ts110 self-powered controller operations guide rev. 5
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Houston, Texas
TS110 Self-Powered Controller
October 2009
TS110 Operations Guide
Revision 5Document No. 4912-0003A
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October 2009 Rev. 5
Copyright
Information in this document is subject to change without notice. Companies, names and data used in
examples herein are fictitious unless otherwise noted. No part of this document may be reproduced ortransmitted in any form or by any means, electronic or mechanical, for any purpose, without the
express written permission of Tri-Sen Systems Corporation.
20082009 by Tri-Sen Systems Corporation. All rights reserved.
Microsoft, Windows, and Windows NT are registered trademarks of Microsoft Corporation.
Modbus is a registered trademark of Modicon Corporation, a division of Schneider.
All other brands or product names may be trademarks or registered trademarks of their respective
owners.
Printed in the United States of America.
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Revision History
Rev. 0 September 1991 Initial Issue.
Rev. A November 1991 General technical revisions.
Rev. B December 1991 General technical revisions.
Rev. C January 1992 Technical changes to sections 5 and 6 only.
Rev. D January 1992 Technical changes to section 6; added min/max output
paragraph.
Rev. E March 1993 Revised Figures 7-1, 7-2, 7-3, and 7-4 for CSA approval.
Rev. F July 1993 Revised the following pages:
i, iv, ix, x, xi, xiii, xiv, 1-1, 2-1, 2-5, 3-1, 3-7, 3-9, 3-10, 5-1, 5-2,
5-8, 5-9, 5-10, 6-7, 7-3, 7-4, 7-5, 7-6, 7-7, 7-13, 7-14, 7-15, 8-2,
8-3, and 8-4.
Drawing 91-1026 was revised and
Drawing 92-2163 was added to Section 7.
Rev. 1 July 1998 General editorial revision including format for A4.
Rev. 2 June 1999 Changes to Figures 5, 6 and 15; and to last paragraph of
Chapter 5.
Rev. 3 Oct 2003 Add calibration procedure for DT9. Update address/legal name.
Update certifications.
Rev. 4 Dec 2008 Made revisions for Tri-Sen acquiring the product; including
company name and logo, address, and contact information.
Rev. 5 Oct 2009 Added Factory Mutual (FM) certification of the TS110.
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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 resultin personal injury and/or property damage.
To prevent ignition of hazardous atmosphere, do not remove covers of Class I Division I(explosion-proof) units with power applied.
All servicing should be performed by qualified technicians. Dangerous voltages may be presenton the circuit boards.
Use extreme caution when working around power-input cables. These cables may havepotentially 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 offthe 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 overspeed (overtemperature oroverpressure, 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 toprevent 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 connectionsagainst 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 Tri-Sen equipment,
contact Tri-Sen.
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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, Tri-Sen cannot assume
responsibility or liability for actual use based upon the illustrative uses and applications.
In no event will Tri-Sen be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
TRI-SEN DISCLAIMS ANY IMPLIED WARRANTY OR FITNESS FOR A PARTICULAR
PURPOSE.
No patent or copyright liability is assumed by Tri-Sen 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 Tri-
Sen, is prohibited.
Warranty
All Tri-Sen products are warranted to be free of defects in materials and workmanship for a period of
twelve months from the date of shipment. In case of failure, Tri-Sen liability shall be limited to
furnishing, but not installing, necessary repair parts; or at the option of Tri-Sen, 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 Tri-Sen. 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.
Tri-Sen will determine if warranty applies when material is received at its manufacturing location. A
purchase order and a Returned Merchandise Authorization (RMA) must accompany all returned
material. The purchase order number as well as the RMA number should be clearly marked on the
outside of the shipping container. Tri-Sen Customer Service Department 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 Tri-Sen, or to impose any liability on behalf of Tri-Sen, or to
impose any obligation on it in connection with the sale of any equipment other than as stated above.
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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. Beforehandling 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 notpick up components. Do nottouch the printed circuit board.
Do notremove 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 table mat.
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 notsubject components to sliding movements over any surface at any time.
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Tri-Sen Office
Tri-Sen Systems Corporation17625 El Camino Real
Houston, Texas 77058Phone: +1-281-286-9700
Fax: +1-281-286-9704
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Contents
COPYRIGHT ................................................................................................................................... IIIREVISION HISTORY ..................................................................................................................... IVWARNINGS! .................................................................................................................................... VDISCLAIMER .................................................................................................................................. VI
WARRANTY ................................................................................................................................... VIELECTROSTATIC DISCHARGE AWARENESS ........................................................................ VII
Tri-Sen Office ........................................................................................................ viii Contents .................................................................................................................. ix
ILLUSTRATIONS ........................................................................................................................... XIChapter 1 - Introduction .......................................................................................... 1
1.1 ABOUT THIS MANUAL ......................................................................................................... 11.2 DOCUMENTATION CONVENTIONS ................................................................................... 21.3 USER EXPERIENCE PREREQUISITES ................................................................................ 21.4 REFERENCE DOCUMENTS .................................................................................................. 2
Chapter 2 - Product Overview ................................................................................. 32.1 FEATURES ............................................................................................................................... 42.2 TYPICAL APPLICATION ....................................................................................................... 52.3 COMPONENTS ........................................................................................................................ 6
Chapter 3 - Component Descriptions ................................................................... 103.1 DIGITAL TACHOMETER..................................................................................................... 103.2 PICKUPS OK LED ................................................................................................................. 103.3 STOP/RUN/START SWITCH ............................................................................................... 103.4 LOCAL SPEED SETPOINT CONTROL ............................................................................... 103.5 M100 CONTROLLER ASSEMBLY ...................................................................................... 11
3.5.1 M100 Speed Signal........................................................................................................ 133.5.2 M100 Power Supply ...................................................................................................... 133.5.3 M100 Setpoint Circuit ................................................................................................... 133.5.4 M100 Control Section ................................................................................................... 133.5.5 M100 Speed Switches ................................................................................................... 14
3.6 M100 TERMINAL STRIPS .................................................................................................... 153.7 AUXILIARY TERMINAL STRIP ......................................................................................... 153.8 9-VOLT BATTERY HOLDER .............................................................................................. 163.9 OVERSPEED TEST SWITCH ............................................................................................... 163.10 I/P TRANSDUCER ................................................................................................................. 163.11 INPUT I/P AIR FITTING ....................................................................................................... 163.12 OUTPUT I/P AIR FITTING ................................................................................................... 163.13 FIELD WIRING CONDUIT CONNECTIONS ...................................................................... 163.14 PURGE AIR FITTING ............................................................................................................ 163.15 PNEUMATIC SETPOINT FITTING ..................................................................................... 163.16 ENCLOSURE ......................................................................................................................... 163.17 MAGNETIC SPEED PICKUPS ............................................................................................. 173.18 GEAR ...................................................................................................................................... 173.19 FINAL ACTUATOR .............................................................................................................. 17
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Chapter 4 Specifications and Certi fications ..................................................... 194.1 SPECIFICATIONS .................................................................................................................. 194.2 CERTIFICATIONS ................................................................................................................. 21
Chapter 5 - Configuration ...................................................................................... 235.1 JUMPER DESCRIPTIONS ..................................................................................................... 235.2 CONFIGURATION SPECIFICATION SHEET ..................................................................... 27
5.2.1 Selection of Frequency Range ....................................................................................... 285.2.2 Jumper Configuration .................................................................................................... 28
Chapter 6 - Calibration Procedures ...................................................................... 316.1 DIGITAL TACHOMETER ..................................................................................................... 31
6.1.1 DT6 Digital Tachometer ................................................................................................ 316.1.2 DT9 Digital Tachometer ................................................................................................ 33
