Woodward MicroNet TMR 5009FT Installation And Hardware Manual
  1. Manuals
  2. Brands
  3. Woodward Manuals
  4. Control Unit
  5. MicroNet TMR 5009FT
  6. Installation and hardware manual

Woodward MicroNet TMR 5009FT Installation And Hardware Manual

Fault-tolerant steam turbine control volume 2
Hide thumbs Also See for MicroNet TMR 5009FT:
Table of Contents

Advertisement

Quick Links

Released
Product Manual 26518V2
(Revision E, 6/2018)
Original Instructions
MicroNet TMR® 5009FT
Fault-Tolerant Steam Turbine Control
Installation / Hardware Manual
Manual 26518 consists of 4 volumes (26518V1, 26518V2, 26518V3, 26518V4).
Volume 2

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the MicroNet TMR 5009FT and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Woodward MicroNet TMR 5009FT

Summary of Contents for Woodward MicroNet TMR 5009FT

  • Page 1 Released Product Manual 26518V2 (Revision E, 6/2018) Original Instructions MicroNet TMR® 5009FT Fault-Tolerant Steam Turbine Control Installation / Hardware Manual Manual 26518 consists of 4 volumes (26518V1, 26518V2, 26518V3, 26518V4). Volume 2...
  • Page 2 Revisions— A bold, black line alongside the text identifies changes in this publication since the last revision. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Cables and Connections ..........................59   Fans ................................59   ® 8. M ............... 60  HAPTER ICRO OMPATIBLE RODUCTS DSLC™ Digital Synchronizer & Load Control ..................... 61   Real Power Sensor (RPS) .......................... 64   A. C ..................67  PPENDIX ONTROL IRING IAGRAM Woodward...
  • Page 4 Figure 8-6. Plant Wiring Diagram for the Real Power Sensor ..............66   Table 2-1. System Components ........................8   Table 4-1. Fuse/Breaker Requirements ...................... 20   Table 5-1. Default IP Addresses ......................... 47   Table 6-1. Environmental Classifications for Options ................. 57   Woodward...

  • Page 5: Warnings And Notices

    Be prepared to make an emergency shutdown when starting the engine, turbine, or other type of prime mover, to protect against runaway or overspeed with possible personal injury, loss of life, or property damage. Start-up Woodward...

  • Page 6: Electrostatic Discharge Awareness

    Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. 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.

  • Page 7: Regulatory Compliance

    125 Vdc digital Input connections located on FTM104-1A, FTM104-1B, FTM104-2A, and FTM104-2B (Woodward # 5453-276) are not to be connected on CSA certified systems or on systems requiring compliance with the European Low Voltage Directive.
  • Page 8 This equipment is intended to be installed in a metal cabinet or enclosure. See manual 26167, Volumes 1 & 2, for installation requirements related to CE Marking requirements. Safety Symbols Direct Current Alternating Current Both Alternating and Direct Current Caution, risk of electrical shock Caution, refer to accompanying documents Protective conductor terminal Frame or chassis terminal Woodward...

  • Page 9: Chapter 1. General Information

    Active 5009FT System part numbers are covered in Volume 1 of this manual and in Appendix B. This volume provides hardware description, installation, and troubleshooting information for the Woodward 5009FT Control System. It includes:  A list of all system hardware ...

  • Page 10: Chapter 2. Hardware Description

    MicroNet system. This manual will reference the Woodward MicroNet TMR manual 26167 Volumes 1 and 2. The 5009FT is a derivative of the MicroNet TMR, and the only difference is that the 5009FT is a pre-configured MicroNet TMR System.

  • Page 11: System Power Supplies (Psm1 And Psm2)

    These fans run any time the 5009FT chassis is powered up. See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 3, Section 1 for more details on the Main Chassis.

