Rockwell Antisurge Signal Conditioning

Users 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 Users Guide
Revision History
Issue 1
12/15/04
PD-6050 Dec 04
First issue
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.
T6050 Users 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 purchasers 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.
PD-6050 Dec 04
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.
Hardware & Installation

Guide
_____________________________________________________________________________________________________
T6050 SurgeGard
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
PD-6050 Dec 04
iii
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.......................................................................................................... 8
T6050 Terminations............................................................................................................. 9
T6050 Simplified Schematic.............................................................................................. 10
Typical Field Wiring With A Current Transmitter Input .................................................. 11
Typical Field Wiring With A Voltage Transmitter Input. .11
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:
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.
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
PD-6050 Dec 04
T6050 Hardware & Installation Guide
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
PD-6050 Dec 04
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. Hardware Block Diagram
PD-6050 Dec 04
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. All
electrical parts are mounted on a rigid 1/16 thick fiberglass circuit board.
Terminations
All wiring to and from the T6050 is connected to the integrated terminal blocks on the component
housing enclosure. The terminal blocks have a KRILEN 6.6 polyamide insulating body, nickelplated copper alloy connectors, and pressure screws. The pressure screws are captive and secured
against self-loosening.
PD-6050 Dec 04
PD-6050 Dec 04
Chapter 4 Installation
Chapter 4 - Installation
Site Selection Considerations
The T6050 requires the following conditions during normal operation:
32 to 130F (0 to 55C)
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
Access Considerations
There are very few restrictions on the mounting position of the T6050. The following should be
taken into consideration:
All input/outputs are connected on the termination type electronic component housing.
Adequate wireway space should be provided.
Outdoor installation is not recommended, but can be accomplished if the module is
placed in an appropriate enclosure.
PD-6050 Dec 04
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)
3.15"
(80)
ics triplex
T6050
SurgeGard
2.76"
(70)
2.98"
(75)
FRONT VIEW
SIDE VIEW
Figure 3. Mounting Dimensions
PD-6050 Dec 04
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.
All wiring should be multi-stranded annealed copper with insulation that meets the
requirements of all applicable electrical codes; recommended shielded twisted pair cable for
Analog Input and 4-20 mA Analog Output to reduce the possibility of noise pickup.
Keep all wire runs as short and direct as possible. Long wire runs are vulnerable to picking
up stray electrical noise. Also, long wire runs are costly, but remote mounting may be
necessary because of area classification, convenience, or other extreme field conditions.
Use care when running signal wiring near to or crossing conduit or wiring that supplies
power to motors, solenoids, lighting, horns, bells, etc.
Avoid bringing T6050 wiring into junction boxes which contain other wiring.
AC power wiring should be run in a separate conduit from the T6050 I/O wiring.
CHECK ALL WIRING RUNS THAT ARE TO BE CONNECTED TO THE T6050.
All field device wiring to and from the T6050 is connected on the enclosure integrated terminal
blocks at the sides of the unit. The T6050 terminations are shown in the figure below.
T6050
SurgeGard
4mA
X5
X30
IN +
IN RESISTOR +
RESISTOR LOOP PWR IN +
4-20mA OUT
AC SIG OUT
AC COM OUT
1
2
3
4
5
6
7
8
SIGNAL
TERMINAL
TOP VIEW
Figure 4. T6050 Terminations
PD-6050 Dec 04
IN +
LOOP
PWR IN +
IN -
4-20mA
OUT
AC SIG OUT
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.
The terminal screw should be tightened while holding the wire in place. Check for
proper clamp pressure with a gentle tug on the wire.
Two-Wire Loop Power Wiring
The T6050 two-wire LOOP POWER IN + should be 22-32VDC.
The two-wire Loop Power current requirments are 45 mA surge maximum at power up, 2
mA + Analog Output Value (20 mA maximum) equals 22 mA maximum after power up.
The two-wire Loop Power power requirments are 1.44 watts surge maximum at power
up, 0.7 watts maximum after power up.
Wiring Note 1: Due to the 45 mA current surge maximum at power up, the 22-32 VDC Loop Power
In + at the T6050 SurgeGard Terminal 5 should be from a source that does not limit the current
below 50 mA.
10
PD-6050 Dec 04
IN +
T
IN -
LOOP
PWR IN +
(22-32VDC)
(SEE WIRING
NOTE 1)
UC
4-20mA
OUT
CURRENT
TRANSMITTER
250
Ohm
(0/4-20mA)
7
AC SIG OUT
JUMPER
4
8
AC COM OUT
Figure 6. Typical Field Wiring with a Current Transmitter Input
IN +
LOOP
PWR IN +
(22-32VDC)
(SEE WIRING
NOTE 1)
T
IN -
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. Typical Field Wiring with a Voltage Transmitter Input
PD-6050 Dec 04
11
12
PD-6050 Dec 04
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 Filtering
differential input band pass (1Hz to 10Hz) amplifier/filter,

