Woodward MicroNet 8237-1252 User manual

Product Manual 26547V1
(Revision G, 1/2021)
Original Instructions
MicroNet™ Safety Module
Fault Tolerant Protection System
Manual 26547 consists of 2 volumes (26547V1 & 26547V2)
Volume 1
-
Installation and
Operation
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General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455 , Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
the publications page of the Woodward website:
http://www.woodward.com/
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to get the latest copy.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifi
cations or listings.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual 26455 , Customer Publication
Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions— A bold, black line alongside the text identifies changes in this publication since the
last revision.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 26547V1
Copyright © Woodward, Inc. 2010 - 2021
All Rights Reserved
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Contents
W ARNINGS AND N OTICES ..............................................................................................................5
E LECTROSTATIC D ISCHARGE A WARENESS ....................................................................................6
R EGULATORY C OMPLIANCE ..........................................................................................................7
A CRONYMS AND D EFINITIONS ........................................................................................................9
C HAPTER 1. G ENERAL I NFORMATION ...........................................................................................10
Description ..................................................................................................................................................10
Applications.................................................................................................................................................11
C HAPTER 2. I NSTALLATION .........................................................................................................14
Introduction..................................................................................................................................................14
Unpacking ...................................................................................................................................................14
System Installation Procedure ....................................................................................................................14
Enclosures...................................................................................................................................................15
Module Removal and Installation – Bulkhead Mount Package...................................................................18
Module Removal and Installation – Panel Mount Package ........................................................................23
Mounting Location Considerations..............................................................................................................25
Environmental Specifications......................................................................................................................26
Power Supply Requirements.......................................................................................................................26
Shielded Wiring...........................................................................................................................................27
Control Wiring Guidelines ...........................................................................................................................27
C HAPTER 3. F UNCTIONALITY .......................................................................................................46
Features......................................................................................................................................................46
Product Models ...........................................................................................................................................47
Inputs and Outputs......................................................................................................................................54
Overspeed and Over-Acceleration Detection and Trip...............................................................................59
Start Logic...................................................................................................................................................60
Configurable Logic ......................................................................................................................................61
Test Routines..............................................................................................................................................62
Alarm, Trip, and Event Latches...................................................................................................................65
System Logs ...............................................................................................................................................66
Response Time Performance .....................................................................................................................68
C HAPTER 4. M ODBUS C OMMUNICATIONS .....................................................................................70
Modbus Communications............................................................................................................................70
Monitor Only................................................................................................................................................70
Monitor and Control.....................................................................................................................................70
Modbus Communication .............................................................................................................................71
Port Adjustments.........................................................................................................................................71
MicroNet Safety Module Parameter Addresses..........................................................................................71
C HAPTER 5. T ROUBLESHOOTING .................................................................................................77
I/O Troubleshooting.....................................................................................................................................78
Trip Indications............................................................................................................................................81
Alarm Indications.........................................................................................................................................83
