Emerson Tescom ER5K User manual

Serving all of your pressure control needs...
Automated Pressure Control Kits
Product Manual 0-30,000 PSI Range
Instruction Manual
DOPSM2095X012A
September 2019
www.pressurecontrolsolutions.co.uk

Table of Contents
September 2019
ER5K Kits
DOPSM2095X012
Table of Contents i
Contents
Section 1: Introduction ........................................................... 1
Section 2: Before You Begin ....................................................... 1
2.1 Safety, Installation and Operations Precautions .......................... 1
2.1.1 TESCOM Electronic Controllers ................................. 1
2.1.2 Installation .................................................. 3
2.1.3 TESCOM Regulators ........................................... 4
Section 3: Product Description ................................................... 7
3.1 Kit Benefits .......................................................... 7
3.1.1 Very high pressure stability .................................... 7
3.1.2 Automation .................................................. 7
3.1.3 ERTune™ Program ............................................ 7
3.1.4 Items Included ............................................... 7
3.2 Regulator Families .................................................... 7
3.3 Controlling System Pressure ........................................... 8
Section 4: Technical Data ........................................................ 10
Section 5: Installation ............................................................ 11
5.1 Two Mounting Types ................................................ 11
5.2 System Leak Check .................................................. 14
5.3 ER5000 Tuning ..................................................... 14
Section 6: Wiring .................................................................. 14
6.1 General Wiring ...................................................... 14
Section 7: Maintenance .......................................................... 16
Section 8: Drawings .............................................................. 17
8.1 Electrical Drawing ................................................... 17
8.2 ER5K Kit Drawing ................................................... 19
8.3 Regulator Drawings ................................................. 22
8.3.1 Regulator Flow Booster ....................................... 22
8.3.2 Pressure Reducing Regulator DK Series ......................... 23
8.3.3 Pressure Reducing Regulator 26-2000 Series .................... 24
8.3.4 Hydraulic Back Pressure Regulator 54-2100 Series ............... 25
8.3.5 Back Pressure Regulator 26-1700 Series ........................ 26
8.3.6 Control Air Regulator 44-5200 Series ........................... 27
8.4 Pressure Transducer ................................................. 28

Section 1: Introduction
September 2019
ER5K Kits
DOPSM2095X012
Section 1: Introduction
1
Section 1: Introduction
This manual is valid only for ER5K kits ER5K-XXXX. The instructions for individual components
must also be read and followed and are either attached in the appendix or supplied separately.
Section 2: Before You Begin
WARNING
This device is not intended for or rated for use in hazardous locations.
1. Please contact your TESCOM representative for Explosion Proof options.
2. Avoid personal injury or property damage from sudden release of pressure or
bursting parts. Before proceeding with any installation procedures:
• Always wear protective clothing, gloves, and eyewear to prevent personal
injury, or property damage.
• Do not remove the ER5000 or any other component of the system while the
system is pressurized.
• Disconnect any operating lines providing air pressure, electric 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 you work on the equipment.
• Check with your process or safety engineer for any additional measures that
must be taken to protect against process media dangers.
Do not install, operate, or maintain an ER5000 controller, or any associated
equipment, without reading and fully understanding the installation guidelines
and operating instructions for every component of your application. To avoid
personal injury or property damage, it is important to carefully read, understand,
and follow all contents of this Getting Started guide, including all safety cautions
and warnings. If you have any questions about these instructions, contact your
TESCOM sales office before proceeding.
2.1 Safety, Installation and Operations Precautions
2.1.1 TESCOM Electronic Controllers
WARNING
Do not attempt to select, install, use, or maintain this controller, or accessory until you have
read and fully understood these instructions. Be sure this information reaches the operator
and stays with the product after installation. Do not permit untrained personnel to install,
use, or maintain this controller, or accessory. Improper selection, installation, maintenance,
misuse, or abuse of this controller, or related accessories can cause death, serious injury,
and/or property damage. Oxygen service requires special expertise and knowledge of
system design and material compatibility in order to minimize the potential for death,
serious injury, and/or property damage.

