mode 43 Glossary of Terms 44 Terms Relating to PID Controllers and Controller Tuning 45 Terms Relating to Regulators 52 Getting Started 57 Before You Begin 58 ER5000 Quick Refe...

Page 11: ...mA External Feedback 100 Three Wire Transducer PC or PLC A D Card Used to Monitor Voltage Produced by the 4 20 mA External Feedback 101 Four Wire Transducer PC or PLC A D Card Used to Monitor Voltage Produced by the 4 20 mA External Feedback 102 Switch Feedback Control to a Second Feedback Source 103 Wiring Variations for Additional Functions 104 Monitoring Additional Analog Inputs 104 Monitoring ...

Page 12: ...les 233 ER5000 Gain Offset Variables 234 ER5000 Control Limit Variables 235 Control Limits for Specified Signals 235 Certifications and Warranty 236 Certifications 237 Hazardous Locations Special Requirements and Certifications for the ER5050 238 LIMITED WARRANTY 240 Appendix A Setting up the ERTune Program on Windows 8 PCs 241 Installing the NET Framework 3 5 242 Installing the ER5000 Device Driv...

Page 13: ...lighted by the IMPORTANT icon contain information that references specific requirements of your operating system Paragraphs highlighted by the CAUTION icon contain information that must be followed to maintain a safe and successful operating environment Paragraphs highlighted by the WARNING icon contain information about practices or circumstances that can lead to personal injury or death property...

Page 14: ...14 Features and Specifications ...

Page 15: ...dows XP VISTA Windows 7 and Windows 8 IMPORTANT IMPORTANT Windows 8 users In order to maintain compatibility with previous Windows operating systems the ERTune program uses the NET Framework 3 5 which is not installed by default in Windows 8 If you are using Windows 8 you will need to download and install NET Framework 3 5 before installing the ERTune program You may also need to disable Driver Si...

Page 16: ...2 14 NPTF Conduit Connection for Internal Wiring Atmospheric Reference for Internal Sensor Exhaust Port 1 8 27 NPTF Mounting Holes 10 32 UNF 50 FULL THREAD M5 X 0 8 12 7 FULL THREAD 4 Places Not Used Not Used ER5000 Dimensions Side Views All dimensions are called out in inches millimeters Contact the factory for dimensions and specifications of models ER5020 ER5040 ER5100 and ER5110 Refer to the E...

Page 17: ...2 SAE 3 4 16 UNF Bottom View Top View All dimensions are called out in inches millimeters 3 72 94 5 3 72 94 5 1 86 47 2 ER5000 Dimensions Top and Bottom View Contact the factory for dimensions and specifications of models ER5020 ER5040 ER5100 and ER5110 Refer to the ER5000 Series Part Numbering System ...

Page 18: ...32 UNF 50 FULL THREAD M5 X 0 8 12 7 FULL THREAD 4 Places 1 8 NPTF Plug Not Used DO NOT REMOVE 1 8 NPTF Plug Not Used DO NOT REMOVE 1 8 NPTF Plug Not Used DO NOT REMOVE All dimensions are called out in inches millimeters ER5050 Hazardous Location Model Dimensions Side Views Contact the factory for dimensions and specifications of models ER5020 ER5040 ER5100 and ER5110 Refer to the ER5000 Series Par...

Page 19: ...iew Top View All dimensions are called out in inches millimeters 3 72 94 5 3 72 94 5 1 86 47 2 Contact the factory for dimensions and specifications of models ER5020 ER5040 ER5100 and ER5110 Refer to the ER5000 Series Part Numbering System ER5050 Hazardous Location Model Dimensions Top and Bottom View ...

Page 20: ... and as small as 10 microns is highly recommended to prevent damage to the solenoid valves Moisture should be kept to a minimum Ports Conduit 1 2 NPTF Pneumatic 1 8 NPTF Inlet Exhaust and Gauge Ports 1 2 SAE Controlled Outlet Port Power Requirement Voltage 24V DC 22V DC to 28V DC Current 340 mA max 180 mA nominal Environment Temperature 30 C to 75 C dry Nitrogen supply gas 5 C to 75 C shop air Pre...

Page 21: ...2ms 90 psig to 10 psig 6 2 bar to 0 7 bar NOTE NOTE CAUTION CAUTION WARNING WARNING Step response into dead end system 1 cubic inch volume External Analog Input Impedance 4 20 mA 250Ω 1 5V 220KΩ single input pin to ground 1 7MΩ differential input 0 10V 100KΩ Digital Inputs Voltage Range Input Impedance 4 20 mA 250Ω 1 5V 220KΩ single input pin to ground 1 7MΩ differential input 0 10V 100KΩ Digital ...

Page 22: ...ndard 7 0 01 Use of an in line filter that meets the requirements of ISA standard 7 0 01 and is less than 40 microns and as small as 10 microns is highly recommended to prevent damage to the solenoid valves Moisture should be kept to a minimum Ports Conduit 1 2 NPTF Pneumatic 1 8 NPTF Inlet Exhaust and Gauge Ports 1 2 SAE Controlled Outlet Port Power Requirement Voltage 24V DC 22V DC to 28V DC Cur...

Page 23: ...lator Accuracy Room temp 0 1 of span maximum Response Time Rise Time 257ms 10 psig to 90 psig 0 7 bar to 6 2 bar Fall Time 552ms 90 psig to 10 psig 6 2 bar to 0 7 bar NOTE NOTE CAUTION CAUTION WARNING WARNING Step response into dead end system 1 cubic inch volume External Analog Input Impedance 4 20 mA 250Ω 1 5V 220KΩ single input pin to ground 1 7MΩ differential input 0 10V 100KΩ Digital Inputs V...

Page 24: ... ER5000s ERSA04539 20 wire shielded twisted pair cable assembly 24 61 cm Included with F model ER5000s 85138 X 12 wire shielded twisted pair cable assembly 5 10 20 50 and 100 ft 1 5 3 6 15 and 30 m options ERSA04539 X 20 wire shielded twisted pair cable assembly 5 10 and 20 ft 1 5 3 and 6 m options 85145 Filter kit ERAA03458 02 Adaptor fitting 1 2 SAE x 1 8 NPTF mates ER5000 to most TESCOM air act...

Page 25: ...25 What s New ...

Page 26: ...meters clearly displayed in the interface Data acquisition can now be triggered automatically by system events such as digital input detection or a monitored variable reaching a target value Profilescannowincludeupto100commandsegments Loop countsarenowdisplayedinrealtime For F modelER5000s Profilescannowincludethesenew commands Soak whichwaitsuntilfeedbackindicatesanewsetpoint hasbeenreachedbefore...

Page 27: ... the new ER5000 Wiring for the F Model ER5000 For F model ER5000s the 12 pin MTA connector and 8 pin auxiliary MTA connector which were previously fed by separate cables are now fed by a single 20 wire cable All wires feeding the 8 pin connector are color striped to distinguish them visually from the solid color wires feeding the 12 pin connector Refer to Figure 18 to see all wire colors and pin t...

Page 28: ...g input signals into the digital language the microprocessor understands while the ER3000 uses a 12 bit converter In order for the ER5000 to correctly interpret the signals generated by a program written for the ER3000 it must use a 12 bit scale NOTE NOTE CAUTION CAUTION WARNING WARNING Installing the ER3000 Mode Jumper will also turn off the new Suspend Control feature as well as the new Profile ...

Page 29: ...29 How It Works ...

Page 30: ...ure using either its internal sensor or an external transducer 4 20 mA 1 5V or 0 10V placed within the actual process line You can operate the ER5000 in one of three control modes Internal Feedback which uses only the internal sensor External Feedback which uses only the external source Cascade which uses both internal and external sources in a loop within a loop configuration During setup you can...

Page 31: ...t the controller works to return the system to its previous level When the error is the result of a scheduled change in the setpoint the controller works to raise or lower the system to the new target level In either case the controller continues to act until setpoint and feedback are equal The controller then generates a zero error and returns to its monitoring function At this point the system i...

Page 32: ... both the wind and the peripheral force accumulated Integral As the car passes the midpoint of the curve the peripheral force decreases and the wind dies down Now the oversteer Proportional and accumulated Integral threatens to put the car into a skid You respond by understeering adding Derivative through the rest of the curve until you are back on straight road As you drive on you remember the wi...

Page 33: ... set Derivative just enough to reestablish control at the end Three controllers three different goals three different responses to the same change By raising and lowering the relative amounts of Proportional Integral and Derivative a process called Tuning the controller you can set up your ER5000 to meet the specific response characteristics and work within the specific limitations of any system A...

Page 34: ...of the generated error and the constant Kp the Proportional Constant The Integral term which is the product of the integral of all accumulated errors and the constant Ki the Integral Constant Control systems based on just the Proportional term or just the Proportional and Integral terms are known as a P and PI configurations The ER5000 can operate in a P or PI configuration if this is appropriate ...

Page 35: ...stood in basic functional terms There are predictable effects both positive and negative to watch for as settings are increased or decreased If necessary default settings can be restored with the click of a button see To reset the ER5000 to its default PID settings Using a few rules of thumb and the real time visual feedback provided by the ERTune program all operators regardless of experience can...

Page 36: ... state that is slightly below the new setpoint Curve A demonstrates the unwanted effects of a fast but also unstable response Tuning this controller will entail lowering the Proportional setting and perhaps the Integral setting as well Alternatively increasing the Derivative will help to stabilize the response Curve D demonstrates the unwanted effects of a stable but overly slow response Tuning th...

Page 37: ...stable state higher Integral settings can eliminate offset Windup can delay the controller s response to new errors as accumulated errors must spool out before new errors can begin charging up Integral The ER5000 features exclusive IntegralLimitstocontrolpositiveandnegativewindup allowing youtousehigherIntegralsettings The Integral of small errors can over time accumulate to the point of causing u...