6.2 M100 CALIBRATION PROCEDURE ................................................................................... 35Chapter 7 - Installation........................................................................................... 41
7.1 LOCATION & MOUNTING .................................................................................................. 417.1.1 Choosing a Location for the TS110Controller .............................................................. 417.1.2 Mounting ........................................................................................................................ 41
7.2 FIELD WIRING FOR STANDARD INSTALLATION ......................................................... 43M100 Termination Board Wiring Details ............................................................................... 45
7.3 FIELD WIRING FOR OPTIONAL CONFIGURATIONS ..................................................... 477.3.1 Remote STOP/RUN/START Switch ............................................................................. 477.3.2 Overspeed Trip Relay .................................................................................................... 49
7.4 PNEUMATIC INSTALLATION ............................................................................................ 507.4.1 Piping ............................................................................................................................. 507.4.2 Optional Pneumatic Speed Setpoint............................................................................... 507.4.3 Final Actuator ................................................................................................................ 50
7.5 HYDRAULIC ACTUATOR SYSTEMS INSTALLATION .................................................. 537.6 MAGNETIC SPEED PICKUPS INSTALLATION ................................................................ 537.7 GEAR INSTALLATION FOR SPEED SENSING ................................................................. 54
Chapter 8 - Operation............................................................................................. 558.1 STARTUP ................................................................................................................................ 55
8.1.1 Battery By-Pass Start ..................................................................................................... 558.1.2 4- 20-mA Start ................................................................................................................ 558.1.3 Remote Start ................................................................................................................... 568.1.4 Manual Loading Station Start (Option) ......................................................................... 56
8.2 TUNING .................................................................................................................................. 568.2.1
Gain and Integral ............................................................................................................ 56
8.2.2 Derivative ....................................................................................................................... 578.2.3 Reduced Gain Band ....................................................................................................... 588.2.4 Droop ............................................................................................................................. 58
8.3 OVERSPEED TEST (MECHANICAL) .................................................................................. 598.4 ELECTRONIC OVERSPEED ................................................................................................. 608.5 UNDERSPEED SWITCH ....................................................................................................... 60
Chapter 9 - Maintenance ........................................................................................ 61Chapter 10 - Troubleshooting ............................................................................... 63
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Illustrations
Figure 1. TS110Self-Powered Controller, Front View .......................................................................... 3
Figure 2. TS110Self-Powered Controller, Inside View ......................................................................... 4Figure 3. TS110Typical Application ..................................................................................................... 5
Figure 4. TS110Front View, Component Locations ............................................................................. 7
Figure 5. TS110Front View with Door Open, Component Locations .................................................. 8
Figure 6. TS110Bottom View, Component Locations .......................................................................... 8
Figure 7. Special High-Output Magnetic Speed Pickup ........................................................................ 9
Figure 8. M100 Controller Assembly .................................................................................................. 11
Figure 9. M100 Block Diagram ........................................................................................................... 12
Figure 10. Calibration/Configuration Diagram - Jumpers ................................................................... 26
Figure 11. DT9 Programming Screens ................................................................................................. 33
Figure 12. Calibration/Configuration Diagram - Potentiometers ......................................................... 36
Figure 13. Calibration/Configuration Diagram - Test Points ............................................................... 37
Figure 14. Mounting Dimensions ......................................................................................................... 42Figure 15. Standard Field Wiring ......................................................................................................... 44
Figure 16. Field Wiring Detail ............................................................................................................. 46
Figure 17. Field Wiring for Remote Start of a Backup Turbine Using a Second TS110..................... 47
Figure 18. Field Wiring for Remote Stop Using 4-20 mA Signal with N.O. or N.C. Switch .............. 48
Figure 19. Field Wiring for Overspeed Trip Relay .............................................................................. 49
Figure 20. Pneumatic Installation, General Guidelines ....................................................................... 51
Figure 21. Pneumatic Installation, Diaphragm Actuator with Air Booster .......................................... 52
Figure 22. Pneumatic Installation, Piston Actuator with Positioner .................................................... 52
Figure 23. Reduced Gain Band ............................................................................................................ 58
Figure 24. Overspeed Trip Test ........................................................................................................... 59
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Chapter 1 - Introduction 1
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Chapter 1 - Introduction
The TS110Self-Powered Controller is a low-cost digital electronic controller, designed as a NEMA
4X compliant, variable speed PID (Proportional, Integral, Derivative) controller with a single control
output. It replaces mechanical-hydraulic controllers that require frequent maintenance and overhauls.
1.1 About This Manual
As its name implies, this manual is a guideto operating the TS110. In-depth user training is available
from Tri-Sen.
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 - IntroductionThis chapter contains information about this document and related reference documents.
Chapter 2 - Product Overview
This chapter presents an overview of the product, including a typical application. Chapter 3 - Component Descriptions
This chapter describes each component of a TS110.
Chapter 4 - SpecificationsThis chapter provides all TS110specifications.
Chapter 5 - ConfigurationThis chapter describes how to configure a TS110for most applications.
Chapter 6 - Calibration ProceduresThis chapter explains how to calibrate the tachometer and the M100.
Chapter 7 - InstallationThis chapter provides mounting and wiring details.
Chapter 8 - OperationThis chapter includes discussions of the various TS110operating modes, as well as
tuning instructions.
Chapter 9 - MaintenanceThis chapter provides minor maintenance information.
Chapter 10 - TroubleshootingThis chapter describes how to trouble shoot the TS110for optimum performance.
By reading this manual, you will be able to:
Understand the components of the TS110Self-Powered Controller.
Configure all control, speed, pressure and synchronization parameters.
Configure all analog inputs, analog outputs, digital inputs, digital outputs and pressureinputs.
Configure all analog trips and alarms.
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1.2 Documentation Conventions
This manual uses the following typographic conventions:
Example DescriptionNOTE Notes contain supplementary information.
CAUTION!
This symbol precedes information about potential equipment damage.
WARNING!
This symbol precedes information about potential personnel hazards.
1.3 User Experience Prerequisites
To use the TS110effectively, users should have some experience with the use of digital control
systems, or have an instrumentation background.
Extremely advantageous, though not required, is experience with turbine control systems, and normal
operations experience within a plant environment.
1.4 Reference Documents
Documentation provided with other components of a system containing a TS110.
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Chapter 3 - Component Descriptions 5
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2.2 Typical Application
The TS110System utilizes one or two high power magnetic pickup(s) for power and speed signal.
The tooth of a ferrous gear passing under the magnetic pickup creates an AC pulse. This pulse is
converted to a DC voltage to power the controller. The pulse rate (or frequency) is also converted
into a DC voltage that is compared to a setpoint voltage. The difference is sent through a
Proportional/Integral/Derivative loop and converted to a 1-5 mA output signal.
The 1-5 mA signal is sent to a current to pressure (I/P) transducer which converts the signal to a 3-15
psi low consumption air signal.
The air signal is sent to a pneumatic diaphragm actuator and air booster or a piston type actuator with
positioner, depending on size and specifications of the turbine. The actuator is coupled directly, or
through linkage, to the valve stem.
The magnetic pickups are mounted around the pickup gear. The pickup gear is mounted on the main
shaft of the turbine or engine.
Figure 3. TS110Typical Application
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2.3 Components
The Tri-Sen TS110consists of the following components:
1. An adjustable timebase 4-digit digital tachometer
2. A PICKUPS OK LED
3. A STOP/RUN/START switch (actuator)
4. A local SPEED SETPOINT control (potentiometer)
5. An M100 self-powered electronic controller assembly (The termination board isvisible. It is hinged, and when the two screws are removed, it lifts up to reveal the
circuit board below.)
6. M100 terminal strip
7. An auxiliary terminal block for wiring external remote run or start with 4 spare sets ofterminals for customer use
8. A 9 V battery holder
9. An overspeed test switch
10. An I/P transducer
11. Input I/P air fitting
12. Output I/P air fitting
13. Field wiring conduit connections
14. Purge air fitting
15. Pneumatic Setpoint Fitting
16. A NEMA 4X stainless steel housing, which can be surface mounted near the turbine
17. Up to 2 special high-output magnetic speed pickups, and standard interconnect cables
These components are shown, with corresponding numbers, on three figures on the following pages,
and are described in detail in Chapter 3.
