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85204 User Manual

1. 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 e name and location where the control is installed name and phone number of contact person complete Woodward part number s and serial number s description of the problem instructions describing the desired type of repair 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 Packing a Control Use the following materials when returning a complete control e protective caps on any connectors e antistatic protective bags on all electronic modules e packing materials that will not damage the surface of the unit e atleast 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls e a strong tape around the outside of the carton for increased strength Woodward 29 ProTech 203 Overspeed Protection System Manual 85204 Return Authorization Number When returning equipment to Woodward please telephone and ask for the Customer Service Department 1 800 523 2831 in North America or 1 97
2. EXPLOSION HAZARD Do not remove covers or connect disconnect electrical connectors unless power has been switched off or the area is known to be non hazardous Substitution of components may impair suitability for Class I Division 2 AVERTISSEMENT RISQUE D EXPLOSION Ne pas enlever les couvercles ni raccorder d brancher les prises lectriques sans vous en assurez auparavant que le syst me a bien t mis hors tension ou que vous vous situez bien dans une zone non explosive La substitution de composants peut rendre ce mat riel inacceptable pour les emplacements de Classe I Division 2 iv Woodward Manual 85204 ProTech 203 Overspeed Protection System Chapter 1 General Information Eeee This manual describes the ProTech electronic two out of three Overspeed Protection System The manual explains the operation and gives the configuration procedures for the system This manual does not contain instructions for the operation of the complete turbine system For turbine or plant operating instructions contact the plant equipment manufacturer Before doing any installation maintenance adjustments or configuration on the ProTech 203 system read manual 82715 Guide for Handling and Protection Electronic Controls Printed Circuit Boards Modules Description The ProTech 203 Overspeed Protection System is a digital overspeed trip device that senses prime mover speed through three magnetic pickups MP Us It con
3. Block Diagram of One Unit of the ProTech 203 System 12 Woodward Manual 85204 ProTech 203 Overspeed Protection System Chapter 4 Configuration and Operation EEE OODWAR Figure 4 1 ProTech 203 Front Panel The ProTech 203 system can be operated in one of two modes MONITOR or PROGRAM Although the system will run in either mode it is recommended that the unit be placed in the PROGRAM mode only during configuration and then placed in the MONITOR mode during normal operation The menu key on the touch pad selects which of the following parameters to display Woodward PRESENT SPEED PEAK SPEED TRIP SPEED SETPOINT MPU FAILED SETPOINT MPU FAILED TIMEOUT MPU GEAR TEETH TRIP ON MPU FAILURE OPTION TIMER STARTS ON RESET OPTION ALARM WHEN SPEED IS lt MPU FAILED SETPOINT OPTION LAMP TEST TRIP CAUSE if applicable 13 ProTech 203 Overspeed Protection System Manual 85204 PRESENT SPEED is the first parameter displayed Each subsequent press of the menu key displays the next parameter in the list Appropriate descriptive units for each parameter are also displayed When the keyswitch is in the MONITOR position the CURSOR ADJ up and ADJ down keys have no effect When the keyswitch is in the PROGRAM position an annunciator appears in the display and a cursor appears if a tunable parameter is being displayed The tunable parameters are e TRIP SPEED SETPOINT MPU FAILED SETPOINT MPU FAILED TIMEOUT MPU GEAR
4. rpm 25 000 rpm MPU Failed Set Point 100 rpm 25 000 rpm MPU Failed Timeout 533 min 20 sec MPU Gear Teeth 14 Woodward Manual 85204 ProTech 203 Overspeed Protection System Programming Programming of the ProTech 203 system consists of entering values for all the tunable parameters The procedure for programming each speed sensing unit is as follows WARNING TRIP POINT PROGRAMMING In order to ensure proper functioning of the ProTech 203 system it is imperative that the tunable parameters in each of the units are programmed to result in identical trip points Failure to do so could result in inadvertent trips or failure to trip at appropriate speed resulting in property damage injury or death 1 Switch the keyswitch to the PROGRAM position 2 Press the MENU key to step through the parameter menu to the first tunable parameter TRIP SPEED SETPOINT 3 Use the CURSOR ADJ up and ADJ down keys to enter the proper rpm for your preferred TRIP SPEED SETPOINT 4 Press the MENU key to step to the next tunable parameter MPU FAILED SETPOINT 5 Use the CURSOR ADJ up and ADJ down to enter the proper rpm for your preferred MPU FAILED SETPOINT 6 Press the MENU key to step to the next tunable parameter MPU FAILED TIMEOUT 7 Use the CURSOR ADJ up and ADJ down keys to enter the appropriate time interval 8 Press the MENU key to step to the next tunable parameter MPU GEAR TEETH 9 Use the CURSOR ADJ up and A
5. 0 482 5811 They will help expedite the processing of your order through our distributors or local service facility 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 NOTE We highly recommend that you make arrangement in advance for return shipments Contact a Woodward customer service representative at 1 800 523 2831 in North America or 1 970 482 5811 for instructions and for a Return Authorization Number Replacement Parts When ordering replacement parts for controls include the following information e the part number s XXXX XXXX that is on the enclosure nameplate e the unit serial number which is also on the nameplate How to Contact Woodward In North America use the following address when shipping or corresponding Woodward Governor Company PO Box 1519 1000 East Drake Rd Fort Collins CO 80522 1519 USA Telephone 1 970 482 5811 24 hours a day Toll free Phone in North America 1 800 523 2831 Fax 1 970 498 3058 For assistance outside North America call one of the following international Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service Facility Phone Number Brazil 55 19 3708 4800 India 91 129 230 7111 Ja
6. 3 Figure 5 3 Board Locations 7 Remove the six mounting screws securing the power supply board to the chassis 8 Unplug the ribbon cables from the power supply board and remove the board 9 Unplug the terminal block and ribbon cable from the corresponding display board 10 Remove the six nuts holding the display board to the ProTech system chassis front door Note the nuts locations in Figure 5 4 so that you don t loosen the 4 nuts that attach the LCD display to the circuit board NOTE If removing Unit A retain the two cable clamps for re installation 11 Holding the display board s terminal block and ribbon cable connector walk and lift the board off of the door CAUTION DISPLAY BOARD Do not use screw drivers or other objects to lift or pry the display board Doing so may damage other ProTech components 26 Woodward Manual 85204 ProTech 203 Overspeed Protection System Ge A YA TL LLL YL EZ YW be f Y ER H A f Y A Z VA F LIA ei E Yj 4 Z 5 f Y y S G j f i i 7 j P f E Cc B A Y H Y A 5 A VM Figure 5 4 Display Boards Procedure to Install a New Unit 1 2 10 11 12 13 Insert and position the new display board in place Figure 5 4 Replace the six display board nuts tighten until they are snug if replacing unit A re install the ribbon cable clamps Plug in the ribbon cable then the terminal block to t
