Summary of Contents for Woodward MicroNet TMR 5009
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® MicroNet TMR 5009 Digital Control System Volume 2 Installation/Hardware Manual Manual 85580V2 (Revision E)
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Revisions—Text changes are indicated by a black line alongside the text. Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken.
EPLACEMENT Introduction......................70 Main Power Supply....................70 Kernel Power Supply (A1) ..................72 CPU Module ......................73 Analog and Discrete I/O Modules.................74 Serial Input/Output (SIO) Module .................75 Termination Modules ....................76 Diagnostics ......................78 System Troubleshooting Guide ................79 6. H ..........86 HAPTER ARDWARE PECIFICATIONS Woodward...
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..............102 HAPTER ERVICE PTIONS Product Service Options..................102 Returning Equipment for Repair................ 103 Replacement Parts .................... 104 How to Contact Woodward................104 Engineering Services..................105 Technical Assistance..................106 ..................108 ECLARATIONS Illustrations and Tables Figure 2-1. Control and Power Chassis ..............3 Figure 2-2.
CAUTION—MAXIMUM VOLTAGE To comply with CE Marking under the European Low Voltage Directive (LVD), the maximum external circuit voltage for both the Discrete Inputs and Relay Output circuit are limited to 18–32 Vdc maximum. Woodward...
PCB from the control cabinet, place it in the antistatic protective bag. CAUTION—ELECTROSTATIC DISCHARGE To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules. Woodward...
9907-886, 9907-887, 9907-889, 9907-890, 9907-991, 9907-1000, 9907-1001, 9907-1002, 9907-1003, 9907-1004, 9907-1005, 9907-1006, 9907-1007, 9907-1011, 9907-1012. This volume provides hardware description, installation, and troubleshooting information for the Woodward 5009 Control System. It includes: • A list of all system hardware •...
Cooling fans are located on the top of the main chassis; with one fan per 6-slot card rack. The power supply chassis contains two cooling fans: one on top and one on the bottom of the chassis. See Figure 2-1. These fans run any time the 5009 chassis is powered up. Woodward...
24 V to each kernel section (A, B, C) of the 5009 control. Mounted in the main control chassis are three Kernel Power Supplies, which convert 24 V to 5 V at 10 A for their kernel’s CPU and I/O modules. Woodward...
Also at the top and bottom are two handles which, when toggled, move the modules out just far enough for the boards to disengage the motherboard connectors. Each module is protected with a molded plastic cover to prevent accidental component damage. Woodward...
PCI engineering workstation, OpView or other RS-232 compatible devices. The CPU has a PCMCIA (Personal Computer Memory Card International Association) slot on its front panel. The PCMCIA slot is used to down load application files to the CPU module. Woodward...
Three filter assemblies (one per CPU) are provided with each system to protect the CPU from external system noise. These filter assemblies are shipped separately from the control and can be easily installed if use of the CPU port is required. Woodward...
5009 control. An ATM houses circuitry to: • route each input signal to the system’s three independent (rack mounted) analog modules • produce each output signal by summing the three independent analog modules’ respective outputs Woodward...
For dual coil actuators, kernels A and B drive one coil and kernel C drives the second coil. Current readback circuitry identifies failed modules and allows the remaining outputs to be adjusted accordingly. Figure 2-6. Analog Termination Module Diagram Woodward...
Each DTM connects to the control’s three independent Discrete I/O modules through individual cables, and provides a common cage-clamp terminal connection for customer field wiring. A DTM contains circuitry for six contact inputs, three relay outputs and houses circuitry to: Woodward...
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When they are open, they are periodically closed individually, to ensure that they close. Any failures are annunciated, and further testing is disabled. Woodward...
A and B kernels. Each SIO module includes four serial ports. Ports 1 and 2 are RS-232 communications based ports only. Ports 3 and 4 can be configured for RS-232, RS-422, or RS-485 communications. Refer to Chapter 4 of this volume for port related communication capabilities. Woodward...
