Trisen TS160 Training

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TRICONEX
The Recognized Leader in Fault Tolerant Control
TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

An Invensys Company
Who is TRICONEX?
• Pioneered the Application of Triple Modular Redundant Technology

(TMR) for Industrial Use
• A Team of Very Experienced and Dedicated People
• Our Critical Success Factors:
- Commitment to Customers
- Commitment to Our Employees
- Commitment to Quality
- Unique Technology
- Continuous Investment in the Future
We Protect People, The Environment, Capital Equipment,

and Customer Profit

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A Brief History Of TRICONEX
• Founded in 1983
• Headquarters in Irvine, California
• Expanded Sales and Service Worldwide
• Highly Successful IPO in March 1992
• Acquired TRISEN Turbo-Machinery System in 1992
• Acquired Premier Engineering in 1993
• Purchased by Siebe in 1994 for US$95M
• Siebe and BTR Merged to Form Invensys in 1999

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TS-160 Controller

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Surge Control Description

È Surge occurs in a compressor when discharge head cannot be sustained
with the available suction flow.
È Surge occurs at specific combinations of head and flow , as predicted
by the compressor manufacturer’s performance curves.
È One or more of the following can result from surge :
- Unstable operation
- Partial or total flow reversal through the compressor
- Disrupted process
- Mechanical damage to the compressor
È Surge is usually accompanied by the following :
- Increase in discharge temperature
- Reduction in discharge pressure
- Increase in Vibration
- Sharp rise in inlet temperature

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Avoiding Surge
È In the gas compressor section, surge can be avoided by recycling a controlled portion
of the discharge flow back to the suction through a surge valve.
È Refer to the figure below, recycling raises the suction pressure and lowers the
discharge pressure, which increases flow and moves the operation away from the
surge
È Raising speed also moves the compressor away from surge but this is a temporary
solution because it also raised Pd and lower Ps, which tends to drive the machine
back toward surge

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Surge Control Line

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Surge Control Line
È To prevent surge, the system must

accurately predict surge and begin to
open the surge valve before surge can
occur.
È The safety margin between the
predicted surge point , and the point
that recycle flow is initiated, is called
the safety margin
È The control line is calculated by adding
the surge margin to the surge line

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Product Overview
È Multi-control loop microprocessor based controller designed to
control compressor surge and performance.
È Scan time = 10 mS (Input/Output), 50 mS for loop cycle time.
È Small size and built-in termination assembly allow the controller to
be mounted virtually any where.
È Integrated operator interface provides a comprehensive window on
compressor operation in readily identifiable format that minimize the
time required for operator training.
È Standard communication features that allow a detailed view of the
compressor operating parameter on a personal computer. (PC IBM
Compatible – via serial port)

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General Environmental Specifications
Specifications Parameters
Normal Limits 0 to 50 deg C
Operative Limits 0 to 55 deg C
Transport Storage -40 to 85 deg C (-40 to 185 deg F)

Relative Humidity 5% to 96%, non-condensing
5 – 60 Hz at 0.030 Inch total excurcion

Vibration along X,Y and Z axes
Conformal coating is applied to board for

protection againts H2S, SO2 and traces
Chemical Corrosion Resistance of sand, salt and dust

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Hardware Block Diagram

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Typical Application

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Surge Control Function

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Surge Control Function

È Surge Calculation : The surge line can be configured with up to 10 line segments
È Margin, Recalibrate Margin, Surge Detect, Control Line :
If the system detects a transition of the operating point across the surge line,
indicating that surge has occurred, it automatically recalculates the surge control
line to add additional safety margin.
Each time a surge transition is detected, the safety margin is increment (control
line moved to right) by a calibrated amount.
The Controller can be configured to increment on each transition by a fixed
amount (i.e., 2%), or by progressive amount (1,2,4,8 %, etc). The maximum
number of times that recalibration occurs is also configurable.
È Dump Out Function :

If desired, a discrete output can be configured to open a high-volume solenoid to
quickly open surge valve, if the operating point moves to the left of the surge
line.
This feature is useful on large valve that have slower stroking times.

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Set point Hover Function
È The following occurs after a small, quick

movement toward surge, past the hover set
point:
- Immediate opening of the surge valve

- Controller setpoint is the ramped down
(at the same rate) until the surge valve closes
- New Operating point is established
È If the setpoint reaches the control line, the

system will maintain recycle flow to operate
on the surge control line

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Adaptive Gain Function
È The surge valve opens, based on the proportional and integral responses, but a
straight ramp function limits the closing rate of the surge valve. This feature
allows the valve to respond quickly to prevent surge. After operating is safely to
the right of surge control line, the valve is ramped closed at a slow (configurable)
rate to allow adjustment to the new operating condition
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Proportional Valve Respond Function
È The surge valve opens, based on the proportional and integral responses, but a
straight ramp function limits the closing rate of the surge valve. This feature
allows the valve to respond quickly to prevent surge. After operating is safely to
the right of surge control line, the valve is ramped closed at a slow (configurable)
rate to allow adjustment to the new operating condition

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Front Panel Operation

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Front Panel Operation

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Display Window

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Alarm Indicator

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Surge Control Application

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Application Overview

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IO Configuration
È Standard IO :
Analog Input = 4 ea,
Analog Output = 2 ea,
Digital Input = 4 ea,
Digital Output = 2 ea,

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IO Failure Handling
È Flow Transmitter failure :
Impossible for the controller to determine the current operating point of
the compressor
The controller will open surge valve upon the failure of flow transmitter to
protect the compressor, if opening the surge valve on the compressor is not
desired upon failure of flow transmitter, the failure mode can be modified.
È Suction or Discharge Transmitter failure :

Impossible for the controller to determine the current operating point of
the compressor
The controller will open surge valve upon the failure of flow transmitter to
protect the compressor, if opening the surge valve on the compressor is not
desired upon failure of flow transmitter, the failure mode can be modified.

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Auto/Manual Control Function

È Full Manual :
It allows the valve to be closed, regardless of the action of the surge controller.
(If the system is left in full manual operation, the surge controller will not be
able to open the valve to prevent surge.
È Limited Manual :
This option allows the operator to manually control the valve, but allows the
surge controller to override the manual control to protect the machine from surge

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Data View via PC

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Software Specification

Document No. GB-101-001-R2
Customer Doc. No
Project No. SG0570
Contract No. 03.100.319
Page 1 of 12
PROJECT NAME : ANTI-SURGE GB-101 P-IB
CUSTOMER NAME : PT PUPUK SRIWIDJAJA
ENDUSER NAME : PT PUPUK SRIWIDJAJA
GB-101 P-IB
CO2 Compressor
Software Specification
For Customer Approval
Customer Representative:
Name:
□ Reviewed & Approved
with No Comment
Signature:
□ Reviewed & Approved
with Comment
Date:
□ Do not proceed
1 14 Mar 06 PVD WSN PS Alarms and Safe Values

0 27 Jan 06 PVD CPY PS Draft
Rev Date Prep Chk’d Apv’d Description
Project Name : Anti-Surge GB-101 P-IB Doc. No. GB-101-001-R2.doc
Project Location : Pusri, Palembeng - Indonesia Project No. SG0570
Doc. Description : Compressor Software Specification Contract No. 03.100.319
Area/Unit/System : GB-101 P-IB Page 2 of 12
TABLE OF CONTENTS
1. GB-101 P-IB CO2 COMPRESSOR ...................................................... 3

1.1. APPLICATION OVERVIEW ............................................................ 3
2. Stage 1 .................................................................................... 4
2.1. Flow transmitter fault ............................................................... 4
2.2. Pressure transmitter fault .......................................................... 4
2.3. Manual Override ...................................................................... 4
2.3.1. Partial Authority 4
2.3.2. Full Manual 4
2.4. Process Override ...................................................................... 5
2.4.1. Minimum Flow control 5
2.5. I/O Configuration ..................................................................... 5
2.6. Universal Surge Curve ............................................................... 6
3. Stage 2 .................................................................................... 7
3.1. Flow transmitter fault ............................................................... 7
3.2. Pressure transmitter fault .......................................................... 7
3.3. Manual Override ...................................................................... 7
3.4. Process Override ...................................................................... 8
3.5. I/O Configuration ..................................................................... 8
3.6. Universal Surge Curve ............................................................... 9
4. Stage 3 / 4 .............................................................................. 10
4.1. Flow transmitter fault .............................................................. 10
4.2. Pressure transmitter fault ......................................................... 10
4.3. Manual Override ..................................................................... 10
4.4. Process Override ..................................................................... 11
4.5. I/O Configuration .................................................................... 11
4.6. Universal Surge Curve .............................................................. 12
TABLE OF FIGURES
Figure 1 Application Overview .............................................................. 3

Figure 2 Stage 1 Surge Curve .............................................................. 6
Figure 3 Stage 2 Surge Curve .............................................................. 9
Figure 4 Stage 3 & 4 Surge Curve ........................................................ 12
Invensys Process Systems

1. GB-101 P-IB CO2 COMPRESSOR

This software specification describes in detail the following anti-surge control
logic sections:
Instrument fail over

Process control override
Anti-surge performance curve
Anti-surge valve sizing
Refer to surge control narrative for control diagram details.
1.1. APPLICATION OVERVIEW

This application covers a compressor control system revamp for a steam turbine
driven multi-stage centrifugal carbon dioxide compressor (GB-101 P-IB).
The compressor normally operates on suction pressure control and is protected

from surge by the anti-surge controllers acting on the compressor’s recycle
valves.
An application overview is illustrated in Figure 1.
F igu re 1 App l ica t ion Ov ervi ew

2. Stage 1
2.1. Flow transmitter fault

If the process flow transmitter fails under-range or over range, the surge control
logic sets a constant value for the failed measurement.
FT-152B Fault Low 4.0 mA

FT-152B Fault High 20.0 mA
Constant Value 30,000 NMCH
FT-152B Base conditions:
Differential 0 - 5000 mmWG

Max flow at base conditions 39,000 NCMH
Base temperature 38.0 Celsius
Base pressure 2.53 kg/cm2A
The logic automatically reverts back to the measured value when the signal
returns to the acceptable range.
2.2. Pressure transmitter fault

When a suction (PT-1S) or discharge pressure (PT-1D) transmitter fails, the
surge control logic sets a constant value for the failed measurement.
Constant value:
Suction pressure 1.63 kg/cm2A

Discharge pressure 4.54 kg/cm2A
2.3. Manual Override

Partial Authority is the surge control mode for normal operation.
2.3.1. Partial Authority
The operator may open and close the anti-surge valve but the surge control and
process control logic (minimum flow control) will override (high select) any
setting that may cause compressor surge or process instability.
2.3.2. Full Manual
In full manual, the surge valve is fully controlled by the manual operator
setpoint. This mode is designed for maintenance (valve stroking when surge
control is disabled) or forcing a valve position to override a faulty transmitter.
Full manual mode access is switch protected.

2.4. Process Override

The surge controller includes a minimum flow controller.
2.4.1. Minimum Flow control
The operator may set a minimum flow setpoint but the surge controller will
override (high select) any setting that may cause compressor surge or process
instability.
2.5. I/O Configuration
Input Tag Description Range Alarm Units

< 20,000
AI – 1 FT-152B Suction flow 0 – 39,000 NMCH
> 38,900
< 0.2
AI – 2 P-1S Suction pressure 0 – 1.5 kg/cm2G
> 1.3
< 3.0
AI – 3 P-1D Discharge pressure 0 – 10.0 kg/cm2G
> 5.5
AI – 4 HIC-152 Manual Over ride 0 – 100.0 % Open
DI – 1 UX-152 Run Permissive 0 - 1 0 On / Off
DI – 2
DI – 3
DI – 4
AO – 1 FY-152B Recycle valve 0 – 100.0 % Open
AO – 2
DO – 1 XV-152 Air supply solenoid 0 – 1 1 On / Off
DO – 2 UA-152 Alarm contact 0 - 1 1 On / Off
VD-51 Surge reset 0 – 1 On / Off
VD-56 Full manual 0 – 1 On / Off

2.6. Universal Surge Curve
F igu re 2 S tage 1 Su rg e C urv e

Note:
1. This surge curve is not affected by MW and may be used for all process
conditions; start up, reduced rates and normal operation.

