Woodward MicroNet TMR 5009FT Assembly Instructions

Product Manual 26518V2
(Revision E, 6/2018)
Original Instructions
MicroNet TMR® 5009FT
Fault-Tolerant Steam Turbine Control
Installation / Hardware Manual
Manual 26518 consists of 4 volumes (26518V1, 26518V2, 26518V3, 26518V4).
Volume 2
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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:
www.woodward.com/publications
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 certifications 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 Out-of-date translations are marked with .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 26518V2
Copyright © Woodward, Inc. 2010-2018
All Rights Reserved
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Contents
WARNINGS AND NOTICES ...............................................................................................................3
ELECTROSTATIC DISCHARGE AWARENESS......................................................................................4
REGULATORY COMPLIANCE............................................................................................................5
CHAPTER 1. GENERAL INFORMATION..............................................................................................7
CHAPTER 2. HARDWARE DESCRIPTION ...........................................................................................8
Introduction ................................................................................................................................................... 8
Main Control Chassis .................................................................................................................................... 8
System Power Supplies (PSM1 and PSM2) ................................................................................................. 9
Module Descriptions.................................................................................................................................... 10
CCT – TouchPanel PC................................................................................................................................ 15
CHAPTER 3. MECHANICAL INSTALLATION......................................................................................17
Storage........................................................................................................................................................ 17
Unpacking ................................................................................................................................................... 17
Unit Location ............................................................................................................................................... 17
CHAPTER 4. ELECTRICAL INSTALLATION.......................................................................................18
Introduction ................................................................................................................................................. 18
Shields and Grounding................................................................................................................................ 18
Input Power ................................................................................................................................................. 20
Analog Inputs—TMR Analog Combo Module............................................................................................. 24
Analog Inputs—TMR 24/8 Analog Module.................................................................................................. 25
Analog Outputs—TMR Analog Combo Module .......................................................................................... 27
Analog Outputs—TMR 24/8 Analog Module............................................................................................... 27
Actuator Outputs—TMR Analog Combo Module........................................................................................ 28
Actuator Outputs—Actuator Controller Module........................................................................................... 29
FTM Contact Inputs (F/T Relay–Discrete In) .............................................................................................. 33
FTM Relay Outputs (F/T Relay Outputs) .................................................................................................... 34
Communications ......................................................................................................................................... 41
Control Wiring Diagrams ............................................................................................................................. 42
System Power-Up ....................................................................................................................................... 42
CHAPTER 5. TROUBLESHOOTING AND MODULE REPLACEMENT .....................................................44
Introduction ................................................................................................................................................. 44
Main Power Supply (PSM1 and PSM2) ...................................................................................................... 44
Kernel Power Supply (Kernel A/B/C: A1).................................................................................................... 45
Replacing a 5009FT CPU while Unit is Running ........................................................................................ 46
Analog and Discrete I/O Modules (Kernel A/B/C: A3-A5)........................................................................... 49
2 Channel Actuator Module (Kernel A/B: A6) ............................................................................................. 51
Termination Modules................................................................................................................................... 51
Diagnostics.................................................................................................................................................. 52
System Troubleshooting Guide................................................................................................................... 54
CHAPTER 6. HARDWARE SPECIFICATIONS.....................................................................................57
CHAPTER 7. SYSTEM MAINTENANCE .............................................................................................59
Cables and Connections ............................................................................................................................. 59
Fans ............................................................................................................................................................ 59
CHAPTER 8. MICRONET TMR®COMPATIBLE PRODUCTS ...............................................................60
DSLC™ Digital Synchronizer & Load Control............................................................................................. 61