The OpView™ Operator Interface is a computer-based work-station that functions as a touch screen annunciator and operator control panel for Woodward digital control systems. This work-station allows an operator to remotely view operating inputs, vary control setpoints, and issue Run mode commands.
Discrete I/O Cable (10 ft/ 3 m) Standard W14 - W19 DTM to DTM Cable (6”/15 cm) Standard Control to PCI Cable (10 ft/3 m) Standard MISC. - A ATM Ground Terminals (used on DIN rail) Standard MISC. - B CPU Comm. Port Filters Standard Woodward...
5. Connect Cabinet to earth ground using a 10 mm² (8 AWG) or larger wire or braid. WARNING—EARTHING CONDUCTOR Leakage current exceeds 3.5 mA. The earthing conductor is required for safety. Woodward...
5. Verify that both the control and power chassis are at earth ground potential, and if they are not, connect them to earth ground via a 3 mm² (12 AWG) or larger yellow/green wire or braid. Figure 3-3. Chassis-to-Chassis Power Cable W1-B Woodward...
CAUTION—INSTALLING MODULES If resistance is encountered when installing a module, do not force the module. Remove the module and check the connectors for bent contacts or foreign objects. Forcing a module into place may break the connector. Woodward...
ATMs. See Figure 3-8. 7. Connect a 12 AWG (4.0 mm²) green/yellow wire between each ground terminal and ATM terminal “Chassis Ground”. This wire should be kept as short as possible and be no longer than six inches (15 cm) in length. Woodward...
4. If the panel the DTMs are mounted on is not at earth ground potential connect it to earth ground via a 12 AWG (4.0 mm²) or larger green/yellow wire or braid; keeping the wire/braid as short as possible. Woodward...
See Figure 3-11. Reference PowerStation manual included for further installation instructions. 2. Drill mounting holes per Figure 3-11. 3. Place the OpView in position, install 8-32 mounting nuts onto the studs, and tighten them securely. Figure 3-11. OpView Outline Drawing Woodward...
5009 Installation/Hardware Manual 85580V2 Option 2— Place the OpView in position, install the six mounting clamps to secure the unit into place, and tighten securely. Figure 3-12. Mounting Template Woodward...
2. Connect a grounding cable, 10 mm² (8 AWG) or larger, from an acceptable earth ground to the cabinet frame. System Cables (if cabinet is not included) If the system was provided with a cabinet, no cable installation is required, and you can go directly to the Input Power installation instructions. Woodward...
Relay outputs, contact inputs, and power supply wiring do not normally require shielding, but can be shielded if desired. For compliance with EMC standards, it is required that all analog and discrete input/output wiring be separated from all power wiring. Woodward...
Use only time-delay fuses or circuit breakers to avoid nuisance trips. A fixed wiring installation is required. Power supply leakage current exceeds 3.5 mA so a protective earth ground connection is required. Woodward...
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Significant inrush currents are possible when current is applied to the main power supply. The magnitude of the inrush current depends on the power source impedance, so Woodward cannot specify the maximum inrush current. Time- delay fuses or circuit breakers must be used to avoid nuisance trips.
MPU clearance is recommended to be 0.25 to 1.02 mm (0.010 to 0.040 inch) from tooth face to pole piece. For information on selecting the correct MPU or gear size, please refer to Woodward manual 82510. See Figure 4-2 for wiring schematic.
Each channel’s prox return input accepts 5–28 Vdc. Alternatively with either 12 Vdc or 24 Vdc open collector probes. When interfacing to open collector type probes a pullup resistor between the four voltage terminal and the proximity return terminal is required. Figure 4-2. Example MPU Interface Wiring Diagram Woodward...
Manual 85580V2 5009 Installation/Hardware Figure 4-3a. Example 24 V Proximity Probe Wiring Diagram Figure 4-3b. Example 12 V Proximity Wiring Diagram Woodward...
