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Installation and Operation Manual

ProTech203Overspeed Protection System

Dual Relay, Remote Overspeed Test9905-903

Manual 85201


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WARNINGDANGER OF DEATH OR PERSONAL INJURYWARNINGFOLLOW INSTRUCTIONSRead 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 inst ructions can cause personal injury and/orproperty damage.

WARNINGOUT-OF-DATE PUBLICATIONThis publication may have been revised or updated since this copy w as produced. To verify

that you have the latest revision, be sure to check the Woodward website:

www.woodward.com/pubs/current.pdfThe revision l evel is shown at the bottom of the front cover after the pub lication number. The

latest version of most publications i s available at:

www.woodward.com/publications

If your pub lication is not there, please contact your customer service representative to getthe latest copy.

WARNINGOVERSPEED PROTECTIONThe 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 shut down device may also be needed for

safety, as appropriate.

WARNINGPROPER USEAny unau thor ized mod if icati ons t o o r use of th is equipment ou ts ide i ts specif ied

mechanical, electrical, or other operating limits may cause personal injury and/or propertydamage, including damage to the equipment. Any such unauthorized modifications: (i)

constitute "mis use" and/or "negligence" within the meaning of the product warranty

thereby excluding warranty coverage for any resulting damage, and (ii) invalidate productcertifications or listings.

CAUTIONPOSSIBLE DAMAGE TO EQUIPMENT OR PROPERTYCAUTIONBATTERY CHARGINGTo 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.

CAUTIONELECTROSTATIC DISCHARGE

Electronic controls contain static-sensitive parts. Observe the following precautions toprevent 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 con trol).

Avoid all plast ic , vinyl , and Styrofoam (except ant istat ic versions) around pr inted ci rcui t

boards.

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

or wit h conductive devices.

IMPORTANT DEFINITIONS

A WARNINGindicates a potentially hazardous situation w hich, if not avoided, could result indeath or serious injury .

A CAUTIONindicates a potentially hazardous situation w hich, if not avoided, could result indamage to equipment or property.

A NOTEprovides other helpful information that does not fall under the warning or cautioncategories.

Woodward Governor Company reserves the right to update any portion of th is publ ication at any time. Information

provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibilit y isassumed by Woodward Governor Company unless otherwise expressly undertaken.

Woodward 1995All Rights Reserved


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Manual 85201 ProTech 203 Overspeed Protection System

Woodward i

Contents

ELECTROSTATIC DISCHARGEAWARENESS .................................................. IICHAPTER 1. GENERAL INFORMATION........................................................... 1Introduction.............................................................................................................1 Description..............................................................................................................1 References .............................................................................................................1CHAPTER 2. INSTALLATION.......................................................................... 2Unpacking...............................................................................................................2 Power Requirements..............................................................................................2Location Considerations.........................................................................................2Shielded Wiring ......................................................................................................2Plant Wiring ............................................................................................................3Installation Check-out Procedure ...........................................................................5CHAPTER 3. DESCRIPTION AND SPECIFICATIONS.......................................... 6Description..............................................................................................................6 Specifications .........................................................................................................7Interposing Relays..................................................................................................9Operator Interface ................................................................................................10Power Supply Description ....................................................................................10CHAPTER 4. CONFIGURATION AND OPERATION .......................................... 12Introduction...........................................................................................................12 Programming ........................................................................................................14Operation..............................................................................................................16 Remote Overspeed Test ......................................................................................17Hardware Faults ...................................................................................................17CHAPTER 5. TROUBLESHOOTING AND USER REPAIRS ................................ 18Troubleshooting....................................................................................................18User Repairs.........................................................................................................19Changing a Power Supply Board Fuse ................................................................19Changing a ProTech Unit On-Line .......................................................................22CHAPTER 6. SERVICE OPTIONS .................................................................26Product Service Options.......................................................................................26Returning Equipment for Repair...........................................................................27Replacement Parts...............................................................................................28How to Contact Woodward...................................................................................28Engineering Services ...........................................................................................29Technical Assistance............................................................................................30


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ProTech 203 Overspeed Protection System Manual 85201

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Illustrations and Tables

Figure 2-1. Plant Wiring Diagram...........................................................................3Figure 2-2. Routing and Stress Relief for Field Wiring Entering the ProTech 203

System ...............................................................................................4Figure 3-1. Outline Drawing of ProTech 203 System.............................................6Figure 3-2. Interposing Relay Field Wiring.............................................................9Figure 3-3. Voter Relay Configuration....................................................................9Figure 3-4. Block Diagram of One Unit of ProTech 203 System .........................11Figure 4-1. ProTech 203 Front Panel...................................................................12Figure 5-1. ProTech System Front Door ..............................................................20Figure 5-2. Unit Covers Inside the ProTech Device .............................................21Figure 5-3. Board Locations .................................................................................23Figure 5-4. Display Boards...................................................................................24Figure 5-5. Heat Sink Spacer Location ................................................................25

Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.To protect these components from static damage, you must take specialprecautions 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 staticelectricity on your body to ground by touching and holding a grounded metalobject (pipes, cabinets, equipment, etc.).

2. Avoid the build-up of static electricity on your body by not wearing clothingmade of synthetic materials. Wear cotton or cotton-blend materials as muchas possible because these do not store static electric charges as much assynthetics.