Section 2: Before You Begin
September 2019
ER5K Kits
DOPSM2095X012
Section 2: Before You Begin 2
Possible consequence include but are not limited to:
• High velocity fluid (gas or liquid) discharge
• Electrocution
• Parts ejected at high speed
• Contact with fluids that may be hot, cold, toxic, or otherwise injurious
• Explosion or burning of the fluid
• Lines/hoses whipping dangerously
• Damage or destruction to other components or equipment in the system
CAUTION
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 controller, or accessory.
6. Never connect the controller, or accessories to a supply source having a pressure greater
than the maximum rated pressure of this controller, or accessory.
7. Never use anything but clean dry inert gases or air into the electropneumatic controller.
8. Start up sequence for electropneumatic controllers is:
a. Feedback loop must be installed and operational.
b. Electrical power should be applied and system setpoint reduced to its lowest
pressure output before turning on the pneumatic supply to the controller.
9. Refer to product label (modification specific) for maximum inlet pressures. If this
rated pressure cannot be found, contact your local Tescom representative for the
rated pressure prior to installation and use. Verify the designed pressure rating of all
equipment (e.g., supply lines, fittings, connections, filters, valves, gauges, etc.) in your
system. All must be capable of handling the supply and operating pressure.
10. Clearly establish flow direction of the fluid before installation of controllers, regulators,
valves, and accessories. It is the responsibility of the user to install the equipment in the
correct direction.
11. Remove pressure from the system before tightening fittings, gauges or components.
12. Never turn controller, regulator or valve body. Instead, hold the controller body and turn
fitting nut.
13. If a controller, regulator or valve leaks or malfunctions, take it out of service immediately.
14. Do not modify equipment or add attachments not approved by the manufacturer.
15. Apply pressure to the system gradually, avoiding a sudden surge of fluid or pressure
shock to the equipment in the system.
16. Regulators are not shut-off valves. Install a pressure relief device downstream of the
regulator to protect the process equipment from operating pressure increases. Shut off
the supply pressure when the regulator is not in use.
17. Periodic inspection and scheduled maintenance of your equipment is required for
continued safe operation.
18. The frequency of servicing is the responsibility of the user based on the application.
Never allow problems or lack of maintenance to go unreported.

Section 2: Before You Begin
September 2019
ER5K Kits
DOPSM2095X012
Section 2: Before You Begin
3
19. Read and follow precautions on compressed gas cylinder labels.
20. It is important that you analyze all aspects of your application and review all available
information concerning the product or system. Obtain, read, and understand the
Material Safety Data Sheet (MSDS) for each fluid used in your system.
21. Never use materials for 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 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.
24. Do not locate controllers, regulators, valves, or accessories using flammable fluids near
open flames or any other source of ignition. Use of Explosion Proof controllers may be
necessary to be in accordance with local electric codes.
25. Some fluids, when burning, do not exhibit a visible flame. Use extreme caution when
inspecting and/or servicing systems using flammable fluids to avoid death or serious
injury to employees. Provide a device to warn employees of these dangerous conditions.
26. Many gases can cause suffocation. Make certain the area is well ventilated. Provide a
device to warn employees of lack of Oxygen.
27. Never use oil or grease on these controllers, regulators, valves, or accessories. Oil and
grease are easily ignited and may combine violently with some fluids under pressure.
28. Have emergency equipment in the area if toxic or flammable fluids are used.
29. Upstream filters are recommended for use with all fluids.
30. Do not bleed system by loosening fittings.
31. Prevent icing of the equipment by removing excess moisture from the gas.
32. Always use proper thread lubricants and sealants on tapered pipe threads.
2.1.2 Installation
Inspect the controller, and accessories for physical damage and contamination. Do not
connect the controller, or accessory if you detect oil, grease, or damaged parts. If the
controller, or accessory is damaged, contact your local TESCOM representative to have the
controller cleaned or repaired.
WARNING
Make sure that the components and materials used in the fluid handling system are
compatible with the fluid and have the proper pressure rating.
Make sure that the components used in the electronic system are compatible
with and have the proper voltage rating.

