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Manual 26710V1

ProTechTPS Total Protection System

Woodward

11

Chapter 1.

General Information

Description

The ProTechTPS (Total Protection System) is an overspeed safety device
designed to safely shut down steam, gas, and hydro turbines of all sizes upon
sensing an overspeed or over-acceleration event. This device accurately
monitors turbine rotor speed and acceleration via active or passive MPUs
(magnetic pickups) and issues a shutdown command to the turbine’s trip valve(s)
or corresponding trip system. In addition, it has programmable logic and
configurable inputs and outputs to address other safety critical functions.

The ProTechTPS consists of three independent modules whose trip outputs,
dependent upon model used, are either independent or voted in a 2-out-of-3
configuration. An isolated bus architecture is used to share all inputs and latch
status information between the three modules. Optionally each ProTechTPS
module can be configured to use only its sensed “local” input signals or the voted
result of all three modules’ signals in its event latch decision logic. Optionally
module trip and alarm latch statuses can also be configured to be shared with all
other modules.

The ProTechTPS includes Overspeed and Over-acceleration functions as well as
time stamped Alarm, and Trip logs. Indication that a test was active at the time of
the event is provided on all logs and first-out indications are provided for Trip and
Event logs. Trip response time monitoring and logging is also built into the
ProTechTPS.

The ProTechTPS provides various pre-defined and user-definable test features
including automated periodic tests.

There are several ways to interface with the ProTechTPS. The front panel allows
the user to view current values, and to perform certain configuration and test
functions. All of the features and most of the information available from the front
panel is also accessible via the Modbus interface. Finally, the Programming and
Configuration Tool (PCT) is software that is run on a PC to define configurable
inputs and programmable logic, download log files, and manage settings files.

This product is designed for critical applications and when installed correctly
meets API-670, API-612, API-611, and IEC61508 (SIL-3) standards.

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Summary of Contents for ProTech TPS

Page 1: ...Revision D 10 2016 Original Instructions ProTechTPS Total Protection System With Voted Inputs 8237 1602 1603 1604 1605 1606 1607 1608 1609 Manual 26710 consists of 2 volumes 26710V1 26710V2 Volume 1 Installation and Operation ...

Page 2: ...age 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 Translated Publications If the cover of this publication states Translation of the Original Instructions please note The original source of this pub...

Page 3: ...hielded Wiring 31 Control Wiring Guidelines 32 CHAPTER 3 FUNCTIONALITY 50 Introduction 50 Features 50 Product Models 55 Inputs and Outputs 62 Overspeed and Over Acceleration Detection and Trip 69 Start Logic 71 Configurable Logic 74 Test Routines 75 Alarm Trip and Event Latches 78 System Logs 80 Response Time Performance 82 CHAPTER 4 MODBUS COMMUNICATIONS 86 Modbus Communications 86 Monitor Only 8...

Page 4: ...following are trademarks of their respective companies Modbus Schneider Automation Inc Illustrations and Tables Figure 1 1 Typical ProTechTPS Application Voted Trip Relay Models 13 Figure 1 2 Typical ProTechTPS Application Independent Trip Relay Models 13 Figure 1 3 Typical Gas Turbine Application Voted Trip Relay Models 14 Figure 1 4 Typical Safety PLC Application Voted Trip Relay Models 14 Figur...

Page 5: ...p Relay Wiring per Module Independent Trip Relay Internal Supply 44 Figure 2 16c Example Trip Relay Wiring per Module Independent Trip Relay External Supply 45 Figure 2 16d Example Trip Relay Wiring Voted Trip Relay Models 45 Figure 2 16e Example Programmable Relay Wiring Internal Supply 46 Figure 2 16f Example Programmable Relay Wiring External Supply 46 Figure 2 17 Power Supply Relationship Diag...

Page 6: ...t Power Supply Specifications 30 Table 2 5 Relay Output Power Supply Specifications 30 Table 3 1a Independent Trip Relay Specifications 57 Table 3 1b Voted Trip Relay Specifications 62 Table 3 2 General I O Specifications 63 Table 3 3a Passive Probe Specifications 63 Table 3 3b Active Probe Specifications 64 Table 3 4 Dedicated Discrete Input Specifications 65 Table 3 5 Configurable Input Specific...

Page 7: ...rsonal 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 needed for safety as appropriate Personal Protective Equipment The products described in this publication may present risks that could lead to personal injury loss of life or property damage Always w...

Page 8: ...dling and Protection of Electronic Controls Printed Circuit Boards and Modules Follow these precautions when working with or near the control 1 Avoid the build up of static electricity on your body by not wearing clothing made of synthetic materials Wear cotton or cotton blend materials as much as possible because these do not store static electric charges as much as synthetics 2 Do not remove the...

Page 9: ...S Directive Exempt from 2002 95 EC of the European Parliament and of the Council of 27 January 2003 on the restriction of the use of certain hazardous substances in electrical and electronic equipment Exempt per Annex IA of Directive 2002 95 EC referring to monitoring and control instruments within the meaning of Category 9 WEEE Directive Exempt Compliant as a component with 2002 96 EC of the Euro...

Page 10: ...liance on panel mount models this equipment must be installed in an area providing adequate protection against the entry of dust or water A minimum ingress protection rating of IP54 is required for the enclosure Personnel must discharge their electrostatic build up to the cabinet ground point or use an ESD strap prior to touching the ProTech interior surfaces if the engine turbine is operational T...