3. Stage 2

FT-153B Fault Low <3.8 mA

FT-153B Fault High >20.5 mA
Differential 0 – 2500 mmWG


surge control logic sets a constant value for the failed pressure measurement.
Constant value:


3.3.2. Full Manual
Full manual mode access is switch protected (confirm).


T h e o p e r a t o r m a y s e t a m i n i m u m f l o w s et p o i n t b u t t h e s u r g e c o n t r o l l e r w i l l
instability.

< 20,000
> 40,900
< 2.0
> 5.5
< 4.0
> 23.0
DI – 2 HS-153 Full Manual 0 - 1 1 On / Off
DI – 3 -
DI – 4 -
AO – 2 -

F igu re 3 S tage 2 Su rg e C urv e

Note:

4. Stage 3 / 4

FT-154B Fault Low 4.0 mA

FT-154B Fault High 20.0 mA
Differential 0 – 6000 mmWG


surge control logic sets a constant value for the failed pressure measurement.
Constant value:


4.3.2. Full Manual
Full manual mode access is switch protected (confirm).


The operator may set a minimum flow setpoint but the surge controller will
instability.

< 20,000
> 40,900
< 14.0
> 20.0
< 140.0
> 220.0
DI – 2 HS-154 Full Manual 0 - 1 1 On / Off
DI – 3 -
DI – 4 -
AO – 2 -

F igu re 4 S tage 3 & 4 Su rge C urve

Note:

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Controller Hardware

TRI-SEN 160 Compressor Controller
Hardware & Installation Guide
Document No. 99-6808(C)

December 2002
Rev. 4
Software Version 2 and Higher
Webster, Texas
Contents iii
Contents
ILLUSTRATIONS ........................................................................................................................... IV
Chapter 1 - Introduction .......................................................................................... 1
ABOUT THIS MANUAL .................................................................................................................. 1
DOCUMENTATION CONVENTIONS............................................................................................ 2
USER EXPERIENCE PREREQUISITES ......................................................................................... 2
REFERENCE DOCUMENTS ........................................................................................................... 2
Chapter 2 - Product Overview................................................................................. 3
Chapter 3 – Hardware Descriptions ....................................................................... 7

FRONT PANEL ................................................................................................................................. 7
ENCLOSURE..................................................................................................................................... 8
CIRCUIT BOARD ............................................................................................................................. 8
TERMINATION PANEL .................................................................................................................. 8
Chapter 4 - Installation ............................................................................................ 9
SITE SELECTION CONSIDERATIONS ......................................................................................... 9
ACCESS CONSIDERATIONS ......................................................................................................... 9
UNPACKING AND INSPECTION................................................................................................. 10
MOUNTING .................................................................................................................................... 11
WIRING ........................................................................................................................................... 12
General ......................................................................................................................................... 12
Electrical Power Wiring & Safety Ground Wiring ...................................................................... 15
Field Terminations Wiring ........................................................................................................... 16
AUX COMM (Auxiliary Communications) Wiring .................................................................. 17
Instrument Ground Wiring ............................................................................................. 18
AI-XX Analog Input Wiring ...................................................................................................... 19
AO-XX Analog Output Wiring.................................................................................................. 22
DI-XX Discrete Input Wiring.................................................................................................... 23
DO-XX Discrete Output Wiring ............................................................................................... 24
Transmitter and Discrete Output Power .................................................................................. 25
I/O Intrinsically Safe Barriers Wiring...................................................................................... 26
PEER-TO-PEER COMM (Lateral Communications) Wiring .................................................. 28
VERT COMM (Vertical/Supervisory Communications) Wiring............................................... 29
KEEP ALIVE Circuit Wiring.................................................................................................... 29
Chapter 5 - Specifications..................................................................................... 31
Appendix A. Glossary of Terms & Acronyms..................................................... 35
December 2002 Rev. 4

Chapter 1 - Introduction 1
Chapter 1 - Introduction
This document applies to the TRI-SEN 160 which is a multi-control loop, microprocessor-based
controller designed to control compressor surge and performance. This manual is one of a three-
volume set.
About This Manual

As its name implies, this manual is a guide to understanding and installing the TRI-SEN 160
hardware. In depth user training is available from Triconex.
Since this document is relatively small, an index is not included. Instead, a detailed table of contents
is provided. This manual contains the following chapters:
• Chapter 1 - Introduction
This chapter contains information about this document and related reference documents.
• Chapter 2 - Product Overview
This chapter presents an overview of the product as a whole, including typical applications.
• Chapter 3 - Hardware Descriptions
This chapter describes all of the hardware which comprises the TRI-SEN 160.
• Chapter 4 - Installation
This chapter explains how to install a TRI-SEN 160, including mounting and wiring.
• Chapter 5 - Specifications
This chapter provides general specification.
This document will be useful to anyone who is responsible for design, installation, and maintenance
of a control system which contains a TRI-SEN 160 Compressor Controller. Information presented
here will enable knowledgeable persons to perform those tasks that are required for successful
installation of the TRI-SEN 160.

2 TRI-SEN 160 Hardware & Installation Guide
Documentation Conventions
This manual uses the following typographic conventions:
Example Description
NOTE Notes contain supplementary information.
! CAUTION This symbol precedes information about potential equipment damage.
! WARNING This symbol precedes information about potential personnel hazards.
User Experience Prerequisites

To effectively use the TRI-SEN 160, users should have some experience with the use of digital control
systems, or have an instrumentation background. It is assumed that the personnel involved
understand the basics of electronic control systems and good wiring practices. It is also assumed that
personnel involved have access to the required tools.
Extremely advantageous, though not required, is experience with Windows-based software programs,
compressor operation, and normal operations experience within a plant environment.
Reference Documents
• TRI-SEN 160 Operations Guide
• TRI-SEN 160 Configuration Guide
• Documentation provided with other components of a system containing a TRI-SEN 160.

Chapter 2 – Product Overview 3
Chapter 2 - Product Overview

The TRI-SEN 160 is a multi-control loop microprocessor based controller designed to control
compressor surge and performance. The TRI-SEN 160 provides the same complex multi-variable
surge algorithms used throughout the Triconex surge control product range in an inexpensive and
easily operated package.
The TRI-SEN 160 is ideally suited for surge prevention because of its fast processing speed (10ms
input/output scan time and 50 ms loop cycle time), and its ability to efficiently perform the complex
algorithms required.
The TRI-SEN 160's small size and built-in termination assembly allow the controller to be mounted
virtually anywhere. The integrated operator interface provides a comprehensive window on
compressor operation in a readily identifiable format that minimizes the time required for operator
training. Easily read front-mounted displays and pushbuttons simplify operations, while standard
communications features allow a detailed view of the compressor operating parameters on a personal
computer (PC).
100 A
90
S
P 8.8.8.8.8
80
P
V 8.8.8.8.8
70
60
50
SP OUT
40 A
M ON
OFF
S/SV
30
20 TRISEN160
Triconex Corporation
10 A
M MAN AUTO
0 A1/A2
PV SP
OUT
0 20 40 60 80 100
SURGE AUX1
SV AUX2
ACK
TS160-3A
Figure 1. TRI-SEN 160 General Appearance

A typical application of the TRI-SEN 160 to a gas compressor is shown in the figure below. The
TRI-SEN 160 performs equally well when applied to an air compressor.
TRISEN 160
COMPRESSOR
CONTROLLER 4
2,4 1,2,3,4 1,2,3,4 1,2,3 1,2,3,4

BLOW-OFF
VALVE
RECYCLE
VALVE
FT PT PT
SUCTION DISCHARGE
THROTTLING THROTTLING
VALVE VALVE
CONFIGURATION OPTIONS:
DRIVER COMPRESSOR 1. SURGE ONLY
(TURBINE OR 2. SURGE & SUCTION THROTTLING
MOTOR) 3. SURGE & DISCHARGE THROTTLING
4. AIR COMP W/SUCTION THROTTLING
TS160-35
Figure 2. Typical Applications
A block diagram of the hardware is shown in the figure below.
VERTICAL
PEER-TO-
MONITOR- AUXILIARY COMMUNI-
PEER
ING PORT COMMUNI- CATIONS
COMMUNI-
(FUTURE) CATIONS 9.6 or 19.2 KB
MEMORY CATIONS
FRONT BAUD RATE
MICROPROCESSOR 8 K RAM
PANEL
UNIT 32 K EPROM
INTERFACE
2 K EEPROM
DUAL
PORT
8 K RAM
ANALOG DIGITAL DIGITAL

ANALOG
INPUTS (4) INPUTS (4) OUTPUTS (2) MEMORY
OUTPUTS (2) COMM uP
8 K EPROM
4 Std mA 4 ON/OFF-IN
OR OR 2 OPEN
4 ISOLATED 2 ON/OFF-IN COLLECTOR
2 Std mA
T/C, RTD, mA 2 PULSE TRANSISTORS
TS160-4

Chapter 3 – Hardware Descriptions 7
Chapter 3 – Hardware Descriptions

The TRI-SEN 160 is a multi-loop compressor surge and performance controller is designed to greatly
simplify surge control applications. Configuration by personal computer makes it easy to control
complex compressor surge and performance in a small, inexpensive package. The hardware is
designed to be easy to install and simple to maintain.
Front Panel
The front panel, on the front of the unit, provides operator interface to the TRI-SEN 160, once the
configuration is loaded. The front panel consists of pushbuttons, bar graphs, and display windows.
These components are shown in the figure below.
ALARM INDICATOR SELF TEST FAULT INDICATOR
SETPOINT BAR GRAPH SMALL DISPLAY WINDOW
PROCESS VARIABLE
LARGE DISPLAY WINDOW
BAR GRAPH
100 A
S
90
S
P 8.8.8.8.8 SETPOINT DISPLAY
80
P
V 8.8.8.8.8 PROCESS VARIABLE DISPLAY
70
60
50 CONFIGURATION
SP OUT ADJUSTMENT BUTTONS
CONTROL LOOP
40 A
STATUS INDICATORS
M ON
OFF
S/SV
30
20 TRISEN160
CONTROL LOOP
STATUS INDICATORS
10 A
M MAN AUTO
0 A1/A2
PV SP
COMMAND SIGNAL OUTPUT
OUT BAR GRAPH
0 20 40 60 80 100
CONTROL LOOP SURGE AUX1

ACK ALARM ACKNOWLEDGEMENT
SELECTOR BUTTONS SV AUX2 BUTTON
& INDICATORS
TS160-51
Figure 4. Front Panel Components

Enclosure
The TRI-SEN 160 enclosure is designed to be panel mounted and is completely self-contained. No
external power or terminations are necessary.
Circuit Board
All circuitry, including power supply, is contained on a single circuit board. Replacement of all
active components can be accomplished by removing two nylon thumbscrews on the rear of the unit,
and replacing the entire controller, without disturbing any field wiring.
Termination Panel
All power and field device wiring to and from the TRI-SEN 160 is connected on the termination panel
at the rear of the unit. The terminal strips have a polyamide 6.6 insulating body, nickel-plated copper
alloy connectors, and pressure screws. The pressure screws are captive and secured against self-
loosening. All electrical parts are mounted on a rigid 3/32” thick fiberglass circuit board.