7. 4 3 Method 2 Block Diagramm 18 Figure 5 1 ProTech System Front Door ssessssseseernenssnnnnnesnnaanannanetnnannannnaaeennaanan 24 Figure 5 2 Unit Covers Inside the ProTech Device eeesrresesrreseerresrrrresree 24 Figure 5 3 Board Locatons ssrcresusiir sensn Tanina EEE OAA EAEEREN 26 Figure 5 4 Display Boards E 27 Table 1 1 De energize to Trip ProTech Models A 2 Table 1 2 Energize to Trip ProTech Models 2 Table 1 3 Voltage Rangos cen sirreii ira inisin Eina ArA NEREA A AERAN E ETNEN AnS ANAA RE EEN 2 Table 4 1 Allowable Ranges sseeesssessssrsseernasssnnanarennannnnnaattnnaanannaaeennaanannnaaeenne 14 Table 4 2 Start Mode Opttons 19 Table 4 3 TrmpCGauses cece eeseceeeaeeeeeeeeeseceeeaeseeeeeesesensenaneeeeeeeetees 20 Table 5 1 Power Supply Fuse Data 23 ii Woodward Manual 85204 ProTech 203 Overspeed Protection System Electrostatic Discharge Awareness All electronic equipment is static sensitive some components more than others To protect these components from static damage you must take special precautions to minimize or eliminate electrostatic discharges Follow these precautions when working with or near the control 1 Before doing maintenance on the electronic control discharge the static electricity on your body to ground by touching and holding a grounded metal object pipes cabinets equipment etc 2 Avoid the build up of static electricity on your body by not wearing clothing made of synthetic
8. DJ down keys to enter the number of gear teeth on the gear being monitored by the MPU connected to this unit 10 Press the MENU key to step to the next tunable parameter TRIP ON MPU FAILURE 11 Use the ADJ up or ADJ down key to enter a yes or no response 12 Press the MENU key to step to the NEXT tunable parameter TIMER STARTS ON RESET 13 Use the ADJ up or ADJ down key to enter a yes or no response 14 Press the MENU key to step to the last tunable parameter ALARM IF SPEED lt MPU FAIL SETPOINT 15 Use the ADJ up or ADJ down key to enter a yes or no response 16 Duplicate this procedure for the other two units 17 Return the keyswitch to the monitor position The LCD displays CHANGES SAVED for two seconds Woodward 15 ProTech 203 Overspeed Protection System Manual 85204 For your convenience a programming worksheet is provided below The worksheet should help ensure proper programming and provide you with a hard copy record of the values entered Feel free to copy the worksheet for future use ProTech 203 Programming Worksheet UNITA UNIT B UNIT C TRIP SPEED TRIP SPEED TRIP SPEED SETPOINT SETPOINT SETPOINT Prime mover speed in rpm at which user expects unit to de energize its alarm relay turn on the TRIP LED and energize de energize depending upon the version chosen its voter relays MPU FAILED MPU FAILED SETPOINT SETPOINT SETPOINT The prime mover speed must exceed this value
9. Failure Indication A separate LED indicates if any unit s CPU is not operating normally Speed Sensing Frequency Range 100 Hz to 32 kHz Trip Point Frequency Range 250 Hz to 25 kHz MPU Input Amplitude 1 Vrms minimum 100 Hz to 25 kHz 2 Vrms minimum 25 kHz to 32 kHz maximum 25 Vrms 8 Woodward Manual 85204 ProTech 203 Overspeed Protection System Shutdown Contact Ratings European Ratings European ratings restrict use to applications with voltages not subject to the Low Voltage Directive 73 23 EEC Rated Voltage Resistive Inductive Tungsten Motor 28 Vdc 10 0 A 1A O 2 1A lt 50 Vrms 50 60 Hz lt 75 Vdc 022A UL Ratings 28 Vdc 10 0 A 115 Vrms 50 60 Hz 125 Vdc SS Alarm Contact Ratings European Ratings European ratings restrict use to applications with voltages not subject to the Low Voltage Directive 73 23 EEC Rated Voltage Resistive O 28 Vdc lt 50Vrms 50 60 Hz UL Ratings Rated Voltage Resistive 28 Vdc 115Vrms 50 60 Hz NOTE The alarm relay de energizes when a trip occurs and momentarily after reset or power up An alarm only annunciates a situation that may require attention it is not synonymous with a trip MPU Measurement Circuit Input Impedance 2kQ Accuracy 0 05 x Trip Point in Hz 2 Hz Operating Temperature 25 to 60 C 13 to 140 F Display Operating Temperature 15 to 60 C 5 to 140 F Sample Time Spe
10. MPU fail set point Similar to ProTech systems 9905 750 through 9905 756 and 9905 989 though 9905 999 Normal Operation Each unit in the ProTech system continually monitors speed for an overspeed condition present speed gt TRIP SPEED SETPOINT or for a loss of signal condition The peak speed is updated whenever the present speed exceeds the peak speed If an overspeed occurs the unit trips After the trip occurs the peak speed continues to be updated and is stored in non volatile memory Non volatile storage means that even if power to the unit is lost the peak speed can be retrieved later Peak speed is not stored in non volatile memory if an overspeed condition has not occurred To reset a unit s peak speed press the menu key repeatedly until PEAK SPEED is displayed If the unit is tripped it must first be reset by pressing the reset key Place the key switch in the PROGRAM position then press the reset key The peak speed is set equal to the present speed Return the key switch to the MONITOR position AN MPU loss of signal occurs when a sudden loss of speed is detected When an MPU frequency of less than 100 Hz is measured the previously measured speed is checked If it was greater than 120 Hz the MPU is assumed to have failed The alarm relay de energizes and the MPU FAIL LED turns on and remains on until the unit is reset or until power is cycled If the TRIP ON MPU FAILURE option is set to Yes a trip occurs When a
11. TEETH TRIP ON MPU FAILURE TIMER STARTS ON RESET ALARM IF SPEED IS lt MPU FAILED SETPOINT If any tunable parameters are changed the LCD displays CHANGES SAVED for two seconds when the keyswitch is returned to the MONITOR mode The CURSOR ADJ up and ADJ down keys perform as follows in the PROGRAM mode CURSOR Moves the cursor one position to the right ADJ up ADJ down For integer values these keys increase decrease the displayed value by the power of ten indicated by the cursor position For example if the cursor were under the 0 of the value 5014 and the ADJ down key were pressed the value would change to 4914 For atime display in minutes and seconds increase decrease the displayed value by the number of seconds or minutes indicated by the cursor position For example if the cursor were under the 4 in 1 MIN 47 SEC and the ADJ up key were pressed the value would change to 1 MIN 57 SEC If the ADJ up were pressed again the value changes to 2 MIN 07 SEC For a YES NO value pressing either ADJ up or ADJ down causes the value to toggle to the opposite value Pressing and holding the ADJ up or the ADJ down key causes the value after a short delay to change at a fixed rate If changing a value would cause it to exceed predetermined limits no change takes place Table 4 1 gives the allowable range for each tunable parameter Table 4 1 Allowable Ranges Tunable Minimum Maximum Trip Speed Set Point 250
12. W wooDwarRD Installation and Operation Manual ProTech 203 Overspeed Protection System 9907 146 147 148 149 150 151 Manual 85204 Revision G WARNING DANGER OF DEATH OR PERSONAL INJURY WARNING FOLLOW INSTRUCTIONS Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage WARNING OUT OF DATE PUBLICATION This publication may have been revised or updated since this copy was produced To verify that you have the latest revision be sure to check the Woodward website www woodward com pubs current pdf The revision level is shown at the bottom of the front cover after the publication number The latest version of most publications is available at www woodward com publications If your publication is not there please contact your customer service representative to get the latest copy WARNING OVERSPEED PROTECTION The engine turbine or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown device must be totally independent of the prime mover control system An overtemperature or overpressure shutdown device may also be
