TS110 Self-Powered Controller Operations Guide Rev. 5

8/13/2019 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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iii

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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iv TS110Self-Powered Controller Operations Guide

October 2009 Rev. 5

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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v

October 2009 Rev. 5

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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vi TS110Self-Powered Controller Operations Guide

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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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vii

October 2009 Rev. 5

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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viii TS110Self-Powered Controller Operations Guide

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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 ix

October 2009 Rev. 5

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

October 2009 Rev. 5

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

October 2009 Rev. 5

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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6 TRISEN 110Self-Powered Controller Operations Guide

October 2009 Rev. 5

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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October 2009 Rev. 5

TRISEN

TS110

RPM

STOP

RUN

START

SPEEDSETPOINT

PICKUPSOK

1

2

4

3

TS110-5

Figure 4. TS110Front View, Component Locations


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October 2009 Rev. 5

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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October 2009 Rev. 5

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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October 2009 Rev. 5

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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October 2009 Rev. 5

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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October 2009 Rev. 5

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 2 - Product Overview 19

October 2009 Rev. 5

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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Chapter 2 - Product Overview 21

October 2009 Rev. 5

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 23

October 2009 Rev. 5

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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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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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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October 2009 Rev. 5

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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October 2009 Rev. 5

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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October 2009 Rev. 5

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 31

October 2009 Rev. 5

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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October 2009 Rev. 5


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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October 2009 Rev. 5


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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October 2009 Rev. 5

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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October 2009 Rev. 5

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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October 2009 Rev. 5

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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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

TS110 Self-Powered Controller Operations Guide Rev. 5

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