  • Page 12: Module Descriptions

    This module receives 24 Vdc from the MicroNet main power supplies and regulates it to 5 Vdc, 10 A for the rest of the kernel section and also creates a 5 Vdc precharge voltage. See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 4, Sections 4–6 for more details on the Kernel Power Supplies.
  • Page 13 Two FTMs are provided and used with each 5009FT control (FTM103-1 and FTM103-2). Refer to Appendix A for an overview of modules and FTMs used. See Woodward MicroNet TMR manual 26167 Volume 2, Chapter 12, Section 2 for more details on the TMR Analog Combo FTM.
  • Page 14 It is highly recommended to design the field wiring such that the latent fault detection can be utilized on critical relays (Trips). Without this feature, a single component fault might not be annunciated – leading to a potential unwanted turbine trip. Woodward...

  • Page 15: Figure 2-1. Fault Tolerant Relay Outline Drawing

    Released Manual 26518V2 5009FT Installation/Hardware Figure 2-1. Fault Tolerant Relay Outline Drawing Woodward...

  • Page 16: Figure 2-2. Ft Relay Block Diagram

    4–20 mA outputs (2-pole 10 ms filter on all input channels, except channels 23 and 24, which have 2-pole 5 ms filter). See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 8, Section 1 for more details on the TMR 24/8 Analog Module.

  • Page 17: Cct - Touchpanel Pc

    See Woodward MicroNet TMR manual 26167 Volume 2, Chapter 9, Section 2 for more details on the Two Channel Actuator Controller Module.
  • Page 18 IEC 61000-4-6 (conducted noise immunity) Criterion A IEC 61000-4-8 (noise immunity against magnetic fields) Criterion A EN 55022 (noise emission) Class A Approvals UL, cUL UL 508 UL, cUL Class I, Division 2, Groups A, B, C, D UL 1604 Woodward...

  • Page 19: Chapter 3. Mechanical Installation

    If the selected location does not already have a conductor to a good earth ground, provide one.  Unless otherwise stated, this equipment is suitable for non-hazardous locations only. Equipment is suitable for use in non-hazardous locations only. Use the following procedures to install a cabinet system in the selected location. Woodward...

  • Page 20: Chapter 4. Electrical Installation

    FTM103-1, -2 and terminal 37 on FTM106-1, -2). In this case, the device shield needs to be grounded at the Woodward FTMs. Grounding bars are installed in the FTMs to support this configuration since it is the most common. If the device shields are grounded (to Chassis ground) at the device end, then REMOVE these shorting bars and follow option two OR the individual tabs from the Grounding bar can be cut off.

  • Page 21: Figure 4-1. Ftm103-1 And Ftm103-2 Grounding Bars

    The shields should be connected to earth ground at all intermediate terminal blocks, as well as terminated at the control terminal block (AC Coupled). In this case the shorting bar is removed to provide a capacitive connection to ground (in addition to the ‘hard’ ground) at the device end. Woodward...

  • Page 22: Input Power

    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.
  • Page 23 For information on selecting the correct MPU or gear size, please refer to Woodward manual 82510. See Figure 4-4 for wiring schematic. Speed channel 4 has to be configured to receive a proximity probe. A proximity probe may be used to sense very low speeds.

  • Page 24: Figure 4-5. Example Mpu Interface Wiring Diagram (Ch 1 Shown)

    When interfacing to open collector type probes a pull-up resistor between the four-voltage terminal and the proximity return terminal is required.   Figure 4-5. Example MPU Interface Wiring Diagram (Ch 1 shown)   Figure 4-6. Example 24 V Proximity Probe Wiring Diagram Woodward...
  • Page 25 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...

  • Page 26: Analog Inputs-Tmr Analog Combo Module

    A 24 Vdc power supply is available from the 5009FT control to power external transducers or other auxiliary devices. 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 FTMs. Woodward...

  • Page 27: Analog Inputs-Tmr 24/8 Analog Module

    The 24 Vdc outputs are capable of providing 24 Vdc with ±10% regulation. The maximum current is 0.8 A. Power connections can be made through terminals located on the 24/8 Analog FTMs. See Chapter 11 for complete field wiring information for the 24/8 Analog FTM. Woodward...