A low pass filter (10Hz), absolute-value, peak detector
Analog Output
Signal Type
4-20 mA two-wire loop powered
Load Resistance
<600 ohms
Accuracy
+/- 2 % of full scale
Ripple
100 mV maximum
Power Source
22-32 VDC loop powered externally supplied
Analog AC Signal Output

Signal Type
Filtered, Amplified AC Signal; 0-7 V peak-to-peak, based upon

Analog Input Amplitude, Frequency and Gain Setting
Power Requirements
Loop Powered
22-32 VDC two-wire loop powered through Analog Output
Current Requirements
45 mA surge maximum at power up, 2 mA + Analog Output

Value (20 mA maximum) equals 22 mA maximum after power
up
Power Requirements
1.44 watts surge maximum at power up, 0.7 watts maximum

after power up
PD-6050 Dec 04
13
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 - 50C
0 - 55C
-40 - 70C
Ambient Relative
Humidity
Non-Condensing
5 - 96 %
5 - 96 %
5 - 96 %
Vibration
5 60 Hz at 0.030 inch total excursion along X, Y, and Z axes
Chemical Corrosion Resistance
Conformal coating is applied to board for protection against

H2S, SO2, and traces of sand, salt, and dust.
Mounting
32 or 35 mm width standard DIN/EN rail
Dimensions
Height
2.98 (75 mm)
Width
3.15 (80 mm)
Depth
0.79 (20 mm)
Weight
0.15 lb (68 g)
Agency Approvals
US Patent
14
PD-6050 Dec 04
Operations &
Maintenance Guide
_____________________________________________________________________________________________________
T6050 SurgeGard
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

T6050 SURGEGARD BENEFITS .................................................................................................4
Increased energy savings ................................................................................................................4
Identifies and corrects for shifts in surge point/line .......................................................................4
Prevents Compressor Trips............................................................................................................4
Facilitates Actual Surge Point Line/ Testing..................................................................................4
HARDWARE FUNCTION ................................................................................................................4
Hardware Block Diagram ...............................................................................................................4
Typical Signal Conditioning...........................................................................................................5
Simplified Schematic......................................................................................................................5
TYPICAL T6050 FIELD WIRING WITH A CURRENT TRANSMITTER.....................................6
TYPICAL T6050 FIELD WIRING WITH A VOLTAGE TRANSMITTER ....................................6
Chapter 3 Applications ......................................................................................... 7