13. ail set point 16 Woodward Manual 85204 ProTech 203 Overspeed Protection System Operation NOTE As used in the following discussions trip refers to the action of an individual speed sensing unit in the ProTech 203 system as it de energizes the alarm relay and turns on the TRIP LED and de energizes its voter relays de energize to trip versions or energizes its voter relays energize to irip versions The trip cause becomes the currently displayed parameter Once a unit is tripped it remains tripped until reset or until the power is cycled Start up The ProTech 203 system allows two methods for turbine start The TIMER STARTS ON RESET menu option determines which method is used The default setting for this option is NO which provides separate reset and start functions When this option is set to YES a combined reset start function is provided by the reset key or remote reset contact The two methods are described below Table 4 2 provides a brief summary of the two start configuration options Method 1 TIMER STARTS ON RESET NO MPU fail timer starts when start key is pressed or when the contact input opens See Figure 4 2 for a block diagram of this method First any trips or alarms are cleared by pressing the reset key or by momentarily closing the reset contact Before the MPU fail timer is started and while it is running the MPU fail trip is overridden When the turbine is ready to be started th
14. am 2 Check for ground 3 Actuating equipment integration assessment Woodward strongly recommends that the user perform an assessment of the actuating equipment that will receive input from the ProTech 203 system to verify that equipment is properly calibrated working correctly properly interfaced and functioning safely before energizing the ProTech 203 system WARNING ACTUATING EQUIPMENT ASSESSMENT If the actuating equipment assessment is not performed and consequently problems are not identified and eliminated turbine damage can occur with possible personal injury and loss of life to personnel near the turbine Woodward ProTech 203 Overspeed Protection System Manual 85204 Figure 2 2 Routing and Stress Relief for Field Wiring Entering the ProTech 203 System 6 Woodward Manual 85204 ProTech 203 Overspeed Protection System Chapter 3 Description The ProTech 203 Overspeed Protection System is a digital overspeed trip device that reads three individual magnetic pickups performs three individual speed calculations and actuates its relay output according to the results of a hardware two out of three vote See Figure 3 1 for the control layout and dimensions l i 7 D Figure 3 1 Outline Drawing of ProTech 203 System Specifications Enclosure Approved for use in Type 4 and 4x environments for North America Enclosure rated IP54 for Europe Woodward 7 ProTech 203 Overspeed Protec
15. be held at one of our locations or at your site This training conducted by experienced personnel will assure that you will be able to maintain system reliability and availability For information concerning training please contact us via telephone email us or use our website and reference Customer Services and then Product Training Field Service engineering on site support is available depending on the product and location from one of our many worldwide locations or from one of our authorized distributors The field engineers are experienced both on Woodward products as well as on much of the non Woodward equipment with which our products interface For field service engineering assistance please contact us via telephone email us or use our website and reference Customer Services and then Technical Support Woodward 31 ProTech 203 Overspeed Protection System Manual 85204 Technical Assistance If you need to telephone for technical assistance you will need to provide the following information Please write it down here before phoning General Your Name Site Location Phone Number Fax Number Prime Mover Information Engine Turbine Model Number Manufacturer Number of Cylinders if applicable 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 Desc
16. ce The ProTech system can also be configured to be compatible with various combinations of power sources Tables 1 1 1 2 and 1 3 show the available ProTech models the corresponding part numbers and the voltage ranges Woodward 1 ProTech 203 Overspeed Protection System Manual 85204 Table 1 1 De energize to Trip ProTech Models UNIT A UNIT B UNIT C 9907 147 24 Vdc 24 Vdc 24 Vdc 9907 149 120 Vac dc 120 Vac de 120 Vac dc 9907 151 220 Vac 220 Vac 220 Vac Table 1 2 Energize to Trip ProTech Models Table 1 3 Voltage Ranges Input Power Requirements Per Kernel 24 Vdc 18 32 Vdc 5 12 W 120 Vac dc 88 132 Vac 12 5 VA 90 150Vdc 4 77 W 220 Vac 180 264 Vac 16 4 VA References The following Woodward publications contain additional product or installation information on overspeed protection systems and related components 82715 Guide for Handling and Protection Electronic Controls Printed Circuit Boards Modules 82510 Magnetic Pickups and Proximity Switches for Electronic Governors 50532 EMI Control for Electronic Governing Systems 2 Woodward Manual 85204 ProTech 203 Overspeed Protection System Chapter 2 Installation EES Unpacking Be careful when unpacking the ProTech 203 system Check the device for signs of damage such as a bent or dented case and loose or broken parts If damage is found notify the shipper immediately The device may be stored in its original shipping containe
17. curred while running NO MPU SIGNAL The contact input was open while speed was below the MPU FAIL SETPOINT and the TIMER STARTS on RESET option is set to Yes HARDWARE FAULT The unit has an internal hardware problem INTERLOCK FAULT An internal cable is disconnected 20 Woodward Manual 85204 ProTech 203 Overspeed Protection System Chapter 5 Troubleshooting and User Repairs EE Troubleshooting The following troubleshooting guide will help isolate problems in the ProTech 203 device actuating system plant wiring MPUs or elsewhere Make the checks in the order indicated NOTE To check the ProTech control thoroughly troubleshoot each unit A B and C separately A unit consists of one complete speed sensing circuit including the power supply I O module and display board Prime mover Prime mover Check for proper operation of overspeeds after the prime mover fuel system operating at rated If actuator moves toward speed for some minimum fuel during time overspeed problem is in the fuel system Prime mover Power is not applied to an Apply power to all ProTech does not trip on energized to trip ProTech units overspeed model The ProTech device is not Check that the ProTech connected or is incorrectly device is installed properly connected to the external actuating system Incorrect set point values Check the MPU GEAR configured for one or more TEETH and TRIP SPEED units SETPOINT configurations for
18. e MPU fail timer is started by pressing the start key or by momentarily opening the contact input The timer expires when it reaches the MPU fail timeout value If speed does not exceed the MPU fail set point before the timer expires the unit trips The MPU fail LED turns on and remains on until the unit is reset MPU Fail Detect Speed gt Trip S peed gt Trip Setpoint Trip Setpoint Compare Value MPU e Speed lt MPU Fail Setpoint SET MPU Fail Compare Setpoint Ak Latch TRIP Greg AND START EXPIRED GEAR Timer CLEAR Speed gt MPU Fail Setpoint RESET i MPU Fail Timeout Value Figure 4 2 Method 1 Block Diagram Woodward 17 ProTech 203 Overspeed Protection System Manual 85204 If the unit is being restarted after a normal rolldown that is there was no trip the unit does not require a reset The MPU fail trip is overridden because the MPU fail timer is cleared whenever speed exceeds the MPU fail set point The MPU fail timer should be started by the operator when the turbine is ready to be started again The MPU fail timer can only be started when speed is below the MPU fail set point Pressing the start key has no effect if speed is above the MPU fail set point Method 2 TIMER STARTS ON RESET YES MPU fail timer starts when the reset key is pressed or remote reset is momentarily closed An open contact input cause