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If the MPU device is not providing a voltage greater than 1.5 Vrms, the MPU device should be moved closer to the gear where speed is being monitored. The following graph shows the minimum voltage necessary to detect speed at the various frequencies. Woodward...
Isolation is provided through diodes on the power and common lines. This 24 Vdc output is capable of providing 24 Vdc with +10% regulation. Power connections are be made through terminals located on system ATMs. Woodward...
Cable shields must be electrically continuous from the signal source to the point the signal wire enters the 5009 Analog Termination Module. • ATM terminals accept wires from 0.08–2.5 mm² (27–12 AWG). Figure 4-4. Example Analog Input Wiring Diagrams Woodward...
The actuator output drive currents can be programmed to interface with Woodward Governor Company actuators (typically 20–160 mA drive currents) or non-Woodward actuators (4–20 mA drive currents). Each actuator output can be individually configured to interface with Woodward or non-Woodward type actuators.
Dither is a low frequency (25 Hz) signal consisting of a 5 millisecond pulse modulated onto the control’s DC actuator-drive current to reduce stiction in linear type actuators. Woodward TM-type actuators typically require dither. See Volume #3 of this manual for details on adjusting dither.
Contacts must change state for a maximum of 40 milliseconds and a minimum of 20 milliseconds for the control to sense and register a change in state. Woodward...
DTM terminals 33 & 34, and terminals 33 & 35. If an external power source is used for contact wetting, the external source’s common must be connected to the DTM’s discrete input commons (terminals 34 & 35). Figure 4-8. Optional Internal 24Vdc Contact Wetting Configuration Woodward...
4 mA @ 14 Vdc (4 mA @ 70 Vdc) to recognize a closure command. • Verify that the correct input terminals are wired to with respect to the level of contact wetting voltage used. Woodward...
The relay output would continue to be closed. Once a relay output is closed, the output’s individual relays are periodically opened and re-closed, to ensure that they were in the correct state, and that they change state. Woodward...
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(on the left of the graph) is the level of voltage that will be developed across the load due to leakage current. 3. If the developed load voltage (from the graph) is less than the load’s drop-out voltage, latent fault detection can be used with the circuit. Woodward...
Vac line to the 110 V line, a total load resistance of 900 Ω is needed. By placing a properly rated 3600 Ω resistor in shunt with the load, (1200//3600 900) LFD can be used. Figure 4-10. Latent Fault Detection Verification Graph—18–32 Vdc Circuitry Woodward...
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Refer to Figure 4-13. LFD can be jumper configured to be compatible with the following circuit voltages: • 18–32 Vdc circuit power (meets CE & UL ratings) • 88–132 Vac circuit power (meets UL ratings only) • 100–150 Vdc circuit power (meets UL ratings only) Woodward...
When using high voltage relay circuit power, it is recommended that care be taken not to touch exposed connectors when replacing relays or cables. If possible remove relay circuit power from all DTM relays before replacing any DTM relay or cable. Woodward...
(unless SIO-B is installed), Alarm/Trip printer driver port. It can also be configured to automatically become the PCI interface port if CPU-C fails. • CPU-C port (RS-232) functions as a DDE communication port for PCI. • SIO-A Port 1 (RS-232) functions as an Alarm/Trip Printer driver port. Woodward...
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5009 Installation/Hardware Manual 85580V2 • SIO-A port 2 (RS-232) functions as an interface port to Woodward’s servPanel program. • SIO-A port 3 (RS-232/422/485) functions as Modbus #1 port 1. • SIO-A port 4 (RS-232/422/485) functions as Modbus #2 port 1 or DDE communication for PCI.
RS-232 communications is limited to 15 m (50 ft) or less. However with the use of an RS-232 to RS-422 converter or Woodward’s SIO module, the OpView can be installed up to 1220 m (4000 ft) from the control (see Volume 4 of this manual).