Real Power Sensor (RPS) .......................................................................................................................... 64
APPENDIX A. CONTROL WIRING DIAGRAM.....................................................................................67
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APPENDIX B. STANDARD CABINET LAYOUT DIAGRAM ...................................................................87
REVISION HISTORY.......................................................................................................................91
DECLARATIONS ............................................................................................................................92
Illustrations and Tables
Figure 2-1. Fault Tolerant Relay Outline Drawing ...................................................................................... 13
Figure 2-2. FT Relay Block Diagram........................................................................................................... 14
Figure 4-1. FTM103-1 and FTM103-2 Grounding Bars .............................................................................. 19
Figure 4-2. FTM106-1 and FTM106-2 Grounding Bars .............................................................................. 19
Figure 4-3. Shield Termination Diagram 1 .................................................................................................. 19
Figure 4-4. Shield Termination Diagram 2 .................................................................................................. 20
Figure 4-5. Example MPU Interface Wiring Diagram (Ch 1 shown) ........................................................... 22
Figure 4-6. Example 24 V Proximity Probe Wiring Diagram....................................................................... 22
Figure 4-7. MPU Pickup Voltage vs Frequency.......................................................................................... 24
Figure 4-8. Example Analog Input Wiring Diagrams................................................................................... 25
Figure 4-9. Analog Input Wiring for a 24/8 Analog FTM ............................................................................. 26
Figure 4-10. Example Analog Output Wiring Diagram................................................................................ 27
Figure 4-11. Example Single Coil Actuator Wiring Diagram ....................................................................... 28
Figure 4-12. Example Dual Coil Actuator Wiring Diagram.......................................................................... 29
Figure 4-13. 5009FT Compatible Position Feedback Schematics.............................................................. 30
Figure 4-12a. Example of Single Loop with Dual Coil and Two LVDTs Type (A–B)/(A+B) on Cylinder
Valve ...................................................................................................................................... 31
Figure 4-12b. Example of Dual Loop with Dual Coil and Two LVDTs Type (A–B)/(A+B) on Cylinder Valve
and Two VDTs Type (A–B)/(A+B) on Pilot Valve................................................................... 32
Figure 4-14. Latent Fault Detection Verification Graph—18–32 Vdc Circuitry ........................................... 36
Figure 4-15. Latent Fault Detection Verification Graph—88–132 Vac Circuitry ......................................... 37
Figure 4-16. Latent Fault Detection Verification Graph—100–150 Vdc Circuitry ....................................... 37
Figure 4-17. Jumper and Relay Location Diagram ..................................................................................... 39
Figure 4-18. FTM Labels............................................................................................................................. 40
Figure 4-19. Example Relay Output Wiring Diagram.................................................................................. 41
Figure 5-1. FTM Fuse Locations................................................................................................................. 52
Figure 8-1. MicroNet™ Compatible Products ............................................................................................. 60
Figure 8-2. Inside View of Door .................................................................................................................. 61
Figure 8-3. DSLC Mounting ........................................................................................................................ 62
Figure 8-4. DSLC Control............................................................................................................................ 63
Figure 8-5. Real Power Sensor................................................................................................................... 65
Figure 8-6. Plant Wiring Diagram for the Real Power Sensor .................................................................... 66
Table 2-1. System Components ................................................................................................................... 8
Table 4-1. Fuse/Breaker Requirements...................................................................................................... 20
Table 5-1. Default IP Addresses ................................................................................................................. 47
Table 6-1. Environmental Classifications for Options ................................................................................. 57
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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.
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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:
These listings are limited only to those units bearing the CE Marking.
EMC Directive 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 of the European Parliament and of the Council of 26
February 2014 on the harmonization 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.
North American Compliance:
These listings are limited only to those units bearing the CSA identification.
CSA: CSA Certified for Ordinary Locations for use in Canada and the United
States
Certificate 2291171
Special Conditions for Safe Use:
This equipment is to be installed by professional service personnel according to the instructions given in
this manual.
Wiring must be in accordance with the authority having jurisdiction. PERMANENTLY CONNECTED
EQUIPMENT requires the special considerations to satisfy the CEC and the Canadian deviations to IEC
61010-1, including overcurrent and fault protection as required.
This device is considered permanently connect and requires a fixed wiring installation. Protective Earth
Grounding is required by the input PE terminals. (See Installation Chapter).
A disconnection device is not supplied with the system. A disconnecting switch or circuit breaker shall be
included in the building installation. It shall be in close proximity to the equipment and within easy reach of
the operator. This device shall be clearly marked as the disconnecting device for the equipment. The
disconnecting switch or circuit breaker shall not interrupt the protective earth conductor.