Chapter 4 – Installation 9
Chapter 4 - Installation
Site Selection Considerations
The TRI-SEN 160 requires the following conditions during normal operation:
• 32 to 130ºF (0 to 55ºC)
• 5 to 96% relative humidity
• Protection from direct contact with water, chemicals, and conductive dust
• Limited exposure to sulfur compounds, acid other corrosive or reactive vapors or fumes,
and conductive dust
• Limited exposure to non-conductive dust and combustible dust and lint
The TRI-SEN 160 produces a maximum of 100 BTU per hour (25 KGM-CAL/hr) of heat.
Access Considerations
There are very few restrictions on the mounting position of the TRI-SEN 160. The following should
be taken into consideration:
• All electrical power and input/outputs are connected on the rear termination panel.
Because as many as 42 conductors can be terminated to each TRI-SEN 160, adequate
wireway space should be provided.
• The TRI-SEN 160 is operated from the front of the unit, and the front panel (with the
circuit board attached) slides out the front of the unit.
• The control configuration is downloaded to the TRI-SEN 160 via the Vertical
Communications port at the back of the controller assembly.
• To ensure a proper viewing angle, the controller should be installed approximately
64 inches (1626 mm) above the floor.
• Outdoor installation is not recommended, but can be accomplished if the face of the
controller is shielded from direct sunlight, and the unit is placed in an appropriate
enclosure. Long-term exposure to ultraviolet light will discolor the plastic.

Unpacking and Inspection

Upon receipt of the TRI-SEN 160, unpack it carefully and visually check for damage. The following
components are provided with a TRI-SEN 160 shipment:
• TRI-SEN 160 controller assembly
Ensure that the power fuse holder on the rear panel is seated properly.
• 3 fuse packs
Main Power Fuses: 1 each, 0.5 A (120 VAC) F5 or 0.25 A (220 VAC) F5
Input/Output Fuses: 2 each, 1/8 A (28 VDC) F1 Analog Input Fuses; and
F2 Discrete Output Fuses
Power Distribution Fuse: 1 each, 0.5 A (28 VDC) F3 or F4
NOTE: A 2 A fuse is required for the 24 VDC optional power supply for the
TRI-SEN 160 Controller.
• 2 panel clamps
These clamps are identical and can be interchanged. One interlocks on the top and the
other on the bottom of the TRI-SEN 160 housing. The panel clamps accommodate a
panel thickness of 7/16 inch.
• 2 hex head bolts, 1/4” x 4”
• TRI-SEN 160 Users Documentation
If anything is damaged, contact the nearest Triconex business center for instructions for returning it to
the factory. If everything appears to be in order, proceed with the instructions in the following
paragraphs.

Mounting
The following figure provides mounting dimensions for the TRI-SEN 160.
Termination
Panel
TRISEN 160
5-5/8" 5-3/8"
TRISEN 160
2-13/16" 2-5/8"
FRONT VIEW REAR VIEW TS160-38
5-3/8"
3/4" 1/2"
14-13/16" 15/16"
16-1/4"
SIDE VIEW TS160-37
Figure 5. Mounting Dimensions

• Use the hex head bolts and panel clamps to mount the TRI-SEN 160 in the desired
location.
• When the TRI-SEN 160 is positioned properly, hand-tighten both panel clamps in place.
NOTE: Do not exceed 4 ft-lbs or 50 in-lbs (57 cm-kgs) of torque on panel clamp bolts.
This torque limit may need to be reduced on thin control panel faces.
! CAUTION The panel clamps are designed to fail above 80 in/lb (92 cm-kgs) of
torque to prevent damaging the controller if the clamp is over-
tightened.
Wiring
General
The following general guidelines apply to all wiring discussed in the following paragraphs.
• Wire size range is 22-12 AWG stranded; recommended wire size range is 18-14 AWG.
• All wiring should be multi-stranded annealed copper with insulation that meets the
requirements of all applicable electrical codes.
• Keep all wire runs as short and direct as possible. Long wire runs are vulnerable to picking
up stray electrical noise. Also, long wire runs are costly, but remote mounting may be
necessary because of area classification, convenience, or other extreme field conditions.
• Use care when running signal wiring near to or crossing conduit or wiring that supplies power
to motors, solenoids, lighting, horns, bells, etc.
• Avoid bringing TRI-SEN 160 wiring into junction boxes which contain other wiring.
• AC power wiring should be run in a separate conduit from the TRI-SEN 160 DC power and
the I/O. All power wiring to and from the TRI-SEN 160 should be in grounded steel conduit.
• The TRI-SEN 160 should be connected to a high quality instrument grade ground with a
14 AWG wire.
• CHECK ALL WIRING RUNS THAT ARE TO BE CONNECTED TO THE TRI-SEN 160.

All power and field device wiring to and from the TRI-SEN 160 is connected on the termination panel
at the rear of the unit. The TRI-SEN 160 termination panel is shown in the figure below.
F1 TB1
TB1
R1 1
22
1
VDC
28
R2
S+ +
A
Termination F1
COMM
DI-21
AUX
Panel R1
S-
B*
R2
S+
DI-22
J1
CR1
S-
C A
TRISEN 160
1 F2
S+
DI-23
U1
F2
T+
S-
AI-01
CR1
T-
S+
DO-22 DO-21 DI-24
F1
A
U2
S-
R1
T+
R2
AI-02
P
T-
F1
L
U3
A
R1
P
T+
R2
AI-03
L
T-
R3
16
PEER COMM
A
U4
PEER TO
R4
A
R5
T+
D1
B*
AI-04
R6 T-
A
F3
COMM
A
F4 VERT
V+
AO-1
1 B*
V-
NO C
ALIVE
KEEP
20
V+
AO-2
G
G
42
V-
H
H
21 42
RIGHT SIDE VIEW

N
N
F5
TB2 TS160-33
MADE IN U.S.A.
J2
TS160-32
Figure 6. TRI-SEN 160 Termination Panel

J1 TB1
B3 A 1 4
AUX
2
COMM
B4 B+ 3
B10 4 28 V
A10 5 RTN
B1 T+ 6
F1 .12A
A1
R1
T- 7 AI-01
A2 A 8
R2
R2
B2 T+ 9
F1 .12A
A3
R1
T- 10 AI-02
A4 A 11
R2
R2
B5 T+ 12
F1 .12A
A5
R1
T- 13 AI-03
A6 A 14
R2
R2
B6 T+ 15
F1 .12A
A7
R1
T- 16 AI-04
A8 A 17
R2
R2
B7 V+ 18
AO-1
C7 V- 19
B8 V+ 20
AO-2
C8 KAP V- 21
F3 .50A
A9,B9
+ 22 +28 VDC IF ANALOG INPUTS AND

F4 1 1 DISCRETE OUTPUTS ARE
C9 S+ 23 TO BE POWERED
DI-21 EXTERNALLY, MOVE FUSE
C10 S- 24 FROM F3 POSITION TO F4
POSITION.
B11 S+ 25
DI-22
C11 S- 26
A11 S+ 27
DI-23
A12 S- 28
B12 S+ 29
DI-24
C12 S- 30
F2 .12A
P 31
DO-21
C13 L 32
F2 .12A
P 33
DO-22
B13 L 34
A14 A 35
R3 PEER TO
THE LAST UNIT ON EITHER
C14 36 PEER 4 END OF A NETWORK MUST
R4 COMM HAVE RESISTORS R5 & R6
B14 B+ 37
INSTALLED; OTHERWISE
A15 A 38 RESISTORS SHOULD BE
R5 4
REMOVED.
VERT
C15 4 39
COMM
R6
B15 B+ 40
A16 C 41 KEEP ALIVE IS A NORMALLY

KEEP 2 OPEN CONTACT RATED AT
B16 NO 42 ALIVE 0.5 AMP 028 VDC (OPEN ON
FAILURE OR LOSS OF
C16 POWER, CLOSED DURING
NORMAL OPERATION)
A13
J2 TB2
FOR REFERENCE ONLY:

1,6 G 1 3
3 120 VAC PRIMARY POWER FUSE F5
PRIMARY 120 VAC 0.5 AMP
3,8 H 2 60 HZ
F5 .5A POWER 240 VAC 0.25 AMP
INPUT 3 24 VDC 2 AMP
5,9 N 3
TS160-59
Figure 7. Termination Panel Schematic

The additional guidelines below should be followed when wiring the TRI-SEN 160:
• The stripped portion of the wires should be 5/16” (8 mm) long.
• Wires should be inserted in the clamp type terminals until they touch the internal stops.
The terminal screw should be tightened while holding the wire in place. Check for
proper clamp pressure with a gentle tug on the wire.
Electrical Power Wiring & Safety Ground Wiring

• The TRI-SEN 160 power terminals can accept wire sizes up to 12 AWG (2.2 mm).
• Electrical power should be provided from a highly reliable, dedicated AC or DC power
source.
• Power consumption is 35 watts maximum.
AC POWER
TB-2
G SAFETY GROUND 90 TO 130 VAC
F5: 120 VAC - 0.5 AMP F5 180 TO 260 VAC
H HOT
45 TO 400 HZ
220 VAC - 0.25 AMP
N NEUTRAL 35 WATTS MAX
DC POWER - OPTIONAL
TB-2
G SAFETY GROUND
F5 24 V NOMINAL
F5: 24 VDC - 2 AMP H 24+ VDC (23-28 VDC)
35 WATTS MAX
N 24 - VDC
TS160-75
NOTE: The TRI-SEN 160 can be supplied with a DC power supply as an option. Contact
Triconex for information.
Figure 8. Typical Electrical Power Wiring

Field Terminations Wiring
TB1
22
1
VDC
28
S+ +
A
COMM
DI-21
This section provides instructions for bringing field wiring to the
AUX
TRI-SEN 160. All field wiring is connected to the termination panel

S-
B*
on the back of the unit.

S+
DI-22
S-
The input/output connectors on the termination panel accept wire

S+
DI-23
sizes from 28 AWG through 14 AWG (1.8 mm). However,

T+
S-
recommended wire sizes are noted in the following paragraphs

AI-01
T-
where applicable.
S+
DO-22 DO-21 DI-24
A
S-
The paragraphs in this section are arranged according to the

T+
AI-02
arrangement of the connectors on the termination panel.

