Emerson TESCOM 44-6800 E Series User manual

Installation, Operations and Maintenance Manual
TR000058ENUS-02_10-20
October 2020
TESCOM™ 44-6800 E Series
Electrically Heated Vaporizing Regulator
Installation, Operations and Maintenance Manual
Do not attempt to select, install,
use or maintain this product until
you have read and fully understood
this manual.

2TESCOM™ 44-6800 E Series
October 2020
Installation, Operations and Maintenance Manual
TR000058ENUS-02_10-20

3
Installation, Operations and Maintenance Manual
Content
October 2020
Installation, Operations and Maintenance Manual
TR000058ENUS-02_10-20
Contents
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Symbols.........................................................................................................................4
Safety Precautions and Repair.........................................................................................4
2.1 44-6800E Series Regulator Safety.......................................................................................4
3. Installation, Operations and Maintenance...................................................................7
3.1 General Information..........................................................................................................7
3.1.1. Operating Parameters/Special Conditions For Safe Use............................................8
3.2.Installation........................................................................................................................9
3.2.1.InstallationPrecautions............................................................................................9
3.3.Operation........................................................................................................................12
3.3.1RegulatorAdjustment.............................................................................................12
3.3.2 Heater Temperature Controller Status.....................................................................12
3.4 Maintenance and Repair Service.......................................................................................13
3.4.1RepairService..........................................................................................................13
3.4.2 Mechanical Pressure Regulator Function.................................................................13
3.4.3 Electric Heater Function..........................................................................................15
4. Certifications and Warranty.....................................................................................16
4.1 Hazardous Location Ratings.......................................................................................16
4.2 Declaration of Conformity..........................................................................................17
4.3LimitedWarranty........................................................................................................18

4TESCOM™ 44-6800 E Series
Content
October 2020
Installation, Operations and Maintenance Manual
TR000058ENUS-02_10-20
1Symbols
WARNING
Paragraphs highlighted by the WARNING icon contain information about practices or
circumstances that can lead to personal injury or death, property damage or economic
loss.
CAUTION
Paragraphs highlighted by the CAUTION icon contain information that must be followed
to maintain a safe and successful operating environment.
Safety Precautions and Repair
44-6800E Series Regulator Safety
WARNING
Do not attempt to select, install, use or maintain this regulator until you have read and
fully and understood these instructions. Do not permit untrained persons to install, use
or maintain this regulator.
The 44-6800E Series regulator should not be installed in an enclosure that is heated above
the regulator’s maximum rated ambient temperature.
Be sure this information reaches the operator and stays with the product after installation.
Improper selection, improper installation, improper maintenance, misuse or abuse of
regulator can cause death, serious injury and property damage.
Possible consequences include but are not limited to:
•High velocity uid (gas or liquid) discharge
•Parts ejected at high speed
•Contact with uids that may be hot, cold, toxic or otherwise injurious
•Explosion or burning of the uid
•Lines/hoses whipping dangerously
•Damage or destruction to other components or equipment in the system
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2.1

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Installation, Operations and Maintenance Manual
Content
October 2020
Installation, Operations and Maintenance Manual
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CAUTION
Safety Precautions
•Inspect the regulator before each use.
•Never connect regulators to a supply source having a pressure greater than the
maximum rated pressure of the regulator, valve or accessory.
•Refer to product label (model specic) for maximum inlet pressures . If this rated
pressure cannot be found, contact your local TESCOM representative for the designed
pressure rating of all equipment (e .g., supply lines, ttings, connections, lters,
valves, gauges, etc.) in your system . All must be capable of handling the supply and
operating pressure.
•Install circuit protection on input voltage to electrical controls of the regulator per
local and environment codes.
•Clearly establish ow direction of the uid before installation of regulators, valves
and accessories. It is the responsibility of the user to install the equipment in the
correct direction
•Remove pressure from the system before tightening ttings, gauges or component.
•Never turn regulator or valve body. Instead hold regulator or valve body and turn
tting nut.
•Take precautions before touching the regulator while in operation.
•If a regulator or valve leaks or malfunctions, take it out of service immediately.
•Do not modify equipment or add attachments not approved by the manufacturer.
•Do not open enclosures when energized. Do not open enclosures when explosive
atmosphere may be present.
•For pressure reducing regulators, it is highly recommended that the control knob
or adjusting screw be turned fully counterclockwise before applying inlet pressure.
•Apply pressure to the system gradually, avoiding a sudden surge of uid or pressure
shock to the equipment in the system.
•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.
•Periodic inspection and scheduled maintenance of your equipment is required for
continued safe operation.
•The frequency of servicing is the responsibility of the user based on the application.
Never allow problems or lack of maintenance to go unreported.
•Read and follow precautions on compressed gas cylinder labels.
•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 uid used in your system.
•Never use materials for regulators, valves or accessories that are not compatible with
the uids being used.
•Users must test components for material compatibility with the system operating
conditions prior to use in the system.
•Vent uids to a safe environment and in an area away from personnel. 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.