To ensure stability and to prevent accidental tipping, lift equipment only as described in the installation
chapter and bolt the system cabinet to the building structure before operation of the equipment.
125 Vdc digital Input connections located on FTM104-1A, FTM104-1B,
FTM104-2A, and FTM104-2B (Woodward # 5453-276) are not to be connected on CSA certified systems
or on systems requiring compliance with the European Low Voltage Directive.
Measurement inputs are classified as permanently connected IEC measurement Category I and are
designed to safely withstand occasional transient overvoltages up to 707 Vpk.
To avoid the danger of electric shock, do not use measurement
inputs to make measurements within measurement categories II, III,
or IV.
The system CCT and 5009 Control Chassis CPU contain single cell primary batteries. These batteries are
not to be charged and are not customer replaceable.
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The control cabinet contains hazardous live voltages. Only
individuals who have received proper training should open the
cabinet door and perform service. Equipment should be isolated or
disconnected from hazards live voltages before servicing.
This equipment is intended to be installed in a metal cabinet or enclosure. See manual 26167, Volumes 1
& 2, for installation requirements related to CE Marking requirements.
Safety Symbols
Direct Current
Alternating Current
Both Alternating and Direct Current
Caution, risk of electrical shock
Caution, refer to accompanying documents
Protective conductor terminal
Frame or chassis terminal
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Chapter 1.
General Information
The technical documentation for the 5009FT control system consists of the following volumes:
Volume 1—provides information on system application, control functionality, fault tolerant logic, control
logic, PID setting instructions, and system operation procedures.
Volume 2—provides hardware descriptions, mechanical and electrical installation instructions, hardware
specifications, hardware troubleshooting help, and basic repair procedures.
Volume 3—provides installation procedures for the 5009FT control’s personal computer based interface
software program (CCT), information on all CCT features and modes (Configure, Service and Run).
Volume 4—provides details on installation and operation of the optional operator control station, if
provided with your system. It contains a list of the control’s Modbus®* registers and tag names.
*—Modbus is a registered trademark of Schneider Automation Inc.
Active 5009FT System part numbers are covered in Volume 1 of this manual and in Appendix B.
This volume provides hardware description, installation, and troubleshooting information for the
Woodward 5009FT Control System. It includes:
A list of all system hardware
A description of all hardware
Mechanical installation instructions
Electrical installation instructions
Troubleshooting Guide, including diagnostic tests
Maintenance procedures (module replacement)
This hardware manual applies to all 5009FT control systems but does not include information that is
unique to your system only.
Appendix A – Control Wiring Diagram
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Chapter 2.
Hardware Description
Introduction
The 5009FT digital control system can be provided in a number of hardware configurations; with different
power supply configurations with or without a 17” Touchscreen PanelPC CCT (Configuration and
Commissioning Tool). An optional 17” PanelPC Operator Interface IFIX Touchscreen HMI is available.
Because this manual addresses all configurations, many of the following hardware descriptions may not
apply to your 5009FT system. Refer to Table 2-1, Appendix A for a complete listing of standard and
optional system components.
The system is shipped disassembled and must be installed in a metal cabinet as dictated in 26167V2.
After a control system is received, each item must be located and installed via this manual’s instructions
and Appendix A. Precautions to eliminate Electrostatic Discharge must be followed any time parts are
handled or entering the cabinet containing the MicroNet system.
This manual will reference the Woodward MicroNet TMR manual 26167 Volumes 1 and 2. The 5009FT is
a derivative of the MicroNet TMR, and the only difference is that the 5009FT is a pre-configured MicroNet
TMR System.