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoamcups, cup holders, cigarette packages, cellophane wrappers, vinyl books orfolders, plastic bottles, and plastic ash trays) away from the control, themodules, and the work area as much as possible.

4. Do not remove the printed circuit board (PCB) from the control cabinetunless absolutely necessary. If you must remove the PCB from the controlcabinet, follow these precautions:

Do not touch any part of the PCB except the edges.

Do not touch the electrical conductors, the connectors, or thecomponents with conductive devices or with your hands.

When replacing a PCB, keep the new PCB in the plastic antistaticprotective bag it comes in until you are ready to install it. Immediatelyafter removing the old PCB from the control cabinet, place it in theantistatic protective bag.

CAUTIONELECTROSTATIC DISCHARGETo prevent damage to electronic components caused by improper handling,read and observe the precautions in Woodward manual 82715, Guide forHandling and Protection of Electronic Controls, Printed Circuit Boards, andModules .


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Chapter 2.Installation

Unpacking

Be careful when unpacking the ProTech203 system. Check the device for signsof damage such as a bent or dented case and loose or broken parts. If damageis found, notify the shipper immediately. The device may be stored in its originalshipping container until it is ready for installation. Protect the device from weatherand from extreme humidity or temperature fluctuations during storage.

Power Requirements

The ProTech 203 system contains three independent power supplies. Each unitis powered with 24 Vdc.

Location Considerations

Carefully study this chapter before choosing a location for the ProTech 203system. Wiring and grounding considerations may influence the selection of alocation for the device.

Consider the following general requirements when selecting the location:

Adequate ventilation for cooling

A location that will provide an operating temperature range of 25 to +60 C(13 to +140 F)

Space for servicing

Protection from direct exposure to sunlight, water, or to a condensation

prone environment Protection from high-voltage or high-current devices which produce

electromagnetic interference

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 braidedshield. All signal lines should be shielded to prevent picking up stray signals fromadjacent equipment. Connect the shields as shown in the plant wiring diagram

(Figure 2-1). Wire exposed beyond the shield must not exceed two inches. Theother 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. Seemanual 50532, EMI Control in Electronic Governing Systems, for moreinformation.

Installations with severe electromagnetic interference (EMI) may require shieldedcable run in conduit, double shielded wire, or other precautions. ContactWoodward for more information.


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Plant Wiring

Figure 2-1 is the plant wiring diagram for the ProTech 203 system. Figure 2-2shows the proper routing and stress relief for all field wiring entering the ProTechsystem. Field wiring to the ProTech system should be between 10 AWG and 16

AWG (1.0 to 5.0 mm) for the power supplies and between 12 AWG and 22 AWG(0.3 to 3.0 mm) for all other I/O runs.

CAUTIONEARTH GROUNDThe ground wires for the power supplies of all three units must be tied toearth ground or an inadvertent shutdown could occur.

Figure 2-1. Plant Wiring Diagram

WARNINGELECTRIC SHOCKWhen wiring the interposing relays, be sure to wire both contacts with thesame polarity. Failure to do so wi ll create a potential shock hazard andtherefore possible injury or death.

If the ProTech 203 system is being installed in a hazardous environment, pleaseattend to the following warnings:

WARNINGEXPLOSION HAZARDDo not disconnect equipment unless power has been switched off or thearea is known to be non-hazardous.

AVERTISSEMENTRISQUE DEXPLOSIONNe pas dbrancher lquipement tant que le courant sest coup, sauf en caslambiance est dcidment non dangereuse.


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NOTEAl l peripheral equipment must be suitable for the location in which they arebeing used.

Figure 2-2. Routing and Stress Relief for Field Wiring Entering the ProTech 203System


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Installation Check-out Procedure

When installation is completed, perform the following check-out procedure beforepowering up the device.

1. Visual inspection

a. Ensure that all mounting hardware is tightened and that no wires orcables are pinched.

b. Check for correct wiring according to the plant wiring diagram.

c. Check for broken terminals or loose terminal screws. Ensure that allribbon cables are fully seated and clamped in place.

d. Check the speed sensor (MPU) for visible damage. Check theclearance between the gear and the sensor and adjust if necessary.See manual 82510, Magnetic Pickups and Proximity Switches forElectronic Controls.

2. Check for ground

3. Actuating equipment integration assessment: Woodward stronglyrecommends that the user perform an assessment of the actuatingequipment that will receive input from the ProTech 203 system to verify thatequipment is properly calibrated, working correctly, properly interfaced, andfunctioning safely before energizing the ProTech 203 system.

WARNINGACTUATING EQUIPMENT ASSESSMENTIf the actuating equipment assessment is no t performed and consequentlyproblems are not identified and eliminated, turbine damage can occur w ithpossib le personal injury and loss of life to personnel near the turbine.


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Chapter 3.Description and Specifications

Description

The ProTech203 Overspeed Protection System is a digital overspeed tripdevice that reads three individual magnetic pickups, performs three individualspeed calculations, and actuates its relay output according to the results of ahardware two- out-of-three vote. See Figure 3-1 for the control layout anddimensions.