T-
L
A
Refer, again, to the illustration at left showing the TRI-SEN 160

P
T+
termination panel.
AI-03
L
T-
PEER COMM
A
PEER TO
A
T+
B*
AI-04
T-
A
COMM
A
VERT
V+
AO-1
B*
V-
NO C
ALIVE
KEEP
V+
AO-2
V-
21 42
RIGHT SIDE VIEW

TS160-33

AUX COMM (Auxiliary Communications) Wiring

This is the Modbus communications port. The AUX COMM port can support RS-485 or RS-232,
depending on which was specified when the TRI-SEN 160 was ordered.
The signals for this port conform to the EIA RS-485 specification at 9600, 19200 or 38400 baud.
1200 or 2400 baud are available and can be used when peer-to-peer communication is not used.
RS-485 transmission distance is limited to 3000 feet (900 mm) when using 20 AWG twisted pair with
an overall shield. The recommended wire is a twisted pair with overall foil and braid shields, similar
to Alpha Wire Corporation SupraShield, catalog number 25152, or equal. RS-232 transmission
distance is limited to 50 feet.
Typical field wiring for auxiliary communications is shown in the following two figures.
WHITE
+ RS-485
TO USER'S
SHIELD SUPERVISORY
(MODBUS MASTER)
- COMPUTER
BLACK
TS160
TERM PANEL
AUX COMM
WHITE TB1-1
A
R54
INTERNAL
SHIELD TB1-2
BLACK TB1-3 R53

B*
TS160-50A
NOTE: The last TRI-SEN 160 unit on either end of a network must have resistors R54
and R53 installed on the Main Circuit Board. (These resistors are installed on
all shipped units.) The resistors must be removed from all other units in the
network. A network would include a Modbus master and one or more
TRI-SEN 160s. Contact Triconex for instructions for removing these resistors.
Figure 9. Typical Wiring, Auxiliary Communications, RS-485
TS160
TERM PANEL
AUX COMM
DB-9
FEMALE TB1-1
A
5
PC 4 TB1-2
3
CONNECTION 2
1
TB1-3
B*
TS160-77
Figure 10. Typical Wiring, Auxiliary Communications, RS-232

Instrument Ground Wiring

A safety ground is required for the chassis; refer to the previous discussion on Power Supply Wiring
and Safety Ground Wiring. In addition, it is recommended that the controller be provided with a
separate instrument ground (signal ground connection) as shown in the figure below. The safety
ground should be isolated from the TRI-SEN 160 instrument ground.
The TRI-SEN 160 instrument ground is connected to the termination panel at TB1-4 or 5.
NOTE: TB1-4 is jumpered to earth ground (four resistors on the back panel, all labeled R2). This
jumper must not be removed unless the application requires floating the analog input
commons.
All common terminals should be connected individually with the final termination point being earth
ground. If absolutely necessary, they can be daisy chained together; however, this is not
recommended. The figure below shows the typical method for system grounding.
TS160 TS160 TS160 TS160 TS160

1 2 3 4 5
TB1-4 TB1-4 TB1-4 TB1-4 TB1-4
INSTRUMENT GROUND NOT RECOMMENDED
EARTH
TS-160-61
Figure 11. Typical Instrument Ground Wiring
The minimum wire size that should be used for the instrument ground connections is 16 AWG;
14 AWG is preferred. A good earth ground will ensure that a static potential does not accumulate
within the controller.

Careful consideration should be given to the shield connections to avoid ground loops. The figure
below shows a typical connection.
TS160
TRANSMITTER
TERM PANEL
AI
+ TERM
AI
- TERM
CUT & TAPE

SHIELD AT
TRANSMITTER
TS160-76
Figure 12. Typical Instrument Ground Shield Wiring
AI-XX Analog Input Wiring

The TRI-SEN 160 analog input circuit is a high impedance differential amplifier with frequency and
voltage limiting circuits. The input terminals are T- (positive) and A (negative). Refer to the figure
below.
TS160
TERM PANEL TS160 MAIN CONTROLLER BOARD
AI-XX
28VDC T+ +15
MULTIPLEXER +15
F1
T- 100K 200
+
R1 INST
A 0.068
AMP
-
100K 200
R2
-15
-15
INSTRUMENT GROUND
TS160-60
Figure 13. Analog Input Circuit
The differential amplifier cancels noise that is common to both of its input wires and amplifies only
those signals that produce a difference of voltage between the input terminals. However, the voltage
applied to the differential amplifier inputs, as referenced to the amplifier’s ground, must be
maintained within the limits of the amplifier’s voltage specifications. The differential amplifier used
in the TRI-SEN 160 has a voltage range typically between +12 to –12 VDC, with a guaranteed
minimum of +10 to –10 VDC. Failure to stay within the recommended voltage range will produce
erratic and incorrect input measurements.
The TRI-SEN 160 is designed to provide the necessary means to maintain the common mode voltage
within its limits. The recommended field wiring connections given in this manual produce minimum
extraneous current paths while maintaining a common voltage reference within the control system.

Generally, the TRI-SEN 160 can accept one of three input voltage ranges depending on the entered
configuration. These ranges are:
• 0.25 to 1.25 VDC
• 1.00 to 5.00 VDC
• 0 to 5.0 VDC
When current loops are used for transmission, the appropriate value of R1 must be installed. Typical
example values are: 6.25 ohms, 100 ohms (10 to 50 mA), or 250 ohms (4 to 20 mA), respectively,
for the ranges given above. The second resistor, R2, is available for dedicated recorder or computer
connections. Unless otherwise specified, the factory installs a 250 ohm, 0.1% resistor for R1 and a
jumper for R2. Resistors R1 and R2 plug into sealed sockets and can be removed easily. Refer to the
previous figure for resistor locations.
! CAUTION Do not attempt to insert resistors with a lead diameter larger than 0.025”
(0.63mm) 22 AWG. Larger leads will permanently damage the sockets.
Loop Powered Transmitters

Two-wire 4 to 20 mA current transmitters are connected to the termination panel T+ (+24 VDC to
drive the current loop) and to T- terminals. These two terminals are adjacent to each other for
convenient twisted pair wire termination. Cable shields, when used, should be terminated at one
point. In most installations, the shield should be instrument ground. Refer to a previous figure
captioned Typical Instrument Ground Wiring.
An external 28 VDC power supply can be connected to the termination panel at terminals +28 VDC
and GND. This option should be specified when equipment is ordered. In such a case, the F3 fuse
must be removed and the F4 fuse installed for TB1-22 on the termination panel.
Externally Powered Transmitters and Devices

There are two types of externally powered (4-wire) transmitters: the current source type and the
current sink type. In either case, it is recommended that the transmitters be isolated from the external
power source to obtain satisfactory results.
• Current Source Transmitters
Control the current flow leaving the transmitter. The current is then returned to the
transmitter’s ground terminal. The wiring connection is shown in a. of the following figure.
Care must be used in providing an adequate system ground (discussed later).
• Current Sink Transmitters
Control the current which is returned to the transmitters. This arrangement requires that the
transmitter is isolated from earth ground. The field wiring is shown in b. of the following
figure. Note that resistor R2 has been removed from the termination panel and replaced by a
jumper.
• Voltage Transmitters
The TRI-SEN 160 can accept a voltage input if connected as shown in c. of the following
figure. Note that resistors R1 and R2 have been removed. Terminal R provides the required
system grounding (discussed later).

• Auxiliary Devices
The A (auxiliary) and the GND terminals (d. of the following figure) can be connected to
other devices, such as a recorder or a computer. Resistor R2 generates a voltage drop that can
be read by a single ended or differential input of the auxiliary device. If the auxiliary device
accepts a 4 to 20 mA input signal, R2 must be removed or replaced with a 5.1 volt 1% zener
diode (1N4689D).
CURRENT SOURCE TS160 CURRENT SINK TS160

TRANSMITER TERM PANEL TRANSMITER TERM PANEL
AI-XX AI-XX
+ VDC + VDC
T+ T+
+ +
T- T-
R1 R1
A A
- REMOVE - REMOVE
R2 R2
EXTERNALLY POWERED
TS160-62
EXTERNALLY POWERED
TS160-63
a. b.
TS160 TS160
VOLTAGE TRANSMITER TERM PANEL TERM PANEL
AI-XX AI-XX
+ VDC
T+
+ T+
+
XMTR
T-
REMOVE - T-
- R1 R1
A
GND JUMPER + A
R2 AUX
DEVICE R2 OR
-
EXTERNALLY POWERED
TS160-64
TS160-65
c. d.
Figure 14. Typical Analog Input Wiring

AO-XX Analog Output Wiring

The TRI-SEN 160 can supply either a 0 to 20 or a 4 to 20 mA signal for each analog output. This is a
current source type signal. The power for these outputs is supplied by the TRI-SEN 160. Field
connections are made to the V+ and V- terminals as shown in the figure below. The TRI-SEN 160
internal ground is connected to the V- terminal. These terminals can be commonly joined together, as
is done for intrinsically safe barriers.
I/P TS160
TERM PANEL
AO-XX
+ V+
- V-
INSTR GND
TS160-46
Figure 15. Typical Analog Output Wiring

DI-XX Discrete Input Wiring

The discrete inputs are powered by the TRI-SEN 160. The TRI-SEN 160 discrete inputs are designed
to support two-wire electronic level switches. Each discrete input is powered internally by the
+28 VDC supply and is opto-isolated from the controller circuits. The discrete input circuit is
designed so that current flow less than 11 mA is considered an open circuit. A closed circuit is
represented by current flow greater than 14 mA. The S- terminal is connected to instrument ground.
To generate a closed condition, the resistance between S+ and S- must be 430 ohms or less. To
generate an open circuit condition, the resistance across the inputs must be more than 1000 ohms or
more. Typical field wiring is shown in the figure below.
FIELD TS160 OPEN TS160

CONTACT TERM PANEL COLLECTOR TERM PANEL
DI-XX TRANSISTOR DI-XX
S+ S+
S- S-
INSTR GND INSTR GND

TS160-47 TS160-48
Figure 16. Typical Discrete Input Wiring

DO-XX Discrete Output Wiring

The TRI-SEN 160 discrete outputs are open-collector transistor drivers. Each driver can sustain
applied voltages up to 50 VDC while maintaining a current of 125 mA maximum.
The P terminals are powered from the internal 28 VDC source and are fused at 125 mA to protect the
power supply. Refer to a. in the figure below.
The collector of the non-isolated transistor driver is connected to the L terminal. The emitter of the
transistor is connected to the ground terminal. The discrete output is closed when the transistor
conducts.
Discrete outputs driving externally powered logic devices are connected as shown in b. of the figure
below, if the negative of the logic device power supply is grounded. Otherwise, an interposing relay
is required.
When the load is inductive, such as a relay, a suppression diode should be connected as close as
possible to the coil. Refer to a. in the figure below. When de-energizing, the collapsing magnetic
field induces a substantial reverse EMF. The diode shorts out this reverse voltage, reducing electrical
noise and the possibility of damaging the discrete output driver. A suitable diode is 1N4004 or
equivalent.
TS160
TERM PANEL
DO-XX
P F2
+28 VDC
DC
L CR1
LOAD
LOGIC DEVICE INPUT TS160
SUPPRESSION TERM PANEL
55 VDC DO-XX
DIODE FOR
INDUCTIVE LOADS MAX
P
TS160 MAIN
CONTROLLER +
300 MA MAX
BOARD L
-
RTN
28 VDC EXTERNALLY POWERED
TS160-71 TS160-70
a. b.
Figure 17. Typical Discrete Output Wiring

Transmitter and Discrete Output Power

The TRI-SEN 160 has provisions for distributing fused 28 VDC power for driving current loops, as
shown in a. of the figure below.
Each individual analog input T+ terminal is protected by a 1/8 amp plug-in fuse. The loop current is
returned to the ground terminal, which is connected to the internal ground terminal. Refer to
Figure 18 below.
In a similar manner, the discrete outputs provide fused 28 VDC power for operating external devices
as shown in Figure 19 below.
! CAUTION Do not attempt to insert fuses with a lead diameter larger than 0.025” (0.63mm)
22 AWG. Larger leads will permanently damage the sockets.
TS160 TS160
TERM PANEL TERM PANEL
AI-XX DO-XX
T+ F1 P F2
+ +28 VDC
1/8 AMP DC
XMTR L CR1
LOAD
- T-
R1 SUPPRESSION
A DIODE FOR
INDUCTIVE LOADS
R2 TS160 MAIN
CONTROLLER
BOARD
TS160
TERM PANEL
RTN
AI-XX
28 VDC
T+ F1
+ + VDC TS160-71
1/8 AMP
XMTR
- T-
R1
A
R2
TS160-66
Figure 18. Transmitter Power Figure 19. Discrete Output Power

PEER-TO-PEER COMM (Lateral Communications) Wiring

The TRI-SEN 160 peer-to-peer communications terminals (port) on the termination panel allow data
residing in a controller to be communicated to one or more additional controllers. The maximum
number of TRI-SEN 160 controllers that can be connected on the peer-to-peer network is 32. The
common mode voltage limit between TRI-SEN 160s on the peer-to-peer communications line is +12
to -7 VDC. The signals for this port conform to the EIA RS485 specification.
The combined transmission distance is limited to 3000 feet (900 mm) when using 20 AWG twisted
pair with an overall shield. The recommended wire for peer-to-peer communications lines is a
twisted pair with overall foil and braid shields, similar to Alpha Wire Corporation SupraShield,
catalog number 25152, or equal.
All TRI-SEN 160 controllers connected to the same peer-to-peer communication party line must
be connected to the same system ground.
The RS485 differential signal driver increases the voltage level on one wire, while grounding the
voltage on the other wire. The receiver is connected across the A and B* terminals, and responds to
the voltage difference on its inputs. The transmission lines must be terminated on the ends with a pair
of 62 ohm resistors, R3 and R4, to prevent echoes. Refer to the figure below.
TS160
TERM PANEL
PEER-TO-PEER
COMM
WHITE
A
R3
SHIELD
BLACK R4
B*
TS160
TERM PANEL
PEER-TO-PEER COMM
WHITE
A
REMOVE
R3
SHIELD
REMOVE
BLACK R4 TS160
B*
TERM PANEL
PEER-TO-PEER
COMM
WHITE A
R3
SHIELD
R4
BLACK B*
TS160-49
Figure 21. Typical Peer-to-Peer Communications Wiring
As shown in the figure above, only two pairs of resistors are required on the peer-to-peer
communications line. One pair of resistors should be located at each end of the party line. Pull out
the unneeded resistors from their sockets on the termination panel. Also, note that the shield drain
wire is terminated on both ends to provide the proper ground referenced voltage levels. This is a
similar requirement to that for System Ground Wiring, discussed above.

