Rockwell Automation T6050 User Manual
User’s Guide
_____________________________________________________________________________________________________
T6050 SurgeGard™
Incipient Surge-Conditioning Module
Issue 1
December 2004
ICS Triplex Turbo Machinery Control
Copyright
Copyright 2004
By ICS Triplex
Houston, Texas, U.S.A.
All rights reserved. No part of this work covered by the copyright hereon may be reproduced or
copied in any form or by any means--graphic, electronic, or mechanical--without first receiving the
written permission of
ICS Triplex, Houston, Texas, U.S.A.
Printed in U.S.A.
ICS Triplex reserves the right to make improvements in the design, construction, and appearance of
its products without prior notice.
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Revision History
Issue 1 12/15/04 First issue
T6050 User’s Guide
PD-6050 Dec 04
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ICS Triplex Turbo Machinery Control
Warnings!
READ THIS ENTIRE MANUAL AND ALL RELATED PUBLICATIONS PERTAINING TO
THE WORK TO BE PERFORMED BEFORE INSTALLING, OPERATING, OR
SERVICING THIS EQUIPMENT.
• Practice all plant and safety codes and standards. Failure to follow instructions can result
in personal injury and/or property damage.
• To prevent ignition of hazardous atmospheres, do not remove covers of Class I Division I
(explosion-proof) units with power applied.
• Qualified technicians should perform all servicing. Dangerous voltages may be present on the
circuit boards.
• Use extreme caution when working around power-input cables. These cables may have
potentially lethal voltages on them.
• Be very careful when working on the digital (or discrete) input/output field termination panels.
The external devices being controlled can have high, potentially lethal voltages on them. Turn
off the power to the external devices before disconnecting or connecting the cable or a wire
between the digital (or discrete) input/output field termination panels and the field wiring.
• Replace fuses only with specified parts for continued safe operation.
• Equip the engine, turbine, or other type of prime mover with an over speed (over temperature or
over pressure, where applicable) shutdown device that operates totally independently of the
prime mover control device. This protects against run-away or damage to the engine, turbine, or
other prime mover, or personal injury or loss of life, should the mechanical-hydraulic or
electronic governor, actuator, fuel control, driving mechanism, linkage, or controlled device fail.
• Make sure the charging device is turned off before disconnecting the battery from the system to
prevent damage to a control system that uses an alternator or battery-charging device.
• Prior to energizing the equipment, have qualified personnel verify all wiring and connections
against vendor drawings. Incorrect wiring and/or connections can result in equipment damage.
• Contact appropriate manufacturer for instructions on operation of engine, turbine, or driven unit.
This manual does not contain this information.
If you have questions or need more information on installing and operating ICS Triplex
equipment, contact ICS Triplex.
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T6050 User’s Guide
Disclaimer
Because of the variety of uses for this equipment, the user of and those responsible for applying this
equipment must satisfy themselves as to the acceptability of each application and the use of the
equipment.
The illustrations in this manual are intended solely to illustrate the text of this manual. Because of the
many variables and requirements associated with any particular installation, ICS Triplex cannot
assume responsibility or liability for actual use based upon the illustrative uses and applications.
In no event will ICS Triplex be responsible or liable for indirect or consequential damages resulting
from the use or application of this equipment.
ICS Triplex DISCLAIMS ANY IMPLIED WARRANTY OR FITNESS FOR A PARTICULAR
PURPOSE.
No patent or copyright liability is assumed by ICS Triplex with respect to use of information,
circuits, equipment, or software described in this text.
Reproduction of the content of this manual in whole or part, without written permission from ICS
Triplex, is prohibited.
Warranty
All ICS Triplex products are warranted to be free of defects in materials and workmanship for a
period of one year from date of start-up of our equipment or 18 months from date of shipment,
whichever comes first. In case of failure, ICS Triplex liability shall be limited to furnishing, but not
installing, necessary repair parts; or at the option of ICS Triplex, to repairing the defective product at
its manufacturing location, providing the equipment is returned at purchaser’s expense.