Figure 3-1. Outline Drawing of ProTech 203 System


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Specifications

EnclosureNEMA 4

Remote ResetCan be reset from a remote location

Built-In Self-TestA built-in frequency generator permits testing of each unit individually whileprime mover is on-line

Remote Overspeed TestContacts permit testing of each unit individually while prime move is on-line

Key LockPrevents any programming or testing by unauthorized personnel

Hot ReplacementEach unit can be replaced with the device running without tripping the primemover

OutputsA separate alarm output and LED indicate if an individual speed-sensingunit has tripped

MPU Failure IndicationsSeparate LEDs indicate if an MPU or its wiring has failed

MPU Fail TimerImmediately after a reset operation, a timer starts; if prime mover speed isnot up to the value programmed when this timer times out, the device willtrip the prime mover. Both the time and the speed are programmable

MPU Fail OptionEach 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 canoutput only an alarm

CPU Failure IndicationA separate LED indicates if any unit's CPU is not operating normally

Speed-Sensing Frequency Range100 Hz to 32 kHz

Trip-Point Frequency Range250 Hz to 25 kHz

MPU Input Amplitude1 Vrms minimum @ 100 Hz to 25 kHz2 Vrms minimum @ 25 kHz to 32 kHz

Shutdown Contact Ratings0.5 A resistive load @ 115 Vrms

Alarm Contacts2 A resistive load @ 28 Vdc0.3 A resistive load @ 115 Vrms


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NOTEThe alarm relay de-energizes when a tri p occurs, when speed is below theMPU fail setpoint, and momentarily after reset or power-up. An alarm onlyannunciates a situation that may require attention, it is not synonymous w itha trip.

MPU Measurement Circuit Input Impedance2 k

Accuracy0.05% of point 2 Hz over the operating temperature range

Operating Temperature25 to +60 C (13 to +140 F)

Display Operating Temperature15 to +60 C (5 to 140 F)

Sample TimeSpeed is sampled every 5 ms

Total Response Time40 ms max

HumidityUS MIL-STD-810D, Method 507.2, Procedure II

VibrationUS MIL-STD-810D, Method 516.3, Procedure I

EMCRadiated and Conducted EmissionsEN 55011, Class A

ESDIEC 801-2, 8 Kv air and 4 Kv contact

Radiated Susceptibil ityIEC 801-3, 10 V/M, 27500 MHz

Fast TransientsEC 801-4, 2 Kv direct to power leads, 2 Kv capacitive to I/O leads

SurgeIEC 801-5, 500 V common mode and differential mode on dc input

Conducted SusceptibilityIEC 801-6, 10 V, 0.15100 MHz, all leads

Weight16 lb (7.3 kg)


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Interposing Relays

The ProTech 203 system has two relays, each with two normally open and twonormally closed relay contacts. Figure 3-2 shows the relay field wiring diagramthat describes these options.

Figure 3-2. Interposing Relay Field Wiring

The interposing relay is in its energized state during normal operation. TB2terminals 1 and 2 are connected, TB2 terminals 4 and 5 are connected, TB2terminals 7 and 8 are connected, and TB2 terminals 10 and 11 are connected.During an overspeed trip event, or when power to the ProTech 203 system islost, the interposing relay is activated. Then TB2 terminals 2 and 3 areconnected, TB2 terminals 5 and 6 are connected, TB2 terminals 8 and 9 areconnected, and TB2 terminals 11 and 12 are connected.

The ProTech 203 system utilizes three separate speed-sensing units that areinterfaced 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 relayseries/parallel configuration. This six-relay configuration drives the interposingrelays shown in Figure 3-3.

Figure 3-3. Voter Relay Configuration


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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 benoted, however, that a single MPU or circuit failure will not cause an inadvertenttrip.

This configuration makes testing of the voter relays in the system a relativelysimple 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 threespeed-sensing circuits, one at a time, using a built-in frequency generator. Youmay then watch the LED indicators and the speed readout to see that each of thesix individual voter relays trip at the correct speed. Because of the series/parallelconfiguration of the trip relays, overspeeding one of the speed sensing circuits ata time will not disturb the load.

Operator Interface

Each speed-sensing unit of the ProTech 203 system includes a touch pad, a two-line by 16-character LCD display, and a potentiometer for adjusting theoverspeed test frequency. A single key switch is connected to all three speed-

sensing units to control whether the system is in the MONITOR or thePROGRAM mode, preventing unauthorized changes.

Power Supply Description

The ProTech 203 consists of three units (A, B, and C). Each unit has its ownseparate power supply. The input voltage range is 1832 Vdc.

Each unit power supply produces +5 V and +24 V. These voltages are isolatedfrom the input voltage. The +24 V for all three units are "OR-ed" together toprovide power to the interposing relay.


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Figure 3-4. Block Diagram of One Unit of ProTech 203 System


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Chapter 4.Configuration and Operation

Introduction

Figure 4-1. ProTech 203 Front Panel

The ProTech 203 system can be operated in one of two modes, MONITOR orPROGRAM. Although the system will "run" in either mode, it is recommendedthat the unit be placed in the PROGRAM mode only during configuration andthen placed in the MONITOR mode during normal operation.

The menu key on the touch pad selects which of the following parameters to

display: PRESENT SPEED

PEAK SPEED

TRIP SPEED SETPOINT

REMOTE TEST TRIP POINT

MPU FAILED SETPOINT

MPU FAILED TIMEOUT

MPU GEAR TEETH

TRIP ON MPU FAILURE

TRIP CAUSE (if applicable)


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PRESENT SPEED is the first parameter displayed. Each subsequent press ofthe menu key displays the next parameter in the list. Appropriate descriptiveunits for each parameter are also displayed.