Page 11: ...nless area is known to be non hazardous Substitution of components may impair suitability for Class I Division 2 or Zone 2 applications Risque d explosion Ne pas raccorder ni débrancher tant que l installation est sous tension sauf en cas l ambiance est décidément non dangereuse La substitution de composants peut rendre ce matériel inacceptable pour les emplacements de Classe I applications Divisi...

Page 12: ...le Functionality contained within one of the three identical sections MPU Magnetic Pick up PC Personal Computer or laptop with Windows operating system PCT Programming and Configuration Tool PFD Probability of Failure on Demand PFH Probability of dangerous Failure per Hour PLC Programmable Logic Controller PROX Proximity Probe RTU Remote Terminal Unit Settings File A file that contains the configu...

Page 13: ...ree modules signals in its event latch decision logic Optionally module trip and alarm latch statuses can also be configured to be shared with all other modules The ProTechTPS includes Overspeed and Over acceleration functions as well as time stamped Alarm and Trip logs Indication that a test was active at the time of the event is provided on all logs and first out indications are provided for Tri...

Page 14: ...sor turbines or engines This standalone safety device accepts 10 discrete or analog inputs per module 30 total and one speed MPU or PROX input 3 total Each ProTechTPS module provides 3 programmable relay outputs 9 total and an analog speed output 3 total in addition to the trip relay outputs Configurable logic allows the customization required to meet specific application requirements to ensure pl...

Page 15: ...t Speed Signals Control Actuator Generator or Compressor or Pump ProTechTPS TS TS TS PS Analog or Discrete Signals Plant DCS LS Trip Valve Monitor Signal Drain Trip Header Serial Com TS Trip Valve Inlet Steam Header 3 Redundant Speed Signals Control Actuator Generator or Compressor or Pump ProTechTPS TS TS TS TS PS Analog or Discrete Signals LS Trip Valve Monitor Signal PS 203 Trip Block TS TS PS ...

Page 16: ...pplication Voted Trip Relay Models Figure 1 4 Typical Safety PLC Application Voted Trip Relay Models Trip Valve Gas Redundant Speed Signals Control Generator or Compressor or Pump ProTechTPS TS PS Analog or Discrete Signals Plant DCS Serial ModBus TS Trip Valve Closed Indication PS Control Valve ...

Page 17: ...ing 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 System Installation Procedure 1 Review system manual to gain a complete understanding of the ProTechTPS system 2 Create a site specific wiring diagram by referencing included wiring diagrams constraints then perform mechanical and electrical installatio...

Page 18: ...er and module C on the right This applies to either the bulkhead mount versions with the front cover open or the panel mount versions with the back cover removed Depending on the model purchased the ProTechTPS has either a bulkhead mounted or a panel mounted enclosure package The bulkhead mounted enclosure models are designed to be mounted on a wall or skid next to the turbine and are rated for IP...

Page 19: ...ward 17 Figure 2 1 Typical ProTechTPS Bulkhead Package Front View Figure 2 2a Typical ProTechTPS Bulkhead Package Front Door Open Figure 2 2b Bulkhead Schematic Showing Front Panel A Connection to Module A and Front Panel C Connection to Module C Top View ...

Page 20: ...ProTechTPS Total Protection System Manual 26710V1 18 Woodward Figure 2 3 Mounting Outline Diagram for Bulkhead Mounted Models ...

Page 21: ...isplay board If a display board is unresponsive contact Woodward for a recommendation regarding service options DO NOT ATTEMPT TO REPAIR Follow this procedure for module removal and installation Removal 1 Disconnect power from the module to be removed 2 Verify power removed by observing power LED is OFF 3 Remove terminal blocks from module terminals 4 Loosen 4 module retention screws Power Termina...

Page 22: ...ProTechTPS Total Protection System Manual 26710V1 20 Woodward Power LED 4 Retaining Screws 5 Remove module by pulling the two handles simultaneously Remove by pulling from handles ...

Page 23: ...pressing firmly on handles The module has guides to assist in location 2 Tighten 4 module retention screws 3 Install terminal blocks 4 Insert power terminal block and observe that the power LED is ON This pin header connects to the header on the CPU module CPU module pin header CPU module insertion guides ...

Page 24: ...ProTechTPS Total Protection System Manual 26710V1 22 Woodward Figure 2 4a Typical ProTechTPS Panel Mount Package Front View Figure 2 4b Typical ProTechTPS Panel Mount Package Rear View with Cover ...

Page 25: ...l Mount Package Rear View without Cover Module identification is always from left to right with module A on the left module B in the center and module C on the right This applies to either the bulkhead mount versions with the front cover open or the panel mount versions with the back cover removed ...

Page 26: ...ion System Manual 26710V1 24 Woodward Figure 2 4d Panel Mount Schematic Showing Front Panel A Connection to Module A and Front Panel C Connection to Module C Top View Figure 2 5a Mounting Outline Diagram for Panel Mount Models ...

Page 27: ...Manual 26710V1 ProTechTPS Total Protection System Woodward 25 Figure 2 5b Mounting Outline Diagram for Panel Mount Models ...

Page 28: ...ProTechTPS Total Protection System Manual 26710V1 26 Woodward Figure 2 5c Panel Cutout Diagram for Panel Mount Models ...