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October 2020
Installation, Operations and Maintenance Manual
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•Do not interconnect vent lines; use separate lines if more than one vent is needed.
Do not locate regulators, valves or accessories controlling ammable uids near open
ames or any other source of ignition.
•Some uids when burning do not exhibit a visible ame. Use extreme caution when in
specting and/or servicing systems using ammable uids to avoid death or serious
injury to personnel. Provide a device to warn personnel of these dangerous conditions.
•Many gases can cause suffocation. Make certain the area is well ventilated. Provide a
device to warn personnel of lack of Oxygen.
•Never use oil or grease on these regulators unless recommended as specied in Operations
and Service procedures. Oil and grease are easily ignited and may combine violently
with some uids under pressure.
•Have emergency equipment in the area if toxic or ammable uids are used.
•Upstream lters are recommended for use with all uids.
•Do not bleed system by loosening ttings.
•Prevent icing of the equipment by removing excess moisture from the gas.
•Always use proper thread lubricants and sealants on tapered pipe threads.

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Installation, Operations and Maintenance Manual
Content
October 2020
Installation, Operations and Maintenance Manual
TR000058ENUS-02_10-20
Installation, Operations and Maintenance
Assembly & installation drawings, Bill of Materials, and parts lists for your product may
be obtained by contacting Emerson. Emerson will provide these by email, fax or mail.
Your local TESCOM™ sales representative can provide additional assistance. Be sure to
have your complete model number ready. See back page for contact information.
General Information
TESCOM™ 44-6800E Series Electrically Heated Vaporizing diaphragm-sensed pressure
reducing regulators are specically engineered for applications requiring dependable
pressure regulation. These regulators are especially appropriate for installations where
high system pressures (up to 6000 psi) must be reduced to levels suitable for actuating
low pressure (0 psig/0 bar to 500 psig/35 bar) instruments and related equipment.
In addition, the 44-6800E Series “Vaporizing” regulator is designed to offset the effects
of the Joule-Thompson cooling effect that occurs when there is a pressure drop in a gas.
It can also be used to vaporize a liquid into a gas in some applications.
The electrical board inside the housing powers an electrical heater that indirectly heats
the process media. This heater is controlled by the electrical board for temperatures
ranging from 122 °F/50 °C to 752 °F/400 °C. There is a thermocouple within the heater
core to provide temperature feedback. There is a secondary thermal device, thermal cut
off (TCO), within the regulator assembly. See Figure 1.
Figure 1:
ELECTRIC (Shown with optional LED display).
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3.1

