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.
T6050 User’s Guide Revision History Issue 1 12/15/04 PD-6050 Dec 04 First issue 3
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.
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.
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.
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 ................................................................................
ICS Triplex Turbo Machinery Control Illustrations Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. iv T6050 General Appearance ................................................................................................. 3 Hardware Block Diagram .................................................................................................... 4 Mounting Dimensions..........................................................................................................
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).
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.
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.
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 DIFFERENTIAL AMPLIFIER FILTER GAIN ABSOLUTE VALUE PEAK DETECTOR VOLTAGE TO CURRENT CONVERTER DC TO DC CONVERTER ANALOG OUTPUT 4-20mA LOOP POWER (22-32VDC) 4-20mA TO ANTI-SURGE CONTROLLER Figure 2.
T6050 Hardware & Installation Guide Chapter 3 – Hardware Descriptions Chapter 3 – Hardware Descriptions Enclosure The T6050 electronic component housing enclosure is designed to be mounted on both 32 and 35 mm width standard DIN/EN rail and is completely self-contained. The electronic component housing enclosure is manufactured of green KRILEN 6.6 Polyamide insulating material. Circuit Board All circuitry, including dc-to-dc converter power supply, is contained on a single circuit board.
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T6050 Hardware & Installation Guide Chapter 4 – Installation Chapter 4 - Installation Site Selection Considerations The T6050 requires the following conditions during normal operation: • 32 to 130ºF (0 to 55ºC) • 5 to 96% relative humidity • Protection from direct contact with water, chemicals, and conductive dust • Limited exposure to sulfur compounds, acid other corrosive or reactive vapors or fumes, and conductive dust • Limited exposure to non-conductive dust and combustible dust and lint Ac
ICS Triplex Turbo Machinery Control Unpacking and Inspection • Upon receipt of the T6050, unpack it carefully and visually check for damage. If anything is damaged, contact ICS Triplex for instructions for returning it to the factory. If everything appears to be in order, proceed with the instructions in the following paragraphs. Mounting The following figure provides mounting dimensions for the T6050. 3.15" (80) T6050 SurgeGard 4mA X5 X30 0.79" (20) TOP VIEW 0.79" (20) 3.
T6050 Hardware & Installation Guide Chapter 4 – Installation Wiring General The following general guidelines apply to all wiring discussed in the following paragraphs. • Wire size range is 22-12 AWG stranded; recommended wire size range is 18-14 AWG.
ICS Triplex Turbo Machinery Control IN + 1 5 LOOP PWR IN + IN - 2 6 4-20mA OUT 3 7 AC SIG OUT 4 8 AC COM OUT 250 Ohm RESISTOR + * RESISTOR - * Remove jumper for voltage input Figure 5. T6050 Simplified Schematic The additional guidelines below should be followed when wiring the T6050: • The stripped portion of the wires should be 5/16” (8 mm) long. • Wires should be inserted in the clamp type terminals until they touch the internal stops.
T6050 Hardware & Installation Guide IN + Chapter 4 – Installation 1 5 2 6 T IN - LOOP PWR IN + (22-32VDC) (SEE WIRING NOTE 1) UC 4-20mA OUT CURRENT TRANSMITTER 250 Ohm (0/4-20mA) 3 7 AC SIG OUT JUMPER 4 8 AC COM OUT Figure 6. Typical Field Wiring with a Current Transmitter Input IN + 1 5 LOOP PWR IN + (22-32VDC) (SEE WIRING NOTE 1) T IN - 2 6 UC 4-20mA OUT VOLTAGE TRANSMITTER 250 Ohm 3 7 AC SIG OUT * 4 8 AC COM OUT * Remove jumper for voltage input Figure 7.
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T6050 Hardware & Installation Guide Chapter 5 – Specifications Chapter 5 - Specifications Analog Input Signal Types -10 - +10 V, 0-5 or 1-5 VDC; 0-20 or 4-20 mA (with jumper installed across terminals 3 and 4) Input Frequency 0-20 Hz Isolation +/- 15 VDC continuous Common Mode Rejection 80 db min at 60 Hz peak input; +/- 10 VDC max Maximum Input Voltage Range +/- 10 VDC operating, non-destructive Transmitter Type 2- or 4-wire; transmitter excitation supplied from external source Input Filterin
ICS Triplex Turbo Machinery Control Environmental The T6050 controller meets the following environmental conditions without loss of accuracy. Operating Temperatures: Condition Normal Limits Operative Limits Transport Storage Ambient Temp 0 - 50ºC 0 - 55ºC -40 - 70ºC Ambient Relative Humidity Non-Condensing 5 - 96 % 5 - 96 % 5 - 96 % Vibration 5 – 60 Hz at 0.
Operations & Maintenance 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 ................................................................................