  • Page 28: Figure 4-9. Analog Input Wiring For A 24/8 Analog Ftm

    Do not place shielded wires in the same cable conduit with high-voltage or large-current-carrying cables.  Cable shields must be electrically continuous from the signal source to the point the signal wire enters the 5009FT Analog Termination Module.  FTM terminals accept wires from 0.08–2.5 mm² (27–12 AWG). Woodward...

  • Page 29: Analog Outputs-Tmr Analog Combo Module

    5009FT Field Terminal Module.  FTM terminals accept wires from 0.08–2.5 mm² (27–12 AWG) wire.  Analog outputs are not isolated; care should be taken when interfacing to other non-isolated devices to prevent wiring faults. The use of an isolator is recommended. Woodward...

  • Page 30: Actuator Outputs-Tmr Analog Combo Module

    The control has two proportional actuator output drivers (one output per FTM). 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.

  • Page 31: Actuator Outputs-Actuator Controller Module

     Actuator FTM terminals accept wires from 0.08–2.5 mm² (27–12 AWG) wire.  Actuator outputs are not isolated, so they should not be connected to non-isolated devices. Some examples are shown below, refer to Appendix A for more information. Woodward...

  • Page 32: Figure 4-13. 5009Ft Compatible Position Feedback Schematics

    Released Manual 26518V2 5009FT Installation/Hardware Figure 4-13. 5009FT Compatible Position Feedback Schematics Woodward...

  • Page 33: Figure 4-12A. Example Of Single Loop With Dual Coil And Two Lvdts Type (A-B)/(A+B) On Cylinder

    Released Manual 26518V2 5009FT Installation/Hardware Figure 4-12a. Example of Single Loop with Dual Coil and Two LVDTs Type (A–B)/(A+B) on Cylinder Valve Woodward...

  • Page 34: Figure 4-12B. Example Of Dual Loop With Dual Coil And Two Lvdts Type (A-B)/(A+B) On Cylinder Valve And Two Vdts Type (A-B)/(A+B) On Pilot Valve

    Released Manual 26518V2 5009FT Installation/Hardware Figure 4-12b. Example of Dual Loop with Dual Coil and Two LVDTs Type (A–B)/(A+B) on Cylinder Valve and Two VDTs Type (A–B)/(A+B) on Pilot Valve Woodward...

  • Page 35: Ftm Contact Inputs (F/T Relay-Discrete In)

    (The FTM’s European CE Compliance and CSA requirements only apply to the 24 V option.)  If the 24 Vdc internal power source is used as for contact wetting, jumpers are required between FTM terminals 33 & 34 and terminals 33 & 35. Woodward...

  • Page 36: Ftm Relay Outputs (F/T Relay Outputs)

    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...
  • Page 37 When selecting a shunt resistor also verify that its voltage and wattage ratings meet that of the circuit. LFD Verification Example: Circuit Power = 110 Vac Load Resistance = 200 Ω Load drop-out voltage = 25 Vac Woodward...

  • Page 38: Figure 4-14. Latent Fault Detection Verification Graph-18-32 Vdc Circuitry

    LFD. By following the graph along the 25 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 4-14. Latent Fault Detection Verification Graph—18–32 Vdc Circuitry Woodward...

  • Page 39: Figure 4-15. Latent Fault Detection Verification Graph-88-132 Vac Circuitry

    Released Manual 26518V2 5009FT Installation/Hardware Figure 4-15. Latent Fault Detection Verification Graph—88–132 Vac Circuitry Figure 4-16. Latent Fault Detection Verification Graph—100–150 Vdc Circuitry Woodward...
  • Page 40 Refer to Figure 4-16. LFD can be jumper configured to be compatible with the following circuit voltages:  18–32 Vdc circuit power (meets CE & CSA ratings)  88–132 Vac circuit power (not listed)  100–150 Vdc circuit power (not listed) Woodward...