Configuration Guidance ..............................................................................................................................85
C HAPTER 6. S AFETY M ANAGEMENT ............................................................................................88
Product Variations Certified ........................................................................................................................88
Safe State....................................................................................................................................................88
SIL Specifications........................................................................................................................................88
Failure Rate Data........................................................................................................................................89
Response time data ....................................................................................................................................89
Limitations...................................................................................................................................................90
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Management of Functional Safety ..............................................................................................................90
Restrictions..................................................................................................................................................90
Competence of Personnel...........................................................................................................................91
Operation and Maintenance Practice..........................................................................................................91
Installation and Site Acceptance Testing....................................................................................................91
Functional Testing after Initial Installation...................................................................................................91
Functional Testing after Changes...............................................................................................................91
Proof Testing (Functional Test)...................................................................................................................91
C HAPTER 7. A SSET M ANAGEMENT ..............................................................................................93
Product Storage Recommendations...........................................................................................................93
Refurbishment Period Recommendation....................................................................................................93
C HAPTER 8. P RODUCT S UPPORT AND S ERVICE O PTIONS .............................................................94
Product Support Options.............................................................................................................................94
Product Service Options .............................................................................................................................94
Returning Equipment for Repair .................................................................................................................95
Replacement Parts......................................................................................................................................96
Engineering Services..................................................................................................................................96
Contacting Woodward’s Support Organization...........................................................................................96
Technical Assistance ..................................................................................................................................97
A PPENDIX . M ODBUS E THERNET G ATEWAY I NFORMATION .............................................................98
Introduction..................................................................................................................................................98
B&B Electronics Setup................................................................................................................................98
Lantronix Setup.........................................................................................................................................103
R EVISION H ISTORY ...................................................................................................................108
D ECLARATIONS ........................................................................................................................109
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Illustrations and Tables
Figure 1-1. Typical MicroNet Safety Module Application (Voted Trip Relay Models).................................11
Figure 1-2. Typical MicroNet Safety Module Application (Independent Trip Relay Models) ......................12
Figure 1-3. Typical Gas Turbine Application (Voted Trip Relay Models)....................................................12
Figure 1-4. Typical Safety PLC Application (Voted Trip Relay Models) .....................................................13
Figure 2-1. Typical MicroNet Safety Module Bulkhead Package—Front View...........................................15
Figure 2-2. Typical MicroNet Safety Module Bulkhead Package—Front Door Open.................................16
Figure 2-2a. Bulkhead Schematic Showing Front Panel A Connection to Module A and Front Panel C
Connection to Module C—Top View......................................................................................16
Figure 2-3. Mounting Outline Diagram for Bulkhead-Mounted Models ......................................................17
Figure 2-4a. Typical MicroNet Safety Module Panel Mount Package—Front View ...................................19
Figure 2-4b. Typical MicroNet Safety Module Panel Mount Package—Rear View with Cover..................19
Figure 2-4c. Typical MicroNet Safety Module Panel Mount Package—Rear View without Cover.............20
Figure 2-4d. Panel Mount Schematic Showing Front Panel A Connection to Module A and Front Panel C
Connection to Module C—Top View......................................................................................20
Figure 2-5a. Mounting Outline Diagram for Panel-Mount Models ..............................................................21
Figure 2-5b. Mounting Outline Diagram for Panel-Mount Models ..............................................................22
Figure 2-5c. Panel Cutout Diagram for Panel-Mount Models.....................................................................23
Figure 2-6. Screw Connection Terminal Block............................................................................................28