Section 2: Before You Begin
September 2019
ER5K Kits
DOPSM2095X012
Section 2: Before You Begin 4
REPAIR SERVICE
If a controller leaks or malfunctions, take it out of service immediately. You must have
instructions before doing any maintenance. Do not make any repairs you do not understand.
Have qualified personnel make repairs. Return any equipment in need of service to your
equipment supplier for evaluation and prompt service. Equipment is restored to the original
factory performance specifications, if repairable. There are flat fee repair charges for each
standard model. The original equipment warranty applies after a complete overhaul.
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 for use with specific media upon request.
Suggestions are based on technical compatibility resources through associations
and manufacturers. Tescom does NOT guarantee materials to be compatible with
specific media — THIS IS THE RESPONSIBILITY OF THE USER!
4. Component function, adequate ratings, proper installation, operation, and
maintenance are the responsibilities of the system user.
5. The user is responsible to be in accordance with all the necessary mechanical
and electrical codes required for installation and operation of the system. These
requirements include but are not limited to all explosion proof controllers.
6. The user is responsible for the selection of the proper model number of the
controller that would meet the application’s possible hazardous environment
or conditions.
WARNING
Do not modify equipment or add attachments not approved by the manufacturer.
2.1.3 TESCOM Regulators
WARNING
Do not attempt to select, install, use, or maintain this regulator, valve, or accessory
until you have read and fully understand these instructions.
Be sure this information reaches the operator and stays with the product after
installation. Do not permit untrained personnel to install, use, or maintain this
regulator, valve or accessory. Improper selection, improper installation, improper
maintenance, misuse, or abuse of regulators, valves or related accessories can cause
death, serious injury, and/or property damage. Oxygen service requires special
expertise and knowledge of system design and material compatibility in order to
minimize the potential for death, serious injury, and/or property damage.
Possible consequences include but are not limited to:
• High velocity fluid (gas or liquid) discharge
• Parts ejected at high speed
• Contact with fluids that may be hot, cold, toxic, or otherwise injurious
• Explosion or burning of the fluid
• Lines/hoses whipping dangerously
• Damage or destruction to other components or equipment in the system

Section 2: Before You Begin
September 2019
ER5K Kits
DOPSM2095X012
Section 2: Before You Begin
5
CAUTION
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 the rated
pressure prior to installation and use. Verify the designed pressure rating of all
equipment (e.g., supply lines, fittings, connections, filters, valves, gauges, etc.) in your
system. All must be capable of handling the supply and operating pressure.
4. Clearly establish flow direction of the fluid before installation of regulators, valves,
and accessories. It is the responsibility of the user to install the equipment in the
correct direction.
5. Remove pressure from the system before tightening fittings, gauges or components.
6. Never turn regulator or valve body. Instead hold regulator or valve body and turn
fitting nut.
7. If a regulator or valve leaks or malfunctions, take it out of service immediately.
8. Do not modify equipment or add attachments not approved by the manufacturer.
9. Apply pressure to the system gradually, avoiding a sudden surge of fluid or pressure
shock to the equipment in the system.
10. Regulators are not shut-off devices. Install a pressure relief device downstream of the
regulator to protect the process equipment from overpressure conditions. Shut off the
supply pressure when the regulator is not in use.
11. Periodic inspection and scheduled maintenance of your equipment is required for
continued safe operation.
12. The frequency of servicing is the responsibility of the user based on the application.
13. Never allow problems or lack of maintenance to go unreported.
14. Read and follow precautions on compressed gas cylinder labels.
15. It is important that you analyze all aspects of your application and review all available
information concerning the product or system. Obtain, read, and understand the
Material Safety Data Sheet (MSDS) for each fluid used in your system.
16. Never use materials for regulators, valves, or accessories that are not compatible with
the fluids being used.
17. Users must test components for material compatibility with the system operating
conditions prior to use in the system.
18. Vent fluids to a safe environment, and in an area away from employees. Be sure
that venting and disposal methods are in accordance with Federal, State, and Local
requirements. Locate and construct vent lines to prevent condensation or gas
accumulation. Make sure the vent outlet is not obstructed by rain, snow, ice, vegetation,
insects, birds, etc. Do not interconnect vent lines; use separate lines if more than one
vent is needed.
19. Do not locate regulators, valves, or accessories controlling flammable fluids near open
flames or any other source of ignition.
20. Some fluids when burning do not exhibit a visible flame. Use extreme caution when
inspecting and/or servicing systems using flammable fluids to avoid death or serious
injury to employees. Provide a device to warn employees of these dangerous conditions.