Page 29: ... module removal and installation Removal 1 Disconnect power from the module to be removed 2 Remove 4 back panel retaining screws 3 Remove back panel 4 Verify power removed by observing power LED is OFF 5 Remove terminal blocks from module terminals 6 Loosen 4 module retaining screws 7 Remove module by pulling the two handles simultaneously ...

Page 30: ...inal blocks 6 Apply power and observe that the power LED is ON Mounting Location Considerations Consider the following general requirements when selecting the mounting location Adequate ventilation for cooling A location that will provide an operating temperature range of 20 to 60 C 4 to 140 F The ProTechTPS weighs approximately 12 kg 26 5 lb Space for opening servicing Space for installing removi...

Page 31: ...ion Approximately 26 lb 12 kg Weight Panel Mount Version Approximately 22 lb 10 kg Pollution Degree 2 per IEC 60664 1 Overvoltage Category II per IEC 60664 1 Power Supply Requirements Each ProTechTPS system consists of three separate internal modules A B C and each of these three modules accept two input power sources for redundancy Depending on the ProTechTPS model purchased the internal modules ...

Page 32: ... the other power supply input disconnected With both power supply inputs connected input current will never exceed the maximum specification however the two power supplies do not load share internally Internally Generated Limited Power Supplies Configurable Input Power Supply 24V_AI Output Voltage 24 Vdc 10 Current Limit 50 mA Table 2 4 Configurable Input Power Supply Specifications Avoid using th...

Page 33: ...the enclosure s PE labeled connection points must have a wire going from the enclosure to a building PE ground point This wire must be of sufficient gauge to handle the rated current of all the interposing relay wires or 1 5 mm2 16 AWG whichever is larger Shielded Wiring All shielded cable must be twisted conductor pairs with either a foil or a braided shield A braided shield is preferred and high...

Page 34: ...sted below The screw lug terminal blocks are designed to flatten stranded wire Do not tin solder the wire s strands that terminate at the ProTech Terminal Blocks If the wire strands are soldered together the solder will cold flow and shrink over time causing the connection to become intermittent or disconnected Woodward recommends the following for ProTechTPS Stranded bare copper wire unless gaseo...

Page 35: ...ends that all field wiring be routed from the bottom of the package The units back cover must be installed Refer to Figure 2 5 for field wiring access information For EMI electromagnetic interference reasons Woodward recommends that all low voltage field wiring be separated from all high voltage field wiring where possible Woodward also recommends that power wiring be segregated in the same manner...

Page 36: ...ProTechTPS Total Protection System Manual 26710V1 34 Woodward Figure 2 7 Inside View of ProTechTPS ...

Page 37: ...Manual 26710V1 ProTechTPS Total Protection System Woodward 35 Figure 2 8 ProTechTPS Control Wiring Diagram ...

Page 38: ...ProTechTPS Total Protection System Manual 26710V1 36 Woodward Figure 2 9 Trip Module Included within Voted Trip Relay Units Only Figure 2 10a Power Supply Field Wiring Routing Stress Relief Diagram ...

Page 39: ...Relay Output Field Wiring Routing Stress Relief Diagram Speed Sensor Inputs To sense speed each ProTechTPS module A B C accepts a signal from a speed sensor mounted on a gear connected to the turbine rotor or engine crankshaft Speed sensors may be any of the following Passive magnetic pickup unit MPU Active proximity probe Eddy current probe ...

Page 40: ...speed probe input voltage must be between 16 and 28 Vdc and the output signal must meet Vlow and Vhigh threshold values specified in Chapter 3 Inputs and Outputs section The voltage for the speed probes must be from the provided voltage port or have its common referenced connected to the provided common pin for proper operation See Figures 2 11b thru 2 11c for proximity and eddy current probe wiri...

Page 41: ...ximity Probe Active Magnetic Pickup Unit Wiring External Power Non preferred Figure 2 11d Example Eddy Current Probe Active Magnetic Pickup Unit Wiring 67 68 69 70 71 _ 24V Proximity Probe 24V Active Probe Configured Active Probe Configured 10K _ 67 68 69 70 71 _ Eddy Current Probe 24V Active Probe Configured Active Probe Configured 10K VT Com Out Bently Proximitor Sensor ...

Page 42: ...e Dedicated Discrete Inputs are Start Reset and Speed Fail Override Refer to Chapter 3 Functionality of this manual for information on each discrete input s functionality Figure 2 12a Example Standard Discrete Input Wiring Internal Power Option Figure 2 12b Example Standard Discrete Input Wiring External Power Option Configurable Discrete and Analog Inputs Ten configurable inputs per module A B C ...

Page 43: ...aw through terminal 37 exceeds 50 mA the power supply s internal breaker will open Upon such a condition all load must be removed from the specified terminals to allow this breaker to reset The internal 24 V provides enough power to operate all 10 inputs in discrete mode For reliability reasons Woodward recommends that input circuitry for each module A B C be fully isolated from the input circuitr...

Page 44: ...able analog input specifications Because analog inputs are not fully isolated take care in their application and maintenance to avoid ground loop type problems If interfacing to a non isolated device with one of these inputs the use of a loop isolator is recommended to break any return current paths which could result in erroneous readings Also if a loop isolator is not used and the non isolated f...