VERT COMM (Vertical/Supervisory Communications) Wiring

The vertical communications terminals on the termination panel link the TRI-SEN 160 to a personal
computer (PC) workstation for the purpose of configuring and monitoring the operation of the
TRI-SEN 160. The signals for this port conform to the EIA RS-232/485 specification at 1200, 2400,
9600, 19200 or 38400 baud.
TS160
TERM PANEL
VERT COMM
DB-9
FEMALE TB1-38
A
5
PC 4 TB1-39
3
CONNECTION 2
1
TB1-40
B*
TS160-77A
Figure 22. Typical Wiring, Vertical Communications, RS-232, Optional
KEEP ALIVE Circuit Wiring

This circuit is used, only for redundant applications, to indicate failures or loss of power.
• Keep alive by the watchdog circuit and controller diagnostics.
• Rated 27.5 VDC, 0.50 amps.
• Mechanical relay, dry contact.
• Wired to an alarm input in a single application.
• Used to initiate a transfer to the backup controller in a redundant application.
TS160
TERM PANEL
KEEP ALIVE
TB1-41
C
TB1-42
NC
TS160-78
Figure 23. Typical Keep Alive Circuit Wiring

Chapter 6 – Troubleshooting 31
Chapter 5 - Specifications
Inputs/Outputs
The common terminals of all I/O circuits are grounded. The analog inputs have filtering networks
that provide transient and spike suppression. The analog input voltage range is +/- 10 VDC
maximum.
Analog-to-Digital Conversion
A/D Conversion Accuracy +/- 0.025 %
Analog Input Accuracy +/- 0.1 %
Long-Term A/D Stability +/- 0.05 % of span shift/year max
Resolution 12 bits
Analog Inputs
Number Available 4
Signal Types Signal Inputs 01 through 04 are high level analog inputs.
0-5, 0.25-1.25, 1-5 VDC; 0-20, 4-20, or 10-50 mA DC
(with appropriate precision resistors installed at input terminals)
Isolation +/- 15 VDC continuous
Common Mode Rejection 80 db min at 60 Hz peak input; +/- 10 VDC max
Maximum Input Voltage Range +/- 10 VDC operating, non-destructive
Input Resistance 100 megohms min
Transmitter Type 2- or 4-wire; 27.5 VDC transmitter excitation supplied from
controller or external source
Input Filtering 12 Hz RC network for each channel
Frequency/Pulse 0 to 10 KHz square wave only, or
pulses converted to a resistance value of 400 Ohm or less
(pulse on or positive half cycle), or
1 KOhm or more (pulse off or negative half cycle).
Signal is connected to the TRI-SEN 160 via a discrete input (see
below).

Digital Inputs
Number Available 4; DI-21 through DI-24
DI-23 and DI-24 can be used to interface to pulse signal source
Signal Type On/Off Status Monitoring (dry contact)
Power Supply Either 27.5 VDC internally supplied, or DC power supply
voltage when that option is used.
Input Isolation Opto-isolated from controller electronics. Shares TRI-SEN 160
PC communications on return side.
Open/Closed Definition Discrete is OPEN when the external circuit resistance is 1 Kohm
or greater (less than 11 mA flow through the contact or device),
and is CLOSED when the external circuit resistance is 430 Ohms
or less (more than 14 mA flow through the contact or device).
Analog Outputs
Number of Outputs 2
Signal Type 4-20 or 0-20 mA DC current source
Output Load Range 0-700 ohms
Signal Ripple +/- 0.025 % of 12-bit scale
Power Source Either 27.5 VDC internally supplied, or DC power supply
Digital Outputs
Number of Outputs 2
Signal Type On/Off logic. Open collector transistor conducts to DC common
when the discrete output is ON.
Rating 125 mA DC at 50 VDC max
Power Source Either 27.5 VDC internally supplied, or DC power supply
Keep-Alive Relay Contact Rating 27.5 VDC, 0.50 A mechanical contact
Contact opens upon fault or power failure.
Serial Ports
Number of Ports 3
Vertical Communications Port To/from operator interface PC.
RS485/232 at 9600, 19200 or 38400 baud. 1200 or 2400 baud
are available and can be used when peer-to-peer communication
is not used.
Peer-to-Peer Communications Port To/from other TRI-SEN 160s.
RS485 at 286 kbaud.
Auxiliary Communications Port Modbus Protocol Communications Port.
Selectable 1200 or 2400 baud for Modbus operations.

Chapter 6 – Troubleshooting 33
Power Supply
Line Voltage 90 to 130 VAC, or 180 to 260 VAC, 45 to 400 Hz
Optional 24 VDC (nominal) power supply (23-28 VDC)
Power Requirements 35 watts max, 20 watts avg (depending on configuration)
Microprocessor (CPU)
Control Processor Motorola 68B09, 8-bit I/O, 16-bit registers
Instruction Cycle Time 500 nanoseconds
Arithmetic Precision 15-bit signed fraction, 7-bit signed 2’s complement exponent,
+/- 0.0003 % accuracy, or greater, of all arithmetic operations
Communications Processor Intel 8031
Memory
RF Interference
Normal Operation is not disrupted when the TRI-SEN 160 operates in the following RF fields:
20 volts/meter at 14 KHz
10 volts/meter above 14 KHz
5 volts/meter from 30 MHz to 10 GHz
The above are equal to or exceed MID-STD-461B qualifications
Environmental
The TRI-SEN 160 controller meets the following environmental conditions without loss of accuracy.
Operating Temperatures: Ambient Relative
Humidity
Condition Ambient Temp Non-Condensing
Normal Limits 0 - 50ºC 5 - 96 %
Operative Limits 0 - 55ºC 5 - 96 %
Transport Storage -40 - 70ºC 5 - 96 %
Vibration 5 – 60 Hz at 0.030 inch total excursion along X, Y, and Z axes
Chemical Corrosion Resistance Conformal coating is applied to boards for protection against
H2S, SO2, and traces of sand, salt, and dust.
Agency Approvals
CE Mark

An Invensys Company
Software Configuration

Chapter 3 – Configuring the TRI-SEN 160 5
Chapter 3 – Configuring the TRI-SEN 160

The TRI-SEN 160 controller and software are designed to greatly simplify compressor surge control
configuration and operation. Prior to beginning configuration of a compressor the user should
familiarize themselves with the TRISEN compressor control algorithms and features. While detailed
understanding of the theory behind the TRISEN algorithms is not required, a basic understanding of
the features provided by the TRI-SEN 160 is required for an overall understanding of compressor
surge control.
The TRI-SEN 160 Compressor Controller is configured on a personal computer (PC), then
downloaded to the TRI-SEN 160. Configuration is accomplished with a Triconex-developed software
program which runs under Windows 95, Windows 98, or NT. This software program has many
features in common with other Windows software programs including point and click interface. The
TRI-SEN 160 configuration software program also provides the following additional features:
• Access to all compressor data within the controller
• Dynamic graphical representation of compressor map
• Real time trending
• Trend data stored in standard spreadsheet format
• Fill in the blank compressor configuration
• Automatic surge map generation
• Remote monitoring via phone line, local area network, or wide area network
• Event logging (user definable)
Once configuration is completed on a PC, it is downloaded to the TRI-SEN 160. The PC is used for
configuration only, not operation of the TRI-SEN 160.
Software Installation on Your PC

The TRI-SEN 160 configuration software is supplied on a floppy disk. To install the software on your
PC, insert the disk into the floppy drive and run the SETUP.exe program. Then, follow the
instructions on the screen. The supplied floppy disk also contains a README.txt file with additional
information.
PC - TRI-SEN 160 Communications

Communications between the TRI-SEN 160 and your PC must be established in order to download
the configuration to the TRI-SEN 160 initially, and to change an existing configuration. Refer to the
Hardware Guide, Wiring chapter, Vertical Communications Wiring paragraphs for details concerning
establishing this communications link.
Once the configuration software is installed and running, the heartbeat light will flash in the
Com Link box on the Main Menu screen. This screen is shown in the Software Quick Reference
paragraph of this chapter.
Modbus protocol information is provided later in this document.

6 TRI-SEN 160 Configuration Guide
Prerequisite Information
Certain information must be collected before a TRI-SEN 160 can be configured:
• Compressor performance map. The compressor manufacturer supplies the compressor
performance map. This map details the base operating conditions for the compressor.
These include:
− Compressor suction pressure
− Compressor suction temperature
− Molecular weight of the gas (MW)
− Heat capacity ratio of the gas (CP/CV referred to as k)
− Compressibility of the gas (Z)
− Information for mapping PdPS vs. flow
• Flow measurement device information
− Maximum range of flow transmitter
− Location of measurement device (compressor suction or discharge)
− Calculation pressure of the flow measurement device
− Calculation temperature of the flow measurement device
• Transmitter information
− Suction pressure minimum and maximum range
− Discharge pressure minimum and maximum range
− Flow minimum and maximum range
− Any auxiliary transmitter minimum and maximum range
− Engineering units of measurements
• Surge valve information
− Linear or equal %
− Air to open or air to close

Starting the Program

The TRI-SEN 160 configuration program is launched from the Windows 95, Windows 98 or NT
desktop. Initially, the following opening screen is displayed.
Figure 3. TRI-SEN 160 Configuration Program Opening Screen
This screen will be displayed for a few seconds and then the Main Menu screen will appear.
Main Menu
Access to configuration changes, data collection, and graphic screens is available from the Main
Menu screen (shown below) by clicking on the appropriate icon or selecting a pull down menu item.
Depending on the user’s access level, some of the features may not be available for selection. A
discussion of passwords and access levels is provided later in this chapter.
Figure 4. Main Menu Screen

Software Quick Reference

The following illustration provides a quick reference to all of the Main Menu screen icons and other
features.
15 16
13 14
17
1 4 7 10
2 5 8 11
3 6 9 12
TS160-73
1 2 3 4 5 6
Real-Time Peer-to-Peer
Download Upload Read Control Loop Real Time Communi-
Configuration Configuration Configuration Tuning Input Ranges cations
Constants
Access Level
Tune Tune View Tune Tune Tune
Description
Download Upload Config View real-time 18 tuning 8 ranges for Unit
Config From From TS160 to data on PC constants for each of 4 Identification
PC to TS160 PC monitor each of 4 analog inputs for comm links
without control loops between
disturbing multiple
control action TS160s
Subsequent Screens
Download Upload One screen for One screen for
Configuration Configuration each of 4 each of 4
control loops analog inputs

7 8 9 10 11 12
Off-Line
View Data Control Loop Off-Line Input Open Save
Tuning Ranges Configuration Configuration Surge Curve
Constants
Access Level
All Tune Tune Tune Tune Configure
Description
Control Loop Same as Real Same as Real Opens existing Saves new or Surge Curve
& Process Time, but Off- Time, but Off- config file revised config Points,
Alarms; Line Line; file Compressor
Print, Record 2 character- Map, Gas &
Data, Trend, istics for each Comp
Compressor of 4 digital Properties,
Map, Remote inputs Controller
Monitor, Event Config;
Log Calculation
Subsequent Screens
Alarm One screen for Open Save Surge Curve
Summary each of 4 Configuration Configuration
digital inputs
Data Compressor
Collection Map
Properties
Controller
Configuration
Lookup Table
13. Lights indicate whether TRI-SEN 160 is communicating with PC configuration

program
14. Text indicating configuration file currently open
15. Pull-down menus associated with opening screen
16. Minimize, maximize and close buttons typical of Windows screens
17. Text indicating current access level

File Pull-Down Menu
This menu appears on the Main Menu screen.