When the key switch is in the MONITOR position, the CURSOR , ADJ, andADJkeys have no effect. When the key switch is in the PROGRAM position,an annunciator appears in the display, and a cursor appears if a tunableparameter is being displayed. The tunable parameters are:

TRIP SPEED SETPOINT REMOTE TEST TRIP POINT

MPU FAILED SETPOINT

MPU FAILED TIMEOUT

MPU GEAR TEETH

TRIP ON MPU FAILURE

If any tunable parameters are changed, the LCD displays CHANGES SAVED fortwo seconds when the key switch is returned to the MONITOR mode.

The CURSOR, ADJ, and ADJkeys perform as follows in the PROGRAMmode:

CURSORMoves the cursor one position to the right.

ADJ, ADJFor integer values, these keys increase/decrease the displayedvalue by the power of ten indicated by the cursor position. For example, if thecursor were under the "0" of the value 5014 and the ADJ key was pressed, thevalue would change to 4914.

For a time display in minutes and seconds, increase/decrease the displayedvalue by the number of seconds or minutes indicated by the cursor position. Forexample, if the cursor were under the "4" in 1 MIN 47 SEC and the ADJkey ispressed, the value changes to 1 MIN 57 SEC. If the ADJis pressed again, thevalue changes to "2 MIN 07 SEC".

For a YES/NO value, pressing either ADJor ADJcauses the value totoggle to the opposite value.

Pressing and holding the ADJor the ADJkey causes the value, after ashort delay, to change at a fixed rate.

If changing a value would cause it to exceed predetermined limits, no changetakes place. The table gives the allowable range for each tunable parameter.

Tunable Minimum Maximum

TRIP SPEED SET POINT 250 rpm 25 000 rpm

REMOTE TEST TRIP POINT 250 rpm 25 000 rpm

MPU FAILED SETPOINT 100 rpm 25 000 rpm

MPU FAILED TIMEOUT 1 sec 533 min 20 secTRIP ON MPU FAILURE NO YES

MPU GEAR TEETH 20 120

The LAMP TEST key causes all LEDs to illuminate and the LCD to display allsolid block characters for as long as the key is pressed.


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NOTEAs used here, " tr ip" refers to the act ion of an individual speed-sensing unitin the ProTech 203 system as it de-energizes the alarm relay, turns on theTRIP LED, and energizes its vo ter relays. The trip cause becomes thecurrently displayed parameter.

Display Shows Cause

MPU>TRIP SETPT Speed has exceeded the TRIP SETPOINT valueOVERSPEED TEST Speed exceeded the TRIP SETPOINT value during an

overspeed test

REMOTE OVERSPD TEST Speed has exceeded the RMT TEST TRIP PT valueduring a remote overspeed test.

MPU FAIL TIMEOUT After reset, speed did not reach the MPU FAILSETPOINT within the MPU FAIL TIMEOUT time

MPU FAILED A sudden loss of speed occurred while running

NO MPU SIGNAL The contact input was open while speed was below theMPU FAIL SETPOINT

NO RESET The unit was not reset before re-starting the turbineafter a rolldown

HARDWARE FAULT The unit has an internal hardware problem

INTERLOCK FAULT An internal cable is disconnected

Once one of the three units is tripped, it remains tripped until reset or until thepower is cycled.

Programming

Programming of the ProTech 203 system consists of entering values for all of thetunable parameters. The procedure for programming each speed-sensing unit isas follows:

WARNINGTRIP POINT PROGRAMMING

In order to ensure proper functioning of the ProTech 203 system, it isimperative that the tunable parameters in each of the un its are programmedto result in identical trip poin ts. Failure to do so cou ld result in inadvertenttrips or failure to trip at appropriate speed resulting in property damage,injury, or death.

1. Switch the key switch to the PROGRAM position.

2. Press the MENU key to step through the parameter menu to the first tunableparameter, TRIP SPEED SETPOINT.

3. Use the CURSOR, ADJ, and ADJkeys to enter the proper rpm foryour preferred TRIP SPEED SETPOINT.

4. Press the MENU key to step to the next tunable parameter, REMOTE TESTTRIP POINT.

5. Use the CURSOR, ADJ, and ADJto enter the proper rpm for yourREMOTE TEST TRIP POINT.

6. Press the MENU key to step to the next tunable parameter, MPU FAILEDSETPOINT.

7. Use the CURSOR, ADJ, and ADJto enter the proper rpm for yourpreferred MPU FAILED SETPOINT.


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8. Press the MENU key to step to the next tunable parameter, MPU FAILEDTMEOUT.

9. Use the CURSOR, ADJ, and ADJkeys to enter the appropriate timeinterval.

10. Press the MENU key to step to the next tunable parameter, MPU GEARTEETH.

11. Use the CURSOR, ADJ, and ADJkeys to enter the number of gearteeth on the gear being monitored by the MPU connected to this unit.

12. Press the MENU key to step to the last tunable parameter, TRIP ON MPUFAILURE OP.

13. Use the ADJor ADJkey to enter a "yes" or "no" response.

14. Duplicate this procedure for the other two units.

15. Return the key switch to the monitor position. The LCD displays CHANGESSAVED for two seconds.

For your convenience, a programming worksheet is provided below. Theworksheet should help ensure proper programming and provide you with a hardcopy record of the values entered. Feel free to copy the worksheet for future use.