ICS Triplex Turbo Machinery Control Illustrations Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. iv T6050 General Appearance ................................................................................................. 3 Hardware Block Diagram .................................................................................................... 4 Typical Internal T6050 SurgeGard™ Signal Conditioning .................................................
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). About This Manual As its name implies, this manual is a guide to operating and maintaining the T6050 SurgeGard™.
ICS Triplex Turbo Machinery Control User Experience Prerequisites To effectively use the T6050 SurgeGard™, 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.
T6050 Operations & Maintenance 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).
ICS Triplex Turbo Machinery Control T6050 SurgeGard™ Benefits Tune your application properly to obtain the T6050 SurgeGard™ benefits: Increased Energy Savings The addition of incipient override control permits closer operation to the actual surge point/line, thus providing a wider operating window and saving energy by minimizing recycle/blowoff.
T6050 Operations & Maintenance Guide Chapter 2 – Product Overview Typical Signal Conditioning Figure 3.
ICS Triplex Turbo Machinery Control Figure 4. T6050 SurgeGard™ Simplified Schematic Typical T6050 Field Wiring with a Current Transmitter IN + 1 5 LOOP PWR IN + (22-32VDC) T UC IN - 2 6 4-20mA OUT CURRENT TRANSMITTER 250 Ohm (0/4-20mA) 3 7 AC SIG OUT JUMPER 4 8 AC COM OUT Figure 5.
T6050 Operations & Maintenance Guide IN + 1 Chapter 2 – Product Overview 5 LOOP PWR IN + (22-32VDC) T UC IN - 2 6 4-20mA OUT VOLTAGE TRANSMITTER 250 Ohm 3 7 AC SIG OUT * 4 8 AC COM OUT * Remove jumper for voltage input Figure 6.
ICS Triplex Turbo Machinery Control Application Considerations Control of turbomachinery presents numerous challenges and opportunities because the surrounding process or pipeline largely depends on the control systems availability, reliability and efficiency.
T6050 Operations & Maintenance Guide Chapter 3 – Applications Typical T6050 SurgeGard™ Applications Motor Driven Compressor Applications The incipient surge conditions (flow oscillations at the inlet of the impeller) are transformed to torsional load oscillations (electric motors are very sensitive to changing torque). Depending on the compressor-motor gear sensitivity, a good parameter for incipient surge detection is the motor power transducer (I or KW, without filtering).
ICS Triplex Turbo Machinery Control Same criteria as for motor driven compressors. The incipient surge conditions (flow oscillations at the inlet of the impeller) are transformed to torsional load oscillations (electric motors are very sensitive to changing torque). The parameter for incipient surge detection is the motor power transducer (I or KW, without filtering).
T6050 Operations & Maintenance Guide Chapter 3 – Applications Factory Calibration Procedure i) ii) iii) iv) v) vi) vii) viii) ix) x) Connect the positive (+) terminal of the 24 VDC power supply to terminal 5 of the T6050 module. Connect the 250-ohm precision resistor in series between terminal 6 of the T6050 module and the negative (-) terminal of the 24 VDC power supply. Connect the waveform generator across the input terminals 1 and 2 of the T6050.
ICS Triplex Turbo Machinery Control Chapter 4 - Operations T6050 SurgeGard™ Field Gain Adjustment Procedure For the T6050 SurgeGard™ field gain adjustment procedure, it is assumed that a current (motor I or KW) or a flow transmitter is used in the process. The transmitter is assumed to have a 4-to-20mA output (that oscillates during incipient surge) which feeds into the T6050 SurgeGard™ module input Terminals 1 and 2.
T6050 Operations & Maintenance Guide Chapter 4 – Operations and confirm the surge line by experimental field testing. For the field tests of incipient surge and surge spike, the raw transmitter signal is monitored and recorded on a high-speed oscillographic recorder or T6050 SG-1:A2 wave-form analyzer. To calibrate the surge limit line, one or several surge tests have to be carried out.
ICS Triplex Turbo Machinery Control Field Surge Testing Procedure In a typical scenario for surge testing a compressor, it is necessary to override some of the protection features of an anti-surge controller (with the T6200 & T6300 controllers these override actions are automatically enabled; already pre-configured). This requires that the controller should be switched to manual mode, and the Surge Control Line (SCL) transgression feature be disabled.
T6050 Operations & Maintenance Guide Actual Strip Chart of Surge Chapter 4 – Operations Surge Avoidance with SurgeGard Figure 8.
ICS Triplex Turbo Machinery Control T6050 SurgeGard™ Maintenance The T6050 SurgeGard™ has no consumable or replaceable components. Once the T6050 SurgeGard™ is in field service, it requires no maintenance and should function for years without failure or replacement under normal conditions. The only field service maintenance one might consider is the T6050 SurgeGard™ Gain Adjustment Procedure.