  • Page 41: Figure 4-17. Jumper And Relay Location Diagram

    Released Manual 26518V2 5009FT Installation/Hardware Figure 4-17. Jumper and Relay Location Diagram Woodward...

  • Page 42: Figure 4-18. Ftm Labels

    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 FTM relays before replacing any FTM relay or cable. Woodward...

  • Page 43: Communications

    LAN switches. This device is factory set with default IP addresses that will automatically connect to the control system for all Woodward software tool interfacing. If the user changes the IP addresses of the control on 1 or both of the Ethernet networks, then the IP address (s) of this computer need to be changed also to be on the same network.

  • Page 44: Control Wiring Diagrams

    At this time, the CPU is performing the self-diagnostics and boot-up processes. If only one CPU has been reset, (other CPUs still failed) the 5009FT will wait for another CPU to boot-up before both CPUs will go to a running state. Woodward...
  • Page 45 Released Manual 26518V2 5009FT Installation/Hardware 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...

  • Page 46: Chapter 5. Troubleshooting And Module Replacement

    This will help verify that the cause of the problem actually is in the suspected module. If after following this chapter’s guidance the cause of a problem cannot be found, contact the Woodward technical assistance group.

  • Page 47: Kernel Power Supply (Kernel A/B/C: A1)

    Unscrew the Kernel Power Supply module’s captive screw fasteners and release the module from the motherboard connectors. Press the momentary reset button on the respective kernel’s CPU to place the kernel in ‘Reset’ mode. Remove the Kernel Power Supply by pressing the top handle up and the bottom handle down. Woodward...

  • Page 48: Replacing A 5009Ft Cpu While Unit Is Running

    Released Manual 26518V2 5009FT Installation/Hardware Remove the module by pulling straight out and place it into a conductive plastic bag (Woodward P/N 4951-041). 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.
  • Page 49 If the control is running and on-line, use the CCT to verify that the other CPUs are running without faults. Review the Alarm Annunciation page to ensure that no IO channels in the selected Kernel are needed to operate. Woodward...
  • Page 50 Remove the CPU module from the motherboard connectors by pressing the top handles up and the bottom handles down. Remove the CPU module by pulling straight out and place it into a conductive plastic bag (Woodward P/N 4951-041). Install the replacement CPU module by aligning the circuit board edge in the card guides and push the module into the slot until the connector on the module and the connector on the motherboard make contact.

  • Page 51: Analog And Discrete I/O Modules (Kernel A/B/C: A3-A5)

    Each Analog I/O Module has a fuse in it. This fuse is visible and can be changed through the bottom of the plastic cover of the module. If this fuse is blown, replace it with a fuse of the same type and size (24 Vdc/0.1 A). Woodward...
  • Page 52 Disconnect the module I/O cable or cables. The I/O cables use a slide latch (to disengage slide the latch up). Remove the module by pulling straight out and place it into conductive plastic bag (Woodward P/N 4951-041). Verify that the replacement module is the same Part number as the module that has been removed.

  • Page 53: Channel Actuator Module (Kernel A/B: A6)

    Caution must be taken whenever replacing a termination module on-line, or a unit trip could result. 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.

  • Page 54: Diagnostics

    Reset switch is asserted. On-line diagnostics run during normal Control System operation when the GAP application is active. More information on diagnostics tests, subsequent LED flash codes, and serial port messages is contained in the VxWorks ® * manual. *—VxWorks is a trademark of Wind River Systems, Inc. Woodward...
  • Page 55 Re-sync -- Lost CPU failed to sync properly ........139 Each CPU performs both off-Line and on-line diagnostics. Off-Line diagnostics are performed at power-up or when the CPU’s Reset button is pushed. On-Line diagnostics are performed when the CPU is in its normal operational mode, under application-program control. Woodward...