TECHNOLOGY PRINCIPLE ............................................................................................................7
APPLICATION CONSIDERATIONS ...............................................................................................7
Multi-Stage (body) Machine or machines with multiple discharge ports ......................................7
AI Activation Delay........................................................................................................................8
Flow Transmitter Mounting............................................................................................................8
TYPICAL T6050 SURGEGARD APPLICATIONS......................................................................8
Motor Driven Compressor Applications ........................................................................................8
Turbine Driven Compressor Applications......................................................................................8
Pipeline Compressor Applications .................................................................................................9
Motor Driven Centrifugal Blower Applications.............................................................................9
Turbine GG Applications ...............................................................................................................9
T6050 SurgeGard Stand-Alone Applications.............................................................................9
T6050 SURGEGARD FACTORY CALIBRATION PROCEDURE...........................................10
Equipment Required for Factory Calibration Procedure..............................................................10
Factory Calibration Procedure......................................................................................................10
Chapter 4 - Operations........................................................................................... 11
T6050 SURGEGARD FIELD GAIN ADJUSTMENT PROCEDURE........................................11
ACTUAL SURGE LIMITS ..............................................................................................................11
SURGE TEST WAVE-FORM ANALYZER...................................................................................12
FIELD SURGE TESTING PROCEDURE .......................................................................................13
Chapter 5 - Maintenance........................................................................................ 15
T6050 SURGEGARD MAINTENANCE.....................................................................................15
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 ................................................. 5
T6050 SurgeGard Simplified Schematic ......................................................................... 5
Typical T6050 Field Wiring With A Current Transmitter................................................. 11
Typical T6050 Field Wiring With A Voltage Transmitter.. 6
Typical Inlet ACFM vs Polytropic Head Ft-lb/lb Graph..12
PD-6050 Dec 04
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.
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:
This chapter contains information about this document and related reference documents.

This chapter presents an overview of the product as a whole, including typical applications.
Chapter 3 - Applications
This chapter describes the typical applications of the T6050 SurgeGard.
Chapter 4 - Operations
This chapter explains the typical operations of the T6050 SurgeGard, including field gain
adjustment procedure.
Chapter 5 - Maintenance
This chapter provides general maintenance required.
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.
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.
Extremely advantageous, though not required, is experience with Windows-based software programs,
compressor operation, and normal operations experience within a plant environment.
Reference Documents
PD-6050 Dec 04

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 3. T6050 General Appearance
PD-6050 Dec 04
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.
Identifies and Corrects for Shifts in Surge Point/Line

Incipient surge detection continuously monitors the compressors operating point behavior in relation
to symptoms of impending surge and allows for automatic correction of surge point/line shifts.
Prevents Compressor Trips

Minimizes the impact of primary surge control and field instrument malfunction by providing
incipient fall-back and override control. Thus, even in the event of key transmitter (such as flow)
failures, the compressor will stay on-line, increasing plant availability.
Facilitates Actual Surge Point/Line Testing

In addition to surge monitoring and override control, the incipient surge detection module facilitates
testing of actual surge points, minimizing operation interference.
Hardware Function
Hardware Block Diagram
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 4. Hardware Block Diagram

4
PD-6050 Dec 04
Typical Signal Conditioning
Figure 3. Typical Internal T6050 SurgeGard Signal Conditioning
Simplified Schematic
IN +
LOOP
PWR IN +
IN -
4-20mA
OUT
AC SIG OUT
AC COM OUT
250
Ohm
RESISTOR +
*
RESISTOR -
Remove jumper
for voltage input
PD-6050 Dec 04