19. e the course of action if a problem does occur In some cases you will need to return the ProTech system to the supplier from whom your purchased it However in other cases the Troubleshooting Guide will suggest one of following remedies e Changing a power supply board fuse e Replacing an entire unit including display I O and power supply boards while the other two units continue to function so that the ProTech device stays on line NOTE To ensure compatibility the entire unit must be replaced as a matched set Do not mix and match boards between units WARNING EXPLOSION HAZARD Substitution of components may impair suitability for Class 1 Division 2 Do not disconnect equipment unless power has been switched off or the area is known to be non hazardous Changing a Power Supply Board Fuse Tools Needed e 2 Phillips screw driver 1 4 inch nut driver small flat blade screw driver 5 32 inch Allen wrench Appropriate replacement fuses are CSA and UL approved slow blow 5 x 20 mm fuses Table 5 1 Power Supply Fuse Data Procedure for Changing a Power Supply Board Fuse 1 Shut off the power to the unit in which you re replacing a fuse WARNING HIGH VOLTAGE Failure to disconnect power to the unit you re replacing prior to proceeding can result in exposure to potentially lethal voltage and therefore possible injury or death 2 To open the front door turn the two door latches counterclockwise
20. each unit to verify that they are appropriate for prime mover and the individual MPUs If two or more units show a Check for incorrect field wiring TRIPPED indication the and inoperable or incorrectly cause is the external actuating calibrated actuating system down line from the equipment ProTech device Prime mover trips Reset the units inappropriately overspeed tested at one time Incorrect set point values Check the MPU GEAR configured for one or more TEETH and TRIP SPEED units SETPOINT configurations for each unit to verify that they are appropriate for prime mover and the individual MPUs Woodward 21 ProTech 203 Overspeed Protection System Manual 85204 Inappropriate trip Contact input was left open If contact input is not used during start up and TIMER STARTS ON jumper together TB5 14 and RESET option is set to Yes TB5 15 of each unit Incorrect set point values Prime mover is not ramping to configured for one or more configured speed in the units allotted time Verify that the MPU FAIL SETPOINT and MPU FAIL TIMEOUT are appropriate for the prime mover Incorrect MPU signal Check that all MPUs are correctly wired to the ProTech device and are functioning properly Inappropriate trip EEPROM doesn t respond Hardware fault correctly If fault continues replace unit annunciated see User Repairs section below Inappropriate trip Internal cables aren t Check ProTech internal Inter
21. ed is sampled every 5 milliseconds Total Response Time 40 ms max Humidity US MIL STD 810D Method 507 2 Procedure II Woodward 9 ProTech 203 Overspeed Protection System Manual 85204 Vibration US MIL STD 810D Method 516 3 Procedure Weight 7 3 kg 16 Ibs Modes of Operation The ProTech 203 system is offered in de energize to trip versions and energize to trip versions Two normally open and two normally closed relay contacts are provided by the system for use in either version Figure 3 2 shows the relay field wiring diagram that describes these options Figure 3 2 Interposing Relay Field Wiring In the de energize to trip version the interposing relay is in its energized state during normal operation TB3 terminals 1 and 2 are connected and TB2 terminals 4 and 5 are connected During an overspeed trip event or when power to the ProTech 203 system is lost the interposing relay is de energized Then TB3 terminals 2 and 3 are connected and TB2 terminals 5 and 6 are connected In the energize to trip version the interposing relay is in its de energized state during normal operation TB3 terminals 2 and 3 are connected and TB2 terminals 5 and 6 are connected Only during an actual overspeed trip event is the interposing relay energized Then TB3 terminals 1 and 2 are connected and TB2 terminals 4 and 5 are connected NOTE In the energize to trip version if input power to the ProTech 203 system is lost the in
22. es a potentially hazardous situation which if not avoided could result in damage to equipment or property A NOTE provides other helpful information that does not fall under the warning or caution categories 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 Woodward 1997 All Rights Reserved Manual 85204 ProTech 203 Overspeed Protection System Contents ELECTROSTATIC DISCHARGE AWARENESS ceccsssseeecceaseensensneeesensneeeseaes Il REGULATORY COMPLIANCE 2 2 sceeeeeeccecesseeeseeeeesceeeeseseeeeeeeseeaeensaseeeeseeses IV CHAPTER 1 GENERAL INFORMATION 1 cccccccecsseseeesneeeeeeeeeeeeeeesneeeeeeeeeeenenas 1 Description seii aa a ENEE SEENEN edd SEENEN 1 elle ir Le E 1 EE Le 2 CHAPTER 2 INSTALLATIONS sissssascticctetnnsssscssicecasanssnvnnstinscetusssassseassntacecntaanws 3 UNPACKING DEE 3 Power e EC 3 Location CONSIGDErALIONS cieeieecievies ceieedinsdee ANEREN eEEREAdE EEN ea 3 Shielded WING EE 3 Plant in e EE A Installation Check out Procedure ssssssessnssssseierrensttsttrnrrnrstrrttrnnnnnsnrrtttnn nennen ent 4 CHAPTER 3 DESCRIPTION sascsivecadiccnddsace studs ed SCENE Ae ENEE Eed e
23. ge 7 Specifications ce 7 Modes of Operation 10 Power Supply Description 11 CHAPTER 4 CONFIGURATION AND OPERATION SEENEN 13 Progiamitin gesein cet vated E TE TE O OEO 15 ProTech 203 Programming Workzbeet AA 16 Operation EE 17 CHAPTER 5 TROUBLESHOOTING AND USER REPAIRS 0 ssssesseeeeeeeeeseeenens 21 TROUDIESNOOUNG BETEN 21 EE ER CHAPTER 6 SERVICE OPTIONS ss sesisettiscccsscccsesssnciwsnsssiececcessacsnssicrecieteaiaians 28 PRODUCE Service ele 28 Returning Equipment for Repair 29 Replacement Parts satictincccieanduannndedceetvanacaauaviadevevad a a a a aa 30 How to Contact Woodward ssssisiiseiiinaiiisaiie i ai 30 Engineering Services ceeeeeeeeeneeeeeeenneeeeeeaaeeeseeaaeeeeeeaaeeeseeaaeeeeeenaeeeeseenaeeeeeeaas 31 Technical ASSISTANCE crsa aa a 32 DECLARATIONS zifcnn eE 33 Woodward ProTech 203 Overspeed Protection System Manual 85204 Illustrations and Tables Figure 2 1 Plant Wiring Diagram cceccceeeeeeeeeneeeeeeenaeeeeeeaeeeeeenaeeeeeenaeeeeeeaes 5 Figure 2 2 Routing and Stress Relief for Field Wiring Entering the ProTech 203 e E E 6 Figure 3 1 Outline Drawing of ProTech 203 Gvstem 7 Figure 3 2 Interposing Relay Field Wiring esseeeesessrreeesrresesrrrsserrrssrrrnssrerresreea 10 Figure 3 3 Voter Relay Contfgouratton 11 Figure 3 4 Block Diagram of One Unit of the ProTech 203 System 0 008 12 Figure 4 1 ProTech 203 Front Panel 13 Figure 4 2 Method 1 Block Diagramm 17 Figure
