ER5000 SeriesElectropneumatic Controllers/Motors DER502060X012

Features and BenefitsER5000SI-1 – Standard ER5000• Preciseaccuracy• 16BitforDataAcquisition• CompatiblewithTESCOM’sextensivedomeloadedand

airactuatedpressureregulatorsavailablefromvacuumto30,000psig/2068bar,withflowcapacitiesfromCv.02toCv12.0

• ControlalgorithmsforInternalFeedback,ExternalFeedbackorCascadeControlmodes

• SelectableSETPOINT Signal Source- USB- RS485- Externalanalog(4-20mAor1-5VDC)- DownloadableProfile(runsindependentofPCor

externalanalogsource)• SelectableFEEDBACK SignalSource

- InternalSensor(0-100psig/0-6.9bar)- ExternalAnalog:4-20mAor1-5VDC

• SelectableControlLimits- Programmablelimitsforanalogsetpoint,

feedbackanderrorsignals- Selectablecontrolstates:“HoldLastPressure”,“Vent”,

or“FullOpen”• TESCOMERTuneTMsoftwareprovidedfordataacquisition,

PIDtuning(realtimegraphicdisplayofsetpointandfeedback),creatinganddownloadingprofiles

• TESCOMDLLprovidedforeasycustomsoftwaredevelopment

• SoftwareexamplesareprovidedforVB.NET,LabVIEW,CandC#

DescriptionTheER5000Series(thelatestgenerationofTESCOMelectroniccontrollers)isamicroprocessorbasedPID(Proportional,Integral,Derivative)controllerthatbringsprecisealgorithmicpressurecontroltoawiderangeofapplications.

Itcanbeusedasastandaloneunittocontrolthepressureofclean,dryinertgasesfrom0–100psig/0–6.9bar,orbeconnectedtoanypneumaticallyactuatedregulatororvalve.UsedwithTESCOMregulators,theER5000providespressurecontrolofgasesandliquidsfromvacuumto30,000psig/2068bar,withaCvofupto12+.Whetherpilotingamechanicalregulatororusedstandalone,itprovidesfortrueclosedloopcontrolwithexceptionalaccuracyandresponsetime.

Applications• Testequipment• Calibrationstands• Proof&bursttesting• Productionequipment• Metalorplasticforming/molding

• USBcableincludedforquickcomputerconnection• NEMA4XIP66enclosure(watertight,corrosionresistant)• 1/2"SAEx1/8"NPTFfittingincluded(matestomost

TESCOMairactuatedregulators)• Automatedsolenoidvalveleaktest• Triggerdataacquisitionbasedonsystemevents

ER5000SV-1 – Standard ER5000

• AllfeaturesoftheER5000SI-1exceptwith0-10VDCSetpointandFeedbacksignals

ER5000FI-1 and ER5000FV-1 –Enhanced ER5000

• AllfeaturesoftheER5000SI-1andER5000SV-1areincludedplustwoadditionalanalog/digitalinputsandtwodigitaloutputsthatallowtheuserto:

- Monitoranexternalsignalinadditiontofeedback(e.g.flow,temp,force)

- Alternatebetweentwoseparateexternalfeedbacksources

- Start/StoporResume/Pausepressureprofiles

- Waitforeventtooccurbeforeproceedingtothenextstepinadownloadedprofile(digitalinput)

- Indicatethataneventoccurredinadownloadedprofile(digitaloutput)

• Analogoutputoftheinternalpressuresensor

• Conditionalcontrolwith"IF/THEN"and"GoTo"profilecommands

• Suspendcontrolfeaturetolockoutputpressureforanextendedperiodoftime

Contact your TESCOM representative for available Explosion Proof options.

www.tescom.com

2

ER5000 Series Electropneumatic Controller

SpecificationsFor other materials or modifications, please consult TESCOM.

ELECTRICAL

Power Requirement22to28.5VDC,340mAmaximum,180mAnominal

Turn-on Time<240milliseconds

Restart from Power Interruption<1.9seconds

SUPPLYREQUIREMENT

Media TypeClean,dryinertgasorinstrumentgradeair

PressureMinimum: Outletpressure+1psig/0.07barMaximum: 120psig/8.2barNominal: 110psig/7.5bar

Temperature-22°Fto167°F/-30°Cto75°C

INPUTSIGNALS

Setpoint USB,RS485,4-20mA,1-5VDC(0-10VDCforER5XX0XV-1),

downloadedProfile

Feedback (external)4-20mAor1-5VDC(0-10VDCforER5XX0XV-1)

PERFORMANCE

AccuracyLinearity: ±0.05%FullScaleOutput(FSO)Hysteresis: ±0.05%(FSO)Repeatability: ±0.05%(FSO)Resolution Sensitivity: ±0.03%(FSO)Measured Reference Accuracy (total accuracy all effects

including zero and span error): ±0.10%(FSO)Low Pressure Capability with External Transducer