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Chapter 3 - Component Descriptions 7
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TRISEN
TS110
RPM
STOP
RUN
START
SPEEDSETPOINT
PICKUPSOK
1
2
4
3
TS110-5
Figure 4. TS110Front View, Component Locations
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6
16
5
8 10
9
7
13 15 14
M100
TS110-6
11 1211 & 12 ARE DIRECTLY
BEHIND 15 & 14
Figure 5. TS110Front View wi th Door Open, Component Locations
13
11 12
3 4
TS110-7
15 14
Figure 6. TS110Bottom View, Component Locations
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BOTTOM VIEW
FRONT VIEW
TOP VIEW
0.250 0.003
0.750, +0.025, -0.000
JAM NUT
5/8-18 UNF-2A THD 4.000 0.015
5.093 REF
1.093 REF
AB
TS110-8
Figure 7. Special High-Output Magnetic Speed Pickup
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Chapter 3 - Component Descriptions
This chapter contains descriptions of the TS110components, as outlined in Chapter 2. Refer to the
previous figures for locations of these components.
3.1 Digital TachometerThe digital tachometer supplied with the TS110is a 4-digit, configurable tachometer. It can be
configured for any number of gear teeth. Older units were configured using DIP switches on the back
of the tachometer, while currently shipping units are configured using push buttons.
NOTE: The gear must have a diametrical pitch of 8 or less for use with the special magnetic speed
pickups.
3.2 PICKUPS OK LED
This LED flashes every three seconds to indicate that both magnetic pickups are working properly. If
one pickup fails, the LED will no longer flash, thus indicating a pickup failure.
3.3 STOP/RUN/START Switch
The START position is used with a battery or a 4 to 20 mA signal to send an output current to the I/P
transducer to open the control valve. In the RUN position, the output of the controller is allowed to
pass to the I/P transducer. In the STOP position the output of the controller is set to minimum.
3.4 Local SPEED SETPOINT Control
This control is a ten-turn potentiometer with a numbered dial and a locking tab. The fully clockwise
position yields maximum governor speed. The numbers on the face of the dial (1-10) represent a
percentage of the governing range, 1.0 being 10% and 10.0 being 100%.EXAMPLE: Min Governor = 3400 RPM = 0.0
Max Governor = 3600 RPM = 10.0
5.0 = 3500 RPM
NOTE: The local speed setpoint can work in conjunction with the remote speed setpoint.
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3.5 M100 Controller Assembly
The M100 controller assembly is located inside the TS110, top left side. The termination board,
which is visible, provides terminal strips for connection of field wiring. This board is hinged, and
when the two screws are removed, it lifts up to reveal the circuit board below. The circuit board
contains all of the jumpers, potentiometers, and test points necessary to configure the TS110for a
particular application.
Refer to the figures below and on the following page for the general appearance and a block diagram
of the M100 controller assembly.
1 +
2 -
3 +
4 -
5 +
6 -
7 +
8 -
9 +
10 -
11+
12 +
13 -
14 +
15 CW
16 W
17 CCW
18 +
19 -
1
2
3
4
5
6
7
8
9
10
11
+ 12
- 13
+ 14
- 15
16
+ 17
- 18
19
GAIN
DERIV
INTEGRAL
O
V
E
R
SP
E
E
D
T
E
ST
R
ST
O
V
ER
SP
E
ED
R
E
M
OT
E
S
E
T
PN
T
A
N
A
D
I
G
T
A
C
H
E
X
T
P
W
R
RE
M
ST
RT
M
A
X
FU
E
L
U
N
D
ER
S
P
E
ED
S
WI
T
C
H
S
P
E
ED
L
O
OP
T
UN
I
N
G
REMOTE
SETPOINT
3 - 15
PSIG
M100
SELF-POWERED
GOVERNOR
TRISEN
TB2TB1
CW
CW
S
WI
T
C
H
R
U
N
PICKUPS
O
K
L
OC
A
L
SE
T
RE
M
SE
T
I/
P
P
ICKUP
2
PICKUP
1
TS110-4
TRI-SEN Systems, Inc.La Marque, TX U.S.A.
ASSY90-0360
AW90-0358
1
3
5
7
9
2
4
6
8
10
J1
W11
W7
W10
W81
3
2
W5
W11 3
W9 W
4
W31 3
W21 3
W6
TS110-200
R1
21
R60
R59R65
R64
R32
R33
R44
R24
R23
R82
R83
R101 R102
R117
R116
R115
TP7 TP8
TP4
TP9
TP6
TP5
TP3
TP1
TP2
GND
M100 Termination Board M100 Circuit Board
Figure 8. M100 Controller Assembly
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4-20mA
REMOTE
SETPOINT
3-15PSI
REMOTE
SETPOINT
REMOTE
POTENTIOMETER
SETPOINT
FREQUENCY
TOVOL
TAGE
CONVERTER
I/V
P/V
OVERSP
EED
TEST
HI/LOSELECT
LOGICW5
SETPOINT
ACTION
SETPOINT
AMP
MAXGOV
MINGOV
SETPOINT
AMP
MAXGOV
MINGOV
W1
W2
W3
LOCAL
POTENTIOMETER
SETPOINT
W7
REMOTE
STARTLOGIC
W4
MAGNETIC
PICKUP#1
MAGNETIC
PICKUP#2
PICKUPSOK
VOLTAGE
DOUBLERS&
FILTERS
PULSE
SELECT
LOGIC
VOLTAGE
REGULA
TION
W6
EXTERNAL
POWER
OVERSPEED
COMPARISON
UNDERSPEED
COMPARISON
STARTUP
PERMIT
DIG
ITALTACH
ANALOGTACH
ALARM
ALARM
+5V
TP3
TP2
REMOTE
START
ERROR
AMP
TP6
+ -
-
-
DERIVATIV
E
R113
INTEGRAL
R4115
REDUCED
GAINBAND
R102
DROOP
R101
GAIN
R117
OUTPUT
CO
NTROL
ACTION
W8
V/I
OUTPUT
0-5mA
MAX/MIN
OUTPUT
R82,R83
+
-
MAXSTARTOUTPUT
+5
-V
TP4
++
R44
POWERSUPPLY
S
PEED
S
WITCHES
SPEEDSIGNAL
SETPOINTCIRCUIT
REMOTESTART
P
IDBLOCK
CURRENTDRIVER
TS110-1
Figure 9. M100 Block Diagram
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3.5.1 M100 Speed Signal
Pulses from the two magnetic pickups are conditioned by the pulse select logic, and the one with the
higher output is routed to the Frequency-to-Voltage converter (F/V). The pulse select logic allows
the M100 to continue to function with just one pickup installed or working.
3.5.2 M100 Power SupplyPulses from the magnetic pickups are also applied to the inputs of two voltage doublers, where the
signals are rectified and filtered. The DC output is then fed to a voltage regulator where it is held at
5.0 volts. This voltage can be monitored between TP2 (+) and GND on the M100 circuit board.
Pulses from the Pulse Select Logic are fed to a charge pump to generate -4.5 V. This can be
measured at TP3 on the M100 circuit board and can vary between -3.5 V to -4.5 V from unit to unit.
This value is not critical and is used only to establish negative bias for the op-amps.
3.5.3 M100 Setpoint Circuit
The M100 features two sources of setpoint control - one local potentiometer and one of three remote
inputs. Hi/Lo Select logic allows the local setpoint to: a) override the high remote setting; b) overridethe low remote setting; or c) disable the local setpoint control. The output of the setpoint circuit is a
DC voltage that can be monitored at TP6 on the M100 circuit board.