ProTech 203 Programming Worksheet

UNIT A UNIT B UNIT C

TRIP SPEEDSETPOINT_______



Prime mover speed in rpm at which user expects unit to de-energize its alarmrelay, turn on the TRIP LED, and energize/de-energize its voter relays(depending on the version chosen).

REMOTE TESTTRIP POINT_______ REMOTE TESTTRIP POINT_______ REMOTE TESTTRIP POINT_______

When the remove overspeed test contact is closed, the unit will trip at theREMOTE TEST TRIP POINT as well as the TRIP SPEED SETPONT.

MPU FAILEDSETPOINT________



After a reset, the prime mover speed must exceed this value within the MPUFAILED TIMEOUT period or the unit will trip.

MPU FAILEDTIMEOUT________



Time period after a reset, during which the prime mover speed must exceed theMPU FAILED SETPOINT or unit will trip.

MPU GEAR TEETH________



Number of gear teeth the MPU is looking at.

TRIP ON MPUFAILURE________



"Yes" or "no" option. If an MPU loss-of-signal occurs, the MPU FAIL LED turnson and the alarm relay de-energizes. If the TRIP ON MPU FAILURE option is setto "yes", the unit trips; this option applies only to a sudden loss of MPU signalwhile running. Trips due to an MPU timer timeout are not affected by this option.


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Operation

Start-up

Each of the three ProTech units must be reset before the turbine is started. Aunit is reset by pressing the front panel RESET button or by momentarily closingthe remote reset contact (TB5-4 to TB5-5). After the power-up self-tests, each

ProTech unit begins executing its speed-sensing algorithm. If the speed does notexceed the MPU FAIL SETPOINT speed within the MPU FAIL TIMEOUT value,the unit trips. At this time the MPU FAIL LED turns on and remains on until thenext reset. This trip is not affected by the TRIP ON MPU FAILURE option. TheProTech overspeed protection system will trip on an overspeed condition duringstart-up.

Normal Operation

If an overspeed is detected, the unit trips. As the speed exceeds the currentlydisplayed peak speed, the peak speed is updated and stored in non-volatilememory. The operator interface is still active. That is, all parameters can be

displayed, and tunable parameters can be changed.

Peak speed is not stored in non-volatile memory if an overspeed condition hasnot occurred.

To reset a unit's peak speed, place the key switch in the PROGRAM position,then press the RESET key. The message "RESET PEAK? ADJ= YES ADJ= NO" appears. Press the ADJkey to reset the peak speed. After pressingeither the ADJor the ADJkeys, the unit resumes normal operation. Ifneither key is pressed within 10 seconds, a "no" response is assumed and theprompt disappears. Return the key switch to the MONITOR position.

An MPU loss-of-signal occurs when an MPU frequency of less than 100 Hz ismeasured and the previously measured speed was greater than 120 Hz. Thealarm relay de-energizes, and the MPU FAIL LED turns on and remains on untila reset or until power is cycled. If the TRIP ON MPU FAILURE option is "yes", atrip occurs. If the previously measured speed is less than 120 Hz, it is assumedthat a normal rolldown has occurred. The MPU FAIL LED does not turn on, thealarm relay does not de-energize, and no trip occurs.

After a normal rolldown, each ProTech unit monitors the MPU. If the MPUfrequency exceeds 110 Hz, the unit trips and annunciates the cause as NORESET.

Overspeed Test

The overspeed test function is activated when the key switch is in thePROGRAM position and the operator presses and holds the OVSP TEST buttonon the touch pad. The microcontroller switches the source of the MPU signalfrom the MPU input to an on-board oscillator. The test speed is annunciated onthe LCD. If the test speed is adjusted above the trip setpoint, using the TestFrequency potentiometer on each unit, a trip occurs. MPU loss-of-signalchecking is disabled, and the peak speed value does not change duringoverspeed test. When the OVSP TEST button is released, the microcontrollerswitches the source of the MPU signal back to MPU input and normal operationis restored. Each ProTech unit must be reset to clear its trip condition.


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NOTEEach individual uni t may be tested as described above while the entiresystem remains on-line. In this case, the two units not being tested take overfull control of the overspeed protection for the prime mover.

NOTEIt is recommended that the overspeed test be performed on each uni t on a

weekly basis and that an actuating equipment integration assessment beperformed any time the prime mover is taken off-line.

Remote Overspeed Test

The remote overspeed test function is activated when the REMOTEOVERSPEED TEST contact input is closed in either the PROGRAM orMONITOR mode. The unit will now trip at the lower of the RMT TEST TRIP PT orthe TRIP SPEED SETPOINT. A REMOTE OVERSPEED TRIP will occur if thepresent prime mover speed is greater than the RMT TEST TRIP PT. When theREMOTE OVERSPEED TEST contact input is opened, the trip sped is the TRIPSPEED SETPOINT. Each ProTech unit must be reset to clear its tri p

conditions.

NOTEEach individual uni t may be tested as described above while the entiresystem remains on-line. In this case, the two units not being tested take overfull control of the overspeed protection for the prime mover.

NOTEIt is recommended that the overspeed test be performed on each uni t on aweekly basis and that an actuating equipment integration assessment beperformed any time the prime mover is taken off-line.