Page 45: ...information on how to program and use this analog output in an application Figure 2 15 Example Analog Output Wiring Relay Outputs Two basic ProTechTPS model variations are available depending on the required trip system architecture the Independent Trip Relay model and the Voted Trip Relay model Either version also has 3 programmable Relay Outputs per module Refer to Figure 2 16a for the general l...

Page 46: ...ly open type contacts and are rated for 24 Vdc 1 A Two of these relay outputs are dedicated as redundant trip signal outputs and the other three relay outputs are user programmable which can be programmed to function independently as required The Independent Trip Relay ProTechTPS models are designed so the each set of trip relays drive one of three external independent trip solenoids typically use...

Page 47: ...odule and the other three relay outputs are user programmable which can be programmed to function independently as required Note that with the Voted Trip Relay ProTechTPS models the two solid state trip relays located on each module A B C are not available for use or connection Each module s trip signal relays are connected internally to the ProTechTPS in a 2 o o 3 voted fashion to drive two redun...

Page 48: ...ree configurable solid state relay outputs These are user programmable and can be programmed to function as required The programmable relay outputs have normally open type contacts and are rated for 24 Vdc 1 A Refer to Figure 2 16e or f for wiring information Figure 2 16e Example Programmable Relay Wiring Internal Supply Figure 2 16f Example Programmable Relay Wiring External Supply ...

Page 49: ...ied terminals to allow this breaker to reset If additional current capability is needed the Voter Programmable relay connections points may be used as controlled switch contact connection points with an external power supply An external supply may be used instead of the internal supply only for the independent trip relays or programmable relays as shown in figure 2 16f The external supply should b...

Page 50: ... Supply Relationship Diagram Serial Modbus Communications One serial communications port per module A B C is available for Modbus communications to a plant DCS distributed control system or local HMI human machine interface This serial port can be wired and configured for RS 232 or RS 485 communications depending on the specific application requirements Refer to Figure 2 18a for RS 232 wiring info...

Page 51: ...is available to interface with a computer for loading program settings into the ProTech and for reading stored log files from the ProTech using the Programming and Configuration Tool PCT This port is designed to communicate to the computer using a serial DB9 extension straight through type of computer cable Figure 2 19 Service Tool Cable Interface Diagram The RS 232 serial cable must be disconnect...

Page 52: ... the sensed speed output The ProTechTPS comes in two basic models the Independent Trip Relay models and the Voted Trip Relay models This relates to the trip signal configuration The differences between these two models and their application are discussed in detail in the Product Models section of this chapter Each of the three ProTechTPS modules A B and C are fully fault isolated from each other s...

Page 53: ...ule to module program copying function Each ProTechTPS module shares its input values speed acceleration analog discrete inputs and dedicated function discrete inputs and its trip and alarm latch outputs with the other two modules Users can then optionally configure the module s trip and alarm logic to use or not use the shared input and latch information This type of redundancy allows users the c...

Page 54: ...roTechTPS Total Protection System Manual 26710V1 52 Woodward Figure 3 1 Module Diagram with Speed Redundancy Manager Configured Configurable Analog Digital inputs Logic Blocks and Output Relays not shown ...

Page 55: ...ual 26710V1 ProTechTPS Total Protection System Woodward 53 Figure 3 2 Module Diagram without Speed Redundancy Manager Configured Configurable Analog Digital inputs Logic Blocks and Output Relays not shown ...

Page 56: ... configuration settings Program differences between modules are detected and alarmed Although the overspeed and over acceleration functionality can be programmed from either the PCT or a module s front panel changes additions to a custom application program can only be changed via the PCT Entry of the correct configuration level password is required to perform any program changes or download a pro...

Page 57: ... with different mounting options bulkhead mount or panel mount and different input power supply options two high voltage power supply inputs or one high voltage and one low voltage power supply input Each ProTechTPS model can be configured to function for energize to trip and de energize to trip applications The de energize to trip functionality is implemented such that a complete loss of power to...

Page 58: ...ModBus Serial Port Auxiliary Power Plant DCS Other ProTech Modules Trip Relay External Logic Start Reset Logic Configurable Trip Alarm Relay Logic Prog Relay Service Tool Port Service Computer To Meter or DCS Analog Readout Password Enable Freq Gen Isolated Power Supply Isolated Power Supply Front Panel Interface Display Keypad LEDs Config Input 9 Config Input 10 Config Input 1 Config Input 2 Conf...

Page 59: ...cations Number of Channels 2 actuated simultaneously Output Type SPST Solid state Normally Open Current Rating 1 A Voltage Rating 24 V 32 V max Isolation 500 Vac from output to chassis and output to all other circuits Signal Cable Length Must be limited to 1000 ft 305 m low capacitance 16 AWG 1 3 mm pair Table 3 1a Independent Trip Relay Specifications ...

Page 60: ...2 out of 3 2oo3 fashion to create the 2oo3 trip output command Two redundant Form C 2oo3 voted relays are used in these models providing four isolated relay output signals with normally open and normally closed contacts Figure 3 6 Basic Functional Overview of Voted Trip Relay Models 2 out of 3 Voted Relays Module B Module C 2 Form C Trip Relays Speed Input Configurable Analog Discrete Inputs Modul...

