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

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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: [phone]
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

_____________________________________________________________________________________________________

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

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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