Hardware Faults

If the microcontroller determines that the EEPROM is not responding correctly, atrip occurs. The trip cause is annunciated as a hardware fault. If this type of faultoccurs, reset the unit. If the fault continues to occur, replace the unit and return itfor 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. Ifthe 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 missinginterlock, a trip occurs. The cause of the trip is annunciated as an interlock fault.If this fault occurs, check all cable connections.

If a monitor circuit determines that the microcontroller is not functioning, a tripoccurs. The CPU FAIL LED turns on. If this fault occurs, replace the unit andreturn it for repair.


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Chapter 5.Troubleshooting and User Repairs

Troubleshooting

The following troubleshooting guide will help isolate problems in the ProTech203 device, actuating system, plant wiring, MPUs, or elsewhere. Make thechecks in the order indicated.

NOTETo check the ProTech thoroughly, troubleshoot each un it (A, B, and C)separately. A unit consists of one complete speed-sensing circuit, includingthe power supply, I/O module, and disp lay board.

Symptom Cause Remedy

Prime moveroverspeeds afteroperating at rated

speed for some time

Prime mover Check for proper operation of the prime-mover fuel system; if actuator moves towardminimum fuel during overspeed, problem is

in the fuel system.The ProTech device is notconnected or is incorrectlyconnected to the external actuatingsystem

Check that the ProTech device is installedproperly.

Incorrect setpoint valuesconfigured for one or more units

Check the MPU GEAR TEETH and TRIPSPEED SETPOINT configurations for eachunit to verify they're appropriate for primemover and the individual MPUs.

Prime mover does nottrip on overspeed

If two or more units show aTRIPPED indication, the cause isthe external actuating systemdown-line from the ProTech device

Check for incorrect field wiring andinoperable or incorrectly calibrated actuatingequipment.

More than one unit has been

overspeed tested at one time

Reset the units.Prime mover trips

inappropriately Incorrect setpoint valuesconfigured for one or more units

Check the MPU GEAR TEETH and TRIPSPEED SETPOINT configurations for eachunit to verify they're appropriate for primemover and the individual MPUs.

Incorrect setpoint valuesconfigured for one or more units

Prime mover is not ramping to configuredspeed in the allotted time. Verify that theMPU FAIL SETPOINT and MPU FAILTIMEOUT are appropriate for the primemover.

Inappropriate trip duringstart-up

Incorrect MPU signal Check that all MPUs are correctly wired tothe ProTech device and are functioningproperly.

Reset the unit.Inappropriate trip.

Hardware faultannunciated

EEPROM doesn't respond

correctly If fault continues, replace unit. (see "UserRepairs" section below).

Inappropriate trip.Interlock faultannunciated

Cables aren't connected correctly Check ProTech cabling and installationprocedure.

Inappropriate trip. CPUFAIL LED lit

The ProTech microcontroller is notfunctioning

Replace the entire unit (see "User Repairs"section below).


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Symptom Cause Remedy

One or more ProTech units do nothave power

Check power supply fuses, wiring, and powersources.

One or more ProTech units needto be reset

Press the RESET pad.

Prime moverwon't start

Actuating wiring from the ProTechdevice is incorrect

Check actuating system for proper normallyopen or normally closed wiring.

Unit has LCD display,but no LEDs display or vice versa

Unit is faulty Replace the entire unit. (see "User Repairs"section below).

Unit has no power Check that power is applied to the unit.

Power supply fuses need to bereplaced

Replace unit's power supply board fuse. (see"User Repairs" section below).

Unit has neither LCDnor LED display

Power supply board is faulty Replace the entire unit. (see "User Repairs"section below).

Unit is not operating;STATUS 1 & 2 andTRIPPED areilluminated

Unit needs to be reset Press the RESET pad.

Unit won't RESET Remote RESET contacts areclosed

Check that the remote RESET operates as amomentary contact.

User Repairs

The ProTech device is highly reliable and should require minimal hardwarerepairs. Use the above troubleshooting guide to determine the course of action ifa problem does occur.

In some cases, you will need to return the ProTech system to the supplier fromwhom your purchased it. However, in other cases, the Troubleshooting Guide willsuggest one of following remedies:

Changing a power-supply board fuse

Replacing an entire unit (including display, I/O, and power supply boards)

while the other two units continue to function so that the ProTech devicestays on-line

WARNINGEXPLOSION HAZARDDo not disconnect equipment unless power has been switched off or thearea is known to be non-hazardous.

AVERTISSEMENTRISQUE DEXPLOSIONNe pas dbrancher lquipement tant que le courant sest coup, sauf en caslambiance est dcidment non dangereuse.

Changing a Power Supply Board Fuse

Tools Needed:

#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 20mm fuses. Each 24 Vdc power supply requires two 1.0 A fuses.


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20 Woodward

Procedure for Changing a Power Supply Board Fuse1. Shut off the power to the unit in which you're replacing a fuse.

WARNINGHIGH VOLTAGEFailure to disconnect power to the unit you're replacing, prior to proceedingcan result in exposure to potentially lethal voltage and therefore possibleinjury or death.

2. To open the front door, turn the two door latches counterclockwise (seeFigure 5-1).

Figure 5-1. ProTech System Front Door

3. If you're replacing a fuse in Unit A, remove the ribbon-cable clamp and retainfor use when re-installing the cover (Figure 5-2).


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Woodward 21

Figure 5-2. Unit Covers Inside the ProTech Device

4. Unplug the power supply board terminal block, then unplug the I/O boardterminal 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 changingthe fuse.