24. he display board Insert and position the new power supply board Figure 5 3 Replace the six screws that secure the power supply board to the chassis Plug the ribbon cables back into the power supply board Replace the unit s metal cover To avoid future confusion make sure the proper cover is on the proper unit This is important because each cover is labeled with the unit I D letter as well as the correct voltage to be applied to that unit Snugly secure the four cover nuts If you ve replaced Unit A replace the ribbon cable clamp onto the cover Figure 5 2 Plug in the unit s terminal blocks Close and latch the front door Re power the unit you just replaced On the replaced unit s display press RESET to activate that unit s operation Woodward 27 ProTech 203 Overspeed Protection System Manual 85204 Chapter 6 Service Options BEE 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 e Replacement Exchange 24 hour service e Flat Rate Repair e Flat Rate Remanufacture If you are experiencing problems with installation or unsatisfactory performance of an installed system the following options are available e Consult the troubleshooting guide in the manual e Contact Woodward technica
25. l assistance see How to Contact Woodward later in this chapter and discuss your problem In most cases your problem can be resolved over the phone If not you can select which course of action you wish to pursue based on the available services listed in this section Replacement Exchange Replacement Exchange is a premium program designed for the user who is in need of immediate service It allows you to request and receive a like new replacement unit in minimum time usually within 24 hours of the request providing a suitable unit is available at the time of the request thereby minimizing costly downtime This is also a flat rate structured program and includes the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option allows you to call in the event of an unexpected outage or in advance of a scheduled outage to request a replacement control unit If the unit is available at the time of the call it can usually be shipped out within 24 hours You replace your field control unit with the like new replacement and return the field unit to the Woodward facility as explained below see Returning Equipment for Repair later in this chapter Charges for the Replacement Exchange service are based on a flat rate plus shipping expenses You are invoiced the flat rate replacement exchange charge plus a core charge at the time the replacement unit is shipped If the core field unit is ret
26. ll not disturb the load Operator Interface Each speed sensing unit of the ProTech 203 system includes a touchpad a two line by 16 character LCD display and a potentiometer for adjusting the overspeed test frequency A single keyswitch is connected to all three speed sensing units to control whether the system is in the MONITOR or the PROGRAM mode preventing unauthorized changes Power Supply Description The ProTech 203 consists of three units A B and C Each unit has its own separate power supply There are three different versions of power supplies which have the following input voltages 18 32 Vdc 90 150 Vdc 88 132Vac and 180 264 Vac Each unit power supply produces 5 V and 24 V These voltages are isolated from the input voltage The 24 V for all three units are or ed together to provide power to the interposing relay Woodward 11 ProTech 203 Overspeed Protection System Manual 85204 13 7 A MPU CONTROL 2 INPUT fo __ CIRCUIT MUX FREQ IN J OVERSPEED 4 lees TES FREQUENCY REMOTE AH LI RESET a z 7 5 ok RESET E emie V PUSHBUTTON CR TRIPPED TE ER o o BR Ayp anes ac ge v MPU Gar T FAILED A TZ FAILED l a LCD 2 ffe DISPLAY 2 a S 1 ES POWER L SUPPLY EEPROM l x ES D GND iG L Figure 3 4
27. lock fault connected correctly cabling and installation annunciated procedure Inappropriate trip The ProTech microcontroller Replace the entire unit see CPU FAIL LED lit is not functioning User Repairs section below Prime mover Check power supply fuses won t start trip units do not have power wiring and power sources need to be reset A de energized to trip Verify the type of ProTech ProTech model is installed model in Chapter 1 when an energized to trip model is appropriate or vice versa Actuating wiring from the Check actuating system for ProTech device is incorrect proper normally open or normally closed wiring Unit has LCD Unit is faulty Replace the entire unit see display but no User Repairs section below LEDs display or vice versa LCD nor LED the unit display Power supply fuses need to Replace unit s power supply be replaced board fuse see User Repairs section below Power supply board is faulty Replace the entire unit see User Repairs section below Unit is not Unit needs to be reset Press the RESET key operating STATUS 1 amp 2 and TRIPPED are illuminated Unit won t RESET Remote RESET contacts are Check that the remote RESET closed operates as a momentary contact 22 Woodward Manual 85204 ProTech 203 Overspeed Protection System User Repairs The ProTech device is highly reliable and should require minimal hardware repairs Use the above troubleshooting guide to determin
28. materials Wear cotton or cotton blend materials as much as possible because these do not store static electric charges as much as synthetics 3 Keep plastic vinyl and Styrofoam materials such as plastic or Styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work area as much as possible 4 Do not remove the printed circuit board PCB from the control cabinet unless absolutely necessary If you must remove the PCB from the control cabinet follow these precautions e Do not touch any part of the PCB except the edges e Do not touch the electrical conductors the connectors or the components with conductive devices or with your hands e When replacing a PCB keep the new PCB in the plastic antistatic protective bag it comes in until you are ready to install it Immediately after removing the old 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 iii ProTech 203 Overspeed Protection System Manual 85204 Regulatory Compliance The ProTech 203 is suitable for use in Class Division 2 Groups A B C and D pe
29. nals from adjacent equipment Connect the shields as shown in the plant wiring diagram Figure 2 1 and install a wire 0 3 0 4 mm 12 22 AWG from terminal 13 to terminal 3 on each unit Wire exposed beyond the shield must not exceed 50 mm 2 inches The other end of the shield must be left open and insulated from any other conductor Do not run shielded signal wires with other wires carrying large currents See manual 50532 EMI Control in Electronic Governing Systems for more information Woodward 3 ProTech 203 Overspeed Protection System Manual 85204 Installations with severe electromagnetic interference EMI may require shielded cable run in conduit double shielded wire or other precautions Contact Woodward for more information Plant Wiring Figure 2 1 is the plant wiring diagram for the ProTech 203 system Figure 2 2 shows the proper routing and stress relief for all field wiring entering the ProTech system Field wiring to the ProTech system should be between 1 5 and 6 mm 10 and 16 AWG wire for the power supplies and between 0 3 and 4 mm 12 and 22 AWG for all other I O runs CAUTION GROUND CONNECTIONS The ground wires for the power supplies of all three units must be connected to the identified PE ground terminal on the chassis Additionally the ground wire for each power supply must also be connected to the applicable connector WARNING HIGH VOLTAGE When wiring the interposing relays be sure to wire both co