±0.25incheswater(0.635g/sq.cm)into2litervolume

Response TimeSensor Update Rate: 25milliseconds Lift Off: <70millisecondsRise Time (10-90 psig / 0.69-6.2 bar): 350milliseconds

(1cubicinchvolume/32.8cc)Fall Time (90-10 psig / 6.2-0.69 bar): 650milliseconds

(1cubicinchvolume/32.8cc)

Frequency ResponseAmplitude Attenuation: -3dbat2HzPhase Shift: -90degreesat2Hz

Flow Capacity: Cv=0.01(MaximumFlow=18SLPM)

Solenoid Valve Rated Cycle Life: >150millioncycles

PHYSICAL

SizeGas Port (Inlet, Exhaust and Gauge): 1/8inch-27NPTFControlled Outlet Port: 1/2inchSAEEnclosure Volume: 16.3cubicinches/267ccFlow Stream Volume: 0.73cubicinches/11.96ccHeight:3.9inches/99mmLength: 3.72inches/94.5mmWidth: 3.72inches/94.5mmConduit Openings: Two,1/2inchNPTF

Weight3.1lbs/49oz/1.4kg

HousingStandard: NEMA4XIP66(aluminumandepoxypolyesterpaint)

Flow Stream MaterialsSolenoids: Nickel-platedBrass,FKMSeatandO-ringsSensor: Glass,Ceramic,Silicon,RTV,NickelTubing: PolyurethanePlug: Brass O-Rings: Silicone,Buna-N,FKM

Outlet FittingStainlessSteel

MountingFour#10-32UNF/M5x0.8mountingholes

Mounting Orientation EffectNone

ENVIRONMENT

Temperature Range-22°Fto167°F/-30°Cto75°C

Relative HumidityTo100%R.H.(non-condensing@32°Fto167°F/0°Cto75°C)

VibrationResonance:10-2000Hzat3.0gconstantaccelerationTestedperIEC61298-3(3.0gstandard)

Storage Temperature-58°Fto200°F/-50°Cto93°C

CERTIFICATIONS

CE ApprovalAllER5000SeriesunitshaveCEapprovalwhenwiredperCEapprovedwiringinstructionsintheER5000 User Manual

3

ER5000 Series Electropneumatic Controller Installation Drawing

All dimensions are reference & nominal Metric [millimeter] equivalents are in brackets

INSTALLATION DIMENSIONS

3.90[99]

.54[13.77]

.54[13.77]

.63[16]

.98[24.9]

.93[23.7]

.93[23.7]

.87[22.1]

.75[19]

.20[5.1]

.75[19](4x)

Gauge Port (Plugged)1/8"–27 NPTF

Inlet Port1/8"–27 NPTF

1/2"–14 NPTFConduitConnectionforInternal Wiring

1/2"–14 NPTFConduitConnectionforUSB Wiring

AtmosphericReference forInternal Sensor

Exhaust Port1/8"–27 NPTF

MountingHoles#10-32 UNF.50 FULL THREAD[M5 X 0.812.7 FULL THREAD](4 Places)

Not Used

Not Used

TM

ER5000

1.86[47.2]

3.72[94.5]

3.72[94.5]

Outlet Port1/2" SAE(3/4 - 12 UNF)

Bottom View

Top View

TM

ER5000

1.86[47.2]

3.72[94.5]

3.72[94.5]

Outlet Port1/2" SAE(3/4 - 12 UNF)

Bottom View

Top View

4

ER5000 Typical Pressure Reducing Application

ER5000 Typical Back Pressure Application

ER5000 Typical Applications

• Teststands• Calibration• Lasercuttingsystems• Vacuumforming• Superplasticmetalforming• Plasticextrusion• Gasassistedplasticinjectionmolding• Laminationandcompositematerialcuring

• Tiremolding• Chromatographycapillaryinletpressure• Spraycoating• Waterjetcutting• Bursttesting• Highpressuregasorliquidinjection• ReplacementforvalvepositionersandI/Ps• Spotweldingpressurecontrol

Thevarietyofapplicationsislimitless.AnyprocessvariablethatcanbemanipulatedusingthepneumaticoutputoftheER5000canbecontrolled.Somepossibilitiesincludecontrollingpressure,flow,temperature,position,speed,force,consistency,torque,andacceleration.TheER5000improvesbothspeedandaccuracybecauseitimplementsthecontrolstrategydirectlyatthecontrolelement(valveorregulator).Somepossibleapplicationsinclude:

DefinitionsSetpoint:SignaltellingthecontrollerwhatpressureisdesiredinthecontrolledpressurelineFeedback:Signaltellingthecontrollerwhattheactualpressureisinthecontrolledpressureline