6 Confirm each connection before operating unit. 7 All analog inputs must be isolated from earth ground. 8 Follow authorized standards for conduit loading and sealing. 9 All wires to terminal blocks shall have wire markers, marked with associated terminal number. Woodward...
CPU to boot-up before both CPUs will go to a running state. WARNING—VERIFY CALIBRATION Improperly calibrated devices can cause turbine damage and possible personnel injury or death. Before starting the turbine for the first time, and periodically thereafter, verify the calibration of all external input and output devices. Woodward...
If after following this chapter’s guidance the cause of a problem cannot be found, contact the Woodward technical assistance group. CAUTION—QUALIFIED PERSONNEL Only qualified service personnel should perform the following module replacement procedures.
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6. With even pressure exerted at the top and bottom of the supply’s front panel, firmly push the unit into place. 7. Tighten the screws that secure the module in place (two at the top and two at the bottom). 8. Re-apply power to the input of the power supply. Woodward...
Remove the module by pulling straight out and place it into a conductive plastic bag (Woodward P/N 4951-041). 5. Install the replacement supply module by aligning the circuit board edge in the card guides and push the module into the slots until the connector on the module and the connector on the motherboard make contact.
3. Switch the CPU’s Reset switch to its reset position (push top of switch in). 4. Disconnect any communication cable. 5. Unscrew the CPU module’s captive-screw fasteners and release the module from the motherboard connectors by pressing the top handles up and the bottom handles down. Woodward...
Manual 85580V2 6. Remove the module by pulling straight out and place it into a conductive plastic bag (Woodward P/N 4951-041). 7. Install the replacement CPU by aligning the circuit board edge in the card guides and push the module into the slots until the connector on the module and the connector on the motherboard make contact.
With this control, the removal of any single kernel will not cause the control to shut down. However, if other faults are present within other kernels, those faults, combined with any faults caused by shutting down the kernel power supply, may cause a system shutdown. Woodward...
The procedure used in the replacement of termination modules on-line varies based on the control’s configuration and system wiring configuration. Contact a Woodward representative to establish the correct termination procedure to use based on your configuration.
If possible remove relay circuit power from all DTM relays before replacing any DTM relay or cable. 1. Read all warnings on pages v and vi of this Volume before replacing any Relay. Woodward...
I/O Lock LED stays on during normal operation replace the module. Table 5-2. On-Line Test Failure Messages Local Ram Failed Checksum Error Application Ram Failed System Error (#) FPU Co-Processor Failed EEPROM Fault Task Overrun Math Exception Rate Group Slip (#) EEPROM Initialization Fault Exception Error Vector # Woodward...
5009 Installation/Hardware System Troubleshooting Guide The following is a troubleshooting guide for areas to check which may present potential difficulties. By making these checks prior to contacting Woodward for technical assistance your system problems can be more quickly and accurately assessed.
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Are all signal wires shielded? • Are shields continuous from the device to the control? • Are the shields terminated according to Woodward specifications? • Are there low voltage signal wires running in the same wiring trays as high voltage wiring? •...
Environmental Classifications for Options For systems with the optional Cabinet, the presence of any of the following options reduces the Environmental Class of the cabinet assembly to the lowest classification of the options present. Woodward Mfg. Temp. Cabinet Max. Part No.
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Rated Maximum Current = 6.5 A • Maximum Power = 1150 VA • Input Power Fuse/Breaker Rating = 10 A slow blow • Wire Size = 2.5 mm² (14 AWG) or larger • Holdup Time = 1 cycle @ 220 Vac Woodward...
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1–25 Vrms Input impedance: 2000 Ω Isolation: Channel to Channel 500 Vdc To Chassis 200 Vdc continuous, 600 Vdc DWV Resolution: dependent on frequency Accuracy: software calibrated to 0.03%, minimum Time Stamping High & Low Alarms to 5 ms resolution Woodward...