Figure 4. T6050 SurgeGard Simplified Schematic
Typical T6050 Field Wiring with a Current Transmitter
IN +
LOOP
PWR IN +
(22-32VDC)
UC
IN -
4-20mA
OUT
CURRENT
TRANSMITTER
250
Ohm
(0/4-20mA)
7
AC SIG OUT
JUMPER
4
8
AC COM OUT
Figure 5. Typical T6050 Field Wiring with a Current Transmitter
Typical T6050 Field Wiring with a Voltage Transmitter
PD-6050 Dec 04
IN +
LOOP
PWR IN +
(22-32VDC)
UC
IN -
4-20mA
OUT
VOLTAGE
TRANSMITTER
250
Ohm
3
7
AC SIG OUT
*
4
8
AC COM OUT
Remove jumper
for voltage input
Figure 6. Typical T6050 Field Wiring with a Voltage Transmitter
Chapter 3 - Applications
Technology Principle
When applying the incipient surge detection module T6050 SurgeGard it is important to understand the
basic technology principle
Fluidic oscillations occur as a precursor to surge. This behavior is the result of momentary backflow at
the inlet of the impeller (the re-circulation zone). Since the momentary backflow is more prevalent at
the outer annulus (wall) of the re-circulation zone than at the central area, it is important that the fluidic
oscillation detection conditioning is of fast response. The speed of response must be such that it does not
obstruct the oscillation signature while allowing for low-pass filtering of the normal flow rate
oscillations.
Fluidic oscillations can be measured as: I torsional load (motor-driven), Flow/Pressure at the inlet of the
compressor or at the discharge (preferably direct at the back of the impeller casing) of the compressor.
See applications below.
In consideration of the fluidic oscillations speed in the re-circulation zone, the analog circuitry of the
T6050 SurgeGard is more efficient (continuous sampling rate) than the software version contained in
the T6100 and T6200 (sampling rate of 2-5 ms) and is therefore recommended for most applications.
PD-6050 Dec 04
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. Among the challenges are:
effective surge control, automation of start-up, adaptable capacity control, optimum load sharing, turbine
overspeed protection and operating close to the process limit to meet increasing production requirements and
efficiency. Most compressor control systems currently on the market are not up to task. They rely on
conventional calculated anti-surge techniques with limited fallback capabilities and inadequate control actions.
Hence, there is risk on tripping a compressor due to surge or field instrument malfunction. Therefore very often
these systems are configured with conservative safety margins that reduce the operating envelope of a
compressor. This leads to lower yield, overall production decrease, loss of revenue and loss of operating profits.
The T6050 SurgeGard with its capability to detect incipient surge (a pre-cursor to actual surge) offers a
reliable solution to increase energy savings, identify and correct for shifts in surge points/line and to prevent
compressor trips. This is achieved by the implementation of patented fluidic oscillation measurement which
determines the actual surge points, therefore allowing closer operation to surge limits, providing a wider
compressor operating window and compensating for certain field transmitter malfunctions (offering fallback
features). The following is an application overview of the T6050 SurgeGard:
Multi-Stage (body) Machines or Machines with Multiple Discharge

Ports
It is necessary to use a differential pressure flow transmitter for each stage or port. Since the differential pressure
signal sensitivity to the velocity pressure changes is critical for detection of fluidic backflow oscillations, it is
important that the flow transmitter does not have a lag of greater than 100 milliseconds. For some applications a
high speed transmitter with a very small sampling delay (ideally less than 7 milliseconds, Statham PD3000 or
equal transmitter) is necessary.
AI Activation Delay
The analog input (AI) from the SurgeGard (4-20 mA output of SurgeGard) is ignored/bypassed (for several
minutes in applications for compressors with large volumes) in the anti-surge compressor controller configuration
until the machine is on-line and starting to build a discharge head (already pre-configured in the T6100, T6200
and T6300).
Flow Transmitter Mounting

If a flow transmitter is used as the incipient surge signal, the transmitter should be mounted directly above the
flow element with no connecting tubing where liquid can condense and accumulate. Since many problems have
been encountered on start-up, incipient surge protection and surge control, ICS TRIPLEX recommends this
simple approach. Alternative installation methods can be used successfully, but a careful review of adherence to
clean and short impulse lines is required.
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). However, where multiple electric driven machines are powered from the same grid, it is necessary to
apply a fall-back level (already pre-configured in T6100/6200/6300) to mask mutual noise from adjacent
machines being started or stopped. Therefore, only Incipient-Surge-PID signals within the limits of the fallback
levels are ramped forward to a safe signal selector, which is ored with the primary Anti-Surge-PID output to
ease the compressor away from a region of instability. It is an optional configuration facility to increment the
surge control line by a small percentage for each incipient surge occurrence. The offset may be cancelled
automatically at the next shutdown of the compressor, or remain in the configuration until the next surge test.
Turbine Driven Compressor Applications