Page 61: ... Reset Logic Configurable Trip Alarm Relay Logic Prog Relay Service Tool Port Service Computer To Meter or DCS Analog Readout Password Enable Freq Gen Isolated Power Supply Isolated Power Supply Voted Interposing Relays Trip Relay Output 1 B 1 B 2 C 1 C 2 Trip Relay Output 2 Only Available with Voted Relay Models Front Panel Interface Display Keypad LEDs Config Input 9 Config Input 10 Config Input...

Page 62: ...ProTechTPS Total Protection System Manual 26710V1 60 Woodward Figure 3 8 Simplex Trip Block Assembly ...

Page 63: ...Manual 26710V1 ProTechTPS Total Protection System Woodward 61 Figure 3 9 Dual Redundant Trip Block Assembly ...

Page 64: ...g and voting logic to manage logic in all three modules Speed Sensor Inputs Each module has one speed input which can be programmed to accept a passive MPU magnetic pickup unit or an active speed sensor proximity probe signal or an eddy current probe signal When configured as an MPU signal input special MPU open wire detection circuitry is used to validate that the MPU is properly connected before...

Page 65: ...ver acceleration detection logic Although not recommended if only one probe is used then the second and third modules can be configured to only use and vote on the shared speed signal from the first module to use in their overspeed and over acceleration detection logic If the unit is configured for only two probes or just one probe there will be a configuration mismatch and associated alarm This a...

Page 66: ...y by the ProTechTPS Shielded cable is required when connecting to the speed input Dedicated Discrete Inputs Each ProTechTPS module A B C accepts three dedicated discrete inputs The Dedicated Discrete Inputs are Start Reset and Speed Fail Override Each module can be configured to use only its local discrete input signals start reset and speed fail override or the ORed result of its local discrete i...

Page 67: ...module s contact inputs to also function as the Speed Fail Override Input for the other modules the module s Boolean Input Manager logic function can be configured to do so Each module s Boolean Input Manager function can be configured to accept only its local Speed Fail Override contact input or a specific module s Speed Fail Override contact input or all modules Speed Fail Override contact input...

Page 68: ...put values Additionally low low LoLo low Lo high Hi and high high HiHi levels can be defined The Boolean outputs associated with these levels for the analog input can be used in the user configured software There is also a Range Error output to indicate that the Input is outside a 2 22 mA range INPUT INPUT MODE Analog Input 4 20 Input 20mA Value HiHi Analog Input Input 4mA Value NAME 24 Char Input...

Page 69: ...ircuits not galvanically isolated to other channels in analog mode Faults or signals on one channel will not affect other channels Anti aliasing Filter 2 poles at 500 Hz Loop power is not provided by the ProTechTPS Shielded twisted pair cable is required when connecting to the analog inputs Note 1 0 25 represents the pk pk noise of the input The average accuracy is 0 1 of 25 mA Discrete Input Mode...

Page 70: ...ble Length Must be limited to 1000 ft 305 m low capacitance 16 AWG 1 3 mm Table 3 6 Programmable Relay Output Specifications Analog Output A single 4 20 mA output is provided on each module to indicate the speed sensed by that module The 4 20 mA range can be configured to any speed range desired The accuracy of the analog output is better than 0 5 of 20 mA over the temperature range of the product...

Page 71: ...ion condition The ProTechTPS control s acceleration detection function can be configured to be enabled disabled or only enabled above a certain speed setpoint The over acceleration trip range is configurable from 0 to 25 000 RPM s Peak speed and peak acceleration are tracked and logged for every overspeed and over acceleration occurrence The last 20 occurrences are logged and can be viewed from th...

Page 72: ...ack Function a Highest signal b Lowest signal 3 One used healthy speed signal condition Two Inputs Failed Action a Used sensed healthy speed signal b Issue a trip command In the Speed Redundancy Manager there is the Difference Alarm Limit and the Difference Alarm Time The Difference Alarm time is the time a difference is allowed before an alarm is set When the Speed Redundancy Manager is used losi...

Page 73: ...dition Two Inputs Failed Action a Used sensed healthy speed acceleration signal b Issue a trip command Start Logic The start signal is generated by selecting the START button on the module front panel or by closing the dedicated Start contact input The start signal is edge triggered and re selecting Start will reset the timer The ProTechTPS control s failed speed signal detection logic is used to ...

Page 74: ...ProTechTPS Total Protection System Manual 26710V1 72 Woodward Figure 3 14 Start Logic Diagram ...

Page 75: ... panel of a module or by closing the predefined Start contact input The start signal is edge triggered and re selecting Start will reset the timer Timer Reset Start Start Expired Speed ok Trip Speed Speed Fail Setpoint Figure 3 16 Speed Fail Timeout Trip Diagram Start Example with Speed Fail Timeout Trip First any trips or alarms are cleared by issuing a reset command either by pressing the reset ...

Page 76: ... the safety system test validation The logic unit provides configurable logic that allows the user to define how the input signals are used in detecting an unsafe condition and generating a trip signal The configurable logic provides the following functions Analog Comparators Analog Redundancy Managers Boolean Redundancy Managers Boolean combinatorial logic AND OR NOT etc Boolean Latches Delays Ti...

Page 77: ... supports 3 User defined Tests There is a configurable test mode permissive that is provided to prevent a test from being started if any module is tripped in test or in alarm This permissive can be configured Not Tripped if another module is tripped or in a test Not In Alarm if another module is in alarm or in a test or None for no permissive Selecting None means that tests can be run on any modul...