30. nd Supplies Needed e 2 Phillips screw driver 1 4 inch nut driver small flat blade screw driver heat sink compound Procedure to Remove a Unit from the ProTech Chassis 1 Shut off the power to the unit you re replacing WARNING HIGH VOLTAGE Failure to disconnect power to the unit you re replacing prior to proceeding can result in exposure to potentially lethal voltage and therefore possible injury or death 2 To open the front door turn the two door latches counterclockwise Figure 5 1 A If you re replacing Unit A remove the ribbon cable clamp and retain for use when installing the replacement unit Figure 5 2 4 Unplug the power supply board terminal block then unplug the I O board terminal block Figure 5 2 5 Remove the four nuts on the unit s cover and carefully lift the cover off Figure 5 2 Retain the cover and the nuts to be reinstalled with the replacement unit CAUTION TAKE CARE OF NUTS SCREWS Be very careful not to drop any of the nuts or screws as you remove or replace them It may be possible for them to get under one of the adjacent unit covers or contact the exposed back of one of the display boards on the front cover If this happens it is possible for the part to cause a short ona unit under power and therefore a possible turbine trip Woodward 25 ProTech 203 Overspeed Protection System Manual 85204 6 Unscrew the four long screws holding the two board pack together Figure 5
31. needed for safety as appropriate WARNING PROPER USE Any unauthorized modifications to or use of this equipment outside its specified mechanical electrical or other operating limits may cause personal injury and or property damage including damage to the equipment Any such unauthorized modifications i constitute misuse and or negligence within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage and ii invalidate product certifications or listings CAUTION POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY CAUTION BATTERY CHARGING To prevent damage to a control system that uses an alternator or battery charging device make sure the charging device is turned off before disconnecting the battery from the system CAUTION ELECTROSTATIC DISCHARGE Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices IMPORTANT DEFINITIONS A WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION indicat
32. ng an MPU fail timeout trip As further protection against a faulty MPU signal to the ProTech system the contact input can trip the turbine if the speed sensed by the unit is below the MPU fail set point regardless of the timer The contact input could come from the turbine control system or could come from a limit switch pressure switch or a combination of such devices which provide positive indication that the turbine speed should be above the MPU fail set point 18 Woodward Manual 85204 ProTech 203 Overspeed Protection System When the TIMER STARTS ON RESET option is set to YES the ALM IF SPD lt MPU FAIL SETPT option is active If ALM IF SPD lt MPU FAIL SETPT option is set to YES the alarm relay de energizes whenever speed is below the MPU fail set point The start key has no effect when the TIMER STARTS ON RESET option is set to YES Table 4 2 Start Mode Options TIMER STARTS ON RESET Option Default operation Reset resets trip and alarm condition Start begins MPU fail timer if the TIMER STARTS ON RESET option is set to NO MPU fail timer starts on Reset Start button and contact input have no effect Speed lt MPU fail point is not an alarm condition Similar to ProTech systems 9905 869 through 9905 886 MPU fail timer starts on Reset Start button has no effect Contact input provides trip input which is independent of the MPU fail timer The alarm is true whenever the speed is below the
33. normal rolldown occurs the alarm relay does not de energize the MPU FAIL LED does not turn on and no trip occurs To perform a lamp test press the menu key repeatedly until PRESS START FOR LAMP TEST is displayed Pressing the start key then illuminates all LED s and causes solid block characters to be displayed on the screen for approximately 2 seconds Woodward 19 ProTech 203 Overspeed Protection System Manual 85204 Overspeed Test The overspeed test function is activated when the keyswitch is in the PROGRAM position and the operator presses and holds the OVSP TEST button on the touchpad The microcontroller switches the source of the MPU signal from the MPU input to an on board oscillator The test speed is annunciated on the LCD If the test speed is adjusted above the trip set point using the Test Frequency potentiometer on each unit a trip occurs MPU loss of signal checking is disabled and the peak speed value does not change during overspeed test When the OVSP TEST button is released the microcontroller switches the source of the MPU signal back to MPU input and normal operation is restored Each ProTech unit must be reset to clear its trip condition NOTE Each individual unit may be tested as described above while the entire system remains on line In this case the two units not being tested take over full control of the overspeed protection for the prime mover NOTE It is recommended that the overspeed test be perf
34. ntacts with the same polarity Failure to do so will create a potential shock hazard and therefore possible injury or death If the ProTech 203 system is being installed in a hazardous environment please attend to the following warnings WARNING EXPLOSION HAZARD Substitution of components may impair suitability for Class 1 Division 2 Do not disconnect equipment unless power has been switched off or the area is known to be non hazardous NOTE All input and output wiring must be in accordance with Class Division 2 wiring methods and in accordance with the authority having jurisdiction All peripheral equipment must be suitable for the location in which they are being used Installation Check out Procedure When installation is completed perform the following check out procedure before powering up the device 1 Visual inspection a Ensure that all mounting hardware is tightened and that no wires or cables are pinched b Check for correct wiring according to the plant wiring diagram c Check for broken terminals or loose terminal screws Ensure that all ribbon cables are fully seated and clamped in place d Check the speed sensor MPU for visible damage Check the clearance between the gear and the sensor and adjust if necessary See manual 82510 Magnetic Pickups and Proximity Switches for Electronic Governors 4 Woodward Manual 85204 ProTech 203 Overspeed Protection System Figure 2 1 Plant Wiring Diagr
35. ormed on each unit ona weekly basis and that an actuating equipment integration assessment be performed any time the prime mover is taken off line Hardware Faults If the microcontroller determines that the EEPROM is not responding correctly a trip occurs The trip cause is annunciated as HARDWARE FAULT If this type of fault occurs reset the unit If the fault continues to occur replace the unit and return it for repair If the microcontroller determines that the data in EEPROM has been corrupted the display shows EEPROM DATA LOST If this type of fault occurs reset the unit If the fault continues to occur replace the unit and return it for repair The microcontroller monitors an interlock signal which indicates that the internal hardware cables are connected correctly If this signal indicates a missing interlock a trip occurs The cause of the trip is annunciated as INTERLOCK FAULT If this fault occurs check all cable connections If a monitor circuit determines that the microcontroller is not functioning a trip occurs The CPU FAIL LED turns on If this fault occurs replace the unit and return it for repair Table 4 3 provides a summary of possible trip causes Table 4 3 Trip Causes Display Shows MPU gt TRIP SETPT Speed has exceeded the TRIP SETPOINT value during an overspeed test After START speed did not reach the MPU FAIL SETPOINT within the MPU FAIL TIMEOUT time MPU FAILED A sudden loss of speed oc