The most suitable parameter for incipient surge detection on turbine-driven machines is normally a differential
flow transmitter signal. Since the inlet flow or eye differential pressure signal sensitivity to the velocity pressure
changes is critical for detection of fluidic backflow oscillations, it is important that the flow transmitter does not
have a lag of greater than 100 milliseconds. For rapid process dynamics (small compressor, rapid upstreamdownstream dynamics, etc), it must be a simple analog device with no filtering - less than 7 milliseconds delay
(Statham PD3000 or equal transmitter, www.gultonstatham.com ). It should ideally be located in the suction
manifold or compressor eye, downstream of any throttling device. A discharge flow or pressure transmitter is
suitable for certain high pressure ratio applications. The incipient surge signature should be verified before
enabling SurgeGard if a discharge pressure transmitter is used. For some applications, for example when the
suction flow signal quality is questionable (excessive noise during normal operation), a combination of suction
and discharge flow measurement may be applied. The primary anti-surge controller configuration must provide
for high signal selection (already pre-configured in the T6100, T6200 & T6300).
Pipeline Compressor Applications

The same incipient surge parameters apply as for motor or turbine driven applications described above. However,
on the detection of surge spikes the signal selection criteria is different. Due to the traditionally low pressure ratio
of pipeline compressors, together with high capacity, the most volatile surge spike parameter is the pressure
transmitter at each compressors discharge. The anti-surge-PID and incipient surge PID should be fast tuned to
the head/flow surge control line, while the surge spike detection and pressure PID should be fast tuned to the
compressor discharge transmitter. This provides protection from mutual interaction between stations, whereby
an unplanned trip of a downstream compressor causes a pressure spike to travel up the pipeline to cause a highpressure shockwave. Typically, this wave causes high vibration trips, as it momentarily causes a rapid surge line
transgression. The suction and discharge SurgeGards, in conjunction with the incipient and surge spike loops,
alleviate this shock by identifying the pressure spike and easing open the recycle valves to a pre-set percentage
for a given time (determined by testing) until the line has stabilized once more. The timing of the surge spike
action depends on the distance between stations and is set per application.
Motor Driven Centrifugal Blower Applications

9
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). However,
where multiple electric motor driven blowers are powered from the same grid, it is necessary to apply a fall-back
level to mask mutual noise from adjacent blowers (or other motor-driven equipment) being started or stopped.
Turbine GG Applications
The most suitable parameter for incipient surge detection on turbine GG is normally the compressor discharge
pressure transmitter signal. Since the pressure signal sensitivity to the velocity pressure changes is critical for
detection of fluidic backflow oscillations, it is important that the pressure transmitter does not have a lag of
greater than 2 milliseconds (Viatran model 548 or equal transmitter, www.viatran.com ). The transmitter should
be located at the compressor discharge manifold.
T6050 SurgeGard Stand-Alone Applications

Same signal selection criteria as for motor driven compressors The T6050 SurgeGard is normally powered by
any two-wire 4 - 20mA primary analog channel (24 Volt DC) as found in typical ICS Triplex or third-party DCS
or PLC control system. The incipient surge detection/override function complements the primary anti-surge
control algorithm. It will enhance the capabilities of most compressor control systems, especially those with
fairly slow loop scan rates. The T6050 SurgeGard can identify and correct for shifts in the compressors surge
point/line. It can also function as an independent backup to the primary anti-surge control system. However, it is
essential that if applied independently and without compressor startup interlock (SurgeGard function bypass)
that conservative SurgeGard Gain tuning is applied to compensate for fluidic oscillations during compressor
startup (build up of discharge head).
T6050 SurgeGard Factory Calibration Procedure