Section 2: Before You Begin
September 2019
ER5K Kits
DOPSM2095X012
Section 2: Before You Begin 6
21. Many gases can cause suffocation. Make certain the area is well ventilated. Provide a
device to warn employees of lack of Oxygen.
22. Never use oil or grease on these regulators, valves, or accessories. Oil and grease are
easily ignited and may combine violently with some fluids under pressure.
23. Have emergency equipment in the area if toxic or flammable fluids are used.
24. Upstream filters are recommended for use with all fluids.
25. Do not bleed system by loosening fittings.
26. Prevent icing of the equipment by removing excess moisture from the gas.
27. Always use proper thread lubricants and sealants on tapered pipe threads.
CAUTION
Do not open packaging until ready for installation or in a clean environment. Product is
cleaned in accordance with CGA 4.1 and ASTM G93, Verification Type 1, Test 1 and Test 2.
With periodic verification of cleaning process to MIL-STD-1330D.
WARNING
Make sure that the components and materials used in the fluid handling system are
compatible with the fluid and have the proper pressure rating. Failure to do so can
result in death, serious injury, and/or property damage.
Inspect the regulator, valve, and accessories for physical damage and contamination.
Do not connect the regulator, valve, or accessory if you detect oil, grease, or damaged
parts. If the regulator, valve, or accessory is damaged, contact your local Tescom
representative to have the regulator cleaned or repaired.
REPAIR SERVICE
If a regulator or valve leaks or malfunctions, take it out of service immediately. You must have
instructions before doing any maintenance. Do not make any repairs you do not understand.
Have qualified personnel make repairs. Return any equipment in need of service to your
equipment supplier for evaluation and prompt service. Equipment is restored to the original
factory performance specifications, if repairable. There are flat fee repair charges for each
standard model. The original equipment warranty applies after a complete overhaul.
CAUTION
Proper Component Selection
1. Consider the total system design when selecting a component for use in a system.
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 for use with specific media upon request. Suggestions are
based on technical compatibility resources through associations and manufacturers.
TESCOM does NOT guarantee materials to be compatible with specific media -- THIS IS
THE RESPONSIBILITY OF THE USER!
4. Component function, adequate ratings, proper installation, operation, and
maintenance are the responsibilities of the system user.
WARNING
Do not modify equipment or add attachments not approved by the manufacturer.
Failure to do so can result in death, serious injury and/or property damage.

Section 3: Product Description
September 2019
ER5K Kits
DOPSM2095X012
Section 3: Product Description
7
Section 3: Product Description
The ER5K Kits are designed to provide a complete pressure control system for the most
common pressure reducing and back pressure control applications. All the components
are completely assembled, professionally plumbed together and tested for proper
operation to save the user time and the inconvenience of not having all the accessories
and interconnections needed to get the system up and running. Kits are available with the
components mounted on a SST plate or mounted inside an enclosure.
The ER5000 is a unique and flexible electropneumatic, closed loop, PID controller. When
combined with a mechanical regulator and pressure transmitter in these kits, the system
provides precise control of pressures up to 10,000 psig / 690 bar. The included ERTune
software program provides an easy means of setup, tuning and data acquisition.
3.1 Kit Benefits
3.1.1 Very high pressure stability
— Pressure is independent of the flow (eliminates droop)
— Pressure is independent of the input pressure (eliminates decaying inlet effect)
3.1.2 Automation
— Pressure can be controlled by a signal from a PC or PLC
— Easy integration into automated test cycles
3.1.3 ERTune™ Program
— Included with every ER5000, provides data acquisition routine
— Setup Wizard loads PID parameters for your regulator series
3.1.4 Items Included
All ER5K kits includes:
— ER5000FI-1 w/ERtune program and Complete User Manual
— Mechanical Regulator (see “Regulator Families” below)
— 4-20 mAmp Feedback Transducer; 0.125% accuracy
— ER Supply Regulator with relief valve and gauge
— Prewired Electrical Junction Box
— All connections and fittings
3.2 Regulator Families
With ER5K kits, the customer has a choice of the most versatile mechanical regulators to
cover a wide range of applications, both pressure reducing and back pressure.
Table 1. Pressure Reducing Regulators
26-2000 High pressure regulator to control various output ranges up to 10,000 psig / 690 bar, segregated captured vent.
DK Highly accurate and sensitive regulator with captured vent for low pressure (90 psig / 6 bar) or mid range
applications (600 psig / 40 bar) requiring significant flow capabilities.
44-5200 Piston sensed, venting regulator for mid-pressure range, low flow applications (600 psig / 40 bar).
Flow booster Low pressure (90 psig / 6 bar), high flow diaphragm regulator for air or nitrogen service. Zinc body.
Table 2. Back Pressure Regulators
26-1700 High pressure regulator to control various back-pressure ranges up to 10,000 psig / 690 bar.
54-2100High pressure regulator to control various back-pressure ranges up to 10,000 psig / 690 bar. Specially designed for
hydraulic applications (metal seat).