M100 I/V CircuitA remote 4-20 mA current is converted to a 0-3 V DC signal. The output of this circuit
can be measured at pin 1 of jumper block W1 on the M100 circuit board.
M100 P/V CircuitThis circuit converts the 3-15 psi setpoint into a DC voltage. The output from the
pressure transducer mounted on the M100 cover is amplified to produce 0-3 V over the
pressure range. This level can be measured at pin 3 of jumper block W1.
3.5.4 M100 Control Section
The control section consists of the Error Amplifier, PID Gain Block and Voltage-to-Current Driver.
3.5.4.1 M100 Error Ampl ifier
The outputs from the setpoint and tachometer circuits are compared in the error amplifier, such that
any difference between the two inputs will produce an error or correction voltage. The gain of the
error amplifier is controlled by the reduced gain band control. As the reduced gain band is increased
(up to 10%) the error amplifier gain is decreased, resulting in less sensitivity to differences between
the setpoint and measured speed. This is shown by the graph in paragraph 8.2.3. When the controller
is tuned and operating properly, the output of the error amplifier should be close to zero volts.
Pushing the overspeed test switch will reduce the voltage, increasing the output of the controller and
subsequently increasing the controlled speed.
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3.5.5.2 M100 Overspeed Switch
Like the Underspeed Switch, the Overspeed Switch monitors the voltage at TP4. The speed signal is
compared to the Overspeed Trip setpoint. When the speed signal is greater than the setpoint, the
Overspeed Switch SCR is triggered which shorts out the externally supplied loop current. The SCR
will remain ON as long as loop current is present, regardless of the state of the controller.
The controller also goes into a latch upmode when an overspeed condition exists, removing all drivecurrent to the I/P output. The only way to reset the controller is to set the STOP/RUN/START switch
to STOP.
The setpoint voltage to the Overspeed Switch can be monitored at TP8, and ranges from 0.625 V to
3.125 V.
Removing the OVERSPEED TEST jumper (from both W7 on the board and TB2:3,4) raises the
setpoint by 20% allowing testing of the mechanical overspeed trip.
NOTE: The Overspeed Switch can be used in conjunction with a 120 VAC, 8 A, solid state relay
(Tri-Sen part no. 7015-0000) to trip the machine by operating the dump solenoid or
unlatching the trip lever. For more information, refer to the Operations section of this
manual.
3.6 M100 Terminal Strips
Two terminal strips, TB1 and TB2, are positioned vertically on the M100 termination board. Each
strip contains 19 terminals for connection of field wiring. Each terminal is labeled on the front of the
M100 termination board. Connections to the terminal strips are discussed in more detail in Chapter 7,
Installation.
3.7 Auxiliary Terminal Strip
This auxiliary terminal block is located at the bottom of the unit for ease of field wiring. The
following is a description of the Auxiliary Terminal Strip Connections:
BATT +/-: In the absence of the 9-volt battery an external 9-12-volt supply can beconnected to these terminals to supply the current for start up. The voltage from these
terminals is routed through the STOP/RUN/START switch.
RMT START: To be used with RMT RUN to start the governor from a remote location.A momentary N.O. switch placed across this terminal, with the 9-volt battery in place or
another power source connected to BATT, will apply a start current to the governor.
RMT RUN: A STOP/RUN/START switch similar to that supplied with the TS110canbe used to start and stop the governor from a remote location. If no switch is placed on
these terminals the jumper provided must be left in place. This is also a convenient placeto insert a current meter to monitor the I/P current.
In addition to these signals, four sets of uncommitted terminals are provided as spares for customer
use.
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3.17 Magnetic Speed Pickups
The speed measurement signal and power for the TS110are generated by special magnetic pickups in
conjunction with a ferrous metal gear that is mounted on the turbine shaft. These pickups must be
mounted approximately 0.005 to 0.020 inch from the gear. This gap allows for the lowest possible
required power-up speed for the controller.
3.18 Gear
A ferrous metal gear with a diametrical pitch of 8 or less attached to the main turbine shaft is needed
in conjunction with the special magnetic pickups to generate the speed measurement signal and the
power for the TS110. Diametrical pitch is calculated using the following equation:
Diametrical Pitch = Number of Teeth + 2
Diameter of Gear
3.19 Final Actuator
The final actuator can be a pneumatically-operated valve or assembly which controls the amount ofsteam or fuel entering the machine. For small turbines, the most economical installation is usually a
standard pneumatic actuator with positioner, mounted on the governor valve. For critical small
drivers, such as lube and seal oil turbines that support large process machines, the best solution is a
standard linear characteristic pneumatic control valve with blocks and a by-pass. This allows on-
stream maintenance of the governor or valve without shutting down the pump. This could prevent
catastrophic damage to the large machine, if the spare pump fails while the governor is being
repaired.
Larger turbines with hydraulically-operated valves or valve racks can be operated by installing a
pneumatic actuator and positioner on the hydraulic pilot, using mechanical feedback principles.
Some medium-to-large turbines with mechanical governors utilize a cup-type hydraulic servomotor,
which is easily converted to pneumatic control. These servomotors provide excellent performanceand reliability.
Regardless of which actuator type is used, it is essential that the complete actuator system have the
fastest possible stroking time and an absolute minimum of reduced gain band. This is especially
important with small drivers that, because of their low rotating mass, have very short time constants.
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Chapter 4 Specifications and Certi fications
This chapter contains specifications and certifications of the TS110.
4.1 Specifications
Inputs
Speed Sensor Tri-Sen Part No. 7131-0004, 2 each
(3 V rms at 15 mA, 200 - 10,000 Hz)
Gear Diametrical Pitch of 8 or less
Remote Start 4-20 mA or 5 V at 4 mA
Remote Power 9 Volts at 10 mA for testing only
Setpoints Local SPEED SETPOINT potentiometer on front panel
AND/OR
User supplied remote potentiometer OR
Remote 4-20 mA current loop OR
3-15 psig pneumatic
Remote max. Output External 200k potentiometer
Overspeed Test Open: Test; Closed: Normal
Start Switch Open: Normal; Closed: Start
Run Switch Open: Stop; Closed: Run
Reset Switch Open: Normal; Closed: Reset
Outputs
Actuator 3 to 15 psig at maximum rate of 2.0 SCFM
at 20 psig supply
Overspeed Isolated SCR, 400 V max, 0.3 A max,
0.15 mA min
Low Speed 5 V at 4 mA when speed < low-speed
switch setting
Analog Tachometer 0-50 A
Digital Tachometer 5 V pulse
Adjustments
Local and Remote
Speed Setpoint Minimum Controller, Maximum Controller,
External 100k Setpoint Potentiometer
Speed Trips & Alarms Overspeed Trip, Low Speed Switch
PID Control Gain, Derivative, Integral, Droop,
Reduced Gain Band
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Output Limits Local and Remote Maximum Output,
Remote Start Maximum Output,
Minimum Output, Overspeed Test
Tachometer F/V Calibration, Analog Tachometer Cal
Selections
Frequency Range 5 ranges from 200 to 10,000 Hz
Setpoint Logic Local and Remote; High or Low Select
Remote Setpoint Potentiometer, 4-20 mA, 3-15 psig;
Direct/Reverse for current and pneumatic.