  • Page 56: System Troubleshooting Guide

    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. MECHANICAL SYSTEM ACTUATORS ...
  • Page 57 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? ...
  • Page 58 EXTERNAL DEVICES  Are there external devices the control is dependent on for input signals?  Are these devices providing the correct signal to the control?  Is the external device configured or programmed to be compatible with the control? Woodward...

  • Page 59: Chapter 6. Hardware Specifications

    Nominal Voltage Rating (24 Vdc), (as on Power Supply Label)  Rated Maximum Current = 33 A  Input Power Fuse/Breaker Rating = 50 A slow blow  Wire Size = 5.5 mm² (10 AWG) or larger  Holdup Time = 5 ms @ 24 Vdc Woodward...
  • Page 60 NiCd, Not User Replaceable; Charge Time: 72 hours @ 25 °C. CPU Storage Temperature with battery operating specifications: –20 to +45 °C. ELECTROCUTION HAZARD—Ground leakage exceeds 3.5 mA. Protective earth grounding is required. General I/O Specifications For details on all I/O specifications consult MicroNet TMR manual 26167. Woodward...

  • Page 61: Chapter 7. System Maintenance

    As a preventive maintenance, it is recommended that the main chassis and power chassis cooling fans be replaced every 50 000 hours. For replacement, use fans of like design and specification, or purchase replacement fans from Woodward. Substitution of components may impair suitability of the equipment and is not recommended.

  • Page 62: Chapter 8. Micro Net Tmr ® Compatible Products

    Manual 26518V2 5009FT 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 5009FT System: DSLC Panel Real Power Sensor Figure 8-1. MicroNet™ Compatible Products Woodward...

  • Page 63: Dslc™ Digital Synchronizer & Load Control

    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.

  • Page 64: Figure 8-3. Dslc Mounting

    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 8-3. DSLC Mounting Woodward...

  • Page 65: Figure 8-4. Dslc Control

    Released Manual 26518V2 5009FT Installation/Hardware Figure 8-4. DSLC Control Woodward...

  • Page 66: Real Power Sensor (Rps)

    “KW Readout” terminals provide a 4–20 mA signal proportional to real power, which is used by, and compatible with, the 5009 control. 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.

  • Page 67: Figure 8-5. Real Power Sensor

    Released Manual 26518V2 5009FT Installation/Hardware Figure 8-5. Real Power Sensor Woodward...

  • Page 68: Figure 8-6. Plant Wiring Diagram For The Real Power Sensor

    Released Manual 26518V2 5009FT Installation/Hardware Figure 8-6. Plant Wiring Diagram for the Real Power Sensor Woodward...

  • Page 69: Appendix A. Control Wiring Diagram

    Released Manual 26518V2 5009FT Installation/Hardware Appendix A. Control Wiring Diagram Woodward...
  • Page 70 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 71 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 72 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 73 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 74 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 75 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 76 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 77 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 78 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 79 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 80 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 81 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 82 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 83 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 84 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 85 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 86 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 87 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 88 Released Manual 26518V2 5009FT Installation/Hardware Woodward...

  • Page 89: Appendix B. Standard Cabinet Layout Diagram

    Released Manual 26518V2 5009FT Installation/Hardware Appendix B. Standard Cabinet Layout Diagram Woodward...
  • Page 90 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 91 Released Manual 26518V2 5009FT Installation/Hardware Woodward...
  • Page 92 Released Manual 26518V2 5009FT Installation/Hardware Woodward...

  • Page 93: Revision History

    Updated Appendix B with new revision of wiring diagram  Added Declaration of Conformity Changes in Revision B—  Added new fuse/breaker entry for 24 V to Table 4-1  Added 24 Vdc information to Power Supply Specifications (page 58) Woodward...

  • Page 94: Declarations

    Released Manual 26518V2 5009FT Installation/Hardware Declarations Woodward...
  • Page 95 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.

Table of Contents