The T6050 SurgeGard output typically feeds into the Incipient Surge PID on the Anti-Surge controller. As
mentioned above, the output of Incipient Surge PID is used in parallel (via a high selector function) with the
Primary Anti-Surge PID control loop to control the recycle/blowoff valve. Based on the selected process signal,
current (motor driven machines= I or KW) flow (h) pressure, etc. if such information is provided the
T6050 SurgeGard is calibrated at the factory such that the output of the Incipient Surge PID signals an
incipient surge only under the correct conditions. This calibration can be accomplished using the following
procedure.
Each T6050 SurgeGard is tested at the factory for complete 4-20mA output range and the two potentiometers
on the T6050 are set to generate this complete range of output signal. The following paragraphs describe the steps
to be executed to perform this same calibration procedure.
Equipment Required for Factory Calibration Procedure

A T6050 SurgeGard, a waveform generator, an oscilloscope, a digital voltmeter, a 250-ohm precision 1 watt
resistor, a 24 Volt DC power supply, test clips, and a separate 0 5 VDC power supply.
10
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. Be sure the Jumper
across the T6050 terminals 3 and 4 has been removed.
Turn on the 24 VDC power supply.
Set the waveform generator output to 0 Hz sinusoidal waveform and amplitude of 0.5 Volts peak-topeak. Adjust the 4 mA (ZERO) potentiometer so that the output voltage from the T6050 across
terminal 6 and the negative (-) terminal of the 24 VDC power supply is 1.0 VDC.
Set the waveform generator output to 10 Hz sinusoidal waveform and amplitude of 0.50 Volts peakto-peak. Adjust the X5 X30 (GAIN) potentiometer so that the output voltage from the T6050 across
terminal 6 and the negative (-) terminal of the 24 VDC power supply is 5.0 VDC.
Repeat steps v and vi until the 1.0 VDC and 5.0 VDC are reached respectfully. Now set the
waveform generator output to 3 Hz and amplitude of 0.5 Volts peak-to-peak; the output voltage from
the T6050 across terminal 6 and the negative (-) terminal of the 24 VDC power supply should be 4.4
VDC.
Set the waveform generator output to 10 Hz and amplitude of 0.30 Volts peak-to-peak; the output
from the T6050 across terminal 6 and the negative (-) terminal of the 24 VDC power supply should
be 3.3 VDC.
Remove the waveform generator from the input terminals 1 and 2 of the T6050.
Connect the 0 - 5 VDC power supply across the input terminals 1 (+) and 2 (-) of the T6050. Set the
output of the 0 - 5 VDC power supply to any voltage between 1 and 5 VDC and turn on the power
supply; adjust the output of the 0 5 VDC power supply between 1 and 5 VDC, the output voltage
from the T6050 across terminal 6 and the negative (-) terminal of the 24 VDC power supply should
stay at 1 VDC.
Notes:
The T6050 SurgeGard output voltage at terminals 5 and 6 has up to 100 mV ripples.
It is important to note that each T6050 SurgeGard gain needs to be adjusted for each individual
machine (each stage, for multi-stage compressors) while in service. See Field Surge Testing following
pages.
11
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. ICS Triplex recommends adjusting the gain (X5 X30 potentiometer) of the
T6050 to show full incipient surge (20 mA at the T6050 output Terminals 5 and 6) when the
oscillations at the input Terminals 1 and 2 are 10% of the full range of the transmitter. Thus, for the
example case, the output of the T6050 at Terminals 5 and 6 should be 20mA when the input signal
indicates oscillation amplitudes of 5.6 mA. This translates to a voltage swing of 0.40 V peak-to-peak
(10Hz) at the input Terminals 1 and 2 of the T6050 (across the internal 250-ohm resistor)
corresponding to a 20mA output from the T6050 Terminals 5 and 6.
Note that if it is desired to indicate a full scale incipient surge from 25% of the full range of the
transmitter (instead of the 10% as used in the example above), the gain (X5 X30 potentiometer)
should be adjusted so that the output of the T6050 at Terminals 5 and 6 should be 20mA when the
input signal at Terminals 1 and 2 indicate oscillation amplitudes of 8.0 mA. This translates to a
voltage swing of 1.00 V peak-to-peak (10Hz) at the input Terminals 1 and 2 of the T6050 (across the
internal 250-ohm resistor) corresponding to a 20mA output from the T6050 Terminals 5 and 6.
Actual Surge Limits