Page 38: ...a rich visual environment and precise intuitive controls for tuning the ER5000 Refer to The Tuning Tab Controls and Functions for Tuning the ER5000 for a detailed explanation of the program s capabilities and features as well as tips and techniques to achieve optimal system performance Every system has unique characteristics every operational environment presents unique challenges and every applic...

Page 39: ...n in Figure 4 SupplyPressureofupto120psig 8 2bar with110psig 7 5bar being typical is provided to the ER5000 by an external source The ER5000 increases Pilot Pressure to the air actuator of the regulator by opening the Pulse Width Modulation PWM solenoid valve at the Inlet Port and reduces pilot pressure by opening the PWM solenoid valve at the Exhaust Port Normally the exhaust vents to atmosphere ...

Page 40: ...tor vent to open exhausting excess system pressure if your application uses a non venting regulator refer to page 41 The result is a decrease in downstream system pressure The ER5000 will continue to exhaust pilot pressure until the feedback signal is equal to the setpoint At that point the exhaust valve closes stabilizing the system at that pressure ER5000 Inlet Port Supply Pressure 110 psig 7 5 ...

Page 41: ...nd until the pilot pressure is completely vented through the exhaust valve This can create two different undesirable conditions If the regulator is a metal diaphragm sensed regulator the differential between the high downstream pressure beneath the diaphragm and the low or even zero pilot pressure above the diaphragm can critically stress the diaphragm Regardless of regulator type if the downstrea...

Page 42: ...rom occurring It should not be considered to be a safety mechanism nor is it intended to be a safety feature or pressure limiting device WhenanER5000configuredtomonitorControlLimitsdetectsasignal indicatingthatalimithasbeenexceeded itactivatesitssolenoidvalves toreachoneofthreeControlLimitConditions Inlet Closed Exhaust Closed Inlet Closed Exhaust Open Inlet Open Exhaust Closed The default Conditi...

Page 43: ...l respond more efficiently to a 5 change in a 0 10 psig 0 0 7 bar range than to a 0 5 change in its full 0 100 psig 0 6 9 bar range There is a need to monitor downstream pressure For example if the output passes through a length of pipe to a vessel and it is expected that there will be pressure drops in the pipe an external sensor installed at the vessel will provide a more responsive feedback sig...

Page 44: ...44 Glossary of Terms ...

Page 45: ... ER5000 to increase system pressure and a negative error causes the ER5000 to decrease system pressure Feedback The input sent from an internal or external sensor that indicates the current level of the process a PID controller manages The controller subtracts feedback from Setpoint generating an Error and any non zero error activates the controller Hazardous Location The Hazardous locations are a...

Page 46: ...ndup can cause the controller to lag in response to new Errors Proper Tuning prevents windup by setting limits on accumulated value through the Integral Limits Integral Limits Pair of filters which limit the amount of Integral Windup that can accumulate during Error correction Maximum limit is set for positive errors Setpoint minus Feedback is positive Minimum limit is set for negative errors setp...

Page 47: ...ecific voltage or current the output acts as either an open circuit or a connection to ground Open collector circuits are used in many systems such as to interface devices that have different operating voltage levels or to connect multiple open collector devices to a single line Overshoot Overcorrection due to a Proportional or Integral setting that is too high Must be carefully controlled to keep...

Page 48: ...er s response that is a direct function of the Error generated by the current level of Feedback from the system Pulse Deadband Stop band filter that deactivates Pulse Mode within a set percentage range around Setpoint Pulse Mode Refer to The Pulse Mode Panel for a complete description of this feature Pulse Width Modulation PWM Method of controlling a device such as a mechanical valve using the con...

Page 49: ...ne within a Profile Setpoint The value that a PID Controller works to maintain within the system it controls The setpoint may remain at one level or change over time depending on the requirements of the system A well tuned controller will maintain a Stable State at setpoint and implement setpoint changes quickly and accurately The ER5000 requires a setpoint signal in order to function This signal ...

Page 50: ...sure The pressure of the gas or liquid in a Process Line that is controlled by the Regulator which is controlled in turn by the Pilot Pressure from the PID Controller There are two components to system pressure the inlet pressure upstream pressure which is the pressure level of the gas or liquid in the process line at the point where it enters the regulator and the outlet pressure downstream press...

Page 51: ...erformance Variable Any configuration setting for the ER5000 such as the Proportional Integral and Derivative constants the setpoint value the Control Mode or the Node Address Refer to the Internal Variables section for a complete list Variable values can be included in data collection and certain variables can be tracked using The Plot Screen of the ERTune program ...

Page 52: ...ig 6 9 bar Captured Venting Feature incorporated in some venting Regulators which provides an additional port that can be connected to piping in order to safely dispose of excess liquid or gas expelled by the regulator s vent valve The vent port should never be plugged Not all venting regulators have this feature Refer to Venting Regulator Control Element One of the three basic elements of a Regul...

Page 53: ... a decrease in inlet pressure In pressure reducing regulators outlet pressure is set when force from the load element which opens the main valve is matched by inlet pressure moving through the valve If inlet pressure decreases for example when a supply cylinder starts to empty and the inlet pressure it supplies starts to decrease this tips the balance in favor of the load element and opens the val...

Page 54: ...xternal force such as the Pilot Pressure from a PID Controller or the downward pressure of a knob activated spring that acts on the Sensing Element and causes the Control Element to respond by opening or closing the main valve The three common types of loading elements are Spring Loaded Dome Loaded and Air Actuated The ER5000 can be used with either dome loaded or air actuated regulators Lock up T...

Page 55: ... in a jump from 1 psig to 26 psig 0 07 bar to 1 8 bar in control pressure Please discuss with your TESCOM representative if you are using a dome loaded regulator with the ER5000 as the amount of negative bias varies among different dome loaded regulator models Piston One type of Sensing Element Used for high pressure applications up to 30 000 psig 2068 bar psia absolute pressure A measure of press...

Page 56: ...to the original set pressure Diaphragm and Piston are the two most commonly used sensing elements Set Pressure The desired operational control pressure for a Regulator normally stated at FIRST FLOW conditions Venting Regulator A pressure reducing Regulator that can vent the Outlet Pressure downstream pressure when the loading actuation force is decreased A decrease in Pilot Pressure causes the reg...

Page 57: ...57 Getting Started ...

Page 58: ...ves or completely shut off the process to isolate the ER5000 and associated equipment from process pressure prior to installation or maintenance Relieve process pressure on both sides of the controller and associated equipment Use lock out procedures to be sure that the above measures stay in effect while you work on the equipment Checkwithyourprocessorsafetyengineerforanyadditionalmeasuresthatmus...

Page 59: ...EDs J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power 8 gray 24V return power ground 9 white 5V output 5 mA max 10 black analog signal board ground 11 pink analog signal output active in Enhanced F models ONLY 12 tan analog signal board ground...

Page 60: ...page 110 before you begin Verify that all of these items are in the box you receive 1 ER5000 or ER5050 Hazardous Location Electronic Pressure Controller 2 3mm hex wrench for cover lock screw ER5050 model only 3 1 2 SAE x 1 8 NPTF adaptor 4 Wiring connectors pre installed with strain relief a 12 pin MTA connector with 12 wire 18 45 7 cm cable standard ER5000 models b 12 pin and 8 pin MTA connectors...

Page 61: ... tape Wire strippers Additional items and tool you will need for an installation in a Hazardous Location Conduit and connectors rated for your Hazardous Location IMPORTANT IMPORTANT ERTuneTM software is compatible with the following operating systems Windows XP Windows Vista Windows 7 and Windows 8 IMPORTANT IMPORTANT Windows 8 users In order to maintain compatibility with previous Windows operati...

Page 62: ...ctions ER5000SI 1 Controller is mounted on top of an air actuated pressure reducing regulator 1 2 SAE x 1 8 NPTF adaptor is used to connect controller to regulator External Feedback control mode Feedback source is a two wire 4 20 mA transducer Controller is connected to a PC which is running the ERTune program connected via USB using the Mini B USB port on the ER5000 s control board For informatio...

Page 63: ...understand all warnings and cautions in the Safety Installation Operations Precautions section WARNING Improperselection improperinstallation impropermaintenance misuseorabuseofthiscontrollerorrelatedaccessoriescancause propertydamage seriousinjuryordeath Supply pressure must be clean dry inert gas or air that meets the requirements of ISA Standard 7 0 01 Severe personal injury or property damage ...

Page 64: ...NING WARNING Your application may require additional fittings Figure 8 Mount the ER5000 on the Regulator WARNING Installation in a hazardous location requires additional steps not described in this section Refer to Installing a Hazardous Location Model ER5050 on page 110 for more information ...

Page 65: ...w the local regional and national codes could result in personal injury or property damage To avoid personal injury resulting from electrical shock never connect the controller or associated equipment to a supply source having a voltage greater than the maximum rated voltage of this controller or the associated equipment Make sure that the components used in the electronic system are compatible wi...

Page 66: ...ignal board ground 11 pink analog signal output active in Enhanced F models ONLY 12 tan analog signal board ground 2 For standard model ER5000s the 12 pin MTA connector comes pre installed to the J3 terminal block For F model ER5000s the standard 12 pin MTA connector and auxiliary 8 pin MTA connector come pre installed to the J3 and J4 blocks 3 Connect the violet wire Pin 7 to the 24V DC wire from...

Page 67: ...ED4 blinks which indicates that the embedded controller software is running NOTE NOTE CAUTION CAUTION WARNING WARNING LED2 green and LED3 amber respond to data transmission when the ER5000 communicates using RS485 These LEDs do not respond to data transmission when the ER5000 communicates using USB and may be on or off depending on the specific configuration of your application They do not need to...