Figure 2-7. Inside View of MicroNet Safety Module....................................................................................30
Figure 2-8. MicroNet Safety Module Control Wiring Diagram.....................................................................31
Figure 2-9. Trip Module – Included within Voted Trip Relay Units Only.....................................................32
Figure 2-10a. Power Supply Field Wiring Routing & Stress Relief Diagram..............................................32
Figure 2-10b. Configurable I/O Wiring Routing & Stress Relief Diagram...................................................33
Figure 2-10c. Relay Output Field Wiring Routing & Stress Relief Diagram................................................33
Figure 2-11a. Example MPU (Passive Magnetic Pickup Unit) Wiring ........................................................34
Figure 2-11b. Example Proximity Probe (Active Magnetic Pickup Unit) Wiring (Internal Power)...............35
Figure 2-11c. Example Proximity Probe (Active Magnetic Pickup Unit) Wiring (External Power, Non-
preferred)................................................................................................................................35
Figure 2-11d. Example Eddy Current Probe (Active Magnetic Pickup Unit) Wiring...................................35
Figure 2-12a. Example Standard Discrete Input Wiring (Internal Power Option).......................................36
Figure 2-12b. Example Standard Discrete Input Wiring (External Power Option)......................................36
Figure 2-13a. Example Configurable Input Wiring—Discrete Input (Internal Power Option) .....................37
Figure 2-13b. Example Configurable Input Wiring—Discrete Input (External Power Option) ....................38
Figure 2-14. Example Configurable Input Wiring—Analog Input................................................................38
Figure 2-15. Example Analog Output Wiring ..............................................................................................39
Figure 2-16a. Example Trip Relay Output Wiring.......................................................................................39
Figure 2-16b. Example Trip Relay Wiring (per Module) (Independent Trip Relay) (Internal Supply).........40
Figure 2-16c. Example Trip Relay Wiring (per Module) (Independent Trip Relay) (External Supply)........40
Figure 2-16d. Example Trip Relay Wiring (Voted Trip Relay Models)........................................................41
Figure 2-16e. Example Programmable Relay Wiring (Internal Supply)......................................................41
Figure 2-16f. Example Programmable Relay Wiring (External Supply)......................................................42
Figure 2-17. Power Supply Relationship Diagram......................................................................................43
Figure 2-18a. Serial Port Interface Diagram—RS-232 ...............................................................................44
Figure 2-18b. Serial Com Port Interface Diagram —RS-485......................................................................44
Figure 2-19. Service Tool Cable/Interface Diagram ...................................................................................45
Figure 3-1. Basic Functional Overview of Independent Trip Relay Models................................................48
Figure 3-2. Functional Diagram of single MicroNet Safety Module with Independent Trip Relay Outputs49
Figure 3-3. Example TMR Trip Block Assembly Interface..........................................................................50
Figure 3-4. Basic Functional Overview of Voted Trip Relay Models...........................................................51
Figure 3-5. Functional Diagram of Single MicroNet Safety Module with Voted Trip Relay Outputs...........51
Figure 3-6. Simplex Trip Block Assembly ...................................................................................................52
Figure 3-7. Dual Redundant Trip Block Assembly......................................................................................52
Figure 3-8. Discrete Input Example ............................................................................................................56
Figure 3-9. Analog Input Example ..............................................................................................................57
Figure 3-10. Programmable Relay Output Diagram ...................................................................................58
Figure 3-11. Over-Acceleration Enabling Diagram.....................................................................................60
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Figure 3-12. Speed Fail Trip Diagram.........................................................................................................60
Figure 3-13. Speed Fail Timeout Trip Diagram...........................................................................................61
Figure 3-14. Response Time Definition ......................................................................................................68
Figure 3-15. Independent Trip Relay Response Time (Typical) Graph......................................................69
Figure 3-16. Voted Trip Relay Response Time (Typical) Graph.................................................................69
Figure 5-1. Configuration Guide - Front Panel Interface with Active Probe................................................86
Figure 5-2. Speed Fail Trip Using PCT.......................................................................................................86
Figure 5-3. Configuration Guidance Flowchart...........................................................................................87
Figure 6-1. MicroNet Safety Module Response Time.................................................................................90
Table 1-1 Available MicroNet Safety Module Models.................................................................................10
Table 3-1. Independent Trip Relay Output Specifications ..........................................................................50
Table 3-2. Voted Trip Relay Output Specifications.....................................................................................53
Table 3-3. Power Supply Specifications .....................................................................................................53
Table 3-4. High Voltage Input .....................................................................................................................53
Table 3-5. Low Voltage Input......................................................................................................................53
Table 3-6. Configurable Input Power Supply (24V_AI)...............................................................................54
Table 3-7. Relay Output Power Supply (24V_P) ........................................................................................54