A request to test the compressors surge limits in order to determine the true surge control line is
understandably unpopular because of the perceived risk of damage to the machine. However, the
anti-surge control system minimizes this danger by allowing to quickly open the recycle/blow-off
valve upon detection of incipient surge (flow reversal at the inlet of the compressor impeller, the recirculation zone).
Field testing of surge points is important since the actual compressor surge limits usually differ
significantly from the limits indicated by the compressor map. The surge line shown on a
manufacturers compressor map results from an analysis of the compressor design and is not
normally verified by testing with the actual gas. The map data is usually conservative. Also, piping
arrangements on the compressor suction side can account for significant surge point discrepancies.
Accommodating these inaccuracies often requires unnecessarily wide surge margins, which can
result in excessive recycling or blow-off. Therefore, a strong economic incentive exists to establish
12
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. For variable speed
compressors (turbine driven units) the surge test should, in addition to the 100 percent RPM, be taken
at several speed settings in order to establish a reasonably complete surge line. The T6200 and
T6300 controllers will automatically store the test points. The points are then linearly interpolated
by a look-up table function to generate a precise surge control line.
Figure 7. Typical Inlet ACFM vs Polytropic Head Ft-lb/lb Graph
Surge Test Wave-form Analyzer

To accurately verify the compressors incipient surge oscillation signature, it is recommended to use
a waveform analyzer. There are several packages available. ICS Triplex offers the T6050 SG-1:A2
low cost wave-form analyzer starter kit, (model DI-194RS from DATAQ), which records data with
10-bits accuracy at rates of 240 samples/second. The module has four 10V analog inputs, two
digital inputs for remote start/stop and remote event marker control and a convenient serial data port
interface to your PC. The included software is Windows 95, 98, NT, ME, 2000, and XP compatible.
Refer to www.dataq.com . The wave-form analyzer speed of 240 samples/sec is adequate for large
process compressors. For rapid oscillation signature analysis applications (small compressors) it is
recommended to use a high-speed waveform monitor.
13
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. The
compressor can now be throttled in order to emulate a potential process upset, or reduced capacity.
Once instability is detected in the compressor instrumentation, the anti-surge loop (ASPID) can then
be switched to automatic mode, in order to open the recycle valve rapidly before the machine
actually reaches the Surge Limit Line. The Incipient Surge control loop can now be used to assist in
detecting the on-set of surge. It is important that the Incipient Surge PID should also be placed in
MANual with a self tracking feature, so that its Output will remain at 0%. The signal from the T6050
SurgeGard should now be observed on a trend display or a wave-form analyzer plot, so that the
oscillations of the selected parameter, (motor current, flow, suction/discharge pressure for example)
can be monitored. The T6050 SurgeGard will integrate these oscillations, to produce a process
value (PV) proportional to the signal noise plus process noise as the compressor approaches surge. It
is normally necessary to adjust the gain of the T6050, in order to have the right amount of sensitivity
for each compressor installation. A T6050 that is set too sensitive will result in early opening of the
recycle valve even though the compressor may be far away from surging.
Once the optimum gain setting has been determined, the trend or wave-form analyzer plots can be
used to repeat surge testing at different base conditions. Each test can be terminated at equal signal
amplitude occurrences, without any necessity to risk actual surge damage by throttling the
compressor too far. An accurate surge limit line can now be established safely and in a repeatable
manner for all future surge tests. Once surge testing has been completed, the anti-surge controls can
be restored to full operating conditions, the Incipient Surge PID Loop can be placed into automatic
mode, with a test-proven set-point for future incipient surge override duty. It is also recommended
that the Incipient Surge PID control block should feature a set-point balance and ramp (standard in
the T6100, T6200 & T6300), so that the set-point will remain at the entered value, as found during
the tests.
The Incipient Surge PID Loop output must be ignored during start-up cycles (configured such that
the Incipient Surge PID loop switches to AUTOmatic only after the start-up timer has expired;
already pre-configured in the T6100, T6200 & T6300), due to the unstable conditions which may
manifest themselves until the machine has stabilized and started to build some head pressure. For
motor I or KW incipient surge parameters, it is also important to use a high signal fallback feature
(FB function; already pre-configured in the T6100, T6200 & T6300), in order to mask out motor
transducer noise from adjacent machines starting or stopping, when powered from the same electrical
power grid.
14
Actual Strip Chart of Surge
Chapter 4 Operations
Surge Avoidance with SurgeGard
Figure 8. Typical Surge Graph and Surge Avoidance Graph with T6050 SurgeGard
15
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.
16