Power Source Speed Pickup or Battery (for test only)
Remote Start Enable/Disable
Overspeed Test Open = Enabled / Shorted = Normal Operation
Control Action Direct or Reverse
Power Requirements
Speed Sensor 3 V rms at 15 mA, 200 - 10,000 Hz
External Battery 9 VDC, 10 mA (for test only)
Performance
Control Action 0.1% Steady State
Droop Control 0 - 10%
Proportional Band 5 - 200%
Reset Time 0 - 10 Seconds/RepeatRate Time 0 - 5 Seconds
Reduced Gain Band 0 - 10%
Frequency Range 200 - 10,000 Hz
I/P
Input 1 to 5 mA
Output 3 to 15 psig
Supply Pressure Normal: 20 psig
Minimum: 18 psigMaximum: 50 psig
Output Capacity 4.5 scfm (7.6 m3hr ANR) at 25 psig (175 kPa) supply
Maximum Air Consumption Less than 0.2 SCFM at 20 psig supply
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Environmental
Temperature Range -20 F to 160 F
Humidity 0 - 95%, non-condensing
Electrical Class/Approvals None
Construction Single PC Board, mounted in die-cast housing
4.75" X 7.4", 3.2" max. ht.
Field Terminations Barrier Strip, 6-32 screws
4.2 Certifications
Factory Mutual (FM) approved the TS110 to these standards.
Standard
NumberTitle Year Issued
3600 Electrical Equipment for Use In Hazardous (Classified) Locations
- General Requirements
1998
3610 Intrinsically Safe Apparatus and Associated Apparatus for Use in
Class I, II & III, Division 1, Hazardous (Classified) Locations
2007
3810 Electrical and Electronic Test, Measuring and Process Control
Equipment
2005
FM Approved
IS/I/1/A,B,C,D
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Chapter 5 - Configuration
Configuring the TS110is accomplished by placing and/or removing jumpers on the M100 circuit
board. (Refer to the figure on the following page.) The circuit board is accessed by removing the two
screws from the termination board and lifting it up and to the left to expose the circuit board.
5.1 Jumper Descr iptions
The following table identifies the jumpers and the placement required for various configurations. The
jumper positions shown in the table are the defaults from the factory.
Jumper Jumper Description Position Position Description
J1 FREQUENCY RANGE
from top to bottom
1 2
200-500 Hz
400-1000 Hz
800-2000 Hz
2000-5000 Hz
4000-10,000 Hz
W1 REMOTE SIGNAL SETPOINT 2 31
4-20 mA setpoint select
NOTE: W1 is valid only when
W3:2,3 is in place.1 2 3
3-15 psi setpoint select
W2 REMOTE SETPOINT ACTION.
W2 is used to choose Reverse or
Direct action when using either
the 4 to 20 mA current (terminals
TB2:7,8) or the 3 to 15 psigPneumatic Remote Setpoints.
2 31
Reverse Action: current/pneumatic
setpoint
means that an increase in signal
will cause a decrease in desired
speed.
NOTE: W2 is valid only when
W3:2,3 is in place.1 2 3
Direct Action: current/pneumatic
setpoint
This is most commonly used and
means that an increase in signal
causes an increase in desired speed.
W3 REMOTE SETPOINT. 2 31
Remote potentiometer setpoint
select
NOTE: If W3:2,3 is selected, W1
and W2 must be used.1 2 3
Current/pneumatic setpoint select
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Jumper Jumper Description Position Position Description
W4 REMOTE START. W4 is used in
conjunction with the 4 to 20 mA
Remote Setpoint (terminals
TB2:7,8). When W4 is installed,
the governor can be started fromthe 4 to 20 MA current loop.
1 2
Remote start from 4-20 mA setpoint
WARNING!If this feature
is applied to the TS110, care
should be taken in training all
personnel. The turbine will start
with no one at the turbine/engine
if the current loop is lost and
regained.Refer to the remote
stop figure in paragraph 7.3.1.
NOTE: If W4 is installed, a (reset)
switch must be installed in
the Remote Setpoint 4 to 20
mA loop to momentarily
interrupt the current loop to
reset the Remote Start
Feature for another startup.
W5SETPOINT SELECT
HIGH/LOW.2 31
Local setpoint high selectcauses the local to override the
remote when the local is set to a
higher value.
NOTE: If W5 is not installed the
Local Setpoint will be
disabled.
1 2 3
Local setpoint low select
causes the local to override the
remote when the local is set to a
lower value.
1 2 3
Local setpoint disabled
W6 1 2
M100 powered by magnetic pickup
W7 NOTE: This jumper is not used if
overspeed test switch is
installed across TB2:3,4.
1 2
Enable overspeed test
W8 CONTROL ACTION.
W8 is used to choose reverse or
direct control action to the final
actuator.
2 31
Direct Control Action
means that an increase in speed
causes an increase in output to the
actuator.
1 2 3
Reverse Control Action
is most commonly used, and means
that an increase in speed causes a
decrease in output to the actuator.NOTE: Reverse Control Action is
more commonly used so
that, as the speed of the
machine increases, the
valve is closed.
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Jumper Jumper Description Position Position Description
W9 EXT +5 VOLT ENABLE. 1 2
+5 Volts are provided at TB2:12,13
for powering a solid state relay for
overspeed trip. For more
information refer to Paragraph 8.4.
NOTE: If external power is appliedto TB2:12,13, W9 must be
removed to prevent damage
to the board.
W10 PNEUMATIC SETPOINT
DISABLE.
1 2
Disable Pneumatic Setpoint
NOTE: W10 and W11 must be
installed if the pneumatic
setpoint is not used.
W11 PNEUMATIC SETPOINT
DISABLE.
1 2
Disable Pneumatic Setpoint
NOTE: W10 and W11 must be
installed if the pneumatic
setpoint is not used.
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Figure 10. Calibration/Configuration Diagram - Jumpers
Tri-Sen Systems, Inc.Houston, TX U.S.A.
ASSY 90-0360
AW90-0358
13579
2468
10J1
W11
W7W1
W81
32
W5
W11 3
W9 W4
W31 3
W21 3
W6
TS110-201
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5.2 Configuration Specification Sheet
COMPLETE THE FOLLOWING FOR YOUR APPLICATION.
This information will be used to determine the configuration of your TS110.
Gear SpecificationsDiameter of Gear = _____ inches (determined by individual turbine)
Number of Gear Teeth = _____ teeth (3" = 20 teeth; 5" = 30 teeth)
Controller Parameters
Minimum Governor Speed = _____ RPM
Maximum Governor Speed = _____ RPM
Overspeed Trip = _____ RPM
Underspeed (if used) = _____ RPM
Setpoint Selection
Chooseoneof the following: _____
1. Local potentiometer only
2. Local potentiometer and remote potentiometer
3. Local potentiometer and 4 to 20 mA current signal
4. Local potentiometer and 3 to 15 psig pneumatic signal
5. 4 to 20 mA current signal only
6. 3 to 15 psig pneumatic signal only
7. Remote potentiometer only
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The information completed on the Configuration Specification Sheet (previous page) will now be
used to configure the TS110.
5.2.1 Selection of Frequency Range
Jumper J1 allows the TS110to be used for a variety of frequency ranges. To determine the frequency
range for your application convert the overspeed trip (OS) to a frequency using the followingequation:
Maximum Frequency (Hz) = OS X 1.2 X Number of Gear Teeth / 60
Now choose a frequency range (J1, see table in paragraph 5.1) whose upper limit is at least the
maximum frequency calculated above. Install a jumper in the proper position.
5.2.2 Jumper Configuration
The following paragraphs use the number entered for the Setpoint Selectionfrom the Configuration
Specification Sheet.
W1 Remote Signal Setpoint Define:
If you selected number 3 or 5, place a jumper on W1:1,2 and connect the remote 4-20 mA current
loop to TB2:7(+) and TB2:8(-)
If you selected number 4 or 6, place a jumper on W1:2,3 and connect 1/8" i.d. flexible pneumatic
tubing to the barbed fitting of the optional 3-15 psig. Remote Signal Transducer.
If you selected number 1, 2 or 7, place jumper on W1:2,3.
W2 Setpoint Control Action:
If you selected number 3, 4, 5, or 6, determine whether you wish to have a Direct or Reverse Setpoint
Action. Refer to table in paragraph 5.1 for explanations. Place jumper on appropriate position.
If you selected number 1, 2, or 7, place the jumper on W2:2,3.