WATER RESERVOIR

TESTVESSELPUMP

P2

P1

PneumaticSupply

80-110 psig5.5-7.5 bar

Exhaust Setpoint signal comes from a computer, PLC or potentiometer

Feedback signal comes from a transducer incontrolled pressure line

Recirculates to Reservoir

5000 psig / 345 bar

ER5000 with26-1700 A regulator

Pressure to

be controlled

Setpoint signal comes from a computer, PLC or potentiometer

Feedback signal comes from a transducer incontrolled pressure line

15,000 psig / 1034 barP1

ER5000 with26-2000 A regulator

8000 psig / 551 barP2

Vent

PneumaticSupply

80-110 psig5.5-7.5 bar

Exhaust

5

ER5000 Standalone Application - External Feedback Mode

ER5000 Standalone Application - Internal Feedback ModeER5000 “Stand Alone” Application

Internal Feedback Mode

2 psig

ER5000 SeriesER pressure supply

(N2 or Instrument Air – 110 psig / 7.5 bar maximum)

Computer or PLC

ER5000 “Stand Alone” ApplicationExternal Feedback Mode

ER5000 SeriesER pressure supply

(N2 or Instrument Air – 110 psig / 7.5 bar maximum)

Computer or PLC

14” Water Column0.50 psig / 0.03 bar

6

ER5000 Basics

ER5000 System RequirementsAllER5000controllersrequire:

•Power:24VDC,340mAmaximum,180mAnominal•Pressure:Upto120psig/8.2barmaximumclean,dryinertgas•Setpointsignal:FromPC,PLC,Analog•Feedbacksignal:InternalorExternal

TheER5000sensessystempressureusingeitheritsinternalsensororausersuppliedexternaltransducer(4–20mA,1–5Vor0–10V)placedwithintheactualprocessline.YoucanoperatetheER5000inoneofthreecontrolmodes:

•InternalFeedback,whichusesonlytheinternalsensor;•ExternalFeedback,whichusesonlytheexternalsource;•Cascade,whichusesbothinternalandexternalsourcesina“loopwithinaloop”configuration

ER5000 CommunicationTheER5000communicatesusingaUSBorRS485interface.TheonboardUSBportandincludedUSBcableprovideforquickandeasydirectcommunicationtoaPC.TherequiredUSBdriverisprovidedontheER5000UserSupportSoftwareandManualCDoronline.AnRS485communicationslinkcanbeestablishedbetweentheER5000andaPCusingeitheraUSBtoRS485orRS232toRS485converter.RS485communicationmustbeusedfordaisy-chainingtwoormore(upto32)ER5000sonthesamenetwork.

ERTune™ Software FeaturesTESCOM’sERTune™programisanallencompassingsoftwarepackagewhichallowstheusertoaddresstheER5000controllerusingaPC.ERTune™allowsuserstotunethePIDloop,monitorsystemoperation,createanddownloadprofiles,specifycontrollimits,enablepasswordprotection,acquiredataandreviewpreviouslyrecordeddata.ThebasicscreensareTuning,Profile,Data,ConfigureandDiagnosticTools.

ER5000 Software Development SupportTheER5000protocoldocumentisprovidedtoassistindevelopingprocesscontrolsoftwarethatcommunicateswiththeER5000onanyplatform.SampleprogramsinVB.NET,LabVIEW,CandC#areavailableontheincludedCDalongwiththesourcecodefortheER5000DLLforWindows.TheTESCOMimplementationoftheprotocolusessixfunctionstocommunicate:StartUp,ReadNetVar,WriteNetVar,ReadProfileSegment,WriteProfileSegmentandShutdown.

ER5000 TuningTheER5000isfactorysettodefaultPIDparametersthatworkwellformanyTESCOMregulatorsinlaboratoryconditions.Duringinitialstartup,theuserhastheoptiontodownloadthePIDparametersforaspecificTESCOMregulatorseries.TheusercanalsoadjusttheProportional,IntegralandDerivative(PID)variablesto: -Achievethequickestresponsetoasetpointchangewithoutovershootoroscillation -Achievethebestperformanceforanon-changingsetpoint -Optimizeperformanceinthespecificapplicationconditions

Windows and Visual Basic are registered trademarks of Microsoft Corporation in the United States and other countries.LabVIEW™ and LabWindows/CVI™ are trademarks of National Instruments.

7

ERTuneTM Software Screens

Tuning Screen

Profile Screen

RED:SETPOINTBLUE:EXTERNALFEEDBACKGREEN:INTERNALSENSOR

8

ERTuneTM Software Screens

Data Acquisition Screen

Configure Screen

9

ERTuneTM Software Screens

Diagnostics Screen-SolenoidValveLeakTest"Pass"

Diagnostics Tools-RegulatorLeakCheck

10

ER5000 Electropneumatic Controller Part Number Selector

ER5000 Accessories

Repair Kits, Accessories & Modifications may be available for this product. Please contact TESCOM for more information.