The Open menu item opens an existing configuration. The Save menu
item saves the currently selected configuration, as indicated in the text
field across the top of the screen under the pull-down menus. Printer
Setup and Printer Font menu items can be used to specify the print
layout, etc. Select Exit to close the TRI-SEN 160 Configuration Program.
Printing Your Application Configuration

It may be advisable to keep a hard-copy record of your operating configuration. When all data entry
is completed and any time thereafter, a configuration can be printed by selecting Print Configuration
from the File menu above, and then entering requested information regarding printer selection, etc. on
the subsequent screens. The currently selected control loop configuration, as indicated in the text
field across the top of the screen under the pull-down menus, will be printed. Printing a configuration
requires Tune access level. The Print Screen menu item will print the screens for the selected
control loop.
Com Port Pull-Down Menu
The Com Port Menu appears on the Main Menu screen. This menu
allows for any RS232 port supported by Windows to be used to configure
the TRI-SEN 160. The selections are Com Port Settings and Save Com
Port Settings.
NOTE: The Com Port must be correctly configured in order to
establish communications with the TRI-SEN 160.
The Save Com Settings saves the choices made on the Com Port Settings
window. The next time the TRI-SEN 160 Configuration Program is
started, these selections will be used by default.
The Com Port Settings window is used to select the PC communications

port and baud rate you wish to use for communications between your PC
and the TRI-SEN 160.
Config & Real Time Pull Down Menus

These menus contain items that correspond to the 12 icons on the Main Menu screen.

Modbus Pull-Down Menu
This menu provides the means to configure the Modbus protocol

on the communications port. Baud rate, parity, and a Modbus
address (1-247) are set in this window.
! CAUTION
Modbus changes made with this pull-down menu take effect
immediately upon download of the configuration to the
TRI-SEN 160.
Password Pull-Down Menu

Access Levels
The TRI-SEN 160 has three levels of access: View, Tune, and Configure. Different access privileges
are available at each level. For example, the Main Menu screen with View access level is shown
below. Notice that all icons not available with View access level are grayed-out.
The View access level does not require a password and allows the real time data to be observed,
compressor maps and real time trends to be displayed, alarms to be acknowledged, and view-only
access to the compressor configuration. No changes to the configuration are allowed at this level.
The Tune access level requires a password, and allows the same access as View. In addition, this
access level allows the configuration to be uploaded and downloaded, loop tuning parameter
modifications, and I/O range changes. The default password is Tune.
The Configure access level requires a different password and allows access for configuration
modifications, as well as all View and Tune access level privileges. In addition the Configure level
allows password changes. The default password is Configure.
This document addresses all aspects of the program at the Configure access level.

Using Passwords
To change access levels, a password must be entered on the Password screen shown in the figure
below. The Password screen is available from the Password pull-down menu on the Main Menu
screen. Passwords are not case sensitive; they can be upper and/or lower case.
Figure 5. Password Screen
Changing Passwords
Default passwords are “tune” for the Tune access level, and “configure” for the Configure access
level.
At the Configure access level, the password for either the Tune or the Configure access level can be
changed by selecting the Password pull-down menu from the Main Menu. Then follow instructions
on the screen.
About Pull-Down Menu

The TRI-SEN 160 software version is displayed when this menu is pulled down.

Download Configuration
Clicking on the download icon (left) on the Main Menu displays the file
selection dialog box (below). Download Configuration requires Tune access
level.
Figure 6. Download Configuration Screen
The configuration program displays TRI-SEN 160 configuration files that are contained in the default
directory. Once a file is selected and the OPEN button is clicked, the selected configuration will be
downloaded to the TRI-SEN 160.
! WARNING Selecting a new configuration and downloading it to the TRI-SEN 160 will
replace any existing configuration residing in the TRI-SEN 160. Care
should be taken to insure the selected configuration is compatible with the
field installation.
Control will be suspended during the download with outputs held constant.
Control action will resume immediately upon completion of the download.
Configuration changes, such as changing valve outputs from air to open to
air to close, will take effect immediately upon completion of the download.
This can cause significant process upsets unless the loop is placed in
manual mode prior to the download.
During the download, a progress bar (left) is displayed indicating the status of
the download.
The front panel of the TRI-SEN 160 will show ‘doing conf’ in the SP (Setpoint) and PV (Process
Variable) display windows.
At a communications speed of 9600 baud downloading requires approximately 20 seconds.

Upload Configuration
Clicking on the Upload Configuration icon (left) will open another file selection
dialog box below. Upload Configuration requires Tune access level.
Figure 7. Upload Configuration Screen
Any valid Windows file name can be entered in the File Name box or a file can be selected from the
file view window and the uploaded configuration will be saved under that name. If the file already
exists, a dialog box will appear asking the user to confirm replacing the existing file with the
configuration upload.
The uploaded configuration can be saved in a different directory by editing the Save In box, or the
Windows file directory tree can be browsed for a suitable location.
NOTE: The TRI-SEN 160 configuration can be uploaded at any time without interfering or
slowing down control actions. Triconex recommends uploading configurations from the
TRI-SEN 160 after online configuration changes or loop tuning to preserve any
modifications.
When the Save button in the file dialog box is pressed, an upload status bar will appear showing the
status of the upload. At a communications speed of 9600 baud, the upload will take approximately
10 seconds.
Read Configuration
The existing configuration can be viewed from a TRI-SEN 160 without saving
to a file by clicking on the Read Configuration icon (left). The configuration
can be read with View access level.
This allows tuning parameters, real time data trending, and other information contained in the
TRI-SEN 160 to be viewed, without disturbing control actions. When this icon is pressed, a status bar
will appear showing the status of the configuration read. At a communications speed of 9600 baud,
reading the configuration will take approximately 10 seconds.

Real Time Control Loop Tuning

The Real Time Control Loop Tuning Constants icon (left) allows access to
tuning parameters of the control loops within the TRI-SEN 160. Tune access
level is required for this icon.
Clicking on the Real Time Control Loop Tuning Constants icon displays a
control loop select dialog box (left) which allows an individual loop to be
selected for tuning. Once a control loop is selected, the Real Time Control
Loop Tuning Constants Screen (below) is displayed.
Figure 8. Real Time Control Loop Tuning Constants Screen
The Real Time Control Loop Tuning Constants Screen has a wide range of configuration items that
can be modified online. Use the scroll bar at the right of the window to view all tuning items.
! CAUTION Any item changed in the Real Time Control Loop Tuning Constants screen will
be immediately changed in the TRI-SEN 160 controller.

The following paragraphs are brief descriptions of the control loop tuning items contained in the Real
Time Control Loop Tuning Constants screen:
• Scan Time: Valid scan times are 0.05 seconds (50 milliseconds) to 300 seconds. Scan
time refers to the total loop cycle time. This is the time required to read available input
data, execute loop algorithms and generate an output. Inputs are scanned every
10 milliseconds, independent of the loop scan time. Only the surge control loop scan
time is set at 0.05 seconds (50 milliseconds). Other loop scan times must be set at 0.1
seconds (100 milliseconds) or greater.
• Gain: Gain is defined as 100/P = Gain, which is the minimum gain setting for dynamic
adaptive gain. Gain is multiplied by the difference (error) between the PV (process
variable) and SP (setpoint) to generate an output.
• Integral: Also known as Reset. Causes the output to change as long as there is a
difference between the PV and the SP. Integral is the time required for the integral
portion of the controller output to equal the gain portion of the controller output.
Integral is expressed in repeats/minute.
• Derivative: Also know as Rate. Increase the output of the controller based on the rate of
change of the PV. Derivative time is expressed in minutes.
• Max Gain: Maximum that gain can change to when dynamic adaptive gain is used.
(Reference the Surge Description chapter in the TRI-SEN 160 Operations Guide.)
• Set Point Ramp Rate: The setpoint ramp rate is the speed at which the setpoint can be
changed. Expressed in %/sec.
• Deviation Alarm Low: Deviation alarm (SP - PV) triggered when the PV is lower than
the SP. Expressed in engineering units for the loop (always a positive number).
• Deviation Alarm High: Deviation alarm (PV - SP) triggered when the PV is higher than
the SP. Expressed in engineering units for the loop (always a positive number).
• Deviation Indication Low: Indicates that PV is decreasing toward SP.
• Deviation Indication High: Indicates that PV is increasing toward SP.
• Loop Scale Low: This is the low range of the control loop, in engineering units.
• Loop Scale High: This is the high range of the control loop, in engineering units.
• Output Limit Low: This puts a low limit on the analog output of the control loop, in
percent.
• Output Limit High: This is the high limit of the analog output of the control loop, in
percent.
• Output Slew Low: This is the rate of change the analog output can decrease, in %/sec.
• Output Slew High: This is the rate of change the analog output can increase, in %/sec.
• PV Alarm Low: This sets a low alarm trigger for the control loop, in engineering units.
• PV Alarm High: This sets a high alarm trigger for the control loop, in engineering units.

The following tuning items are for Adaptive Gain:

• PV Slope 1: Rate of change of the gain as the Process Variable (PV) decreases below
breakpoint 1 (PV BP1).
• PV BP1: The value of the PV below which the gain begins to change as determined by
PV Slope 1.
• PV BP2: The value of the PV above which the gain begins to change as determined by
PV Slope 2.
• PV Slope 2: Rate of change of the gain as the PV increases above breakpoint 2 (PV
BP2).
• DEV Slope 1: Rate of change of the gain as the PV deviates more than breakpoint 1
(Dev BP1) from the loop setpoint.
• Dev BP1: The value of the deviation below which the gain begins to change as
determined by Dev Slope 1. Dev BP1 must be defined as a negative number.
• Dev BP2: The value of the deviation above which the gain begins to change as
determined by Dev Slope 2.
• Dev Slope 2: Rate of change of the gain as the PV deviates more than breakpoint 2 (Dev
BP2) from the loop setpoint.
• Out Slope 1: Rate of change of the gain as the loop output decreases below breakpoint 1
(Out BP1).
• Out PB1: The value of the loop output below which the gain begins to change as
determined by Out Slope 1.
• Out PB2: The value of the loop output above which the gain begins to change as
determined by Out Slope 2.
• Out Slope 2: Rate of change of the gain as the loop output increases above breakpoint 2
(Out BP2).
• Contact Number: Defines the contact number (DI 21-22, VD 41-56, or Internal Switch
60-90) which will initiate the adaptive gain action.
• Contact Status: Defines the discrete status (0 or 1) that the Contact Number must have
to initiate adaptive gain action.
• Contact Gain: Defines the adaptive gain value.
• Contact Replace: Replace only the base gain (normally configured gain) if answer here
is 0. Replace ALL adaptive gains defined above if answer here is 1.