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500 Vdc continuous, 600 Vdc DWV; HD Max load resistance: 600 Ω Current Readback: 10 bits Resolution: 10 bits Accuracy: software calibrated to 0.2% Temperature Drift: 125 ppm/°C, maximum Readback accuracy: 0.1% Readback temp drift: 400 ppm/°C, worst case Woodward...
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20 ms max. Release Time: 10 ms max. Shock: 5G for 11 ms Temperature: –45 to +70 °C Dielectric Strength: 500 Vrms across open contacts 2500 Vrms between all other conductive elements Expected Life: 100 000 operations @ rated load Woodward...
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Fan Air Filter—Replacement recommended every 60 days to 18 months based on environment. OpView (optional) Power Requirements (for Color or Monochrome units) • 90–250 Vac, 50/60 Hz, (110 W max.) For all OpView specifications, refer to documentation included with the CTC Power Station. Woodward...
50 000 hours, and the cabinet front door fan every 60 000 hours. For replacement, use fans of like design and specification, or purchase replacement fans from Woodward. See Chapter 6 of this Volume for fan voltage and power specifications.
Manual 85580V2 5009 Installation/Hardware Chapter 8. ® MicroNet TMR Compatible Products The following is a list of compatible Woodward products that may be used with ® the MicroNet TMR 5009 System: Operator Control Panel DSLC Panel Real Power Sensor Figure 8-1. MicroNet™ Compatible Products...
1. Mark the panel location and mounting holes (see Figure 8-2). 2. Drill and tap the mounting holes using the appropriate size hardware. 3. Place the panel in position, insert the mounting screws into the tapped holes, and tighten the hardware securely. Woodward...
This device is used with generator applications only. The DSLC is a microprocessor-based generator load sharing control designed for use on three phase ac generators with Woodward speed controls and automatic voltage regulators. The DSLC is a synchronizer, an isochronous load sharing control, a dead bus closing system, a VAR/PF control, and a process control, integrated into one package.
3. Place the panel in position, insert the mounting screws into the tapped holes, and tighten the hardware securely. 4. If the DSLC Panel is not at earth ground potential, connect it to earth ground via a 4.0 mm² (12 AWG) or larger green/yellow wire or braid. Figure 8-4. DSLC Mounting Woodward...
Real Power Sensor (RPS) The Real Power Sensor is used to sense the real power being produced by a generator, or flowing through a tie line. Woodward Real Power Sensors sense three phase voltages and three phase currents. The RPS compares each phase’s voltage to current relationship and develops a 4–20 mA output...
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Manual 85580V2 5009 Installation/Hardware Woodward-manufactured Real Power Sensors have a 2.5 Hz low pass filter (400 ms lag time) on the output to filter out the high frequency noise typically created in a switchgear-type environment. If another vendor’s watt transducer is used, verify that it has similar filtering criteria before it is applied with the 5009.
Product Service Options The following factory options are available for servicing Woodward equipment, based on the standard Woodward Product and Service Warranty (5-01-1205) that is in effect at the time the product is purchased from Woodward or the service is performed: •...
Returning Equipment for Repair If a control (or any part of an electronic control) is to be returned to Woodward for repair, please contact Woodward in advance to obtain a Return Authorization Number. When shipping the item(s), attach a tag with the following information: •...
To expedite the repair process, contact Woodward in advance to obtain a Return Authorization Number, and arrange for issue of a purchase order for the item(s) to be repaired. No work can be started until a purchase order is received.
Manual 85580V2 5009 Installation/Hardware Engineering Services Woodward Industrial Controls Engineering Services offers the following after- sales support for Woodward products. For these services, you can contact us by telephone, by email, or through the Woodward website. • Technical Support •...
Type of Fuel (gas, gaseous, steam, etc) Rating Application Control/Governor Information Please list all Woodward governors, actuators, and electronic controls in your system: Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter...
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Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.
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