This warranty does not apply to equipment showing abuse or damage or to equipment which has
been altered or repaired by others, except as authorized by ICS Triplex. Nor does it extend to
products that have been subjected to a corrosive and/or abnormal atmosphere, or to product
components (such as batteries, lamps, etc.) which have provided a normal service life.
ICS Triplex will determine if warranty applies when material is received at its manufacturing
location. A purchase order and a Returned Material Authorization (RMA) must accompany all
returned material to ICS Triplex Customer Care Department:
Regional Technical Services
4325 West Sam Houston Pkwy. North
Suite 100
Houston, TX 77043-1219 USA
Telephone: 713-353-2400
The purchase order number as well as the RMA number should be clearly marked on the outside of
the shipping container. Regional Technical Services issues RMA numbers.
In no event will responsibility be assumed or implied for consequential damages arising from
interrupted operation or any other causes.
This warranty is in lieu of all other warranties expressed or implied, and no one is authorized to
assume any liability on behalf of ICS Triplex, or to impose any liability on behalf of ICS Triplex, or
to impose any obligation on it in connection with the sale of any equipment other than as stated
above.
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ICS Triplex Turbo Machinery Control
Electrostatic Discharge Awareness
Electrostatic discharge can damage or destroy electronic components, assemblies, or systems.
1. Keep the following materials away from components and work area:
• Styrofoam® (polystyrene): cups, packing material
• cellophane: cigarette packages or candy wrappers
• vinyl: books or folders
• plastic: cups, bottles, ash trays
2. Avoid synthetic clothing. Instead wear cotton or cotton-blend materials. Keep components away
from elastics, clothing, and hair.
3. Before handling electronic components, discharge static electricity buildup from your body by
using a properly connected wrist strap.
4. Do not handle components in the field unless properly grounded via wrist strap. If you are not
properly grounded:
• Do not pick up components.
• Do not touch the printed circuit board.
• Do not remove components from the chassis.
5. Transport all static-sensitive components only in static-shielding carriers or packages. Place
static awareness labels on all components to prevent removal from static-shielding container
during transit.
6. Handle all static-sensitive components at a static-safe work area including floor mat, wrist strap,
air ionizer, ground cord, and conductive tablemat.
7. Wear a grounded wrist strap in the field whenever possible. Where wrist straps are impractical,
wear grounded heel straps or special footwear on properly grounded dissipative flooring.
8. Do not subject components to sliding movements over any surface at any time.
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Hardware & Installation
Guide
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T6050 SurgeGard™
Incipient Surge-Conditioning Module
Issue 1
December 2004
Contents
ILLUSTRATIONS........................................................................................................................... IV
Chapter 1 - Introduction...........................................................................................1
ABOUT THIS MANUAL ..................................................................................................................1
USER EXPERIENCE PREREQUISITES..........................................................................................2
REFERENCE DOCUMENTS............................................................................................................2
Chapter 2 - Product Overview.................................................................................3
Chapter 3 – Hardware Descriptions........................................................................5
ENCLOSURE.....................................................................................................................................5
CIRCUIT BOARD..............................................................................................................................5
TERMINATIONS...............................................................................................................................5
Chapter 4 - Installation.............................................................................................7
SITE SELECTION CONSIDERATIONS..........................................................................................7
ACCESS CONSIDERATIONS..........................................................................................................7
UNPACKING AND INSPECTION ...................................................................................................8
MOUNTING.......................................................................................................................................8
WIRING..............................................................................................................................................9
General............................................................................................................................................9
Electrical Power Wiring ...............................................................................................................10
Chapter 5 - Specifications.....................................................................................13
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ICS Triplex Turbo Machinery Control
Illustrations
Figure 1. T6050 General Appearance ................................................................................................. 3
Figure 2. Hardware Block Diagram.................................................................................................... 4
Figure 3. Mounting Dimensions.......................................................................................................... 8
Figure 4. T6050 Terminations............................................................................................................. 9
Figure 5. T6050 Simplified Schematic.............................................................................................. 10
Figure 6. Typical Field Wiring With A Current Transmitter Input .................................................. 11
Figure 7. Typical Field Wiring With A Voltage Transmitter Input. ……………………………….11
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PD-6050 Dec 04
T6050 Operations & Maintenance Guide Chapter 1 – Introduction
Chapter 1 - Introduction
This document applies to the T6050 SurgeGard™ which is an incipient surge-conditioning module
designed to continuously monitor the frequency flow, pressure or current oscillations occurring
before the compressor reaches the actual surge point(s). SurgeGard™ is patented and has been
successfully used in many compressor control systems
About This Manual
As its name implies, this manual is a guide to understanding and installing the T6050 hardware.