Real Time Input Ranges
The Real Time Input Ranges icon (left) allows access to the analog input (AI)
configuration screens. This icon requires Tune access level.
When the Real Time Input Ranges icon is clicked, the AI Range Point Select
dialog box (left) allows selection of individual AI points.
The TRI-SEN 160 has 4 analog inputs, AI-1 through AI-4. When an analog
input point is selected the following screen is displayed.
Analog Inputs
Figure 9. Real Time AI Ranges Screen
The Real Time AI Ranges screen (above) allows the analog input ranges to be defined in engineering
units that correspond to the 4-20 mA inputs.
The following paragraphs are brief descriptions of the analog input ranges contained in the Real Time
AI 2 Ranges screen in the figure on the previous page:
• Xmtr Range Lo: The engineering value associated with the transmitter 4ma signal.
• Xmtr Range Hi: The engineering value associated with the transmitter 20ma signal.
• Xmtr Alarm Lo: The low alarm initiation point, in engineering units. To disable this
alarm enter a number lower than the low transmitter range.
• Xmtr Alarm Hi: The high alarm initiation point, in engineering units. To disable this
alarm enter a number higher than the high transmitter range.
• Safe Input Value (SIV): A configured safe input value to use if the transmitter input
exceeds the SIV low or high limits defined below. If the SIV limits are exceeded, a
Fallback alarm is generated and the safe input value will be substituted for the analog
input. To disable this feature, define SIV limits that are higher and lower than the
transmitter ranges.
• SIV Limit Lo: The safe input value low limit. Defines the low limit at which a Fallback
alarm will be generated, the analog input will be ignored, and the safe input value will be
used.

• SIV Limit Hi: The safe input value high limit. Defines the high limit at which a
Fallback alarm will be generated, the analog input will be ignored, and the safe input
value will be used.
NOTE: Changes in SIV ranges take effect immediately and could disable control
functionality.
• Digital Filter: Implements a digital filter on the analog input. This is a first order lag
(low pass) filter. The value entered is time in seconds. Digital filters can eliminate signal
transients, however a filter should not be used on the compressor flow signal. Entering a
value of 0 disables the digital filter.
Peer-to-Peer Communications
The TRI-SEN 160 is capable of exchanging information with other TRI-SEN 160s to accomplish
complex control strategies such as load sharing.
The Peer-to-Peer icon (left) allows the lateral communication port number to be
defined. It requires Tune access level.
When the Peer-to-Peer icon is clicked the Peer-to-Peer Selection dialog box
(left) is displayed. Up to 32 TRI-SEN 160s can be connected together using
Peer-to-Peer communications. The Peer-to-Peer number can be entered directly
or the up and down arrow buttons can be used to select a number. The number
is changed in the TRI-SEN 160 as soon as the DONE button is pressed.
If Peer-to-Peer communications has not been configured in the control strategy, then changing this
number has no effect on the TRI-SEN 160. The Peer-to-Peer number can be viewed on the front panel
of the TRI-SEN 160 in the large display window.
View Data
The View Data icon (left) is used to view real time data from the TRI-SEN 160.
Selecting this icon is possible from all access levels. However, some of the
screen features require Configure access level.
When the View Data icon is selected, the View Data dialog box (left) is
displayed.
Real time data can be collected or an alarm summary can be selected from this dialog box. If Alarm
Summary is selected the Alarm Summary screen is displayed, showing the current status of various
process and diagnostic alarms, as well as the number of compressor surges and the control margin
since the last reset. If Collect Data is selected, the Data Acquisition screen is displayed. These two
choices are discussed in the following paragraphs.

Alarm Summary
When Alarm Summary is selected from the View Data dialog box, the Alarm Summary screen shown
below is displayed.
Figure 10. Alarm Summary Screen
This screen is available at all access levels, however, Margin Adjust, Margin Reset, and Surge
Counter Reset require Configure access level. This real time display shows the alarm status of the
control loops, analog inputs, discrete inputs, diagnostics, and process information for the compressor.
When an alarm is generated, the alarm source is highlighted in red; SURGE LOOP in the figure
above. The alarm type LED (Process or Deviation; Process or Fallback) flashes until acknowledged.
When the alarm is acknowledged from the ACK button on the front panel of the TRI-SEN 160 or
from the ACK button on the Alarm Summary screen, the flashing alarm type LED becomes a steady
red color. If an alarm has been acknowledged and the condition returns to normal, the highlighted
alarm source returns to its normal color (usually Windows defaults) and the alarm type LED returns
to black.
Alarms are arranged on the Alarm Summary screen in three groups:
• Control Loop Alarms
Control loop alarm setpoints are entered in the Real Time Control Loop Tuning Constants
screen and consist of Process and Deviation alarms. Process alarms are defined as a variation
of the process variable of the control loop beyond high or low limits. Deviation alarms are a
difference between the setpoint of the control loop and the process variable. A deviation
alarm may or may not be outside the process alarm setpoints.
• Input Alarms
Analog input alarm setpoints are entered in the Real Time AI Ranges Screen and consist of
Process and Fallback alarms. Process alarms are defined as a variation of the process input
beyond high or low limits. Fallback alarms are generated when a Safe Input Value has been
defined and the process variable exceeds the SIV high or low limit.
Discrete input alarms are generated by field contact closures. Each of four discrete inputs
can be configured for change of state and/or alarm indication.
• System Alarms
The Self Test alarm is generated when the TRI-SEN 160 detects an internal fault.
The Com Fail alarm indicates that there has been a communications failure.
The Backup Fail alarm indicates that a peer-to-peer communications link has failed.

The buttons on the left side of the Alarm Summary screen operate as follows:
• Margin buttons require Configure access level.
The Margin Adjust button allows the margin to be adjusted between the minimum and
maximum configured margins. The margin ranges are defined in the Controller
Configuration screen from the Surge Curve icon.
The Margin Reset button resets the margin to the minimum configured margin defined in the
Controller Configuration screen from the Surge Curve icon.
• Surge Counter Reset button requires Configure access level.
The Surge Counter Reset button resets the TRI-SEN 160 surge counter to zero.
• Alarm ACK button
An alarm can be acknowledged from the ACK button on the front panel of the TRI-SEN 160
or from the ACK button on the Alarm Summary screen. When the ACK button is clicked,
the flashing alarm type LED becomes a steady red color.

Data Collection
Real time data can be displayed if Data Collection is selected from the View Data dialog box. A
graphic screen is displayed which represents the particular compressor installation currently
configured. A typical graphic screen is shown below.
Figure 11. Data Collection Screen with Surge Plot Window
NOTE: Both of the graphics on this screen can be enlarged to full screen size by double-clicking
anywhere on the desired graphic. Double clicking again while the graphic is full screen
size will return to the Data Collection screen.
Also, you can ‘zoom in’ on a particular area on a graphic by clicking the Zoom button, and
then placing the mouse pointer at the top left of the area you want to enlarge and dragging
diagonally down and to the right until you have enclosed the entire area. Dragging the
mouse pointer diagonally from bottom right to top left on any part of the graphic will
return it to normal size.
In addition, you can scroll left and right on the Trend Plot graphic at the bottom of the
screen by placing the cursor anywhere on the graphic, press and hold the right mouse
button, and drag to the left or right to scroll forward or backward in time.
These screen features are discussed in more detail in the Operations Guide.
The Data Collection screen is available to all access levels, however Tune access level is required to
store data to a file.

The menus at the top of the Data Collection screen offer several options for viewing and recording
real time data from the TRI-SEN 160. These menus are discussed in the following paragraphs.
Print Menu
The Print menu allows the graphic screen to be sent to a printer and the printer
to be set up. This menu is available at all access levels.
Record Data Menu
The Record Data menu allows real time data collected from the TRI-SEN 160 to
be stored to disk in a spreadsheet compatible format (Comma Separated
Variable, CSV). Tune access level is required to record data to disk.
If the Open Data File item is selected from the Record Data menu the following screen is displayed.
An existing file can be selected or a new file name can be typed into the File Name box. If an
existing file is selected, the new data will be appended to the existing data file. If a name is entered, a
new file will be created by that name.
If the Close Data File item is selected from the Record Data menu any data file currently open will
be closed.
Various options exist to record data at various data collection rates. The Max Rate item from the
Record Data menu will record data as fast as possible from the TRI-SEN 160. If the BAUD rate in
use is 19200, the data will be saved to disk approximately every 110 mSec. Other data recording
rates can be selected from the Record Data menu.

Trend Menu
A conventional trend style of displaying data can be selected for

each of the four control loops in the TRI-SEN 160. In addition, the
time interval of the trend update can be selected. This menu is
available at all access levels.
Compressor Map Menu
The Compressor Map menu allows the current operating point of

the compressor to be displayed in an X-Y plot, together with the
surge curve being used in the TRI-SEN 160. The x-axis can be
modified from 20 to 100% to better display the operating point.
The pressure ratio displayed on the y-axis is scaled automatically.
Remote Monitor Menu

Remote Monitor is an optional feature which allows data to be transmitted around a plant site or
around the world to remote users using the separate TRI-SEN 160 Remote Monitor software program.
Real time data, graphics, event logs, and configuration files can be transmitted to remote users via
local networks, wide area networks, or even over telephone connections. The Remote Monitor allows
graphic views of real time data, data logging capabilities, trouble shooting, and event analysis from
remote locations.
The Remote Monitor optional program is discussed in greater detail in Appendix A of the
TRI-SEN 160 Operations Guide.
Event Log Menu

Event Playback is an optional feature which allows user-definable events to automatically trigger data
capture for 5 minutes prior and 2 minutes after an event. All data in the TRI-SEN 160 are recorded at
approximately 250 mS intervals in a Microsoft Excel Spreadsheet format. Excel (or compatible)
program can then analyze the data to help troubleshoot the cause of the event.
The Event Playback optional rogram is discussed in greater detail in Appendix B of the

Trigger Menu
If Event Log is on (enabled), the Trigger menu option is enabled. If Event Logging is not enabled
this option is grayed out and cannot be selected.
The Trigger option allows the user to manually trigger an Event Log, even if no event limits have
been exceeded. This is useful if a process upset has occurred that was not severe enough to trigger an
event, but it is desired to record the data prior to the upset.
If an event occurs, or the Trigger option is activated manually, data will be written to the hard disk.
The Data Collection screen shows “Writing Data” for approximately 2 minutes. During this period
the data following the event is recorded. This ensures that data before and after the event are present
in the Event Log to assist in troubleshooting.
Off-Line Control Loop Tuning Constants

There are two Control Loop-Tuning Constants icons on the TRI-SEN 160 configuration program
Main Menu screen.
The icon with the image of a hard disk (left) allows tuning parameters to be
modified off-line, without affecting the TRI-SEN 160. Tune access level is
required to change the tuning parameters.
Refer to the earlier discussion of Real Time Control Loop Tuning Constants. Both work exactly the
same, this one is just off-line.