Table 2-1. System Components
Designation Description Qty Remarks
U1 Main chassis 1 Standard
U2 Power Chassis 1 Standard
PSM1, PSM2 Main Power Supply Module 2 Standard
A1 Kernel Power Supply Module 3 Standard
A2 CPU Module 3 Standard
A3 MPU & Analog I/O Module 3 Standard
A4 Discrete I/O Module (24 In/12 Out) 3 Standard
A5 Analog HD I/O Module 3 Optional
A6 Actuator Controller Module 2 Optional
FTM103-1, 2 Analog Termination Module 2 Standard
FTM104.1A, 1B, 2A,
2B
Discrete Termination Module (F/T Relay–Discrete
In)
4 Standard
FTM105-1, -2 Analog HD I/O Termination Module 2 Optional
FTM106-1, -2 Actuator Controller Termination Module 2 Optional
CCT Touchscreen PanelPC with Toolkit Software 1 Optional
HMI Touchscreen PanelPC with IFIX Software 1 Optional
ETH1, ETH2 Hirschmann 8-Port Ethernet Switch 2 Standard
W101-1 Power Chassis to Main Chassis Cable (1 ft/30 cm) 1 Standard
W101-2 Power Chassis to Main Chassis Cable 1 Standard
W102-A, -B, -C Ethernet Cable (7’) 6 Standard
W103-A, -B, -C Analog I/O Cable 6 Standard
W104-A, -B, -C Discrete I/O Cable 6 Standard
W104-1AB, -2AB FTM to FTM Cable (6”/15 cm) 6 Standard
W105-A, -B, -C Analog Cable 6 Optional
W106-A, -B Actuator Controller Cable 2 Optional
W107-1, -2 Ethernet Cable (10’) 2 Standard
Main Control Chassis
The main chassis of the 5009FT consists of three six-slot kernel sections. Each kernel section is isolated
from the other two. With this configuration the failure of any one section will not cause a shutdown.
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Each kernel section includes a kernel power supply, a CPU, an analog combo I/O module, and a discrete
I/O module. Optionally an integrating actuator module (Position Controller) and/or a High Density Analog
I/O module may be included. Slot-to-slot logic and power connections are made through an etched-circuit
motherboard located on the back of the chassis. The motherboard and modules are all VERSA module
Eurocard (VME) type. I/O connections are made through cables from the front of the modules to
termination modules in the cabinet. See Appendix A for an overview of the main chassis, control
modules, and termination modules.
From a module connector standpoint, any I/O module can be installed in any of the chassis slots
designated for I/O modules. However, when the application software is designed, each module is
assigned to a specific slot, thus the software expects each specific I/O module to always be in its
designated slot.
The 5009FT control chassis is cooled by forced air. In order not to starve modules of air flow, either a
module or a blank module must be installed and secured in each slot. Cooling fans are located on the top
of the main chassis; with one fan per 6-slot card rack. The power supply chassis contains two cooling
fans: one on top and one on the bottom of the chassis. These fans run any time the 5009FT chassis is
powered up.
See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 3, Section 1 for more details on the
Main Chassis.
System Power Supplies (PSM1 and PSM2)
The 5009FT main control power supply chassis uses redundant power supplies. A motherboard located
on the back of the power supply chassis allows the two power supplies to form a redundant power system
providing six separately regulated 24 Vdc, 6 A outputs to the control. Power output regulation, including
line, load, and temperature effects, is less than +5%.
When redundant power supplies are running, current-sharing circuitry balances the load to reduce heat
and improve the reliability of the power supplies. In the event that one supply needs replacement, this
feature also ensures hot replacement of the power supplies without disrupting the operation of the control.
When hot swapping a Power Supply, avoid reaching into the chassis
opening, as the top and bottom fan blades will be exposed.
Input power connections are made to the main power supply through terminals on the front of the power
supplies. For convenience, the user input power connections are made through panel mounted Phoenix
type terminal blocks. See Appendix B. A standard 50-pin ribbon cable is used for connecting the power
supply chassis to the 5009FT control chassis. As redundancy to this, a wire harness cable connects
power from the back of the power supply chassis to the back of the main chassis.
A set of two main power supplies are provided with each system. Different models of power supplies
allow the control to interface with different input source voltages.
Main power supplies are available in the following models:
AC/DC – 88–132 Vac or 100–150 Vdc
HVAC/DC – 180–264 Vac or 200–300 Vdc
See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 4, Sections 1–3 for more details on the
Main Power Supplies.