Page 68: ... WARNING WARNING If you are replacing an ER3000 in an existing application and wish to continue using your current software such as the Windows Tune program you will need to install Jumper J9 The default configuration for Jumper J9 is NOT installed With the cover still removed inspect Jumper J6 Refer to Figure 11 For connection to a 4 20 mA transducer the jumper should be installed For connection ...

Page 69: ...ormation 1 Refer to Table 3 below to verify correct wiring Table 3 Main Cable Wiring for Power Supply J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power Standard Installation 8 gray 24V return power ground 9 white 5V output 5 mA max 10 black an...

Page 70: ...the positive wire from the 24V DC power supply to the power input of the transducer which is Pin 1 or A on TESCOM transducers 4 Connect the yellow feedback return wire Pin 4 to the tan analog ground wire Pin 12 NOTE NOTE CAUTION CAUTION WARNING WARNING This is necessary to complete the ground circuit for the signal from the transducer For other applications and wiring configurations refer to the I...

Page 71: ... correct wiring variations using RS485 The cable included with the ER5000 has a standard USB A connector on one end and a 90 Mini B connector on the other 1 Slide the Mini B connector into the left conduit port in the base of the ER5000 as shown in Figure 13 2 Thread the cable over the control board and plug it into the Mini B USB port 3 Remove any excess slack in the cable and secure the integrat...

Page 72: ...ick Close NOTE NOTE CAUTION CAUTION WARNING WARNING The ERTune program is available in English German and Chinese versions When installation begins the installer checks the default language settings for the computer and if German or Chinese are detected the corresponding translated version is installed Otherwise the English version is installed 4 Locate the ERTune program listing in the Start menu...

Page 73: ...e remotely vented to a safe location to prevent asphyxiation due to lack of Oxygen in the surrounding atmosphere Connect the inlet pressure source to the Inlet Port markedINonthebaseoftheER5000 RefertoFigure16 a The Exhaust Port vents to atmosphere b The output pressure is the regulated pressure that passes through the Outlet Port on the bottom of the controller into the dome of the regulator Refe...

Page 74: ... plugged to prevent leakage or attach a pressure gauge as shown in Figure 16 on the previous page NOTE NOTE CAUTION CAUTION WARNING WARNING For side mounted applications the Gauge Port can be used as the outlet Plug the Outlet Port at the bottom of the controller for these applications ...

Page 75: ...alinjuryorpropertydamage Most controls in the ERTune program operate in real time and have an immediate effect on system performance Be aware of system limitations before you change the settings of a control Depending on the application these changes may upset the process control which may result in personal injury or property damage The ER5000 is now fully installed Connect the regulator supply p...

Page 76: ...76 Installation Variations ...

Page 77: ...ic power or a control signal to the ER5000 prior to installation or maintenance Use bypass valves or completely shut off the process to isolate the ER5000 and associated equipment from process pressure prior to installation or maintenance Relieve process pressure on both sides of the controller and associated equipment Use lock out procedures to be sure that the above measures stay in effect while...

Page 78: ...erter page 89 Digital USBtoRS485Converter page 90 Digital RS232toRS485Network page 91 Digital USBtoRS485Network page 93 Digital USB USB cable Feedback Source Internal None Two Wire Transducer page 95 Three Wire Transducer page 96 Four Wire Transducer page 97 4 20 mA External Feedback Floating Input FeedbackSignalMonitoredbyPCorPLCA DCard page 98 4 20 mA External Feedback Ground Referenced Input Fe...

Page 79: ...n 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power 8 gray 24V return power ground 9 white 5V output 5 mA max 10 black analog signal board ground 11 pink analog signal output active in Enhanced F models ONLY 12 tan analog signal board ground J4 Pins Wire Color Function 1...

Page 80: ...tpoint external feedback auxiliary input 1 and auxiliary input 2 respectively For these jumpers having the jumper installed ON configures the controller for 4 20 mA input and having the jumper not installed OFF configures the controller for 1 5V input NOTE NOTE CAUTION CAUTION WARNING WARNING 0 10V models of the ER5000 do not have these jumpers continued next page Figure 19 Jumpers Jumper J5 Setpo...

Page 81: ...d LED3 amber verify that the ER5000 is sending and receiving data NOTE NOTE CAUTION CAUTION WARNING WARNING Refer to page 89 through page 93 for correct wiring to connect the ER5000 to an RS485 converter NOTE NOTE CAUTION CAUTION WARNING WARNING LED2 and LED3 respond to data transmission when the ER5000 communicates using RS485 These LEDs do not respond to data transmission when the ER5000 communi...

Page 82: ... signal board ground 11 pink analog signal output active in Enhanced F models ONLY 12 tan analog signal board ground WARNING Selectwiringand orcableglandsthatareratedfortheenvironment ofuse Failuretouseproperlyratedwiringand orcableglandscan result inpersonalinjuryorpropertydamage Wiring connections must be in accordance with local regional and national codes for any given area Failure to follow t...

Page 83: ... wiring or change to jumper configuration is performed Do not reconnect the power supply until all additional wiring connections have been made and are properly installed Refer to Table 5 to verify correct wiring Table 5 Wiring for Potentiometer Analog Setpoint J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 netw...

Page 84: ...before any additional wiring or change to jumper configuration is performed Do not reconnect the power supply until all additional wiring connections have been made and are properly installed Refer to Table 6 to verify correct wiring Table 6 Wiring for Current Voltage Analog Setpoint J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback i...

Page 85: ...ll additional wiring connections have been made and are properly installed Refer to Table 7 to verify correct wiring Table 7 Wiring for Passive PC or PLC D A Card Analog Setpoint J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power 8 gray 24V ret...

Page 86: ...onnections have been made and are properly installed Refer to Table 8 to verify correct wiring Table 8 Wiring for Active PC or PLC D A Card Analog Setpoint J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power 8 gray 24V return power ground 9 whit...

Page 87: ... wiring or change to jumper configuration is performed Do not reconnect the power supply until all additional wiring connections have been made and are properly installed Refer to Table 9 to verify correct wiring Table 9 Wiring for Profile Control Using Auxiliary Inputs J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green R...

Page 88: ...ofile Start Stop signal and Auxiliary Input 1 brown white wire J4 Pin 1 is used as the Digital Input signal the ER5000 allows you to adjust the toggle level also referred to as the trip point of the input This is the level where the analog input switches between a logical 0 and a logical 1 For example when a pressure transducer is connected to the Digital Input this feature allows the ER5000 to wa...

Page 89: ...additional wiring connections have been made and are properly installed Refer to Table 10 to verify correct wiring Table 10 Wiring for RS485 Connection RS232 to RS485 Converter J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power 8 gray 24V retur...

Page 90: ...med Do not reconnect the power supply until all additional wiring connections have been made and are properly installed Refer to Table 11 to verify correct wiring Table 11 Wiring for RS485 Connection USB to RS485 Converter J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network con...

Page 91: ...for up to 32 ER5000s to be daisychained in a network WARNING The controller must be disconnected from the power supply before any additional wiring or change to jumper configuration is performed Do not reconnect the power supply until all additional wiring connections have been made and are properly installed continued next page GRAY GRAY GRAY RS485 24 V DC RS485 GROUND GREEN GREEN GREEN VIOLET VI...

Page 92: ...NING WARNING The number you assign should be lower than 250 Numbers higher than 250 will be truncated to the first two digits NOTE NOTE CAUTION CAUTION WARNING WARNING The power supply for your network must be able to provide 300 mA to each ER5000 in the daisychain Refer to Table 12 to verify correct wiring Table 12 Wiring for Networked Connection RS232 to RS485 Converter J3 Pins Wire Color Functi...

Page 93: ...s shown in Figure 30 allows for up to 32 ER5000s to be daisychained in a network WARNING The controller must be disconnected from the power supply before any additional wiring or change to jumper configuration is performed Do not reconnect the power supply until all additional wiring connections have been made and are properly installed continued next page TDB TDA GREEN GREEN GREEN BLUE BLUE BLUE ...

Page 94: ...ave one ER5000 at the default value NOTE NOTE CAUTION CAUTION WARNING WARNING The number you assign should be lower than 250 Numbers higher than 250 will be truncated to the first two digits NOTE NOTE CAUTION CAUTION WARNING WARNING The power supply for your network must be able to provide 300 mA to each ER5000 in the daisychain Refer to Table 13 to verify correct wiring Table 13 Wiring for Networ...

Page 95: ...have been made and are properly installed Refer to Table 14 to verify correct wiring Table 14 Wiring for Two Wire Transducer J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power 8 gray 24V return power ground 9 white 5V output 5 mA max 10 black a...

Page 96: ...properly installed Refer to Table 15 to verify correct wiring Table 15 Wiring for Three Wire Transducer J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power 8 gray 24V return power ground 9 white 5V output 5 mA max 10 black analog signal board gr...

Page 97: ...operly installed Refer to Table 16 to verify correct wiring Table 16 Wiring for Four Wire Transducer J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power 8 gray 24V return power ground 9 white 5V output 5 mA max 10 black analog signal board groun...

Page 98: ...wiring or change to jumper configuration is performed Do not reconnect the power supply until all additional wiring connections have been made and are properly installed Refer to Table 17 to verify correct wiring Table 17 Wiring for Monitoring 4 20 mA External Feedback Floating Input J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback i...

Page 99: ...additional wiring connections have been made and are properly installed Refer to Table 18 to verify correct wiring Table 18 Wiring for Monitoring 4 20 mA External Feedback Ground Referenced Input J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC pow...

Page 100: ...t the power supply until all additional wiring connections have been made and are properly installed The feedback signal can alternatively be monitored through the USB connection between the ER5000 and the PC by reading variable 44 ID_FEEDBACK Refer to Table 19 for correct wiring Table 19 Wiring for Monitoring Voltage from 4 20 mA External Feedback Two Wire Transducer J3 Pins Wire Color Function 1...