Table 3-8. General Specifications...............................................................................................................55
Table 3-9. Passive Probe (MPU) Inputs .....................................................................................................55
Table 3-10: Active Probe (Proximity, Eddy Current)...................................................................................55
Table 3-11. Dedicated Discrete Inputs Specifications ................................................................................56
Table 3-12. General Specifications.............................................................................................................57
Table 3-13. Analog Input Mode...................................................................................................................58
Table 3-14: Discrete Input Mode.................................................................................................................58
Table 3-15. Programmable Relay Output Specifications............................................................................58
Table 3-16. Analog Output Specifications...................................................................................................59
Table 3-17. IRIG-B Input Specifications......................................................................................................59
Table 4-1. Serial Communication Port (RS-232/RS-485) Specifications....................................................70
Table 4-2. Supported Modbus Function Codes..........................................................................................71
Table 4-3. Modbus Communication Port Settings ......................................................................................71
Table 4-4. Boolean Write Addresses (Code 05).........................................................................................73
Table 4-5. Boolean Read Addresses (Code 02).........................................................................................74
Table 4-6 (continued). Boolean Read Addresses (Code 02)......................................................................75
Table 4-7. Analog Read Addresses (Code 04)...........................................................................................76
Table 6-1. Module Configuration, Power Loss, and Power Up...................................................................88
Table 6-2. SIL 3 Calculation Types and Values..........................................................................................88
Table 6-3. MicroNet Safety Module SIL3 numbers:....................................................................................89
Table 6-4. Mean Time to Failure (MTTF)....................................................................................................89
Table 6-5. Response Time..........................................................................................................................89
Table 6-6. Environmental Specifications:....................................................................................................90
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Warnings and Notices
Important Definitions
This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
•DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
•WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
•CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
•NOTICE - Indicates a hazard that could result in property damage only (including damage to the
control).
•IMPORTANT - Designates an operating tip or maintenance suggestion.
Overspeed /
Overtemperature /
Overpressure
The engine, turbine, or other type of prime mover should be
equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be 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 wear the appropriate personal protective equipment (PPE) for
the job at hand. Equipment that should be considered includes but is
not limited to:
•Eye Protection
•Hearing Protection
•Hard Hat
•Gloves
•Safety Boots
•Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Start
-
up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
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Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
•Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
•Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
•Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715 , Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules
.
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 printed circuit board (PCB) from the control cabinet unless absolutely necessary.
If you must remove the PCB from the control cabinet, follow these precautions:
•Do not touch any part of the PCB except the edges.
•Do not touch the electrical conductors, the connectors, or the components with conductive
devices or with your hands.
•When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in
until you are ready to install it. Immediately after removing the old PCB from the control cabinet,
place it in the antistatic protective bag.
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Regulatory Compliance
European Compliance for CE Marking
EMC Directive: Declared to Directive 2014/30/EU of the European Parliament and of
the Council of 26 February 2014 on the harmonization of the laws of
the Member States relating to electromagnetic compatibility (EMC)
Low Voltage Directive: Directive 2014/35/EU on the harmonisation of the laws of the Member
States relating to the making available on the market of electrical
equipment designed for use within certain voltage limits
ATEX – Potentially
Explosive Atmospheres
Directive:
Directive 2014/34/EU on the harmonisation of the laws of the Member
States relating to equipment and protective systems intended for use
in potentially explosive atmospheres
II 3 G, Ex nA IIC T4
Other European Compliance
Compliance with the following European Directives or standards does not qualify this product for
application of the CE Marking:
RoHS Directive: Restriction of Hazardous Substances 2011/65/EU:
Woodward Turbomachinery Systems products are intended
exclusively for sale and use only as a part of Large Scale Fixed
Installations per the meaning of Art.2.4(e) of directive 2011/65/EU.
This fulfills the requirements stated in Art.2.4(c) and as such the
product is excluded from the scope of RoHS2.
North American Compliance
CSA: Certified for Class I, Division 2, Groups A, B, C, and D, T4 at 60 °C
Ambient for use in the United States and Canada.
Certificate 160584-2217246
Other International Compliance
Australia (& New Zealand)
RCM:Compliance is limited to application for those units bearing the Regulatory Compliance Mark (RCM). Only EMC is applicable in
virtually all Woodward intended applications. RCM on WWD products
is very limited due to allowed exemptions from applying the RCM or
having a DoC
EMC: Electromagnetic Compatibility (EMC) Declaration of Conformity
(DoC) RCM requirements for the Australian (& New Zealand)
Radiocommunications Act is a separate document only created for
products applying the RCM to the label.