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Module Descriptions
Physical Description
All chassis mounted control modules are VME-type (VERSA module Eurocard) modules.
Modules slide into card guides in the 5009FT control’s chassis and plug into the motherboard. All modules
have their circuitry on a single printed-circuit board. Each module has a front panel extending from the
bottom to the top of the cabinet.
The modules are held in place by two screws: one at the top and one at the bottom. Also at the top and
bottom are two handles which, when toggled, move the modules out just far enough for the boards to
disengage the motherboard connectors. Each module is protected with a molded plastic cover to prevent
accidental component damage.
Kernel Power Supply Module (Kernel A/B/C: A1)
The 5009FT contains three kernel power supply modules. Each kernel section (A, B, and C) will contain
one kernel power supply module. The kernel power supply will be located in the first slot of each kernel
section. This module receives 24 Vdc from the MicroNet main power supplies and regulates it to 5 Vdc,
10 A for the rest of the kernel section and also creates a 5 Vdc precharge voltage.
See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 4, Sections 4–6 for more details on the
Kernel Power Supplies.
Central Processor Unit (CPU) Module (Kernel A/B/C: A2)
The MicroNet TMR 5200 CPU module contains an MPC5200 processor,
128 Mbyte DDR RAM, 64 MB of flash memory, a Real Time clock, and various communication
peripherals. These peripherals include (2) general use Ethernet ports, (1) Real Time Network port, (1)
serial port, (1) one service port, and (2) CAN ports. This module includes an FPGA to provide VMEbus
master/slave capability as well as other functions necessary for redundant systems.
This module, following the instructions of the application program, controls the circuits of the 5009FT
control so that they perform all the required control and sequencing functions. There are three CPU
modules provided with each system. Each CPU utilizes a PowerPC Motorola 5200 microprocessor to
perform its data processing. The VME bus arbitrator block controls the VME bus and determines what
device may use the bus when there is a conflict.
See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 5, Section 1 for more details on the
TMR 5200 CPU Module.
Analog Combo Module (Kernel A/B/C: A3)
Each High Density Analog Combo module supplied with the 5009FT contains circuitry for three passive
speed sensor inputs (magnetic pickups), one proximity probe (active probe, low speed detection only),
eight analog inputs, four analog outputs, and two proportional actuator driver outputs.
Each analog input must be 4–20 mA, and each actuator driver may be configured as 4–20 mA or 20–160
mA.
See Woodward MicroNet TMR manual 26167 Volume 1 for more details on the TMR Analog Combo
Module.
Analog Termination Modules (FTM103-1, FTM103-2)
The FTM for the TMR Analog Combo can connect to two speed sensor inputs, four analog inputs, two
analog outputs, and one proportional actuator driver output. Three MicroNet Low Density Analog cables
are used to connect the FTM with each of the three TMR Analog Combo Modules.
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There are several connections for power on the FTM, each for a dedicated purpose. There are four +24
Vdc connections available for sourcing 4–20 mA inputs. Each connection is protected with a 0.1 A fuse
(F1-F4). There is a +24/12 Vdc output connection available for powering one proximity sensor. Each of
these connections is protected with a 0.1 A fuse (F5, F6).
Two FTMs are provided and used with each 5009FT control (FTM103-1 and FTM103-2). Refer to
Appendix A for an overview of modules and FTMs used.
See Woodward MicroNet TMR manual 26167 Volume 2, Chapter 12, Section 2 for more details on the
TMR Analog Combo FTM.
Discrete I/O Module (Kernel A/B/C: A4)
Each 24/12 TMR Discrete I/O module (TMR High Density Discrete module) contains circuitry for twenty-
four (24) discrete inputs and twelve (12) TMR discrete outputs, and provides latent fault detection for
each relay output. Each discrete input may be 24 V, or 125 Vdc. Each relay output provides the option of
using a normally open contact, or a normally closed contact.
See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 7, Section 2 for more details on the
TMR 24/12 TMR Discrete I/O Module.