Page 78: ... is defaulted to use the highest level Test Mode Permissive so that a module cannot be placed in test while any other unit is tripped in test or in alarm If it is desired to test a unit trip by tripping multiple modules through these simulated speed tests the Test Mode Permissive can be set to a lower level Manual Simulated Speed Test This allows the user to manually increase decrease a modules in...

Page 79: ...d wait for a continue acknowledge signal from configurable logic inputs The test will wait for a configurable amount of time and if that time is exceeded the test will abort The operator can disable the Auto Sequence test from the front panel of the module When the Auto Sequence test is disabled or if any module is in trip alarm or test the Time Remaining Until Next Test will be prevented from cou...

Page 80: ...th all of the following latches A Reset can be generated by pressing the reset key on the front panel from the pre defined reset contact input via Modbus or from a user defined Configurable Reset Source It is possible to configure one Discrete Input to function as a Resettable Trip input where the Reset Function will clear the associated trip even if the contact is still open This is used in cases...

Page 81: ...y version of the ProTechTPS the trip action of each module may put part of the trip system into a tripped state and at least two modules must be tripped to trip the unit In the Voted Trip Relay version of the ProTechTPS at least two modules would have to be in the tripped state for the voter relay to go to its tripped state A trip of the module refers to the action of the ProTechTPS module changin...

Page 82: ... In each module one Event Latch is provided It is to be used in conjunction with the user defined software and can be used to log any desired event The latch is structured like the Trip Latch When any of the Event Latch inputs becomes true the output of the Event latch is set TRUE Each Event Input is individually latched and those latched outputs are available on Modbus The individual latches are ...

Page 83: ...the Trip Log screen This screen displays the most recent TRIP event at the top of the list and allows users to scroll through all logged events Alarm Log Each module logs the last 50 alarms sensed This log stores the alarm description time and date of the event and indication if the module was performing a test when the trip occurred Pressing the ALARM VIEW button on the ProTechTPS s front panel w...

Page 84: ...ation use of the Speed Redundancy Manager function The definition of total throughput response time as used within this manual and is displayed within the below graphs is the following the average time difference between a change of input speed at the input terminal is made to the time a change of output relay state at the output terminal is detected Average time difference is displayed as event o...

Page 85: ...e 3 17 Total System Response Time Based on Sensed Frequency Level for Independent Trip Relay Models when Speed Redundancy Manager Function is not Configured Figure 3 18 Total System Response Time Based on Sensed Frequency Level for Independent Trip Relay Models when Speed Redundancy Manager Function is Configured ...

Page 86: ...3 19 Total System Response Time Based on Sensed Frequency Level for 2oo3 Voted Trip Relay Models when Speed Redundancy Manager Function is not Configured Figure 3 20 Total System Response Time Based on Sensed Frequency Level for 2oo3 Voted Trip Relay Models when Speed Redundancy Manager Function is Configured ...

Page 87: ...otection System Woodward 85 Frequency rpm number of teeth 60 Figure 3 21 Response Time Definition Analog Output The response time of the analog output is less than 12 ms measured from a change in speed to a change in the output current ...

Page 88: ...atch State other two modules Trip Latch State other two modules 10 Discrete Inputs other two modules 10 Analog Inputs other two modules Note Modbus based write commands for test purposes to each module can only be given to the module via its respective Modbus port Serial Communication Port RS 232 RS 485 Specifications Number of Ports 1 Comm Type RS 232 RS 485 user selectable Termination Resistor R...

Page 89: ...te terminal unit transmission protocol For more information on Modbus networks and the RTU transmission protocol refer to Modbus Protocol Reference Guide PI MBUS 300 Rev J A Modbus function code tells the addressed slaves what function to perform The following table lists the function codes supported by the ProTechTPS Code Definition Reference Address 02 Boolean Read Read Input Status 1XXXX Status...

Page 90: ...vice are multiplied by a scaling constant before being sent by ProTechTPS See the Modbus list for the scaling used on each analog parameter Boolean Writes Code 05 Boolean Write registers are used by an external master device plant DCS etc to issue Boolean commands to a ProTechTPS module No password is required when issuing a command using Modbus The available write commands are listed in Table 4 3...

Page 91: ...are sent using more than one register The available Analog read registers units scaling and range are listed in Table 4 5 Heartbeat indication 1 1501 The Heartbeat indication provides an indication that toggles every 1 second between logic 1 and logic 0 Last Trip time and date indication 3 1001 1007 Last Trip Date Time represents the Date Time of the most recent first out trip Unit Health indicati...

Page 92: ...hed 1 1005 Speed Fail Timeout 1 1006 Speed Lost Alarm Non Latched 1 1007 Speed Lost Trip Non Latched 1 1008 Speed Probe Open Wire Trip Non Latched 1 1009 Tmp Ovrspd Setpoint On 1 1010 Simulated Speed Active 1 1011 Auto Speed Test Active 1 1012 Auto Speed Test Failed 1 1013 Auto Sequence Test Active 1 1014 Auto Sequence Continue Timeout 1 1015 User Defined Test 1 ADDRESS DESCRIPTION 1 1016 User Def...