Off-Line Input Ranges

There are two Input Range configuration icons on the TRI-SEN 160 configuration program
Main Menu screen.
The icon shown at left allows input ranges to be modified off-line, without
affecting the TRI-SEN 160. Tune access level is required to change the I/O
ranges.
The selections at left for analog inputs and digital inputs are presented when the
icon above is clicked.
Refer to the earlier discussion of Real Time Input Ranges. Both work exactly
the same, this one is just off-line.
Digital Inputs
The following dialog box is presented when a digital input is selected for configuration.
Changes to digital inputs do not take effect until the configuration is downloaded again.

Open Configuration
The Open Configuration icon (left) is used to select and open an existing
configuration from the PC. When this icon is selected the screen below is
displayed. Tune access level is required to load configurations from disk.
Figure 12. Open Configuration Screen
Save Configuration
When modifications are made to the configuration or tuning parameters the
Save Configuration icon (left) is selected to save the changes to the PC. Tune
access level is required to save a TRI-SEN 160 configuration. When this icon is
selected the screen below is displayed.
Figure 13. Save Configuration Screen

Surge Curve
The Surge Curve icon (left) allows access to the compressor Surge Curve
screen. Configure access level is required to access any compressor
configuration function. When this icon is selected, the screen below is
displayed.
Figure 14. Surge Curve Screen
The Surge Curve screen requires information from the compressor manufacturer, the compressor flow
transmitter, and knowledge of the engineering units being used. In addition, information necessary to
define the surge control tuning parameters must be entered on this and subsequent screens.
Compressor Map Curve Points

The Surge Curve screen contains an example of a typical manufacturers compressor map. This map
shows the compressor surge line together with speed lines. The intersection coordinates, the place
where the surge line and the speed lines intersect, are entered into the table of Selected Curve Points.
The positions of the intersections are labeled with the letters A, B, C, and so forth. These intersection
coordinates are entered into the Selected Curve Points table corresponding to the row and column
labels. Up to 10 coordinate point pairs can be entered. The remaining table positions do not need to
be filled in.
Manual Entry Button

When this button is clicked on the Surge Curve screen, manual entry of surge data collected in the
field can be used to plot a compressor map. This is useful for comparing an existing surge curve to a
newly calculated curve with real time data from the TRI-SEN 160.

Compressor Map Units Button

The Compressor Map Units button on the Surge Curve screen displays the
following screen.
Figure 15. Compressor Map [Units] Screen
In order to perform the calculations necessary to characterize the compressor, the engineering units
the manufacturer used to prepare the map must be known. One choice in each box, Pressure, Head,
Head Units, Temperature Units, and Flow Units, must be selected. If Not Used is selected for
Head, then Head Units are not needed and will be deselected automatically when the screen is
refreshed.

Compressor map Flow Units are determined by selecting the appropriate Flow Units, Time and Size
categories. The choices for flow and time are self-explanatory. The Size selection determines the
magnitude of the measurement: in Ones, Thousands, or Millions.
The example below is in ACFM, Actual Cubic In the following example, the flow units are
Feet per Minute, sometimes referred to as ICFM MMSCFD, or millions of standard cubic feet per
or Inlet Cubic Feet per Minute. day.
This example is in thousands of standard cubic This example is thousands of kilograms per day.
feet per hour.

Gas & Compressor Properties Button

Clicking the Gas & Compressor Properties button (left) on the Surge Curve
screen displays the following screen.
Figure 16. Properties Screen
This screen contains the information required for gas properties, compressor base properties, and flow
measurement information.
Gas Properties and Compressor Base Properties can be found on the compressor performance map
or data sheet. (Use 0.77 for efficiency if not provided.) These properties are necessary to perform the
calculations required to generate the Triconex Universal Surge Curve. The specific calculations are
discussed in detail in the Surge Description chapter of the TRI-SEN 160 Operations Guide.
Flow Orifice Properties are required if the flow measurement is located in the compressor discharge.
Flow measured in the discharge of the compressor must be compensated to compressor suction
conditions (where the compressor surge map is valid). This is handled automatically by the
TRI-SEN 160. Maximum flow of the transmitter is required to calculate the operating point, which
provides the X coordinate (% h/Ps) for the Triconex Universal Surge Curve.
Clicking the Units button on the Flow Orifice Properties portion of the
screen presents the screen shown at right. This screen allows the
pressure, head, and flow measurement units of the transmitter to be
defined differently than those on the compressor surge map. Unit
conversion is then handled automatically by the TRI-SEN 160. Flow
measurement units are the same as for the Compressor Map discussed
previously.

Controller Configuration Button

Clicking the Controller Configuration button (left) on the Surge Curve screen
displays the following screen, which allows the various control features of the
TRI-SEN 160 to be defined.
Figure 17. Controller Configuration Screen
This screen is divided into sections that deal with individual features and functions of the
TRI-SEN 160.
Margin Configuration
NOTE: Margin and Setpoint Hover are in relation to the x coordinate % hC
Margin is defined as the distance between the surge line and the control line. Margin configuration
defines the minimum, maximum, and increment distance that the control line is separated from the
surge line.
The Minimum Margin is the minimum configurable distance between the surge line and the control
line. The minimum margin can be adjusted from -2% to 100% of % hC (x axis). Using a value of
-2% places the control line 2% to the left of the surge line. This value is used for surge testing, since
under normal conditions the TRI-SEN 160 will not allow the compressor to be brought this close to
the surge curve.
The Maximum Margin is the greatest distance that is allowed between the control line and the surge
line.
The Margin Increment is the amount that the margin will be changed when the operating point
crosses the surge line. This is designed to move the compressor away from a surge condition and
prevent a recurrence.
NOTE: The margin can be manually adjusted between the minimum and maximum limits, or reset
to the normal operating margin on the Data Collection/Alarm Summary screens (with Tune
level access).
Additional details on Margin Configuration can be found in the Surge Description chapter of the
Proportional Valve Response

This function forces the recycle valve open independent of the surge PI control algorithm for severe
process upsets.
The Proportional Enable ranging from 0 to 100% is the distance between the surge line and the
control line that the recycle valve will begin to open. If a value of 70 were entered here, the recycle
valve would begin to open when the operating point is 70% of the operating margin from the surge
line.
The Proportional Maximum term is the upper limit that the Proportional Valve Response is allowed
to drive the recycle valve. A value of 100 will allow the valve to be opened to 100%; a value of 80
will allow the recycle valve to be opened to 80%, etc. This limits the amount the recycle valve may
open under Proportional Valve control.
Details of the Proportional valve Response Function can be found in the Surge Description chapter of
the TRI-SEN 160 Operations Guide.
Setpoint Hover
NOTE: Setpoint Hover and Margin are in relation to the x coordinate % hC
The Setpoint Hover feature allows the setpoint of the surge control loop to track the compressor
operating point. The setpoint will track the operating point to within the Hover Margin of the
operating point. If a Hover Margin of 10% is entered here, the surge controller setpoint will hover
10% to the left of the operating point. The surge controller setpoint will move to the right, away from
surge, instantaneously but can only move to the left toward surge, at the Hover Increment rate.
Details of the Setpoint Hover Function can be found in the Surge Description chapter of the
Dynamic Adaptive Gain

The surge control loop is provided with an adaptive gain feature. This feature decreases the controller
gain when operation is to the right of the surge control line, and increases it as operation moves
toward the control line. Dynamic Adaptive Gain follows a cubic function with minimum and
maximum gain settings determined in Loop Tuning from the Main Menu, and the normal gain set
here in the Controller Configuration.
Details of the Dynamic Adaptive Gain Function can be found in the Surge Description chapter of the

Recycle Valve
Two features of the recycle valve must be defined: valve characteristics (linear or equal percentage)
and action (air to open or air to close).
Triconex recommends that a valve with linear characteristics be used for recycle applications. If a
linear valve is installed, select Linear. If an equal percentage valve has been installed, the output to
the valve from the controller can be made to compensate and give a linear system response by
selecting Equal Percentage.
Valve action must be selected, Air-to-Open or Air-to-Close, so the proper signal output direction is
sent to the recycle valve.
Performance Control
Depending on the particular compressor control application a performance output may have been
supplied with the TRI-SEN 160. This performance controller may drive a valve in the compressor
suction or discharge, or it may be an output to a turbine governor or inlet guide vanes. If the
performance controller sends an output to a governor or to inlet guide vanes, the proper selection is
Air-to-Open. If a suction or discharge valve is used for performance control, then Air-to-Open or
Air-to-Close must be selected to send the proper output signal to the performance valve.
Measurement Location
To properly calculate the compressor operating point the flow through the compressor must be related
to suction conditions. If the flow measurement is taken at the discharge of the compressor it must be
compensated to suction conditions. For this reason the location of the flow measurement must be
selected by selecting either Flow in Suction or Flow in Discharge.

Surge Curve Entry Complete

When all of the required information has been entered from the Surge Curve screen (on the
Compressor Map, Gas & Compressor Properties, Controller Configuration screens), a new button will
appear on the Surge Curve screen, the Calculate button.
Figure 18. Surge Curve Screen with Calculate Button
Calculate Button
When the Calculate button is selected the compressor surge curve calculations will be performed and
the results will be displayed in a table (below).
Figure 19. Calculated Surge Curve & Lookup Table

Save to Configuration Button

The data in the table can then be saved to the current configuration held in the PC’s memory by
clicking the Save to Configuration button. If the calculated values are not saved, they will be
discarded when the Surge Curve screen is closed.
When a calculated surge curve is saved to the current configuration in the PC’s memory, it has not
been saved to disk. This allows a new surge curve to be calculated and used to view real time data.
This provides a method for comparing an existing surge curve to a newly calculated curve with real
time data from the TRI-SEN 160.
NOTE: If it is desired to save the new surge curve to disk the Save Configuration Icon on the Main
Menu screen should be used. This will save all the TRI-SEN 160 data, as well as the
manufacturer’s surge curve data entered in the tables. The manufacturer’s surge curve
point table is not saved in the TRI-SEN 160 controller. These data are held in the
configuration stored on the disk and can be recalled by opening an existing configuration.
If the Upload or Read Configuration icons on the Main Menu screen are used to read the
configuration from the TRI-SEN 160, the tuning parameters and calculated surge curve
data are recovered but the manufacturer’s surge curve point table is not.
Clear Map Button

Clicking this button clears the x and y values and resets the Compressor Map Units, the Gas &
Compressor Properties and the Controller Configuration values to their defaults (methane gas and
English units).

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An Invensys Company

The Recognized Leader in Fault Tolerant Control

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

• Pioneered the Application of Triple Modular Redundant Technology

We Protect People, The Environment, Capital Equipment,

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

A Brief History Of TRICONEX

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TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Surge Control Description

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Surge Control Line

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Surge Control Line

È To prevent surge, the system must

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

General Environmental Specifications

Transport Storage -40 to 85 deg C (-40 to 185 deg F)

5 – 60 Hz at 0.030 Inch total excurcion

Conformal coating is applied to board for

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Hardware Block Diagram

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Surge Control Function

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Surge Control Function

È Dump Out Function :

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Set point Hover Function

È The following occurs after a small, quick

- Immediate opening of the surge valve

È If the setpoint reaches the control line, the

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Adaptive Gain Function

Proportional Valve Respond Function

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Front Panel Operation

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Front Panel Operation

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Surge Control Application

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

È Suction or Discharge Transmitter failure :

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Auto/Manual Control Function

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

Data View via PC

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

TS-160 Controller PT DUTA INSTRUMENT ALFA SAKTI @2006

For Customer Approval

1 14 Mar 06 PVD WSN PS Alarms and Safe Values

1. GB-101 P-IB CO2 COMPRESSOR ...................................................... 3

Figure 1 Application Overview .............................................................. 3

Invensys Process Systems

1. GB-101 P-IB CO2 COMPRESSOR

 Instrument fail over

Instrument fail over