6. With the cover off, the power supply board fuses will be visible in the lowerleft hand corner of the power supply board, just above the power supplyterminal block.

7. Remove the fuses and examine them for defects. Replace any defective orsuspect fuse.

8. Replace the unit's cover and snugly secure the four nuts that hold the coverin place.

9. If you've been working on Unit A, replace the ribbon-cable clamp onto thecover (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.


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22 Woodward

Changing a ProTech Unit On-Line

Tools and Supplies Needed:1. #2 Phillips screw driver2. 1/4-inch nut driver3. small flat blade screw driver4. heat sink compound

Procedure to Remove a Unit from the ProTech Chassis1. Shut off the power to the unit you're replacing.

WARNINGHIGH VOLTAGEFailure to disconnect power to the unit you're replacing, prior to proceedingcan result in exposure to potentially lethal voltage and therefore possibleinjury or death.

2. To open the front door, turn the two door latches counterclockwise (Figure5-1).

3. 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 boardterminal 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 thereplacement unit.

CAUTIONTAKE CARE OF NUTS/SCREWSBe very careful not to drop any of the nuts or screws as you remove orreplace them. It may be possible for them to get under one of the adjacentunit covers or contact the exposed back of one of the display boards on the

front cover. If this does happen, it is possible for the part to cause a short ona unit under power and therefore a possib le turbine trip.

6. Unscrew the four long screws holding the two-board pack together (Figure5-3).

7. Disconnect the ribbon cables from the top (I/O) board, and remove the boardfrom the unit (Figure 5-3).

8. Using a small flat blade screw driver, remove the nylon screw holding thetransistor against the heat sink.

NOTEBe careful not to drop or lose the ceramic insulator located under thetransistor. Retain it for reinstallation.

9. Remove the two remaining screws securing the power supply board to thechassis.

10. Unplug the ribbon cable from the power supply board, and remove the board.

11. Unplug the terminal block and ribbon cable from the corresponding displayboard.


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Woodward 23

Figure 5-3. Board Locations

12. Remove the six nuts holding the display board to the ProTech systemchassis front door. Note the nuts' locations in Figure 5-4 so that you don'tloosen the 4 nuts that attach the LCD (display) to the circuit board.

NOTEIf removing Unit A, retain the two cable clamps for re-installation.

13. Holding the display board's terminal block and ribbon cable connector, "walk"and lift the board off of the door.

CAUTIONDISPLAY BOARDDo not use screw drivers or other objects to li ft or pry the display board.Doing so may damage other ProTech components.


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24 Woodward

Figure 5-4. Display Boards

Procedure to Install a New Unit

1. Insert and position the new display board in place (Figure 5-4).

2. Replace the six display board nuts, tighten until they are snug (if replacingunit A, re-install the ribbon-cable clamps).

3. Plug in the ribbon cable, then the terminal block to the display board.

4. Insert and position the new power supply board (Figure 5-3).

NOTEAdd heat sink compound to the unders ide of the transistor located on thepower supply board.

5. Replace the two short screws that secure the lower portion of the board tothe chassis.

6. Replace the nylon screw through the transistor and ceramic insulator into theheat sink spacer located on the chassis.

CAUTIONCERAMIC INSULATORCeramic insulator must be installed between the transistor and the heat sinkspacer. Failure to do so will result in line voltage being shorted to chassisground and immediate failure of the unit upon application of power.


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Woodward 25

Figure 5-5. Heat Sink Spacer Location

7. Plug the ribbon cable back into the power supply board.

8. Insert and position the I/O board on top of the power supply board (Figure5-3).

9. Replace the four long screws through the corners of both the I/O and powersupply boards.

10. Attach both ribbon cables to the I/O board (Figure 5-1).

11. Replace the unit's metal cover. To avoid future confusion, make sure theproper cover is on the proper unit. This is important because each cover islabeled with the unit I.D. letter as well as the correct voltage to be applied tothat unit.

12. Snugly secure the four cover nuts.

13. If you've replaced Unit A, replace the ribbon-cable clamp onto the cover(Figure 5-2).

14. Plug in the unit's terminal blocks.

15. Close and latch the front door.

16. Re-power the unit you just replaced.

17. On the replaced unit's display, press RESET to activate that unit's operation.


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26 Woodward

Chapter 6.Service Options

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 theservice is performed:

Replacement/Exchange (24-hour service)

Flat Rate Repair

Flat Rate Remanufacture

If you are experiencing problems with installation or unsatisfactory performanceof an installed system, the following options are available:

Consult the troubleshooting guide in the manual.

Contact Woodward technical assistance (see How to Contact Woodwardlater 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 ofaction you wish to pursue based on the available services listed in thissection.

Replacement/Exchange

Replacement/Exchange is a premium program designed for the user who is inneed of immediate service. It allows you to request and receive a like-newreplacement unit in minimum time (usually within 24 hours of the request),providing a suitable unit is available at the time of the request, therebyminimizing costly downtime. This is also a flat rate structured program andincludes 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 inadvance of a scheduled outage, to request a replacement control unit. If the unitis 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 thefield unit to the Woodward facility as explained below (see Returning Equipmentfor Repair later in this chapter).