Page 93: ...Gate 11 1 1109 Logic Gate 12 1 1110 Logic Gate 13 1 1111 Logic Gate 14 1 1112 Logic Gate 15 1 1113 Logic Gate 16 1 1114 Logic Gate 17 1 1115 Logic Gate 18 1 1116 Logic Gate 19 1 1117 Logic Gate 20 1 1118 Logic Gate 21 1 1119 Logic Gate 22 1 1120 Logic Gate 23 1 1121 Logic Gate 24 1 1122 Logic Gate 25 1 1123 Logic Gate 26 1 1124 Logic Gate 27 1 1125 Logic Gate 28 ADDRESS DESCRIPTION 1 1126 Logic Ga...

Page 94: ...8 Input 2 Invalid 1 1237 Analog Red Mgr 8 Input 3 Invalid 1 1238 Analog Red Mgr 9 Input 1 Invalid 1 1239 Analog Red Mgr 9 Input 2 Invalid 1 1240 Analog Red Mgr 9 Input 3 Invalid 1 1241 Analog Red Mgr 10 Input 1 Invalid 1 1242 Analog Red Mgr 10 Input 2 Invalid 1 1243 Analog Red Mgr 10 Input 3 Invalid 1 1244 Analog Red Mgr 11 Input 1 Invalid 1 1245 Analog Red Mgr 11 Input 2 Invalid 1 1246 Analog Red...

Page 95: ...ference Detection 12 1 1331 Difference Detection 13 1 1332 Difference Detection 14 1 1333 Difference Detection 15 1 1334 Speed Red Mgr Input 1 Invalid 1 1335 Speed Red Mgr Input 2 Invalid 1 1336 Speed Red Mgr Input 3 Invalid 1 1337 Speed Red Mgr Input Difference 1 1338 Accel Red Mgr Input 1 Invalid 1 1339 Accel Red Mgr Input 2 Invalid 1 1340 Accel Red Mgr Input 3 Invalid 1 1341 Speed Probe Open Wi...

Page 96: ...tpoint Local RPM 0 to 32500 3 0101 to 0110 Analog Inputs Local 1 to 10 User Units 32768 to 32767 3 0201 to 0210 Module A Analog Inputs 1 to 10 User Units 32768 to 32767 3 0301 to 0310 Module B Analog Inputs 1 to 10 User Units 32768 to 32767 3 0401 to 0410 Module C Analog Inputs 1 to 10 User Units 32768 to 32767 3 0501 Trip Cycle Time 1 ms 0 to 65535 3 0502 Trip Cycle Time 2 ms 0 to 65535 3 0601 Te...

Page 97: ...art of the front panel The Trip Log and the Alarm Log can also be viewed from the front panel The Programming and Configuration Tool also provides more detailed information in the log pages UNIT HEALTH LED The UNIT HEALTH LED indicates module health status Green Unit OK and functioning properly Red Safety Functionality is not running internal fault trip is present Unlit Status unknown because of a...

Page 98: ...igure Menu and verify all proper configuration options are selected Verify there are no alarms or faults that may indicate a setup problem open wire trip speed lost speed fail etc Verify the input signal levels are within the electrical specifications Also verify shield connections If using an active probe verify probe power is correct by disconnecting the probe and measuring from terminals 69 to ...

Page 99: ... within acceptable electrical specifications Verify the wiring and terminal block connections On the front panel check the Configurable Inputs Monitor Menu and verify the correct analog input level is displayed A signal out of range indicates the input is less than 2 mA or greater than 22 mA Using the Programming and Configuration Tool verify the input is configured as analog input and the Lo LoLo...

Page 100: ... that the analog output is reading an expected output value Measure the current from terminal 64 and verify it corresponds to the previous step Verify the load on the analog output is within the electrical specifications Using the Programming and Configuration Tool or front panel verify the scaling is correct MODBUS not working Wiring fault terminal block loose Configuration Verify the wiring and ...

Page 101: ...module Parameter Error An error has been detected in the internally stored parameters Internally stored parameters are constantly checked for data integrity Non volatile memory hardware fault or internal fault Reload configuration settings using the PCT Cycle input power If Parameter Error persists return unit to Woodward according to the instructions in Chapter 8 of this manual Overspeed Trip if ...

Page 102: ...be integrity Speed Fail Trip if speed redundancy or the speed probe is used Start logic Speed Fail Trip is enabled and the module has detected the Speed Fail Override contact input is open while speed is below the user configured Speed Fail Setpoint Wiring fault speed probe fault Speed Fail Override contact input operation not correct Incorrect speed fail setpoint configured Check wiring continuit...

Page 103: ...d or the power is disconnected Check the power source breaker fuse and connections Note the module will continue to operate normally on power supply 1 Speed Fail Alarm if the speed probe is used Start logic Speed Fail Alarm is enabled and the module has detected the Speed Fail Override contact input is open while speed is below the user configured Speed Fail Setpoint Wiring fault speed probe fault...

Page 104: ...as been activated User initiated simulated speed test See manual for description and limitations Auto Sim Speed Test Indicates the automated simulated overspeed test has been activated User initiated simulated speed test See manual for description and limitations Auto Sim Spd Test Failed Indicates the automated simulated overspeed test failed Internal problem with the unit Return unit to Woodward ...

Page 105: ...eck external system by following the trip signal around the loop until it returns back to the ProTechTPS input that is designated as the trip indicator input Trip Cycle Time Mon 2 Alarm Indicates the Trip Cycle Monitor Time 2 Alarm has been set Trip Cycle Monitor Time 2 Alarm is set when the maximum cycle time has been exceeded during a trip cycle time test Check the Trip Cycle Time Monitor Menu a...