Products with a RCM on the label have an EMC Declaration of
Conformity available: Woodward products typically comply with at
least CISPR11 Group1, Class A emissions limits, Electromagnetic
Interference (EMI) testing, even if not marked with the RCM: as long
as the “CE mark” is on the label.
TÜV: TÜV certified for SIL-3 per IEC 61508 Parts 1-7, Functional Safety of
Electrical / Electronic / Programmable Electronic Safety Related
Systems
Other Compliance
Gas Corrosion: IEC60068-2-60:1995 Part 2.60 Methods 1 and 4 (conformal coating)
Machinery
Protection:
API670, API612, & API-611 compliant
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Special Conditions for Safe Use
This Equipment is Suitable for use in Class I, Division 2, Groups A, B, C, D or Non-Hazardous Locations
Only.
This equipment is suitable for use in European Zone 2, Group IIC environments or Non-Hazardous
Locations Only.
Wiring must be in accordance with North American Class I, Division 2, or European Zone 2, Category 3
wiring methods as applicable, and in accordance with the authority having jurisdiction.
A fixed wiring installation is required, and a switch or circuit breaker shall be included in the building
installation that is in close proximity to the equipment and within easy reach of the operator and that is
clearly marked as the disconnecting device for the equipment. The switch or circuit breaker shall not
interrupt the protective earth conductor.
Protective Earth Grounding is required by the input PE terminal.
Field wiring must be rated at least 85 °C for operating ambient temperatures expected to exceed 50 °C.
For European ATEX compliance 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. The unit is designed to
have one of three modules be removed during operation; however ESD to the remaining operational
modules may cause signal deviations. Signal deviations due to direct ESD may be large enough to result
in the operational module to trip, shutting down the engine since two modules are in a tripped mode.
Signal deviations were noted when ESD testing was done to the Speed pins, the IRIG-B pins, Service
Port pins, and RS-232/RS-485 Modbus communications port pins.
Do not remove module unless module is de-energized and all wire
connections have been disconnected
The Service Port (RS-232 communication) is not designed to remain connected during operation except
at servicing & programming intervals. It should not have a cable connected to it other than during
programming & servicing.
This device contains a single cell primary battery. This battery is not to be charged and is not customer
replaceable.
Control is suitable for installation in pollution degree 2 environments.
Measurement inputs are classified as permanently connected IEC
measurement Category I and are designed to safely withstand
occasional transient overvoltages up to 1260 V (pk). To avoid the
danger of electric shock, do not use these inputs to make
measurements within measurement categories II, III, or IV.
Explosion Hazard—Do not connect or disconnect while circuit is live
unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2 or Zone 2 applications.
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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 Division 2 ou Zone 2.
Safety Symbols
Both direct and alternating current
Alternating current
Direct current
Caution, risk of electrical shock
Caution, refer to accompanying documents
Protective conductor terminal
Frame or chassis terminal
Acronyms and Definitions
2oo3
2-out-of-3
Block Identifier
The identifier used for each logic block for configuration purposes (Chapter 9)
CAN
Controller Area Network
DC
Diagnostic Coverage
DCS
Distributed Control System
Module
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 configuration settings loaded with the ProTech Service Tool
(.wset).
MSM
MicroNet™ Safety Module
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Chapter 1.
General Information
Description
The MicroNet™ Safety Module is a safety system that provides specialized overspeed protection
functions plus additional programmable logic and configurable inputs and outputs to address other safety
critical functions.
The MicroNet Safety Module consists of three independent modules whose trip outputs are either
independent or voted in a 2-out-of-3 configuration.
The MicroNet Safety Module includes Alarm, Event, Trip and Sequence of Event log functions with time-
stamping. Indication that a test was active at the time of the event is provided on all logs and first-out
indications are provided for Event and Trip logs. Trip response time monitoring and logging is also built
into the MicroNet Safety Module.