36. pan 81 476 93 4661 The Netherlands 31 23 5661111 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward s website www woodward com for the name of your nearest Woodward distributor or service facility 30 Woodward Manual 85204 ProTech 203 Overspeed Protection System 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 e Technical Support e Product Training e Field Service Contact information Telephone 1 970 482 5811 Toll free Phone in North America 1 800 523 2831 Email icinfo woodward com Website www woodward com Technical Support is available through our many worldwide locations or our authorized distributors depending upon the product This service can assist you with technical questions or problem solving during normal business hours Emergency assistance is also available during non business hours by phoning our toll free number and stating the urgency of your problem For technical support please contact us via telephone email us or use our website and reference Customer Services and then Technical Support Product Training is available at many of our worldwide locations standard classes We also offer customized classes which can be tailored to your needs and can
37. pparatus for potentially explosive atmospheres Type of protection n EN61000 6 2 2001 EMC Part 6 2 Generic Standards Immunity for Industrial Environments EN61000 6 4 2001 EMC Part 6 4 Generic Standards Emissions for Industrial Environments ENS0178 1997 Electronic Equipment for Use in Power Installations We the undersigned hereby declare that the equipment specified above conforms to the above Directive s Douglas W Salter Full Name Engineering Manager Position WGC Fort Collins CO USA Place D Date 5 09 1183 Rev 6 16 Oct 2002 00142 04 CE 02 01 We appreciate your comments about the content of our publications Send comments to icinfo woodward com Please include the manual number from the front cover of this publication W wooDwarRD PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 e 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 06 6 F
38. r UL for Canada and US or non hazardous locations only The ProTech 203 is suitable for use in European Zone 2 Group II environments per compliance with EN60079 15 Electrical apparatus for explosive atmospheres Type of protection n Wiring must be in accordance with North American Class Division 2 or European Zone 2 wiring methods as applicable and in accordance with the authority having jurisdiction European Compliance for CE Marking These listings are limited only to those units bearing the CE Marking EMC Directive Declared to 89 336 EEC COUNCIL DIRECTIVE of 03 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility Low Voltage Declared to 73 23 EEC COUNCIL DIRECTIVE of 10 Directive February 1973 on the harmonization of the laws of the Member States relating to electrical equipment designed for use within certain voltage limits ATEX Potentially Declared to 94 9 EEC COUNCIL DIRECTIVE of 23 Explosive March 1994 on the approximation of the laws of the Atmospheres Member States concerning equipment and Directive protective systems intended for use in potentially explosive atmospheres EEx nA Il T4 North American Compliance These listings are limited only to those units bearing the UL agency identification UL UL Listed for Class Division 2 Groups A B C and D T4A at 60 C Ambient For use in Canada and the United States UL File E156028 WARNING
39. r until it is ready for installation Protect the device from weather and from extreme humidity or temperature fluctuations during storage Power Requirements The ProTech 203 system can be configured to operate with numerous power sources Each unit contains an independent power supply module that can be ordered in the configurations described in Tables 1 1 1 2 and 1 3 in Chapter 1 WARNING POWER SUPPLIES Each power supply must be provided with an external disconnecting means that is identifiable to the specific power supply A B or C Location Considerations Carefully study this chapter before choosing a location for the ProTech 203 system Wiring and grounding considerations may influence the selection of a location for the device Consider the following general requirements when selecting the location e Adequate ventilation for cooling e A location that will provide an operating temperature range of 25 to 60 C 13 to 140 F e Space for servicing e Protection from direct exposure to sunlight water or to a condensation prone environment e Protection from high voltage or high current devices which produce electromagnetic interference e Avoidance of vibration Field wiring is provided to reset the device from a remote location Shielded Wiring All shielded cable must be twisted conductor pairs with either a foil or a braided shield All signal lines should be shielded to prevent picking up stray sig
40. ription or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number If you have an electronic or programmable control please have the adjustment setting positions or the menu settings written down and with you at the time of the call 32 Woodward DECLARATION OF CONFORMITY According to EN 45014 Manufacturer s Name WOODWARD GOVERNOR COMPANY WGC Industrial Controls Group Manufacturer s Address 1000 E Drake Rd Fort Collins CO USA 80525 Model Name s Number s ProTech 203 18 32 VDC 9907 146 147 344 through 347 ProTech 203 120 VAC 9907 148 amp 149 8200 202 203 208 amp 209 ProTech 203 230 VAC 9907 150 amp 151 8200 204 205 210 amp 211 Conformance to Directive s 89 336 EEC COUNCIL DIRECTIVE of 03 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 73 23 EEC COUNCIL DIRECTIVE of 19 February 1973 on the harmonization of the laws of the Member States relating to electrical equipment designed for use within certain voltage limits 94 9 EC COUNCIL DIRECTIVE of 23 March 1994 on the approximation of the laws of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres Applicable Standards EN 60079 15 2003 Electrical a
41. s a trip if speed is below the MPU fail set point regardless of the timer See Figure 4 3 for a block diagram of this method It is the method used in earlier versions of the ProTech system When the turbine is ready to be started the MPU fail timer is started by pressing the reset key or by momentarily closing the remote reset input If speed does not exceed the MPU fail set point within the MPU fail timeout value the unit trips MPU Fail Detect Speed gt Trip S peed gt Trip Setpoint Trip Setpoint Compare Vale H MPU A7 e Speed lt MPU Fail Setpoint z MPU Fail Compare Speed gt MPU Fail Setpoint See Ge Setpoint Value Latch TRIP RESET START EXPIRED CLEAR Timer CLEAR Contact AND Input Open TRUE MPU Fail Timeout Value Figure 4 3 Method 2 Block Diagram If the unit is being restarted after a normal rolldown that is there was no trip it should be reset when the turbine is ready to be started again Earlier versions of the ProTech system remained disabled if the remote reset contact was held closed In the present version holding the remote reset contact closed will not disable the unit If the unit is reset to clear a trip condition but the turbine will not be immediately re started the remote reset contact must be periodically momentarily closed in order to prevent the timer from causi
42. see Figure 5 1 Woodward 23 ProTech 203 Overspeed Protection System Manual 85204 Figure 5 1 ProTech System Front Door 3 If you re replacing a fuse in Unit A remove the ribbon cable clamp and retain for use when re installing the cover Figure 5 2 Figure 5 2 Unit Covers Inside the ProTech Device 4 Unplug the power supply board terminal block then unplug the I O board terminal block Figure 5 2 5 Remove the four nuts on the unit s cover and carefully lift the cover off Figure 5 2 Retain the cover and the nuts to be reinstalled after changing the fuse 6 With the cover off the power supply board fuses will be visible in the lower left hand corner of the power supply board just above the power supply terminal block 24 Woodward Manual 85204 ProTech 203 Overspeed Protection System 7 Remove the fuses and examine them for defects Replace any defective or suspect fuse 8 Replace the unit s cover and snugly secure the four nuts that hold the cover in place 9 If you ve been working on Unit A replace the ribbon cable clamp onto the cover Figure 5 2 10 Plug in the unit s terminal blocks 11 Close and latch the front door 12 Re power the unit 13 On the unit s keypad press RESET to activate the unit s operation Changing a ProTech Unit On Line NOTE To ensure compatibility the entire unit must be replaced as a matched set Do not mix and match boards between units Tools a