Page 101: ...ditional wiring connections have been made and are properly installed The feedback signal can alternatively be monitored through the USB connection between the ER5000 and the PC by reading variable 44 ID_FEEDBACK Refer to Table 20 for correct wiring Table 20 Wiring for Monitoring Voltage from 4 20 mA External Feedback Three Wire Transducer J3 Pins Wire Color Function 1 brown setpoint input 2 red s...

Page 102: ...dditional wiring connections have been made and are properly installed The feedback signal can alternatively be monitored through the USB connection between the ER5000 and the PC by reading variable 44 ID_FEEDBACK Refer to Table 21 for correct wiring Table 21 Wiring for Monitoring Voltage from 4 20 mA External Feedback Four Wire Transducer J3 Pins Wire Color Function 1 brown setpoint input 2 red s...

Page 103: ...put 5 green RS485 network connection 6 blue RS485 network connection 7 violet 24V DC power 8 gray 24V return power ground 9 white 5V output 5 mA max 10 black analog signal board ground 11 pink analog signal output active in Enhanced F models ONLY 12 tan analog signal board ground J4 Pins Wire Color Function 1 brown white aux input 1 2 red black aux input 1 3 orange black aux input 2 4 yellow black...

Page 104: ...cal range to 0 5 psig 0 03 bar NOTE NOTE CAUTION CAUTION WARNING WARNING The wiring shown in Figure 39 on the previous page is for two wire transducers Refer to Figure 32 and Figure 33 respectively for correct wiring of three wire and four wire transducers Wiring Variations for Additional Functions Monitoring Additional Analog Inputs The ER5000 can monitor signals from a number of analog sources a...

Page 105: ...al Sensor 4 20 mA Wiring WARNING The controller must be disconnected from the power supply before any additional wiring or change to jumper configuration is performed Do not reconnect the power supply until all additional wiring connections have been made and are properly installed Refer to Table 23 to verify correct wiring Table 23 Wiring for Monitoring Internal Sensor 4 20 mA J3 Pins Wire Color ...

Page 106: ...nal Sensor 0 10V Wiring WARNING The controller must be disconnected from the power supply before any additional wiring or change to jumper configuration is performed Do not reconnect the power supply until all additional wiring connections have been made and are properly installed Refer to Table 24 to verify correct wiring Table 24 Wiring for Monitoring Internal Sensor 0 10V J3 Pins Wire Color Fun...

Page 107: ...og signal board ground 11 pink analog signal output active in Enhanced F models ONLY 12 tan analog signal board ground J4 Pins Wire Color Function 1 brown white aux input 1 2 red black aux input 1 3 orange black aux input 2 4 yellow black aux input 2 5 green white suspend control 6 black white digital output board ground 7 blue white digital output 1 8 gray black digital output 2 continued next pa...

Page 108: ... audio or visual alarm or to start a conveyor belt As shown in Figure 42 Output 1 uses an external power supply to switch a 12V DC solid state relay which controls Load 1 Output 2 uses the ER5000 s power supply to switch a 24V DC relay which controls Load 2 NOTE NOTE CAUTION CAUTION WARNING WARNING Digital Output 1 and Digital Output 2 are Open Collector circuits Refer to the Glossary of Terms sec...

Page 109: ...y before any additional wiring or change to jumper configuration is performed Do not reconnect the power supply until all additional wiring connections have been made and are properly installed Refer to Table 26 for correct wiring Table 26 Wiring for Suspend Mode J3 Pins Wire Color Function 1 brown setpoint input 2 red setpoint input 3 orange feedback input 4 yellow feedback input 5 green RS485 ne...

Page 110: ...ations and specifications ER5050 Supply Pressure 110 psig 7 5 bar Adaptor External Transducer Rated For Use In Hazardous Location Junction Box Rated For Use In Hazardous Location Hazardous Location Conduit Cables and Hubs Typical Conduit Hub Installation using a hole through the enclosure with a grounding locknut instead of a metal backplate Conduit O Ring Set Screw Ground Wire Increased Safety Gr...

Page 111: ...111 The ERTune Program ...

Page 112: ...ot Screen Buttons The Print Button 135 The Plot Screen Variable Controls 137 The Footer Area 142 The Tuning Tab Controls and Functions for Tuning the ER5000 143 Tuning the ER5000 144 Before You Begin 144 The Setpoint Panel 145 Selecting a Setpoint Source 145 Analog Input Setpoint Source 145 ERTune Program 145 Profile 145 External Device Setpoint Source 145 Toggle Mode Setpoint Source 145 Ramp Mode...

Page 113: ...76 The Configure Tab 178 The Mechanical Regulator Panel 179 The ER Settings Panel 179 ER Model 179 Control Mode 179 ER Node 180 Calibration 180 The Control Limits Panel 181 The Diaphragm Protection Panel 183 The Diagnostic Tools Tab 184 The System Check Panel 184 The ER Solenoid Leak Test Panel 184 The Regulator Leak Check Panel 186 The Tuning Tips Panel 186 The ERTune Program Power User 187 The P...

Page 114: ... Menu 136 To reset the main left vertical axis to its original values using the Main Axis Menu 136 The Plot Screen Variable Controls 137 To track an additional variable 138 To add a variable to the Plot Screen display 138 To set or change the range for an added variable 138 To optimize the display when both additional variables have been added to the Plot Screen 139 To change which variable is bei...

Page 115: ...ab 178 To change the Regulator Series 179 To change the regulator model number or serial number 179 To change the Control Mode of the ER5000 179 To change the Node Address of the ER5000 180 To change the calibration of the ER5000 180 To add a Control Limit for the ER5000 to monitor 182 To remove a Control Limit 182 To remove all Control Limits 182 To change the Control Limit Condition 182 To activ...

Page 116: ...116 The ERTune Program Basic Features ...

Page 117: ...ns of Windows this is located at C Program Files Emerson ERTune A separate folder is created for data files generated by the program On PCs running Windows 7 this is located at C Program Data Emerson ERTune On PCs running previous versions of Windows this is located at C Documents and Settings All Users Application Data Emerson ERTune This folder is the default location for configuration files Pro...

Page 118: ...oting NOTE NOTE CAUTION CAUTION WARNING WARNING The ERTune program is available in English German and Chinese versions When installation begins the installer checks the default language settings for the computer and if German or Chinese are detected the corresponding translated version is installed Otherwise the English version is installed To install the ERTune program 1 Download the ER5000 Softw...

Page 119: ...ly If the ER5000DR driver does not install automatically refer to the Troubleshooting section To open the ERTune program IMPORTANT IMPORTANT The ER5000 controller must be powered up and connected to the computer for the ERTune program to open If the program does not open and instead you see the Comm Error window refer to If the ERTune program does not open 1 Click the ERTune icon in your START men...

Page 120: ...ller If you are using a TESCOM regulator the series number model number and serial number of the regulator you are using The range of your external feedback transducer 1 Click the Next button The Node and Model window opens 2 The Node Address is set to a default of 250 If you are using multiple controllers in a daisychain on the same network you must assign each controller a unique Node Address du...

Page 121: ...ntrol Mode for your controller External Feedback is default for new controllers The other options are Internal Feedback and Cascade 6 Select the Control Mode that is appropriate for your application and click the Next button The Sensor Range window opens The fields in this window set the default range and the unit of measurement for the Plot Screen in the ERTune program The default is percentage y...

Page 122: ... the specifications for the external transducer you will be using for your application NOTE NOTE CAUTION CAUTION WARNING WARNING As a general rule the Internal Feedback range should be left at default for Cascade Control Mode so only the External Feedback range is shown in this window 8 Click the Next button The Mechanical Regulator Information window opens 9 Enter the information for the regulato...

Page 123: ...sensed regulator the Regulator Diaphragm Protection windowopens YoucanconfiguretheER5000fordiaphragmprotection Non venting regulators which do not feature a regulator vent to exhaust excess system pressure pose a particular challenge in closed loop applications when the downstream flow is blocked Regulator Diaphragm Protection is designed for applications that use a non venting regulator in a syst...

Page 124: ...nter in the Delta Pressure entry field sets the maximum difference between the setpoint and the dome pressure of the regulator to which the ER5000 will respond expressed as a percentage of the Sensor Range you set in Step 7 When Delta Pressure exceeds the value entered in this field the ER5000 stops responding to error This prevents the high differential pressure situations and delayed response de...

Page 125: ...Programs ERTune ERTune Simulator 2 Click the menu item The ERTune program opens in Simulation Mode Figure 45 The Simulation Warning Above The Plot Screen IMPORTANT IMPORTANT When the ERTune program is operating in Simulation mode the right side of The Plot Screen Menu Bar displays a Simulation warning Configuration changes you make while in Simulation mode have no effect on the controller Simulati...

Page 126: ...asic Features The ERTune Program User Interface The Footer Area The Tab Area The Menu Bar The Plot Screen Variable Controls The Plot Screen Click a heading to learn more about the features and functions of that area of the interface ...

Page 127: ...his command exits the program The Node Menu The Node menu has two commands Node Select This command opens the Select Node window which allows you to select between ER5000s when you have multiple controllers in the same network To switch between controllers based on Node Address 1 Select Node Node Select The Select Node window opens 2 Enter the Node Address of the controller you wish to access NOTE...

Page 128: ...ated list to select it The ERTune program will begin communicating with the controller at that Node Address and will display its configuration information The Help Menu The Help Menu has three commands Power User This command toggles the display of The Power User Tab on and off The Power User Tab gives you access to advanced configuration options Most applications of the ER5000 do not require acce...

Page 129: ... command sequences for the ER5000 The Data Tab This tab displays the controls for collecting exporting and retrieving data generated during tuning or operation of the ER5000 using text files with the dat file extension which can be stored on your computer or network The Configure Tab This tab displays the controls for setting and changing basic configuration options for the ER5000 including regula...