Charges for the Replacement/Exchange service are based on a flat rate plusshipping expenses. You are invoiced the flat rate replacement/exchange chargeplus a core charge at the time the replacement unit is shipped. If the core (fieldunit) is returned to Woodward within 60 days, Woodward will issue a credit for

the core charge. [The core charge is the average difference between the flat ratereplacement/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 returnauthorization label is included with every Replacement/Exchange unit that leavesWoodward. The core should be repackaged and the return authorization labelaffixed to the outside of the package. Without the authorization label, receipt ofthe returned core could be delayed and cause additional charges to be applied.


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Woodward 27

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 ofknowing in advance what the cost will be. All repair work carries the standardWoodward service warranty (Woodward Product and Service Warranty5-01-1205) on replaced parts and labor.

Flat Rate Remanufacture

Flat Rate Remanufacture is very similar to the Flat Rate Repair option with theexception that the unit will be returned to you in like-new condition and carrywith it the full standard Woodward product warranty (Woodward Product andService Warranty 5-01-1205). This option is applicable to mechanical productsonly.

Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned to Woodward forrepair, please contact Woodward in advance to obtain a Return AuthorizationNumber. When shipping the item(s), attach a tag with the following information:

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.

CAUTIONELECTROSTATIC DISCHARGETo prevent damage to electronic components caused by improper handling,read and observe the precautions in Woodward manual 82715, Guide forHandling and Protection of Electronic Controls, Printed Circuit Boards, and

Modules.

Packing a Contro l

Use the following materials when returning a complete control:

protective caps on any connectors;

antistatic protective bags on all electronic modules;

packing materials that will not damage the surface of the unit;

at least 100 mm (4 inches) of tightly packed, industry-approved packingmaterial;

a packing carton with double walls;

a strong tape around the outside of the carton for increased strength.


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28 Woodward

Return Author ization Number

When returning equipment to Woodward, please telephone and ask for theCustomer Service Department [1 (800) 523-2831 in North America or+1 (970) 482-5811]. They will help expedite the processing of your order throughour distributors or local service facility. To expedite the repair process, contactWoodward in advance to obtain a Return Authorization Number, and arrange forissue of a purchase order for the item(s) to be repaired. No work can be started

until a purchase order is received.

NOTEWe highly recommend that you make arrangement in advance for returnshipments. Contact a Woodward customer service representative at1 (800) 523-2831 in North America or +1 (970) 482-5811 for inst ructions andfor a Return Authorization Number.

Replacement Parts

When ordering replacement parts for controls, include the following information:

the part number(s) (XXXX-XXXX) that is on the enclosure nameplate; 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 CompanyPO Box 15191000 East Drake RdFort Collins CO 80522-1519, USA

Telephone+1 (970) 482-5811 (24 hours a day)

Toll-free Phone (in North America)1 (800) 523-2831Fax+1 (970) 498-3058

For assistance outside North America, call one of the following internationalWoodward facilities to obtain the address and phone number of the facilitynearest your location where you will be able to get information and service.

Facility Phone NumberBrazil +55 (19) 3708 4800India +91 (129) 230 7111

Japan +81 (476) 93-4661The Netherlands +31 (23) 5661111

You can also contact the Woodward Customer Service Department or consultour worldwide directory on Woodwards website (www.woodward.com) for thename of your nearest Woodward distributor or service facility.


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Engineering Services

Woodward Industrial Controls Engineering Services offers the following after-sales support for Woodward products. For these services, you can contact us bytelephone, by email, or through the Woodward website.

Technical Support

Product Training Field Service

Contact information:Telephone+1 (970) 482-5811Toll-free Phone (in North America)1 (800) [email protected]

Technical Suppor tis available through our many worldwide locations or ourauthorized distributors, depending upon the product. This service can assist youwith technical questions or problem solving during normal business hours.Emergency assistance is also available during non-business hours by phoningour toll-free number and stating the urgency of your problem. For technicalsupport, please contact us via telephone, email us, or use our website andreference Customer Servicesand then Technical Support.

Product Trainingis available at many of our worldwide locations (standardclasses). We also offer customized classes, which can be tailored to your needsand can be held at one of our locations or at your site. This training, conductedby experienced personnel, will assure that you will be able to maintain systemreliability and availability. For information concerning training, please contact usvia telephone, email us, or use our website and reference Customer Servicesand then Product Training.

Field Serviceengineering on-site support is available, depending on the productand location, from one of our many worldwide locations or from one of our

authorized distributors. The field engineers are experienced both on Woodwardproducts as well as on much of the non-Woodward equipment with which ourproducts interface. For field service engineering assistance, please contact usvia telephone, email us, or use our website and reference Customer Servicesand then Technical Support.


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30 Woodward

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:

GeneralYour Name

Site LocationPhone NumberFax Number

Prime Mover InformationEngine/Turbine Model NumberManufacturerNumber of Cylinders (if applicable)Type of Fuel (gas, gaseous, steam, etc)Rating

Application

Control/Governor InformationPlease list all Woodward governors, actuators, and electronic controls in your system:

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number



Serial Number



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.


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We appreciate your comments about the content of our pub lications.

Send comments to: icin [email protected]

Please include the manual number from the front cover of this publication.

PO Box 1519, Fort Collins CO 80522-1519, USA1000 East Drake Road, Fort Collins CO 80525, USA

Phone +1 (970) 482-5811 Fax +1 (970) 498-3058

Email and Websitewww .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 l ocations is available on our website

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