The MicroNet Safety Module provides various pre-defined and user-definable test features including
automated periodic tests.
There are several ways to interface with the MicroNet Safety Module. The front panel of allows the user to
view current values, and 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.
*—Modbus is a trademark of Schneider Automation Inc.
This product is designed for critical applications and when installed correctly meets API-670, API-612,
API-611, and IEC61508 (SIL-3) standards.
The following Table shows the various hardware configurations (mounting options, power supplies, and
trip relay options) available:
Table 1-1 Available MicroNet Safety Module Models
Part Number
Description
8237-1252 MicroNet Safety Module – Bulkhead Mount, HV/LV, Ind relay
8237-1253 MicroNet Safety Module – Bulkhead Mount, HV/HV, Ind relay
8237-1254 MicroNet Safety Module – Bulkhead Mount, HV/LV, voted relays
8237-1255 MicroNet Safety Module – Bulkhead Mount, HV/HV, voted relays
8237-1375 MicroNet Safety Module – Panel Mount, HV/LV, Ind relay
8237-1376 MicroNet Safety Module – Panel Mount, HV/HV, Ind relay
8237-1377 MicroNet Safety Module – Panel Mount, HV/LV, voted relays
8237-1378 MicroNet Safety Module – Panel Mount, HV/HV, voted relays
5437-1104 Spare Module for MSM models 8237-1254, -1377
5437-1105 Spare Module for MSM models 8237-1255, -1378
5437-1106 Spare Module for MSM models 8237-1252, -1375
5437-1107 Spare Module for MSM models 8237-1253, -1376
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Applications
The MicroNet Safety Module is designed to be applied as a safety system for any size steam, gas, or
hydro turbine, reciprocating engine, or plant process equipment. This safety PLC’s fast (12 millisecond)
response time, 0.5 to 32 000 rpm speed range, and integrated overspeed and acceleration
detection/protection functionality, make it ideal for application on critical low-speed or high-speed rotating
motors, compressor, 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 individual module
(kernel) of the MicroNet Safety 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 plant protection.
The MicroNet Safety Module utilizes a triple modular redundant architecture and 2-out-of-3 voting logic to
accurately determine unsafe conditions and ensure that no single-point failure will affect system reliability
or availability. With this design, system failures (switches, transducers, modules) are detected,
annunciated, and allowed to be repaired or replaced while the monitored system continues to operate on-
line.
Alternatively, this standalone safety device can be configured to protect any plant system or device, and
report the system’s device’s status to the plant DCS. The MicroNet Safety Module control’s versatile
inputs, outputs, programming environment, and communications make it ideal as a safety protection
device for use in small applications that could possibly reach an unsafe state or condition and that must
communicate directly to the plant DCS. The MicroNet Safety Module is designed for critical applications
where both personnel safety and unit availability (operation run time) is a concern or necessity.
Figure 1-1. Typical MicroNet Safety Module Application (Voted Trip Relay Models)
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Figure 1-2. Typical MicroNet Safety Module Application (Independent Trip Relay Models)
Figure 1-3. Typical Gas Turbine Application (Voted Trip Relay Models)
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The MicroNet Safety Module is certified as an IEC61508 SIL-3 (Safety Integrity Level 3) safety device and
can be applied as a stand-alone IEC61508-based device or within an IEC61511-based plant safety
system.
Figure 1-4. Typical Safety PLC Application (Voted Trip Relay Models)
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Chapter 2.
Installation
Introduction
This chapter provides instructions on how to mount and connect the MicroNet™ Safety Module into a
system. Hardware dimensions, ratings, and jumper configurations are given to allow a customer to mount,
wire, and configure the MicroNet Safety Module package to a specific application.
Electrical ratings, wiring requirements, and options are provided to allow a customer to fully install the
MicroNet Safety Module into a new or existing application.