Page 130: ... these values The horizontal axis defaults to a cycle of 10 seconds You can change the cycle time and the range of values shown in the Plot Screen displays using commands in The Plot Screen Menu Bar or by interacting directly with the Plot Screen using your mouse Youcanchangetheactualrange ofvalues trackedbytheERTune programby changingtherangeoftheFeedback 44 variableinThePlotScreenVariableControl...

Page 131: ... feedback blue line The main left vertical axis and the horizontal axis have been customized using the commands in The Plot Screen Menus The Main Axis Menu In this application the ER5000 s internal sensor is also being tracked directly as an Added Variable green line which has been added to the Plot Screen using The Plot Screen Variable Controls The Secondary Axis displays the range for the intern...

Page 132: ...ithin the Plot Screen This toggles the display between a 0 to 100 display and a 20 to 120 display NOTE NOTE CAUTION CAUTION WARNING WARNING If your application makes full use of the display range the 20 to 120 display makes it easier to visually track setpoints and responses near the 0 and 100 levels To zoom the vertical axis display 1 Click once within the Plot Screen at the level you want to set...

Page 133: ...his process to progressively increase the zoom level Figure 49 Marquee select in the Plot Screen To return both axes to the default display settings 1 Double click anywhere within the Plot Screen NOTE NOTE CAUTION CAUTION WARNING WARNING If you have zoomed multiple times using a marquee each double click will zoom out one level Continue to double click until you reach the default settings NOTE NOT...

Page 134: ...ical This command resets the main axis to its original minimum and maximum values if they have been changed by the Maximum Vertical and or Minimum Vertical commands The Plot Screen Menus The Secondary Axis Menu The commands in this menu control the secondary right axis of the display This axis tracks the optional additional variables and displays independently from the main axis It is not affected...

Page 135: ...third green line variable Rescale Vertical This command resets the secondary axis to its original minimum and maximum values if they have been changed by the Maximum Vertical and or Minimum Vertical commands The Plot Screen Buttons The Start Plot Stop Plot Button This button toggles to start and stop the real time display of the Plot Screen The Plot Screen Buttons The Print Button This button take...

Page 136: ... axis display Select Main Axis Maximum Vertical to change the maximum value for the main axis display 2 Enter a new value 3 Click OK The display rescales using the new value NOTE NOTE CAUTION CAUTION WARNING WARNING Repeat these steps for both menu items if you wish to set new values for both the minimum and maximum of the display To reset the main left vertical axis to its original values using t...

Page 137: ...a variable to add it to the Plot Screen display This also adds the variable to any data acquisition that takes place while it is checked Uncheck the box to remove a variable from display and data acquisition You can continue to monitor its value in the Value field Value Field Displays the current value for a variable and updates continually when the Plot Screen is active Shows values even when the...

Page 138: ...d variable controls the range of the secondary right axis NOTE NOTE CAUTION CAUTION WARNING WARNING The first added variable appears as a green line The second added variable appears as a black line 3 The variable displays as a new line in the Plot Screen the next time the screen is active NOTE NOTE CAUTION CAUTION WARNING WARNING The variable is also added to data acquisition To set or change the...

Page 139: ...ensor will often be beyond the maximum of the display If the secondary axis is set to the larger range of the external sensor the feedback from the internal sensor will be difficult to differentiate The best of both worlds approach in this scenario is to set the range for both variables to 0 100 rather than using a unit of measure based on pressure values At this setting both variables will displa...

Page 140: ...down list for the variable you wish to remove 2 Select Remove Variable To change the secondary axis using the Secondary Axis Menu IMPORTANT IMPORTANT Changes made to the Plot Screen display using the Plot Screen menu commands only change the display of the Plot Screen The ERTune program continues to track the full range of values entered for the variable s being tracked The secondary axis does not...

Page 141: ... system conditions 1 Click the Range button to the right of drop down list for Feedback 44 The Define Feedback Transducer Range screen opens 2 Enter values for minimum maximum and or units of measure 3 Click Save To change the display of the main left axis to the new range 1 Select Main Axis Rescale Vertical 2 The main axis rescales to display the new range IMPORTANT IMPORTANT If you double click ...

Page 142: ...lowing information Model number of the ER5000 Serial number of the ER5000 Node Address of the ER5000 Model Number of the regulator Serial Number of the regulator If you have multiple controllers daisychained in a network the information in the footer tells you which controller is currently communicating with the ERTune program ...

Page 143: ...Tune program the Tuning Tab will display the PID values that were set at the factory or that were downloaded to the controller during setup WARNING Most controls in the ERTune program operate in real time and have an immediate effect on system performance Be aware of system limitations before you change the settings of a control Depending on the application these changes may upset the process cont...

Page 144: ...result if you tune the ER5000 at a number of different pressure ranges from maximum system limits to minimum anticipated step change Tuning the ER5000 at a number of intermediate ranges will give you a fuller picture of the controller s response characteristics Your final tuning should be done using a range that approximates typical operating conditions Understand the characteristics of your appli...

Page 145: ...the ERTune program generates setpoints based on values you have entered in the program There are two tuning modes Toggle and Ramp Profile When this is selected the ER5000 follows the command sequence of the Profile that is currently loaded in the ER5000 External Device Setpoint Source When this is selected the ER5000 accepts digital setpoints USB or RS485 from an external device such as a PC The s...

Page 146: ...he words Hit Space Bar to Toggle Appear 3 Press the Space Bar Each press toggles the setpoint value NOTE NOTE CAUTION CAUTION WARNING WARNING If you click outside of the Tuning Tab for example to zoom the Plot Screen the toggle function is turned off and the words Hit Space Bar to Toggle disappear Click below the Setpoint fields to restore the setpoint toggle function ERTune Program Ramp Mode Setp...

Page 147: ...the Profile you wish to use then click the Download button You may also build a Profile using The Profile Builder Panel then click the Download button To tune the ER5000 using a Profile 1 Click the Profile Tab 2 Load a Profile into the Profile Tab You may upload it from the ER5000 create it using the Profile Builder or open a previously saved Profile 3 Click the Tuning Tab 4 Click the Start button...

Page 148: ...plays for the internal and external PID controllers Click the Cascade Show External Cascade Show Internal button to toggle between these two displays within the panel NOTE NOTE CAUTION CAUTION WARNING WARNING The slider ranges shown for each controller do not correspond to any actual mechanical setting within the ER5000 They are set to give a level of precision that is appropriate for each term a ...

Page 149: ...oller This slider sets the Proportional term for the ER5000 Proportional Tuning Tips In most applications the first step in tuning is to see how high the Proportional term can be increased The primary goal when increasing Proportional is to minimize the response time Proportional should be gradually increased until overshoot or ringing become too pronounced Then it should be stepped back until the...

Page 150: ...g environment If you note that the controller is not remaining in Stable State after setpoint has been reached try reducing the Derivative term The Integral Controller This slider sets the Integral term for the ER5000 Integral Tuning Tips In most tuning applications the Integral term is first zeroed out so the effect of adjustments to the Proportional term is not amplified It is then added gradual...

Page 151: ...can accumulate for the Integral term during error correction typically after a change from a high to a low setpoint The Integral will stop subtracting negative value when it reaches the level set by this limit regardless of feedback Deadband This controller sets a range around the setpoint where the Integral term will not respond to error The deadband range is measured as a percentage of the full ...

Page 152: ...ning as well as the detailed Tuning Tips beginning on page 149 and build your own configuration from scratch You can return to the default settings at any time by following the steps To reset the ER5000 to its default PID settings Tuning is a gradual process with repeated cycles of changing settings and monitoring system response Most of the steps in this example will be repeated multiple times un...

Page 153: ...sing Proportional will speed up response time 3 Move the Proportional slider to the right or enter a higher number in the field next to the slider Refer to Proportional Tuning Tips 4 Continue to toggle the setpoint Note the change in the response of the ER5000 5 Continue to move the Proportional slider right until you begin to see excessive overshoot ringing or until there is no appreciable improv...

Page 154: ...Derivative will be used to correct the small amount of residual overshoot To add the Derivative Term 1 Move the Derivative slider slightly to the right or enter a higher number in the field next to the slider 2 Toggle the setpoint and note the change to the response curve Figure 54 Typical Tuning Derivative Added A higher Derivative setting will completely correct the overshoot continued next page...

Page 155: ...g Critically Damped Response is now both quick and stable 4 Repeat the process until you note the effects of overdamping Figure 56 Typical Tuning Overdamped Response A Derivative setting that is too high results in a slower rise time 5 Step back the Derivative slider or enter a smaller number in the field until instability reaches unacceptable levels ...

Page 156: ...the effect of the Integral Term using the Integral Limits 1 Increase magnification in the Plot Screen to zoom in closely at the level of Setpoint 2 75 Refer to Resizing the Range Displayed by the Plot Screen Using the Mouse 2 Toggle the setpoint to Setpoint 2 3 Wait for the system to reach a stable state 4 Look closely for offset between the setpoint and feedback level once the system reaches stab...

Page 157: ...zoom in closely at the level of Setpoint 1 25 8 Look closely for offset between the setpoint and feedback level once the system reaches stable state If there is offset move the Minimum slider slightly to the left to increase the level of negative Integral that will be allowed to accumulate 9 Repeat until the offset is eliminated Figure 59 Typical Tuning Checking for Offset at Setpoint 1 As was tru...

Page 158: ... the Integral Limit levels are too high allowing Integral windup to affect the response NOTE NOTE CAUTION CAUTION WARNING WARNING If you find that you cannot eliminate offset and windup without increasing instability you will need to reduce the Integral Term To add Integral Deadband 1 Allow the ER5000 to cycle through the Plot Screen several times at the current setpoint 2 If the ER5000 activates ...

Page 159: ...nal loop are Maximum 32767 Minimum 0 These settings are optimal for most applications and should not be changed unless you have verified that this is required by your application Increasing the Integral Term of the External PID generally has a more pronounced effect on rise time than increasing the Proportional Term In some applications increasing the Proportional Term of the External PID in Casca...