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Users Guide

ICS Triplex Turbo Machinery Control

T6050 Users Guide

ICS Triplex Turbo Machinery Control

To prevent ignition of hazardous atmospheres, do not remove covers of Class I Division I

T6050 Users Guide

ICS Triplex Turbo Machinery Control

Electrostatic Discharge Awareness

Hardware & Installation

Chapter 2 - Product Overview ................................................................................. 3

Chapter 5 - Specifications ..................................................................................... 13

ICS Triplex Turbo Machinery Control

T6050 General Appearance ................................................................................................. 3

T6050 Operations & Maintenance Guide

About This Manual

Chapter 2 - Product Overview

Chapter 3 - Hardware Descriptions

ICS Triplex Turbo Machinery Control

User Experience Prerequisites

T6050 Operations & Maintenance Guide

T6050 Hardware & Installation Guide

Chapter 2 Product Overview

Chapter 2 - Product Overview

Figure 1. T6050 General Appearance

ICS Triplex Turbo Machinery Control

A block diagram of the hardware is shown in the figure below.

Figure 2. Hardware Block Diagram

T6050 Hardware & Installation Guide

Chapter 3 Hardware Descriptions

Chapter 3 Hardware Descriptions

ICS Triplex Turbo Machinery Control

T6050 Hardware & Installation Guide

5 to 96% relative humidity

Limited exposure to non-conductive dust and combustible dust and lint

ICS Triplex Turbo Machinery Control

Unpacking and Inspection

Figure 3. Mounting Dimensions

T6050 Hardware & Installation Guide

CHECK ALL WIRING RUNS THAT ARE TO BE CONNECTED TO THE T6050.

ICS Triplex Turbo Machinery Control

Figure 5. T6050 Simplified Schematic

The stripped portion of the wires should be 5/16 (8 mm) long.

Two-Wire Loop Power Wiring

The T6050 two-wire LOOP POWER IN + should be 22-32VDC.

T6050 Hardware & Installation Guide

Figure 6. Typical Field Wiring with a Current Transmitter Input

Figure 7. Typical Field Wiring with a Voltage Transmitter Input

ICS Triplex Turbo Machinery Control

T6050 Hardware & Installation Guide

-10 - +10 V, 0-5 or 1-5 VDC; 0-20 or 4-20 mA

+/- 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

2- or 4-wire; transmitter excitation supplied from external source

differential input band pass (1Hz to 10Hz) amplifier/filter,

4-20 mA two-wire loop powered

+/- 2 % of full scale

22-32 VDC loop powered externally supplied

Analog AC Signal Output

Filtered, Amplified AC Signal; 0-7 V peak-to-peak, based upon

22-32 VDC two-wire loop powered through Analog Output

45 mA surge maximum at power up, 2 mA + Analog Output