Example for selecting a part number:

ER5 00 0 S I - 1

BASICSERIES BASE/ENCLOSURE STYLE

INTERNALSENSOR FEATURES SIGNAL TYPE Cv CONFIGURATION

ER5 00 – StandardNEMA4X

02 – IntegratedDoublepiston

04 – OEMbase

10 – Integrated44-4000

11 – Integrated44-5200

0 – 0-100psig/0-6.9bar 0.1%accuracy

S – Basic

F – Enhanced

I – 4-20mAmp/1-5VDC

V – 0-10VDC

1 – Standard,Cv= 0.01

PART NUMBER DESCRIPTION

8514585061829488291982575-25ERAA03409ERAA05146

FilterKitRS232toRS485ConverterKit(plugsintostandardPCserialport).Includes:2.75"x4.8"x1.2"converterand6foot,9pincableUSBtoRS485converterPotentiometerwithdigitaldisplayPowerSupplyforER5000(Output:24VDCat250mA/Input:120VAC,60HZ)USBCable(oneincluded)MTAConnectorReplacementKit

11

Compatible TESCOM Pressure Regulators

SPECIFICATION REQUIRED EXPLANATION

Pressure

Flow Rate

Media

Selectedregulatormustbecapableofhandlingthesystempressures.Forbestresolution,thecontrolpressurerangeoftheregulatorshouldbenearest(yetabove)themaximumapplicationcontrolpressurerequirement.

Regulatormustbecapableofhandlingtherequiredflowrateoftheapplication.

Regulatormaterialsofconstructionmustbecompatiblewiththeprocessmediausedfortheapplication.

*Contact your TESCOM Representative for assistance in selecting a suitable pressure regulator

REGULATOR SERIES MAXIMUM INLET PRESSURE OUTLET PRESSURE RANGES FLOW CAPACITYCv

Pressure Reducing Regulators

Cv = .06 - .30

26-2000A Upto20,000psig/1379bar Upto20,000psig/1379bar 0.02,0.06,0.12,0.30

44-1500A 6000psig/414bar 600psig/41.4bar 0.30

44-1500D(DomeLoad) 6000psig/414bar 90psig/6.2bar* 0.30

44-5200(VA027) 3500psig/241bar 500psig/34.5bar 0.06,0.15

50-2000A Upto30,000psig/2068bar Upto22,500psig/1551bar 0.06,0.12,0.30

54-2000A Upto20,000psig/1379bar Upto20,000psig/1379bar 0.06

Cv = greater than .30

269-529 300psig/21.0bar 90,300psig/6.2,21.0bar 1.5to10.0

44-1300A 6000psig/414bar Upto2500psig/172.4bar 0.8,2.0

44-4000A 6000psig/414bar Upto6000psig/414bar 0.70,2.0

54-2200A Upto10,000psig/689bar Upto10,000psig/689bar 2.0

54-2800A 5000psig/345bar Upto5000psig/345bar 8.0

DG(AirLoad) 600psig/41.4bar 500psig/34.5bar 10.0

DG(DomeLoad) 300psig/21.0bar 90psig/6.2bar* 10.0

DH(AirLoad) 500,600psig/34.5,41.4bar Upto500psig/34.5bar 5.0

DH(DomeLoad) 500psig/34.5bar 90psig/6.2bar* 5.0

DK(AirLoad) 1000psig/69.0bar 600psig/41.4bar 0.35

DK(DomeLoad) 1000psig/69.0bar 90psig/6.2bar* 0.35

PH16(DomeLoad) 300psig/21.0bar 90psig/6.2bar* 5.0

PH18(DomeLoad) 300psig/21.0bar 90psig/6.2bar* 10.0

Backpressure Regulators

26-1700A Upto20,000psig/1379bar N/A 0.02,0.10,0.14,0.60

26-2300(DomeLoad) 90psig/6.2bar N/A 0.06,0.12,0.60,1.0

26-2300(AirLoad) 500psig/34.5bar N/A 0.06,0.12,0.60,1.0

54-2100A Upto30,000psig/2068bar N/A 0.08,0.60

54-2700A 500psig/34.5bar N/A 5.0

54-2900A 10,000psig/689bar N/A 4.3

*Assuming 110 psig / 7.5 bar available to the ER5000

Regulator Selection for use with the ER5000*

12

WARNING! Do not attempt to select, install, use or maintain this product until you have read and fully understood the TESCOM Safety, Installation and Operation Precautions.

DER502060X012 © 2013 Emerson Process Management Regulator Technologies, Inc. All rights reserved. 06/2013.Tescom, Emerson Process Management, and the Emerson Process Management design are marks of one of the Emerson Process Management group of companies. All other marks are the property of their respective owners.

www.tescom.com