Page 160: ...nel in the Profile Tab provides a simple intuitive interface for creating and editing Profiles Profiles are built one command line called a segment at a time Commands are chosen from a drop down list the three most commonly used commands Ramp Dwell and Step can also be quickly selected by clicking a button Parameters for each command are set using simple text entry fields and select lists Complete...

Page 161: ... Window The Profile Comment Block Panel allows you to add a comment which is included as part of the Profile when it is downloaded or saved Profile Builder Holds hot buttons to select commands as well as the Segment Types Window Profile Panel Holds buttons for printing uploading and saving as well as the Profile Window Profile Window Displays the command lines segments of the Profile in sequence C...

Page 162: ...eted when you exit the ERTune program Profiles are only stored in your computer s short term memory until they are downloaded or saved The Profile Window The Profile Window shows the command lines of the currently loaded Profile Selecting a command in the window opens it for editing in the Profile Builder Scroll bars appear when the line count goes beyond the frame of the window There are also fiv...

Page 163: ...op down list or by clicking one of the three buttons The Ramp Dwell and Step buttons allow you to quickly select the three most commonly used commands The Segment Editor Window There are three buttons in this window Insert This button adds a new segment to the Profile The new segment is added above the segment that is currently selected in the Profile Window Modify This button saves the edits made...

Page 164: ...ct the values for the command 5 Click the Insert Button The command is added to the Profile Window above the selected segment To modify a segment in a Profile 1 Click within the Profile Window to select the segment It may be necessary to scroll to locate the segment line 2 The parameter entry fields will appear in the Segment Type Window with the current values displayed 3 Enter the new values 4 C...

Page 165: ...s a ramp setpoint change to the value entered in the Setpoint to Ramp to entry field The duration in seconds of the ramp up or ramp down is set in the Time to Ramp sec entry field Dwell Maintains the current setpoint for the amount of time in seconds entered in the Time to Dwell sec entry field Loop Allows the Profile to loop multiple times through a sequence of command segments beginning with the...

Page 166: ...of smaller setpoint step changes In the Profile below segments 3 through 5 combine to increase pressure from 50 psig to 70 psig over four loops and segments 6 through 8 return the pressure to 50 psig over four loops Change Variable Sets the value of an internal variable of the ER5000 selected from the Variable drop down list to the value entered in the Value entry field Refer to the Internal Varia...

Page 167: ... The Dwell command counts off the specified time regardless of ER5000 response The Soak command accounts for rise and settling time before counting off the specified time If Allows the Profile to respond to the current state of the system Checks whether a parameter of the current system status matches the condition specified in the Condition Operator and Value fields If the condition is TRUE the n...

Page 168: ...t entry field NOTE NOTE CAUTION CAUTION WARNING WARNING To execute a multi line command sequence based on the same condition use the Goto command together with the If command which is described on the previous page In the Profile shown to the right the If and Goto commands are used to break the loop and end the session ...

Page 169: ...he Port Number field and the ER5000 port state 0 open circuit 1 closed circuit in the Port State entry field Digital Input ER Input is Port 3 Pauses the Profile until the specified input is set to the specified state Refer to the Profile with External Control Digital Inputs wiring configuration for an example of an ER5000 with digital inputs Enter the ER5000 port number for the digital input in th...

Page 170: ...ta files in the Plot Screen to review previous tuning sessions or monitor system performance The saved dat file can also be opened in a text editor or imported into a spreadsheet or database The ER5000 automatically adds a header to the file that includes date time sample rate and collection time The default variables that are collected are setpoint and feedback Using controls in The Plot Screen V...

Page 171: ...e for an added variable IMPORTANT IMPORTANT Changes made using the Range buttons in the Plot Screen Variable Controls change the actual range of values tracked by the ERTune program Be sure the values you enter are correct for your application so that the values the program tracks are an accurate representation of system conditions 1 Click the Range button to the right of drop down list The Define...

Page 172: ...ning the program The Collection Time entry field sets the default timeframe for data collection The maximum value you can enter is 31 536 000 seconds which is 1 year To control data collection manually 1 Enter a value in the Collection Time entry field that is considerably higher than your intended collection time This will prevent the program from automatically terminating data collection prematu...

Page 173: ...y Browse Button The Browse button opens a Windows Explorer window to select the folder where the data file will be stored You can also change the file name here Delimiter The Delimiter drop down list sets the delimiter that separates the data columns in the file Select Space Comma or Tab DAQ Comment Block Add comments in this entry field They will be added to the header of the data file Plot File ...

Page 174: ...ches the name and location of a previously saved file the Overwrite window opens to warn you Click the Yes button to proceed with the data acquisition and overwrite the previously saved file Click the No button to cancel the acquisition so that you can change the file name and or folder location of the new file To start data collection 1 Click the Start DAQ button The button changes to display Sto...

Page 175: ... and double click it or click the OPEN button 3 The data file opens in the Plot Screen window The file opens as a single static image of the complete data set You can use the mouse techniques described in Resizing the Range Displayed by the Plot Screen Using the Mouse to view different sections of the data at close range Figure 62 An Acquired Data File Opened in the Plot Screen ...

Page 176: ...ou wish to track IMPORTANT IMPORTANT You must click the check box to activate the input source The entry fields will accept entries when the box is unchecked but will revert to Disabled when you leave the Data Tab 2 Set a Less than minimum value and or Greater than maximum value that will trigger an event IMPORTANT IMPORTANT When you click in an entry field the limit is displayed as the default va...

Page 177: ...ring conditions is met data acquisition will begin The program alerts you that acquisition has been activated with a message in the Menu Bar To deactivate data collection based on a triggered event 1 Click the Stop DAQ button To remove a triggered event from data collection 1 In the Triggers Panel uncheck the box next to the input source you no longer wish to track ...

Page 178: ...Depending on the application these changes may upset the process control which may result in personal injury or property damage NOTE NOTE CAUTION CAUTION WARNING WARNING Be aware of the operational and mechanical limitations of your system when using the fields in this tab The fields have real time control over the ER5000 NOTE NOTE CAUTION CAUTION WARNING WARNING After you enter a new value in an ...

Page 179: ...new settings will be downloaded to the ER5000 If you click the No button the current settings will be used To change the regulator model number or serial number 1 Enter a new value in the Model Number or Serial Number entry field and press the Tab key The ER Settings Panel The fields in this panel control the basic configuration of the ER5000 ER Model This drop down list allows you to change the m...

Page 180: ...window then closes and the new node address is registered NOTE NOTE CAUTION CAUTION WARNING WARNING The Serial Number of the ER Series controller cannot be changed from the Configure tab NOTE NOTE CAUTION CAUTION WARNING WARNING The Version Number refers to the current version of the ER5000 internal software It cannot be changed Calibration These entry fields allow for fine adjustment of the ER500...

Page 181: ...e ruptures The default Condition is Inlet Closed Exhaust Open which ensures that a pressure reducing system will be vented if a limit is exceeded If your application uses a non venting regulator refer to A Note Concerning Non Venting Regulators in Closed Loop Applications if you intend to use the ER5000 in this condition CAUTION The Control Limits feature provides an additional level of system mon...

Page 182: ...enter a value below the Min or above the Max limit the filed will immediately revert to the default value and will revert to Disabled when you click out of the field 2 To monitor for both minimum and maximum limits enter values in both fields IMPORTANT IMPORTANT When you click in an entry field the limit is displayed as the default value You must change this value or the field will revert to Disab...

Page 183: ...ese conditions The regulator you will be using is a non venting metal diaphragm sensed regulator The regulator you will be using is non venting and the application is not continuous flow CAUTION Regulator Diaphragm Protection is not recommended for applications which do not meet one or both of these conditions To activate Regulator Diaphragm Protection 1 Click the Enable radio button 2 Enter a val...

Page 184: ...R5000 The ER Solenoid Leak Test Panel The Start button in this panel initiates a solenoid valve leak test CAUTION This procedure will hold the ER5000 Inlet Valve open resulting in full inlet pressure at the ER5000 Outlet Port The test should be performed with the Outlet Port plugged and isolated from the regulator If it is not possible to isolate the Outlet Port of the ER5000 take steps to prevent...

Page 185: ...reen opens Verify that the Outlet Port of the ER5000 is plugged and a minimum of 100 psig 6 9 bar inlet pressure is being applied to the Inlet Port of the controller 6 Click the Start button to start the test 7 The test begins The program first tests the Inlet Valve 8 The program then tests the Outlet Exhaust Valve The Solenoid Leak Test reads variable 44 ID_FEEDBACK which during the test is the f...

Page 186: ...tly from 3700 If the reading falls by more than 10 counts over the next 30 seconds that means more than 0 3 psig 0 02 bar of pressure has escaped which is considered an Outlet Valve failure 9 The program returns the results NOTE NOTE CAUTION CAUTION WARNING WARNING If the ER5000 is connected to a regulator when the Solenoid Leak Test is run and a failure is recorded it may indicate a leak in the r...

Page 187: ...187 The ERTune Program Power User ...

Page 188: ... the basic operational parameters of the ER5000 The default values should not be changed if you are not certain how this will effect the performance of the controller To display the Power User Tab 1 Select Help Power User The Power User Tab appears to the right of the Diagnostic Tools Tab 2 Click the Power User Tab to make it active NOTE NOTE CAUTION CAUTION WARNING WARNING On most screens you wil...

Page 189: ...ugh the brown white wire J4 Pin 1 To switch the external feedback source 1 Click the radio button next the source you wish to track IMPORTANT IMPORTANT Refer to the steps To change the display of the main left axis to the new range after you change the feedback source to be sure the ERTune program is tracking the correct range of values for the new source Setpoint to 0 on Power Up The ER5000 store...