W3 Remote Setpoint Define:
If you selected number 1, place jumper on W3:1,2.
If you selected number 2 or 7, place a jumper on W3:1,2 and connect a remote 100k potentiometer to
TB1:9-11. Connect the wiper to TB1:10, and the clockwise (CW) end of the potentiometer to TB1:9.
If you selected number 3, 4, 5, or 6, place a jumper on W3:2,3.
W4 Remote Start:
If you selected number 3 or 5 and wish to start the TS110using the 4-20 mA current, place a jumper
on W4.
If you selected any other number or do not wish to start the TS110from the 4-20 mA current, do not
install a jumper.
NOTE: If W4 is installed, a (reset) switch must be installed in the Remote Setpoint 4 to 20 mA loop
to momentarily interrupt the current loop to reset the Remote Start Feature for another
startup.
Refer to paragraph 7.3.1
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W5 Local Setpoint Select:
If you selected number 1, place a jumper on W5:1,2
If you selected number 5, 6, or 7, do not install a jumper.
For any other selection, refer to table in paragraph 5.1 and place W5 jumper in appropriate position.
W6 Power from Pickups:
Always install W6 when powering the governor from the pickups.
W7 Overspeed Test Enable:
No jumper is needed on W7 when the overspeed test switch is installed across TB2:3,4 on the
Termination Board.
W8 Control Action:
Reverse Control Action, which means that an increase in speed will close the control valve, will be
used in most situations. Place a jumper on W8:2,3.
W9 External +5 Volts Enable:
Only install W9 when you will be using a solid state relay for an electronic overspeed trip. See
paragraph 7.3.2.
CAUTION!
Powering the board with W9 installed can cause damage to some electronic
components.
W10 and W11 Pneumatic Setpoint Disable:
If you selected number 1, 2, 3, 5, or 7, place a jumper on both W10 and W11.
If you selected number 4 or 6, both W10 and W11 must be removed.
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Chapter 6 - Calibration Procedures
6.1 Digital Tachometer
The TS110controls from the frequency received from the pickups and gear. This frequency is related
to the speed of the gear turning on the shaft and the number of teeth on the gear. The digitaltachometer converts this frequency to RPM to allow the user to see the speed from the display
window.
The TS110uses one of two digital tachometers, depending on date of manufacture. Units
manufactured prior to October, 2003 use the Red Lion DT6 digital tachometer. It is identified by a
removable plastic cover on its back side, with DIP switches present underneath the cover. Newer
units use the Red Lion DT9 digital tachometer. It is identified by two buttons marked PAR and
SEL on the tachometer face: There is no removable cover on the back side; instead, there is a
product label with DT9 marked on it. The calibration procedure is different for each of the two
tachometers.
6.1.1 DT6 Digi tal TachometerThe DT6 digital tachometer converts the frequency from the pickups to RPM by use of a
configurable Timebase. This configuration is entered via the DIP switches on the rear of the
tachometer.
The Timebase for a given gear is calculated by using the following equation
Timebase = 7680
No. of gear teeth
Switch Increments Switch Increments
SWA1 1 SWB1 256
SWA2 2 SWB2 512
SWA3 4 SWB3 1024
SWA4 8 SWB4 2048
SWA5 16 SWB5 4096
SWA6 32
SWA7 64
SWA8 128
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EXAMPLE: Find the appropriate DIP switch setting for a desired display reading with a 20-tooth
gear.
TB = 7680 = 384
20
TB = 384
DIP SWB1 - 256 Needed = 128
DIP SWA8 - 128 Needed = 0
Set SWB1, SWA8 to the ON position.
Frequency Doubling
DIP switch SWB6 is thefrequency doubling disableswitch. This switch is set to the OFF position at
the factory. SWB6 should always remain in the OFF position since this position allows for the fastest
update time without sacrificing accuracy.
NOTE: If SWB6 is in the ON position, the RPM on the digital tachometer will read one-half of theactual RPM.
Decimal Point Selection
The selection of Decimal Point is accomplished by DIP switches SWB7 and SWB8. The following
table shows which combination of switches is needed to obtain the desired decimal point location.
The tachometer always has leading zero blanking.
SWB7 SWB8 DP Location
factory test mode
0 (preset at factory)
0.0
0.00
NOTE: Decimal point will change only at the normal display update times.
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6.1.2 DT9 Digi tal Tachometer
The DT9 has three configuration parameters that must be programmed properly for the unit to
accurately display speed. The three parameters are Rate Multiplier, Decimal Point, and Timebase. To
enter the programming mode, place a jumper between the Push Button Enable (P. B. En.) and
Common screw terminals on the rear of the tachometer.
Once in programming mode, you scroll to the Rate Multiplier, Decimal Point, and Timebase entry
screens by pressing the PAR button. (Screens change when the button is released.) Press PAR again
to reach the fourth screen, which is the main display or run mode. Once programming is complete,
the unit must be returned to the main display before exiting the programming mode to obtain normal
operation. You leave the programming mode by removing the P. B. En. jumper after the DT 9 is
returned to the main display.
Note: The display changes on PAR or SEL push button release.
Figure 11. DT9 Programming Screens
Rate Multiplier
The DT9 has a Rate Multiplier (RM) selection range from 0.0001 to 1.9999. See the Programming
Calculations section below to determine the calculated value. After entering the programming mode,
the least significant digit will be flashing. To increment this digit, press the SEL button. After the
value 9, the digit will start over at 0. To move to the next digit press PAR and then that digit can be
changed by pressing SEL. When reaching the most significant digit, pressing PAR will advance the
meter to the Decimal Point selection.
Decimal Point Selection
The selection of the decimal point position for the display (DDP) is accomplished by repeatedly
pressing SEL. This selection will always default to 0.0000 when advancing to it from the Rate
Multiplier selection. By pressing PAR, the DT9 accepts the shown decimal point position and
advances to the Timebase selection screen.
Timebase Selection
The DT9 has a Time Base selection range from 1 second to 7 seconds. See Programming
Calculations to determine the calculated Rounded Time Base (RTB) value. The value is changed by
pressing SEL. The value is entered by pressing PAR, after which time the Main Display/Run Mode is
shown.
Main Display / Run Mode
The Main Display follows the Timebase Selection. The unit must be in this mode to exit the
Programming Mode and have the unit display properly. The push button enable jumper can be
removed after the DT9 is returned to the main display.
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Programming Calculations
The equations presented in this section will allow you to determine the values for entry above in the
DT9 configuration process. The following variables are referenced in the equations.
#TEETH Number of Teeth on Pickup Gear
CTB Calculated Time Base
RTB Rounded Time Base
DDP Display Decimal Point
Use the following corresponding numbers in the equations below
Decimal Point:
0 = 1
0.0 = 10
0.00 = 100
0.000 = 1000
Use the following equations to determine the values for Rate Multiplier, Decimal Point Selection,
and Rounded Timebase to be entered in the DT9 configuration process.
TEETH#
DDPCTB = 60
RTB = (CTB) rounded to the nearest integer value
TEETH#RTB
DDPRM
=
60
EXAMPLE: As an example, say you have a 30-tooth pickup gear and you want to view speed as
an integer, i.e. DDP = 1. The equations yield the following values: CTB = 2, RTB = 2, and RM = 1.0.
You would then enter these values in the DT9 configuration screens described above.
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TRI-SEN Systems, Inc.La Marque, TX U.S.A.
ASSY90-0360
AW90
-0358
1
3
5
7
9
2
4
6
8
10
J1
W11
W7
W10
W81
3
2
W5
W11 3
W9 W
4
W31 3
W21 3
W6
TS110-202
R121
R60
R59R65
R64
R32
R33
R44
R24
R23
R82
R83
R101 R102
R117
R116
R115
Figure 12. Calibration/Configuration Diagram - Potentiometers
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TRI-SEN Systems, Inc.La Marque, TX U.S.A.