Discrete Termination Modules (F/T Relay Module)
(FTM104-1A, FTM104-1B, FTM104-2A, FTM104-2B)
The Fault Tolerant Relay modules are used to connect discrete field wiring to the 5009FT control. Four FT
Relays (FTM104-1A, FTM104-1B, FTM104-2A, and FTM104-2B) are provided and used with each
5009FT control. Refer to Appendix B for an overview of FTMs. Each FTM connects to the control’s three
independent Discrete I/O modules through individual cables, and provides a common cage-clamp
terminal connection for customer field wiring. Each FT Relay box contains circuitry for six contact inputs,
three relay outputs and houses circuitry to:
route each contact input signal to the system’s three independent (rack mounted) discrete modules
provide an open / closed contact output based on associated discrete module commands
indicate the health of all relays (latent fault detection)
Discrete input power (contact wetting voltage) can be supplied by the 5009FT control or from an external
source. The 5009FT control provides an isolated 24 Vdc power source for contact wetting. The external
source may be 24 Vdc or 125 Vdc (North American installations only). Separate discrete input terminals
are provided based on the level of contact wetting voltage used. See Appendix B.
To comply with CE Marking under the European Low Voltage
Directive (LVD) and CSA requirements, the maximum external circuit
voltage for both the Discrete Inputs and Relay Output circuit are
limited to 18–32 Vdc maximum.
The discrete output relays are mounted on sockets, with 18 relays per FTM. Six relays are used to create
each relay output (normally open and normally closed contacts) and allow latent fault detection. See
Appendix B. This configuration allows independent testing of each relay output (latent fault detection)
without concern of relay position. Customer power is connected to one side of the configuration and load
to the other.
Discrete outputs can be configured to use latent fault detection to identify output relay failures without
affecting operation. When the contacts are closed, they are periodically opened in pairs, to ensure that they
are in the correct state, and that they change state. When they are open, they are periodically closed
individually, to ensure that they close. Any failures are annunciated, and further testing is disabled.
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It is highly recommended to design the field wiring such that the
latent fault detection can be utilized on critical relays (Trips). Without
this feature, a single component fault might not be annunciated –
leading to a potential unwanted turbine trip.
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Figure 2-1. Fault Tolerant Relay Outline Drawing
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Figure 2-2. FT Relay Block Diagram
Field wiring constraints are detailed in the standard TMR manual—follow all shielding and wiring
constraints listed. See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 7, Section 2 for more
details on the FT Relay Module.
Optional TMR 24/8 Analog Module (Kernel A/B/C: A5)
The 24/8 Analog module contains circuitry for twenty-four analog inputs and eight 4–20 mA outputs.
These modules have no potentiometers and require no calibration. A module may be replaced with
another module of the same part number without any adjustment.
The TMR 24/8 Analog module comes in the following configuration: 24 channels of 4–20 mA inputs with 8
channels of 4–20 mA outputs (2-pole 10 ms filter on all input channels, except channels 23 and 24, which
have 2-pole 5 ms filter).
See Woodward MicroNet TMR manual 26167 Volume 1, Chapter 8, Section 1 for more details on the
TMR 24/8 Analog Module.
Optional TMR 24/8 Field Termination Module (FTM105-1, FTM105-2)
The TMR 24/8 Analog FTM is used with the TMR 24/8 Analog Modules. Three MicroNet High Density
Analog/Discrete cables are used to connect the FTM with the three TMR 24/8 Analog Modules. There are
twelve +24 Vdc connections available for sourcing 4–20 mA inputs. Each connection is protected with a
0.1 A fuse.
See Woodward MicroNet TMR manual 26167 Volume 2, Chapter 12, Section 2 for more details on the
TMR 24/8 Analog FTM.
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Optional Two Channel Actuator Controller Module (Kernel A/B: A6)
Each channel controls an integrating or proportional, hydromechanical or pneumatic actuator. Each
actuator may have up to two position feedback devices. There are several versions available, and the
module part number indicates the module's maximum output current capability. A discrete (gray) cable
must be used with this module. Do not use an analog (black) cable.