8TESCOM™ 44-6800 E Series
Content
October 2020
Installation, Operations and Maintenance Manual
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Operating Parameters/Special Conditions For Safe Use
Maximum Inlet Pressure:
3,500 psig / 241 bar / 24,132 kPa Standard
6,000 psig / 414 bar / 41368 kPa Optional
Maximum Outlet Pressure:
500 psig / 34 5 bar / 3,448 kPa
Outlet Pressure Ranges:
0-25, 0-50, 0-100, 0-250, 0-500 psig
0-17, 0-34, 0-69, 0-172, 0-345 bar
0-172, 0-345, 0-690, 0-1724, 0-3448 kPa
Design Proof Pressure
150% maximum rated
Leakage:
Internal: Bubble-tight
External: Designed to meet ≤ 2x10-8 atm cc/sec He
Voltage:
100 - 240 VAC, 50/60 Hz, 400W at 240VAC, 100W at 120VAC
Full Load Amps:
2.0 Amps at 240VAC, 1.1 Amps at 120 VAC*
*Controller has 3 Amp fuse rated for 350 VAC
Flow Capacity:
Cv = 0.02 - Standard
Refer to catalog and part number for options.
Supply Voltage
(VAC)
Heater Watts
(W)
Max. Ambient
Temperature
100 - 240 100 - 400 Electrical Housing
149 °F/65 °C
Regulator Body
185 °F/85 °C
All cables, cable glands and conductors need >95 °C rating.
For integral applications the electronics enclosure must engage the regulator assembly by
at least 5 full threads made wrench tight.
3.1.1

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Installation, Operations and Maintenance Manual
Content
October 2020
Installation, Operations and Maintenance Manual
TR000058ENUS-02_10-20
Installation
Installation Precautions
WARNING
Make sure that the components and materials used in the uid handling system are
compatible with the uid and have the proper pressure rating. Failure to do so can result
in death, serious injury and/or property damage.
A regulator is not intended to be used as a shutoff device. When the regulator is not in
use, the inlet supply should be turned off. As a safety precaution, a pressure relief device
should be installed downstream of the regulator.
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, Verication Type 1, Test 1 and Test
2. With periodic verication of cleaning process to MIL-STD-1330D.
Inspect the regulator for physical damage and contamination. Do not connect the regulator
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.
CAUTION
Follow all laws, regulations and industry requirements for electrical wiring. All electrical
wiring must be terminated in an inaccessible location. Where the electrical housing is
separate from the regulator body appropriate wiring to connect the two assemblies shall
follow hazardous location requirements per applicable laws and regulations.
Possible consequences include but are not limited to:
a. Make sure the regulator and electrical housing is mounted securely.
b. Make sure the electrical power is turned off and locked out.
c. Connect external ground if required to electrical housing.
d. Remove electrical housing cover.
e. Remove power supply connector and (if used) the 4-20 mA output connector from
the electrical board. See Figure 2.
f. Feed power supply wires and (if used) the 4-20 mA output wires through the 1/2” NPT
port. See Figure 2.
g. Screw the power supply and (if used) 4-20 mA output wires to the connectors and
internal ground. See Figure 2.
h. Verify all connections before applying power. Make sure the supply power is in working
range of unit purchased.
i. If the 4-20 mA output is used, an isolated excitation voltage of 20-28 volts is needed.
The 4-20 mA output correlates to a thermocouple temperature reading of 50 to
400 °C / 122 to 752 °F. See Figure 2.
Notice
Should the thermocouple fail the analog output would read greater than 25 mA
and no electrical power will be supplied to the heating element. Disconnect
power and check wiring.
3.2
3.2.1

10 TESCOM™ 44-6800 E Series
Content
October 2020
Installation, Operations and Maintenance Manual
TR000058ENUS-02_10-20
j. Adjust the temperature with the TRIM1 potentiometer. TRIM1 potentiometer, located
on the electrical board, provides a 270° of adjustment. The temperature set point
range is from 50 °C /122 °F (fully counter clockwise position) to 400 °C /752 °F (fully
clockwise position). See Figure 3.
Product does not provide actual media temperature. Actual media temperature
should be taken from a different device.
k. Heater Temperature Feedback Display (Optional):
The display reads the temperature of the heater in degrees Celsius.
l. Temperature Set Button (Only with Optional Display):
This button is located on the control board. See Figure 4.
When pressed down the display will show the heater set point temperature.
m. Place stopping plugs in any unclosed conduit entry.
Figure 2:
Figure 2
Separated assembly is supplied with
electrical housing shipped separately from
the regulator assembly. Extra wire is
provided. Connectors J4 and J2 from the
regulator assembly must be attached to
the corresponding control board terminals.
For integral applications the electronics
enclosure must engage the regulator
assembly by at least 5 full threads made
wrench tight.
(J4)
(J5)
(J2)
(J1)