ASSY90-0360
AW90
-0358
1
3
5
7
9
2
4
6
8
10
J1
W11
W7
W10
W81
3
2
W5
W11 3
W9 W
4
W31 3
W21 3
W6
TS110-203
R121
R60
R59R65
R64
R32
R33
R44
R24
R23
R82
R83
R101 R102
R117
R116
R115
TP7 TP8
TP4
TP9
TP6
TP5
TP3
TP1
TP2
GND
Figure 13. Calibration/Configuration Diagram - Test Points
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Overspeed Setpoint
20. Connect DMM negative lead to GND and the positive lead to TP7. This voltage will be
approximately -3.5 volts. This indicates that the unit is not in overspeed trip.
21. Set M115 SIM-CALIB to CALIB and adjust calibrate pot to the overspeed setting.
22. DT should read the overspeed setting.
23. Turn R60 CCW until DMM reading goes from a negative voltage to approximately
+5 volts.
24. Switch to STOP, and turn M115 power OFF.
25. Move M115 calibrate pot to slightly below the overspeed setting.
26. Switch to RUN, and turn M115 power ON.
27. Slowly turn freq pot CW while watching the DT, and confirm that the DMM reading
goes to +5 volts at a DT reading of the overspeed value.
28. Switch to STOP and turn M115 power OFF.
29. Turn M115 freq pot CCW to 0.0.
Underspeed Switch
30. Connect the DMM positive lead to TB2:18, and the negative lead to TB2:19.
31. Switch to RUN and turn M115 power ON.
32. Set M115 freq pot to the UNDERSPEED TRIP setting and the SIM-CALIB switch to
CALIB.
33. DT should read underspeed trip setting.
34. Turn R65 CW until DMM indicates +5 volts.
Mechanical Overspeed Test
35. Switch to STOP and turn M115 power OFF for about 5 seconds.
36. Set SIM/CAL switch to SIM.
37. Turn M115 power ON and switch to START momentarily (switch will revert back to
RUN).
38. If you have problems starting the TS110, increase the LOAD and LAG on the M115.
Always turn M115 power OFF for about 5 seconds between starts to allow the residual
power to dissipate.
39. Push and hold the OVERSPEED TEST switch.
40. Adjust R121 to achieve the maximum rpm that you want to reach while testing the
mechanical trip on the turbine.
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Min/Max Output
41. Switch to STOP and turn the M115 power OFF.
42. Remove the jumper from the RMT RUN (terminals 9 and 10 on the auxiliary terminal
strip).
43. Place DMM positive lead on terminal 9 and the negative lead on terminal 10.
44. Place the DMM in MA CURRENT mode.
45. Set the M115 SIM/CAL switch to CAL.
46. Switch to run and turn the M115 power ON.
47. Adjust the freq pot to slightly above maximum governor speed. This should make the
current on the DMM integrate to about 0 mA.
48. Adjust R83 CW until the DMM reads 1 mA.
NOTE: If the current stays at 0 mA the governor may be in an overspeed trip condition.
Make sure that the speed is adjusted below the overspeed trip setpoint. Turn theSTOP/RUN/START switch to STOP and then back to RUN. This should reset the
controller. Also check the DMM leads to insure that they are firmly attached and
making a good connection.
49. Adjust the freq pot to slightly below minimum governor speed. This should make the
current on the DMM integrate to about 6.5 mA.
50. Adjust R82 CCW until the DMM reads 5 mA.
You have now adjusted the controller to operate between 1 and 5 mA.
NOTE: After adjusting the min and max output, the M115 valve position will show 20% or more,
unless the controller has tripped or the STOP/RUN/START switch is in the STOP position.Simulation
51. Switch to STOP and turn M115 power OFF for about 5 seconds.
52. Set the SIM-CALIB switch to SIM.
53. Turn speed setpoint pot CCW (0.0).
54. Turn M115 power ON and switch to START momentarily (switch will revert back to
RUN).
55. If you have problems starting the TS110, increase the LOAD and LAG on the M115.
Always turn M115 power OFF for about 5 seconds between starts to allow the residual
power to dissipate.
56. DT should read minimum governor speed.
57. Increase speed setpoint CW to 5.0. The valve meter on the M115 should deflect upward
(open). The DT should read approximately mid-range.
58. Increase the load on the M115 and the valve should deflect further upward.
You have now tested the TS110functionally, and it is ready to be configured to your application.
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Chapter 7 - Installation
7.1 Location & Mounting
Tri-Sen controllers are high performance, high speed controllers designed for industrial applications.
However, as with all equipment, good mounting and wiring practices must be used duringinstallation. Failure to follow these mounting and wiring guidelines will result in instability of
control and/or intermittent shutdown of controlled equipment from random electrical noise.
Of course, compromises may be necessary, but careful attention to these factors will result in a more
successful installation.
7.1.1 Choosing a Location for the TS110Controller
The TS110is designed to be field mounted at the turbine. The location where the TS110is mounted
in the field is a critical decision. Factors such as
accessibility,
lighting, and
temperature
affect the success of the installation.
Other important factors include
area classification,
length of wiring and pneumatic tubing, and
proximity to sources of electrical noise.
7.1.2 Mounting
Refer to the figure on the following page.
Mount the TS110as close to the turbine as possible. Keep the output air line to theactuator short and direct.
Consider the heat generated by the turbine or auxiliary equipment in the mounting area.The TS110will function in ambient temperatures up to 160F, but every effort should be
made to place the unit in a reasonably cool area.
Since the TS110controller usually is operated through the front panel, it should be
mounted so that the operator can stand in front of the controller comfortably. The displayshould be at eye level; the most common installations are between 5 feet and 5 feet, 6
inches high.
The liquid crystal display is difficult to read in low light, so avoid dark areas; but do notmount the TS110controller in direct sunlight.
The TS110controller should be mounted to rigid structures only that will not sway.
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Service access should also be considered. Assure that:
the door can be fully opened;
the unit will not be subjected to steam or dripping water or other liquids; and
that locating the Tri-Sen controller in a given area will not be in violation of area
classification.
If any of these items is doubtful, consider another location.
TS110-206
Figure 14. Mounting Dimensions
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7.2 Field Wiring for Standard Installation
The TS110System is shipped 90% pre-wired. The only field wiring required is for the magnetic
pickups, and the remote speed setpoint, if used.
Magnetic pickups and remote speed setpoint use shielded pairs of 16 - 18 AWG wires.
Pickup #2 terminates on TB1-14 and TB1-15 with the shield on TB1-16.
Pickup #1 terminates on TB1-17 and TB1-18 with the shield on TB1-19.
The remote speed setpoint, if used, should be a 4 - 20 mA signal.The positive lead terminates on TB2-7; and
the negative lead terminates on TB2-8 with
the shield terminated on TB1-8.
Connect TB1-8 to a suitable earth gound.
This wiring configuration is shown in the figure on the following page.
CONSULT THE FACTORY WHEN IN DOUBT ABOUT ANY INSTALLATION PROCEDURE.
WARNING!
Have qualified personnel verify all wiring and connections against
appropriate drawings prior to energizing the equipment. Incorrect wiring
and/or connections can result in equipment damage.
CAUTION!
For installations in hazardous locations refer to the notes on the figures in this
chapter.
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2
3
1
5
6
4
8
9
7
11
12
10
14
15
13
16
18
19
17
2
3
1
5
6
4
8
9
7
11
12
10
14
15
13
16
18
19
17
TB1 TB2
REMOTE SPEED SETPOINT4-20 mA (Optional)
EARTH GROUND
1
RED
BLACK
RED
BLACK
MAGNETIC SPEED PICKUP #1
MAGNETIC SPEED PICKUP #2
2
M100
1
2
USE AN INTRINSIC SAFETY BARRIER APPROVED BY CSA OR FM TO MAINTAINAPPLICABLE SAFETY CERTIFICATIONS.