43. sists of three identical independent speed sensing units which continuously monitor prime mover speed and activate a trip relay when an overspeed condition is detected The trip relays of the three units are connected in a two out of three voting configuration so that if any single unit fails the ProTech system will still provide the correct output The units functions include the ability to display the actual speed from each speed probe display the highest speed signal on line testing and modular design that allows a single failed unit to be replaced while the device is running Light emitting diodes LEDs and digital displays on the unit front panel indicate the functional status Applications The ProTech system can be ordered in either a de energize to trip model or an energize to trip model WARNING RECOMMENDED MODEL Woodward strongly recommends use of the de energize to trip model for reasons of general safety With an energized to trip model the prime mover may not trip on loss of power That failure to trip may result in property damage or personal injury and loss of life However Woodward recognizes that some applications will require the energize to trip option Because Woodward recognizes that some installations will use energized to trip models all ProTech systems have been designed with components of the highest quality and relays with operating characteristics that far exceed the anticipated requirements of the devi
44. terposing relay will not actuate and TB3 terminals 2 and 3 and TB2 terminals 5 and 6 will remain connected The ProTech 203 system utilizes three separate speed sensing units that are interfaced to three individual magnetic pickups MPUs Each speed sensing unit A B and C actuates two voter relays that are internally wired in a six relay series parallel configuration This six relay configuration drives the interposing relay shown in Figure 3 3 Whenever two of the three speed sensing circuits sense an overspeed condition the voter relay configuration will change state causing a turbine trip It should be noted however that a single MPU or circuit failure will not cause an inadvertent trip 10 Woodward Manual 85204 ProTech 203 Overspeed Protection System Figure 3 3 Voter Relay Configuration This configuration makes testing of the voter relays in the system a relatively simple operation Six relay status indicator LEDs STATUS A1 STATUS A2 STATUS B1 STATUS B2 etc are mounted on the control panel Each LED is on when its corresponding relay is tripped You may overspeed each of the three speed sensing circuits one at a time using a built in frequency generator You may then watch the LED indicators and the speed readout to see that each of the six individual voter relays trip at the correct speed Because of the series parallel configuration of the trip relays overspeeding one of the speed sensing circuits at a time wi
45. tion System Manual 85204 Remote Reset Can be reset from a remote location NOTE The external field wiring to the Remote Reset and Contact Input terminals must be protected from user accessibility It must be hard wired like a hazardous voltage circuit Contact Input Depending on how the unit is configured this input can act as a remote start input or as an indication to the ProTech system that it should be sensing speed greater than the MPU fail set point Built In Self Test A built in frequency generator permits testing of each unit individually while prime mover is on line Key Lock Prevents any programming or testing by unauthorized personnel Replacement Each subsystem can be replaced after disconnecting the supply power at the external disconnecting means while the other two subsystems are powered without tripping the prime mover Outputs A separate alarm output and LED indicate if an individual speed sensing unit has tripped MPU Failure Indications Separate LEDs indicate if an MPU or its wiring has failed MPU Fail Timer A timer is provided for start up if prime mover speed is not up to the value programmed when this timer times out the device will trip the prime mover Both the time and the speed are programmable MPU Fail Option Each unit can be configured so that on the sudden loss of that unit s MPU the unit can either output both an alarm plus a trip signal or the unit can output only an alarm CPU
46. urned to Woodward within 60 days Woodward will issue a credit for the core charge The core charge is the average difference between the flat rate replacement exchange charge and the current list price of a new unit Return Shipment Authorization Label To ensure prompt receipt of the core and avoid additional charges the package must be properly marked A return authorization label is included with every Replacement Exchange unit that leaves Woodward The core should be repackaged and the return authorization label affixed to the outside of the package Without the authorization label receipt of the returned core could be delayed and cause additional charges to be applied 28 Woodward Manual 85204 ProTech 203 Overspeed Protection System Flat Rate Repair Flat Rate Repair is available for the majority of standard products in the field This program offers you repair service for your products with the advantage of knowing in advance what the cost will be All repair work carries the standard Woodward service warranty Woodward Product and Service Warranty 5 01 1205 on replaced parts and labor Flat Rate Remanufacture Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the exception that the unit will be returned to you in like new condition and carry with it the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option is applicable to mechanical products only
47. within the MPU FAILED TIMEOUT period or the unit will trip If the TIMER STARTS on RESET option is set to Yes the speed must also exceed this value whenever the contact input is open or the unit will trip MPU FAILED MPU FAILED TIMEOUT TIMEOUT TIMEOUT Time period after a reset during which the prime mover speed must exceed the MPU FAILED SETPOINT or unit will trip MPU GEAR MPU GEAR MPU GEAR TEETH TEETH TEETH Number of gear teeth the MPU is looking at TRIP ON MPU TRIP ON MPU FAILURE FAILURE FAILURE Yes or No option If an MPU loss of signal occurs the MPU FAIL LED turns on and the alarm relay de energizes If the TRIP ON MPU FAILURE option is set to Yes the unit trips This option applies only to a sudden loss of MPU signal while running Trips due to an MPU timer timeout or an open contact input are not affected by this option TIMER STARTS ON RESET TIMER STARTS ON RESET Yes or No option If set to No the MPU fail timer starts when start key is pressed or when the contact input opens If set to Yes the MPU fail timer starts when the reset key is pressed or remote reset is momentarily closed ALARM IF SPEED ALARM IF SPEED ALARM IF SPEED lt MPU FAIL lt MPU FAIL lt MPU FAIL SETPOINT SETPOINT SETPOINT This option only applies when the TIMER STARTS ON RESET option is set to Yes If this option is set to Yes the alarm relay de energizes whenever speed is below the MPU f

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