Page 106: ...such that a complete loss of power to the module does not result in a trip of that module When configured as de energize to trip the modules power up in the tripped state When configured as energize to trip the modules power up such that they do not enter the tripped state unless a trip condition is present Configuration Module Power Loss State Module Power Up State De energize to trip Tripped Tri...

Page 107: ... process Response Time Data The response time for a safety system must be less than the process safety time The system integrator must determine the process safety time and the response time of all elements sensors ProTechTPS actuators etc that make up the total process safety time For this purpose the ProTechTPS response time is given in this manual Refer to Chapter 3 of this manual and Figures 3...

Page 108: ...ation is in the Proof Test section of this chapter The frequency of the proof test is determined by the overall safety system design of which the ProTechTPS is part of the safety system The safety numbers are given in the following sections to help the system integrator determine the appropriate test interval This will require password access to the front panel menus Installation and Site Acceptan...

Page 109: ...s selected in Speed Configuration Menu make the measurement and insure probe type is in original configuration 23 1 V 6 Test Speed input by using one of the internal speed test modes in the Test Menu Resistance measurement of each of the voter outputs is required Verify as follows a With module not tripped resistance measurement from 1A 1B or 2A 2B must be less than 100 b With module tripped resis...

Page 110: ...his procedure re establishes an electrical charge into the product s electrolytic capacitors extending their shelf life See the Unpacking section in the chapter on Installation for unpacking Refurbishment Period Recommendation This product is designed for continuous operation in a typical industrial environment and includes no components that require periodic service However to take advantage of r...

Page 111: ...ward Business Partner Support Woodward works with and supports a global network of independent business partners whose mission is to serve the users of Woodward controls as described here A Full Service Distributor has the primary responsibility for sales service system integration solutions technical desk support and aftermarket marketing of standard Woodward products within a specific geographic...

Page 112: ... 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 ...

Page 113: ... our worldwide locations or from one of our Full Service 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 information on these services please contact us via telephone email us or use our website www woodward com Contacting Woodward s Support Organization For the name of your nearest Wo...

Page 114: ...mber Type of Fuel gas steam etc Power Output Rating Application power generation marine etc Control Governor Information Control Governor 1 Woodward Part Number Rev Letter Control Description or Governor Type Serial Number Control Governor 2 Woodward Part Number Rev Letter Control Description or Governor Type Serial Number Control Governor 3 Woodward Part Number Rev Letter Control Description or G...

Page 115: ...bb elec com Web www bb elec com 2 Lantronix Model UDS100 Xpress DR IAP Serial RS 232 RS 485 or RS 422 Power Input 9 30 Vdc 9 24 Vac Lantronix 15353 Barranca Parkway Irvine CA 92618 USA Phone 1 800 422 7055 Email sales lantronix com Web www lantronix com B B Electronics Setup Below you will find the wiring setup and software configuration for the MESR901 Remember that the pictures below are for ref...

Page 116: ...Total Protection System Manual 26710V1 114 Woodward Wiring RS 232 NOTE The Serial DB9 connection is used for RS 232 communication only RS 485 2 wire NOTE Use the terminal block for wiring of RS 485 communications ...

Page 117: ...location of the resistor on the device The ProTech has the termination resistor built into the module jumpers are necessary between terminals 14 15 and 18 19 to activate the termination Configuration Configuration of the MESR901 is done through Vlinx Modbus Gateway Manager The configuration software is provided with the device Network Settings Modbus TCP Settings ...

Page 118: ...Settings Lantronix Setup Below you will find the wiring setup and software configuration for the UDS100 Xpress DR IAP Remember that the pictures below are for reference you will need to setup the serial configuration to match the settings you chose in the ProTech When multi dropping the 3 modules together using RS 485 422 you will need to assign each module a unique node address which can be found...

Page 119: ...Manual 26710V1 ProTechTPS Total Protection System Woodward 117 Wiring RS 232 Verify that the dip switch on the front of the device is in the up position indicating RS 232 communications RS 485 2 wire ...

Page 120: ...n resistors 120 are needed at each end of the network Note the location of the resistor on the device The ProTech has the termination resistor built into the module jumpers are necessary between terminals 14 15 and 18 19 to activate the termination Configuration Configuration of the UDS100 Xpress DR IAP is done through DeviceInstaller The configuration software is provided with the device Overview...

Page 121: ...oTechTPS Total Protection System Woodward 119 Serial Settings Menu NOTE For RS 485 communications choose option 3 under interface type and don t forget to set the dip switch on the front of the device Modem Control Menu ...

Page 122: ...ProTechTPS Total Protection System Manual 26710V1 120 Woodward Advanced Menu ...

Page 123: ...rotection System Woodward 121 Revision History Changes in Revision C Updated Figures 3 1 3 2 3 14 Changes in Revision B Corrected title on Table 2 2 Changes in Revision A Expanded clarified Module Removal Installation section Chapter 2 ...

Page 124: ...ProTechTPS Total Protection System Manual 26710V1 122 Woodward Declarations ...

Page 125: ...lins CO 80522 1519 USA 1041 Woodward Way Fort Collins CO 80524 USA Phone 1 970 482 5811 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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