DO NOT USE IN HAZARDOUS AREA. TS110-11
Figure 15. Standard Field Wiring
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Chapter 7 - Installation 45
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M100 Termination Board Wiring Details
Refer to the table below and the figure on the following page for details concerning field wiring
terminations on the M100 terminal strips.
Terminal Description
TB1:1,2 RUN SWITCH - Closed to run; open to stop. Opening this switch removes all electricalcurrent to the I/P.
TB1:3,4 PICKUPS OK - An LED connected across these terminals as shown will flash periodically
when both magnetic pickups are functioning.
TB1:5-7 LOCAL SET - A 10-turn, 100k-ohm potentiometer installed across these terminals provides
the Local Setpoint.
TB1:8 GROUND - For terminating the shield around the Remote Potentiometer Setpoint wiring.
TB1:9-11 RMT SET - A 10-turn, 100k-ohm potentiometer installed across these terminals provides the
Remote Potentiometer Setpoint. A shielded, three-wire cable should be used to connect the
potentiometer, with the shield connected only to TB1:8. (Do not terminate other end of
shield.)
TB1:12,13 I/P - 0-5 mA output signal from the M100 to the Current-to-Pneumatic converter
TB1:14-19 PICKUP 2 and PICKUP 1 - Connection for the two magnetic pickups. Each set of wires
should be individually shielded, twisted pair, with the shields connected ONLY to
TB1:16/TB1:19. (Do not connect shield at other end.)
TB2:1,2 O/S ALM - Alarm output indicating an over speed condition has occurred. The output is an
SCR that remains latched on, even after M100 is powered down as long as external loop
current flows.
TB2:3,4 OVERSPEED TEST - Open: raises electronic overspeed trip approximately 20% and
increases governor range an adjustable amount. This is used to check external mechanical
overspeed trip.
TB2:5,6 OVERSPEED RST - a normally open switch is placed across these terminals to reset the
governor after an electronic overspeed.
TB2:7,8 REMOTE SETPNT - Input from remote 4-20 mA setpoint signal.
TB2:9-11 TACHOMETER - A 50 A current meter connected across terminals 9 and 10 indicates
analog speed. A digital tachometer (frequency counter) is connected across terminals 10 and
11. The digital tachometer signal is sufficient to drive most self-powered tachometers.
TB2:12,13 EXT PWR - External power input to M100 for test purposes only. Voltage must be 9-12 volts.
When jumper W9 is in place, 5 V/4 mA is available at these terminals for tripping a solid state
relay. See paragraph 7.3.2.
TB2:14,13 RMT STRT - Remote start input; applying 5 V to these terminals on an unpowered TS110will cause a current to flow out of the I/P terminal (TB1:12). Once the unit is powered and
controlling, the Remote Start signal is disabled internally. The Remote Start signal must be
interrupted externally to restart a unit that has been powered down. This input is designed towork with the SPEED SWITCH output of another TS110.
TB2:15-17 MAX OUTPUT - A 200k-ohm potentiometer connected across these terminals allows the
maximum output limit to be set externally. To use these terminals, R82 on the M100 board
must be removed.
TB2:18,19 UNDERSPEED SWITCH - Output goes to 5 V when speed drops below the speed switch
setpoint. This is a low-current signal designed to start a second TS110(see RMT STRTabove) in the event the first one drops below a specified speed.
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3
2
4
2
1 2 2
1
2
3
4
USED FOR BENCH TEST ONLY.
TO MAINTAIN APPLICABLE SAFETY CERTIFICATIONS,USE CSA OR FM APPROVED BARRIER SUCH AS MTLPIN 787S, 28V MAX 300 OHMS.
DO NOT USE BATTERY IN HAZARDOUS AREAS.
DO NOT USE EXTERNAL TACH IN HAZARDOUS AREAS.
TS110-205
AUXILIARYTERMINAL STRIP
Figure 16. Field Wiring Detail
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7.3 Field Wiring for Optional Configurations
7.3.1 Remote STOP/RUN/START Switch
A switch (Tri-Sen P/N 91-1482) can be wired to the RMT START and RMT RUN terminals on the
auxiliary terminal strip to remotely start and stop the turbine.
Also refer to the figure on the previous page.
Remote Start using a Second TS110To start a backup turbine, controlled by a TS110, when the primary turbine falls below a
preset speed, connect the two TS110sand an underspeed switch as shown in the figure
below.
M100M100
19
18
17
16
1514
13
12
11
10
9
8
7
6
5
4
3
2
1TB2TB1
19
18
17
16
1514
13
12
11
10
9
8
7
6
5
4
3
2
1
19
18
17
16
1514
13
12
11
10
9
8
7
6
5
4
3
2
1
19
18
17
16
1514
13
12
11
10
9
8
7
6
5
4
3
2
1
SPARE BAT
+ -
RMTSTART
RMTRUN
THIS TERMINAL STRIP IS
LOCATED INSIDE THE TS110,
BELOW THE M100 TERMINAL
STRIPS.
11
2
2DO NOT USE IN A HAZARDOUS
AREA.
3THE 9-VOLT BATTERY OPTION
CANNOT BE USED WITH THISAPPLICATION.
TS110 ON PRIMARY TURBINE TS110 ON BACKUP TURBINE
TS110-12
TB2TB1
Figure 17. Field Wiring for Remote Start of a Backup Turbine Using a Second TS110
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Remote StopUsing remote setpoint, 4-20 mA signal, normally open or normally closed switch.
1
6
8
9
7
19
1
6
8
9
7
19
TB1 TB2
N.O. SWITCH
4-20 mA LOOP
M100
1USE AN INTRINSIC SAFETY BARRIER APPROVED BY CSA OR
FM TO MAINTAIN APPLICABLE SAFETY CERTIFICATIONS.
1
1
6
8
9
7
19
1
6
8
9
7
19
TB1 TB2
N.O. SWITCH
4-20 mA LOOP
M100
1
- OR -
TS110-13
Figure 18. Field Wiring for Remote Stop
Using 4-20 mA Signal with N.O. or N.C. Switch
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7.3.2 Overspeed Trip Relay
An optional Solid State Relay (Tri-Sen P/N 7015-0000) can be used to trip the machine in an
overspeed condition by operating the dump solenoid, or by unlatching the trip lever. Refer to the
figure below. For more information, refer to Section 8, Operations, of this manual.
2
3
1
5
6
4
8
9
7
11
12
10
14
15
13
16
18
19
17
2
3
1
5
6
4
8
9
7
11
12
10
14
15
13
16
18
19
17
TB1 TB2
1
M100
1
2
USE AN INTRINSIC SAFETYBARRIER APPROVED BY CSA ORFM TO MAINTAIN APPLICABLESAFETY CERTIFICATIONS.
JUMPER W9 MUST BEINSTALLED.
SOLID STATE
RELAY(TRICONEX
PN 7015-0000)
+ -
SOLENOID
AC LINE
1
TS110-14
Figure 19. Field Wiring for Overspeed Trip Relay
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7.4 Pneumatic Installation
7.4.1 Piping
Recommended supply piping for the I/P supply air is at least 3/8". The recommended piping for the
connection from the Governor I/P output to the final actuator is 1/4". A 0-30 PSIG gauge should be
installed on the governor I/P output to aid in troubleshooting and tuning. This connection should bekept as short as possible for the fastest response of the control valve. Though copper tubing is
adequate, stainless steel is recommended.
7.4.2 Optional Pneumatic Speed Setpoint
This is a 3-15 PSIG signal that can be used to remotely set the running speed of the governor when
the optional Pneumatic Transducer (Tri-Sen P/N 91-1455) is used. This line can be 1/4" tubing.
7.4.3 Final Actuator
Two types of pneumatic actuators can be used
top related