Page 190: ...The Variable ID number displays to the right of the list The variable value displays in the Raw entry field The list to the right indicates whether it is a signed or an unsigned value NOTE NOTE CAUTION CAUTION WARNING WARNING Values are grayed out when Read is checked To modify the value of an Internal Variable 1 Click the Write radio button The entry fields become active 2 Enter a new value and p...

Page 191: ... pulse width too high can cause the ER5000 to activate in response to transient errors which do not require correction Setting it too low may delay response to error CAUTION These settings have an immediate and profound effect on the performance of the ER5000 The default settings are optimal for most applications and should not be changed if you are not certain how this will effect the performance...

Page 192: ...her which slows the response of the ER5000 To change the Algorithm Update Rate 1 Move the slider control to the right or enter a multiple of 25 ms in the entry field to increase the rate NOTE NOTE CAUTION CAUTION WARNING WARNING The default rate is 25 ms which is also the minimum value the field will accept Changes to this field must be made in increments of 25 ms CAUTION The Algorithm Update Rate...

Page 193: ...tions during steady state Pulse mode responds to errors within the Integral Deadband range with short pulsed activation of the solenoid valves These pulsed responses continue until feedback falls within the Pulse Mode Deadband range in effect the deadband within the deadband When feedback falls within this inner deadband the solenoid valves remain closed To enable Pulse Mode 1 Click the Enable rad...

Page 194: ...espond to a very small level or error Integral Deadband is generally set within a range of 0 0 5 of feedback Pulse Width Deadband is set by counts of error Each count equates to 03 of feedback Pulse deadband is generally set at 1 3 counts which equates to 03 09 of feedback To change the Pulse Width settings 1 Enter a new value in the Period Width or Deadband field and press the Tab key NOTE NOTE C...

Page 195: ... can be any combination of alphanumeric characters and can be of any length 3 Re enter the password and click the Verify button NOTE NOTE CAUTION CAUTION WARNING WARNING The passwords must match 4 The password will become effective the next time the ERTune program is opened The Enter Password window opens instead 5 Enter the password and click the Verify button To disable password protection 1 Cli...

Page 196: ...196 ER5000 Software Development Support ...

Page 197: ... TESCOM model 82948 or an RS232 to RS485 TESCOM model 85061 converter RS485 must be used if your application calls for multiple controllers and you wish to daisychain them in the same network You can link up to 32 ER5000s in a single network Wiring diagrams for RS485 communication can be found in this manual beginning on page 89 There are diagrams for both USB to RS485 and RS232 to RS485 converter...

Page 198: ...provided in the Resources section of the ER5000 Software in the following languages LabVIEW VB NET C C To view the sample programs 1 Download the ER5000 Software and Manual file which can be found at TESCOM com under the Download ER5000 Software and Manual link Once the file is downloaded extract the zip file click on the exe file and the ER5000 User Support Software and Manual menu will open 2 Th...

Page 199: ...file 1 Download the ER5000 Software and Manual file which can be found at TESCOM com under the Download ER5000 Software and Manual link Once the file is downloaded extract the zip file click on the exe file and the ER5000 User Support Software and Manual menu will open 2 The ER5000 User Support Software and Manual menu gives you access to the programs and reference materials Click the Resources bu...

Page 200: ...on must be called during program initialization before any other function to allow PC initialization including the serial port It does not send any data to the ER5000 This function needs to be called only once WriteNetVar ThisfunctionisusedtowritetoanyoftheER5000internalvariables ReadNetVar This function is used to read any of the ER5000 internal variables WriteProfileSegment This function is used...

Page 201: ...Once the file is downloaded extract the zip file click on the exe file and the ER5000 User Support Software and Manual menu will open 2 The ER5000 User Support Software and Manual menu gives you access to the programs and reference materials Click the Resources button 3 Click the Protocol button 4 Click the Source Code button to directly access the code or the Protocol pdf button to open the PDF f...

Page 202: ...202 Troubleshooting ...

Page 203: ...default location for configuration files Profiles and data acquisition files The Windows Navigator window will default to this folder You may save the data files generated by your application in another location if you prefer IMPORTANT IMPORTANT Windows 8 users In order to maintain compatibility with previous Windows operating systems the ERTune program uses the NET Framework 3 5 which is not inst...

Page 204: ...ardware and Sound Device Manager 3 Locate the ER5000 USB Serial Port in the list of devices 4 Double click the listing The Properties window opens 5 Click the Driver tab 6 Click the Update Driver button 7 Click the Browse my computer for driver software button 8 Enter C Program Files x86 Emerson ERTune in the Search for driver software in this location field OR Click the Browse button and navigate...

Page 205: ...lick the No not this time radio button then click Next 4 In the next window click the Install from a list or a specific location Advanced radio button then click Next 5 In the Installation Options window click the Search for the best driver in these locations radio button check the Include this location in the search check box and enter C Program Files Emerson ERTune in the entry field OR Click th...

Page 206: ...for 1 5V input NOTE NOTE CAUTION CAUTION WARNING WARNING As seen in Figure 63 0 10V models of the ER5000 do not have these jumpers The Ground Filter Bypass Jumper The recommended configuration for the Ground Filter Bypass jumper J1 is not installed OFF Installing this jumper connects signal ground directly to the power supply ground continued next page Figure 63 Jumpers Jumper J5 Setpoint ON 4 20 ...

Page 207: ...er if you are having issues with noise installing this jumper may help The ER3000 ER5000 Mode Select Jumper By default the ER5000 uses a 16 bit A D converter to translate analog input signals to digital The previous model the ER3000 used a 12 bit converter For applications where the ER5000 will be controlled by software originally written for the ER3000 Jumper J9 allows the ER5000 to switch from 1...

Page 208: ...that the ER5000 is sending and receiving data NOTE NOTE CAUTION CAUTION WARNING WARNING Refer to page 89 through page 93 for correct wiring to connect the ER5000 to an RS485 converter NOTE NOTE CAUTION CAUTION WARNING WARNING LED2 and LED3 respond to data transmission when the ER5000 communicates using RS485 These LEDs do not respond to data transmission when the ER5000 communicates using USB and ...

Page 209: ...d verify that the ER5000 is correctly wired to the power supply Using the LED Indicators to Verify RS485 Communication 1 Power up the ER5000 and verify the power supply as described above 2 Open the ERTune program 3 Check the LED indicators on the ER5000 They should appear as follows LED2 FLASHING ON AND OFF LED3 FLASHING ON AND OFF 4 If the LED indicators do not appear this way refer to page 89 t...

Page 210: ... Check all power and communication wiring per your application 2 Click the Search Ports button The ERTune program scans all COM ports that are in use 3 Click the Search button below the Node Address The ERTune program scans all 250 Node Addresses 4 If the program does not open close the Comm Error window and check that the ER5000 is correctly configured to communicate with the PC a If you are comm...

Page 211: ...d correctly A common error is not connecting the yellow wire pin 4 and the tan wire pin 12 when using a 4 20 mA feedback transducer Also check to make sure the voltage current select jumpers are in the proper position for your application Refer to Checking the Configuration of the Jumpers earlier in this section The Simulation warning indicates that the ERTune program has been opened in Simulation...

Page 212: ...n installing this unit in a confined area the exhaust port should be remotely vented to a safe location to prevent asphyxiation due to lack of Oxygen in the surrounding atmosphere If there is a problem with controlling the pressure 1 Check the pneumatic connections The inlet pressure must go into the Inlet Port which is the left port as shown in Figure 65 There must be a proper air tight seal usin...

Page 213: ...de as displayed in The ER Settings Panel and setpoint source as displayed in The Setpoint Panel 3 If you are using an analog setpoint source check that the Analog setpoint source is selected in The Setpoint Panel Also check to make sure the voltage current select jumpers are in the proper position for your application Refer to Checking the Configuration of the Jumpers earlier in this section 4 Che...

Page 214: ...int Changes cont 5 Make sure that a Control Limit has not been triggered Refer to The Control Limits Panel for more information 6 If the problem persists use The Plot Screen Buttons The Print Button to take a snapshot of your current configuration and gather all tuning parameters then contact your TESCOM representative ...

Page 215: ...Refer to The ER Solenoid Leak Test Panel section for a step by step explanation of the process Checking Other Components of the Application for Leaks TESCOM includes a suite of diagnostic tools and reference materials in The Diagnostic Tools Tab of the ERTune program Reference The System Check Panel and The Regulator Leak Check Panel as a first step towards problem solving ...

Page 216: ...mitted 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 Acceptable Resistance Values The resistance values must be measured with all external wiring disconnected including the power Ensure converter screw terminals are tight Resistance levels outside the acceptable ranges may indicate damage...

Page 217: ...hese applications generally involves checking that all wiring is configured properly and correctly setting the internal variables which control how the ER5000 interprets digital signals Input If the Profile Stops at a Digital Input Command for Digital Input 1 1 Check Jumper J14 It must be OFF to use Input 1 as a digital input Refer to Checking the Configuration of the Jumpers earlier in this secti...

Page 218: ...fer to the ER5000 Software Development Support section for more information on accessing the Resources section Input If the Profile Does Not Start at a Digital Input from Digital Input 2 1 Check Jumper J15 It must be OFF to use Input 2 as a digital input Refer to Checking the Configuration of the Jumpers earlier in this section 2 Check variable 78 ID_COMPENSATED_EXTRA_AD2 The value should read hig...

Page 219: ...lue_percent value_counts 400 100 3 300 value_counts value_percent 3 300 100 400 The default toggle level is 50 or 2050 counts The ER5000 Software includes a Unit Converter program which can assist you in conversion calculations It is accessed by clicking the Unit Converter button in the Resources section Refer to the ER5000 Software Development Support section for more information on accessing the...