Unpacking
Before opening the shipping packaging, inspect the shipping container for damage and document any
damage.
Be careful when opening & removing the shipping container. You may retain the original shipping
container for unit storage or return shipping for suggested refurbishment. (See Asset Management
chapter for storage details.)
Be careful when unpacking the MicroNet Safety Module system from the shipping container. The
precautions called out in the Electrostatic Discharge Awareness section should be followed during
unpacking, handling, installation and operation during maintenance.
Once removed from the shipping packaging, 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 MicroNet Safety Module system.
2. Create a site specific wiring diagram by referencing included wiring diagrams & constraints then
perform mechanical and electrical installation following this chapter’s instructions.
3. Visual inspection
a. Verify that all mounting hardware is tightened and that no wires are pinched.
b. Verify that no wiring insulation is nicked or abraded.
c. Verify that all terminal blocks are installed and terminal screws are tight. (Follow control wiring
instructions for all terminal blocks.)
d. If used, verify that speed sensors have been correctly installed, and have the correct clearance
from the speed gear (adjust if necessary). See manual 82510, Magnetic Pickups and Proximity
Switches for Electronic Governors.
4. Apply power to each module (one at a time), and verify that each module boots up and its front panel
screen displays turbine speed
5. If no special programming logic is used skip to step 11
6. If special programming logic is required install MicroNet Safety Module programming and
configuration tool (PCT) from provided PCT Installation CD on to the desired computer and create
system application program
7. Once the system application program is complete connect an extension (i.e. straight-through, not
null-modem) RS-232 serial cable from the respective computer to any module’s (A, B, C) service
port, and download the program into the module
8. From the respective module’s front panel copy downloaded program to other unit modules
9. From each module’s front panel verify that the correct program has been installed in each module by
comparing unit CRC codes.
10. From each module’s front panel, enter the configuration mode and verify that each of the overspeed
and over-acceleration settings are correct.
11. Enter the configuration mode and configure all settings to the specific application’s requirements
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12. Perform a full system checkout by verifying all system trips, alarms, and test routines function
correctly before starting the machinery/system.
13. When ready, start the turbine/machinery following the equipment manufacturer’s recommended
starting procedure
Enclosures
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.
Depending on the model purchased, the MicroNet Safety Module 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 IP56-based environments. With these models, field wiring access is through
gland plates located on the bottom of the enclosure. Figures 2-1, 2-2, and 2-3 display the bulkhead
mounted MicroNet Safety Module model’s physical layout and mounting pattern.
The MicroNet Safety Module panel-mounted enclosure models are designed for installation within a
control room panel or cabinet, and by itself, it cannot be bulkhead mounted. Once installed within an IP56
rated panel or cabinet, the MicroNet Safety Module panel-mounted models are rated for IP56-based
environments. A gasket is attached to the rear side of the package’s bezel to properly seal the MicroNet
Safety Module control’s face-plate & around the mounting studs to a panel. With these models, field
wiring access is located on the MicroNet Safety Module control’s back side, and a back cover is included
to protect wiring terminals after installation. Figures 2-4 and 2-5 display the Panel-Mount MicroNet Safety
Module model’s layout and mounting pattern.
Figure 2-1. Typical MicroNet Safety Module Bulkhead Package—Front View
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Figure 2-2. Typical MicroNet Safety Module Bulkhead Package—Front Door Open
Figure 2-2a. Bulkhead Schematic Showing Front Panel A Connection to
Module A and Front Panel C Connection to Module C—Top View
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Figure 2-3. Mounting Outline Diagram for Bulkhead-Mounted Models
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Module Removal and Installation – Bulkhead Mount Package
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
5. Remove module by pulling the two handles simultaneously
Installation:
1. Insert module into slot by pressing firmly on handles. The module has guides to assist in location.
2. Tighten 4 module retention screws
3. Install terminal blocks
4. Apply power and observe that the power LED is ON
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