Since this document is relatively small, an index is not included. Instead, a detailed table of contents
is provided. This manual contains the following chapters:
• Chapter 1 - Introduction
This chapter contains information about this document and related reference documents.
• Chapter 2 - Product Overview
This chapter presents an overview of the product as a whole.
• Chapter 3 - Hardware Descriptions
This chapter describes all of the hardware which comprises the T6050.
• Chapter 4 - Installation
This chapter explains how to install a T6050, including mounting and wiring.
• Chapter 5 - Specifications
This chapter provides general specification.
This document will be useful to anyone who is responsible for design, installation, and maintenance
of a control system that contains a T6100, T6200 or T6300 Compressor Controller. Information
presented here will enable knowledgeable persons to perform those tasks that are required for
successful installation and maintenance of the T6050.
ICS Triplex Turbo Machinery Control
User Experience Prerequisites
To effectively use the T6050, users should have some experience with the use of digital control
systems, or have an instrumentation background. It is assumed that the personnel involved
understand the basics of electronic control systems and good wiring practices. It is also assumed that
personnel involved have access to the required tools.
Extremely advantageous, though not required, is experience with Windows-based software programs,
compressor operation, and normal operations experience within a plant environment.
Reference Documents
• T6050 Operations & Maintenance Guide
2
PD-6050 Dec 04
T6050 Hardware & Installation Guide Chapter 2 – Product Overview
Chapter 2 - Product Overview
The T6050 SurgeGard™ is an incipient surge-conditioning module designed to continuously monitor
the frequency flow, pressure or current oscillations occurring before the compressor reaches the
actual surge point(s). SurgeGard™ is patented and has been successfully used in many compressor
control systems.
The T6050 continuous analog peak-detector circuit is more efficient (less than 1 ms) and reliable
than the digital sampling (2-10 ms sample rate) for both incipient surge control and for surge spike
detection. In both applications (analog or digital), high speed transmitters should be used when
implementing incipient surge detection techniques.
The T6050 is loop powered and consists of a differential input band pass (1Hz to 10Hz)
amplifier/filter, a low pass filter (10Hz), absolute-value, peak detector and a voltage-to-current
converter; all enclosed in a termination type electronic component housing.
The T6050's small size and built-in termination assembly allow the module to be mounted virtually
anywhere on 32 or 35mm width standard DIN/EN rail.
Figure 1. T6050 General Appearance
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ICS Triplex Turbo Machinery Control
A block diagram of the hardware is shown in the figure below.
CURRENT
OR VOLTAGE
FROM FLOW
TRANSMITTER
AC SIGNAL
OUT
ANALOG
INPUT
Current
or Voltage
AC SIG
DIFFER-
ENTIAL
AMPLIFIER
ABSOLUTE
VALUE
FILTER
PEAK
DETECTOR
GAIN
VOLTAGE
TO
CURRENT
CONVERTER
Figure 2. Hardware Block Diagram
DC TO DC
CONVERTER
ANALOG
OUTPUT
4-20mA
LOOP POWER
(22-32VDC)
4-20mA
TO ANTI-SURGE
CONTROLLER
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PD-6050 Dec 04
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