Page 220: ...he wiring diagram for Digital Outputs b Ensure the power being supplied to the load is sufficient for the device and the application Output If the Profile Doesn t Activate Digital Load 2 1 Use a Read Write field in The Read Write Panel to monitor 89 DIGITAL_OUTPUT2 while running the Profile The value should read 1 when the input is activated and should read 0 when not activated 2 If variable 89 ID...

Page 221: ...221 Internal Variables ...

Page 222: ...gned 0 4095 0 0fff 21 ID_OUTER_INTEGRAL_CONSTANT RW Signed 32768 32767 8000 7fff 22 ID_OUTER_INTEGRAL_MAXIMUM RW Signed 32768 32767 8000 7fff Variable Index and Name Access Type Range Decimal Range Hex 23 ID_OUTER_INTEGRAL_SUM RW Signed 32768 32767 8000 7fff 24 RESERVED 25 ID_OUTER_PROPORTIONAL_CONSTANT RW Signed 32768 32767 8000 7fff 26 ID_FACTORY_MIN_INLET RW Unsigned 0 250 0 fa 27 ID_FACTORY_MI...

Page 223: ... 65 ID_PWM_VALUE RO Signed 250 250 fa fa 66 ID_INNER_INTEGRAL_DEADBAND RW Unsigned 0 4095 0 0fff 67 ID_OUTER_INTEGRAL_DEADBAND RW Unsigned 0 4095 0 0fff 68 ID_FEEDBACK_FILTER RW Unsigned 0 1 0 1 69 ID_PROFILE_TYPE RO Unsigned 0 11 0 b Variable Index and Name Access Type Range Decimal Range Hex 70 ID_PROFILE_STATE RW Unsigned 0 2 0 2 71 ID_PROFILE_STEP RO Unsigned 0 31 0 1f 72 ID_ESTOP_FLAG RW Unsi...

Page 224: ...RW Signed 32768 32767 8000 7fff 105 ID_CAL_GAIN_EXTRA1 RW Unsigned 0 65535 0 ffff 106 ID_CAL_OFFSET_EXTRA2 RW Signed 32768 32767 8000 7fff 107 ID_CAL_GAIN_EXTRA2 RW Unsigned 0 65535 0 ffff 108 RESERVED 109 RESERVED 110 RESERVED Variable Index and Name Access Type Range Decimal Range Hex 111 RESERVED 112 ID_CAL_OFFSET_ANALOG_OUT RW Signed 32768 32767 8000 7fff 113 ID_CAL_GAIN_ANALOG_OUT RW Unsigned...

Page 225: ...ng formulas value_percent value_counts 400 100 3 300 value_counts value_percent 3 300 100 400 37 ID_SETPOINT This is the controller s setpoint 43 ID_SETPOINT_FLAG This variable determines the source of the setpoint variable 37 ID_SETPOINT 0 setpoint from A D analog setpoint input 1 setpoint from RS485 or USB network typically a PC 2 setpoint from internal Profile 3 setpoint from A D analog setpoin...

Page 226: ...ad only 42 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 52 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 53 ID_VERSION_NUMBER This is the version number of the embedded software 120 ID_MODE_ER3000_ER5000 Thi...

Page 227: ...o and span have been applied to the raw signal A value of 6400 is 0 and 59200 is 100 When the controller is in ER5000 mode this variable records data in 16 bit mode which gives more accurate data acquisition than variable 44 ID_FEEDBACK 28 ID_INNER_INTEGRAL_CONSTANT This is the I term Integral Constant for the inner loop 29 ID_INNER_INTEGRAL_MAXIMUM This is the maximum value allowed for the Integr...

Page 228: ... error and summing the result with the previous value for the Integral sum 25 ID_OUTER_PROPORTIONAL_CONSTANT This is the P term Proportional Constant for the outer loop 49 ID_OUTER_INTEGRAL_MINIMUM This is the minimum value allowed for the Integral sum on the outer loop 67 ID_OUTER_INTEGRAL_DEADBAND This is the outer loop minimum error required for the Integral sum to be changing in value Often it...

Page 229: ...between counts and percent use the following formulas value_percent value_counts 400 100 3 300 value_counts value_percent 3300 100 400 01 ID_AD_SETPOINT This is the value of the analog setpoint A value of 6400 is 0 and 59200 is 100 Note that the analog setpoint is not used unless the controller is programmed to use it by variable 43 ID_SETPOINT_FLAG When the controller is in ER5000 mode this varia...

Page 230: ...used to adjust the level that the ER5000 interprets variable 78 ID_COMPENSATED_EXTRA_AD2 as a Logical 0 or a Logical 1 ER5000 Pressure Profile Variables 45 ID_PROFILE_LOOP_COUNT This variable displays the count of times through a Profile loop The counter starts at the number of loops entered in the Number of Loops 0 forever field of the Profile Builder when the Loop command segment is added to the...

Page 231: ...h valves closed 0x0706 Exhaust full open ER5000 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 25 ms 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 compen...

Page 232: ...oint 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 ER5000 Setpoint and Feedback Variables to translate between counts and percent This variable is written to Digital Output 2 which is J4 Pin 8 white wire 90 ID_DIGITAL_OUT1_INIT Power up state of variable 88 ID_DIGITAL_OUTPUT1 91 ID_DIG...

Page 233: ...NSOR_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 34 ID_OUTPUT This is the value of the output from the controller It is this value which controls the ER5000 s valves A positive number will open the ...

Page 234: ...are for the exhaust solenoid A value of 250 represents a 100 duty cycle full on 121 ID_SUSPEND This is the state of the Suspend Mode input signal When suspend mode is activated 1 Activated the inlet and exhaust valves remain fully closed and the PID algorithm is suspended When it is deactivated 0 Deactivated the control returns to normal operation ER5000 Gain Offset Variables 39 ID_GAIN This is th...

Page 235: ..._EX_OPEN 3 IN_OPEN_EX_OPEN Control 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 the specified Control Limit Condition Table 28 Control Limits for Specified Signals Minimum Maximum Limited Signal 54 ID_MIN_AD_SETPOINT 55 ID_MAX_AD_SETPOINT 1 ID_AD_SETPOINT 56 ID_...

Page 236: ...236 Certifications and Warranty ...

Page 237: ...ications Copies of all certification documents are available at www tescom com Click on the CERTIFICATIONS Quick Link CE Conforms to all known European Union requirements EMC DIRECTIVE 2014 30 EU IEC EN 61000 6 2 2005 IEC EN 61000 6 4 2007 A1 2011 ...

Page 238: ...C IEC 60079 0 2011 IEC 60079 1 2014 IEC 60079 31 2014 cCSAus MC Cert 155335 70013318 Class I DIV 1 Groups B C D Class II DIV 1 Groups E F G Class III Ex d IIB H2 T5 Gb Ex tb IIIC T100 C Db AEx d IIB H2 T5 Zone 21 Ex tb IIIC T100 C 20 C T5 60 C CSA Std C22 2 No 30 M1986 UL1203 5th Edition Hazardous Locations Special Requirements and Certification for the ER5050 Copies of all certification documents...

Page 239: ...ed flame proof types suitable for the conditions of use and correctly installed Unused conduit entry must be closed with suitable blanking element Seal conduit entry within 18 inches Rated for 20 5 to 28 5 VDC 340 mAmps Max working pressure 110 PSIG 20 C Tamb 60 C Thread entry sizes are 1 8 27 NPT and 1 2 14 NPT Reference page 18 for locations The user installer shall not remove any of the three 1...

Page 240: ... F O B point of manufacture that portion of the goods or firmware found by Seller to be defective or refund the purchase price of the defective portion of the goods services All replacements or repairs necessitated by inadequate maintenance normal wear and usage unsuitable power sources or environmental conditions accident misuse improper installation modification repair storage or handling or any...

Page 241: ...241 Appendix A Setting up the ERTune Program on Windows 8 PCs ...

Page 242: ...nd does not include NET Framework 3 5 by default However the NET Framework 3 5 can easily be downloaded and installed Note that you will need to be connected to the Internet before you begin The procedure is as follows 1 Click Download and install this feature in the message window Windows will oversee the download and installation 2 Once the NETFramework3 5 has been installed you will need to ver...

Page 243: ... the ERTune Program on Windows 8 PCs 5 Type control panel into the Search box and click on the Control Panel icon 6 Select Programs 7 Select Programs and Features 8 Select Turn Windows features on or off continued next page ...

Page 244: ...Device Driver When loading the ER5000 USB Serial Port driver onto Windows 8 you may encounter the following error message Windows found driver software for your device but encountered an error while attempting to install it The third party INF does not contain digital signature information Windows 8 has a Driver Signature Enforcement DSE feature This feature allows the PC administrator or the user...

Page 245: ...signed to be compatible with previous versions of Windows If you get the Error Screen you will need to temporarily disable the DSE To accomplish this do the following 1 Open the Charms Bar and select Settings 2 Select Change PC settings 3 Select General scroll down to Advanced startup and click Restart now continued next page ...

Page 246: ...up the ERTune Program on Windows 8 PCs 4 After Windows has restarted the Choose an option window appears Select Troubleshoot 5 Select Advanced options 6 Select Windows Startup Settings 7 Click Restart continued next page ...

Page 247: ...s 8 PCs 8 After the operating system has rebooted the Startup Settings window appears Press the F7 key to disable the Driver Signature Enforcement feature 9 Windows 8 will restart The Driver Signature Enforcement will be disabled until the next reboot ...

Page 248: ... der Trave 23 25 23923 Selmsdorf Germany T 49 38823 31 284 Asia Pacific Emerson TESCOM Building 40B 2 1006 Jin Min Road Shanghai Pu Dong District Shanghai 201206 China T 86 21 2892 9000 China T 65 6777 8211 Singapore https www emerson com DOPSM2064X012 Rev 1 4 2019 The Emerson logo is a trademark and service mark of Emerson Electric Co TESCOM is a registered trademark All other marks are the prope...

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