The 2 Channel Actuator Module’s circuitry is divided into two channels. Each channel incorporates an
output current driver and two position resolver feedbacks. Because the 5009FT is a redundant controller,
two actuator drivers from separate modules provide control for each actuator / valve whether wired
separately to dual actuator coils or wired in parallel to a single actuator coil. The redundancy is managed
in the application program and Actuator Module microprocessors so that the two output drivers share load
unless a problem is detected. If one of the drivers goes out of operation, the remaining driver will assume
the required load. When redundant drivers are implemented, only one resolver feedback is available per
channel for direct control. Even though only one position input can be used per channel, the availability of
two channels allows for redundant feedback.
When pilot valves are used, the signal must be connected on the second LVDT input of the card. The
Pilot signal can be redundant, if sent to card A106 and card B106. If physically, only one LVDT signal is
available, the excitation can only be taken from one card, but the signal can be put in parallel.
See Woodward MicroNet TMR manual 26167 Volume 2, Chapter 9, Section 2 for more details on the Two
Channel Actuator Controller Module.
Optional 2-Channel Actuator Field Termination Module (FTM106-1, FTM106-2)
The Two Channel Actuator Controller FTM is used with the 2Ch Actuator Modules. One MicroNet Low
Density Analog cable is used to connect the FTM with the 2Ch Actuator module.
See Woodward MicroNet TMR manual 26167 Volume 2, Chapter 9, Section 2 for more details on the Two
Channel Actuator Controller FTM.
CCT – TouchPanel PC
The 5009FT control system may include an engineering workstation as a Configuration and
Commissioning Tool (CCT) for the control. The software on this device is covered in Volume 3 of this
manual; the hardware used is listed here.
© PHOENIX CONTACT - 2010-01
Phoenix Contact - Valueline Industrial PC
Technical Data
Ambient temperature (operating) 5 to 55 °C
Ambient temperature (storage/transport) –40 to +70 °C
Permissible humidity (relative) 5 to 95%
Display, 17 in. (dimensions/weight) 452 x 356.5 x 50 mm / 5.85 kg
Degree of protection IP65 (front), IP20 (back)
Panel Mounting / LED indicators Power, HDD, Run, Error
Electrical Data
Power supply nominal 24 Vdc
Power supply range 19.2—28.8 Vdc
Current draw, typical 1.0—1.5 A
Current draw, maximum 2.0—5.2 A
Power consumption, typical 36.0 W
Power consumption, maximum 124.8 W
RTC battery, typical life 5 years
NOTE: Protective earth ground and circuit ground (return) are connected.
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Computer Data
Operating system Windows XP
Processor 1.5 GHz Intel Core2 Duo, 667 FSB, 4 MB L2 Cache
RAM 2 GB
Data memory 2.5 in. SATA solid state drive 32 GB
Interfaces USB 4x Type A, USB 1.1/2.0
Serial RS-232 (configurable option) DB-9, male
Video (configurable option) VGA (DB-15, female)
NVRAM size 128 kB
Number of Ethernet ports Two RJ45 Ethernet ports (10/100/1000 Mbps)
Display (17 inch)
Screen size, diagonal 430 mm (16.93 in.)
Screen size, horizontal x vertical 337.92 x 270.34 mm
Resolution 1280 x 1024
Type Resistive touch screen with serial/USB interface
Brightness 350 Cd/m²
Number of colors 16.7 million
Contrast ratio 1000:1
View angle, horizontal/vertical (CR=10) 170°/160°
Installation cutout dimensions (width x height) 424.0 x 329.5 mm
Outside bezel dimensions (width x height x depth) 452.0 x 356.5 x 10 mm
Backlight life, minimum 50 000 hours
Interface (configurable option) USB 1.1/2.0, Type A
Mechanical Tests
Shock test according to IEC 60068-2-27 15G, 11 ms impulse
Vibration resistance according to IEC 61131-2 Hard Drive: 0.5G
Conformance With EMC Directives
Developed according to IEC 61000-6-2
IEC 61000-4-2 (ESD) Criterion B
IEC 61000-4-3 (radiated-noise immunity) Criterion A
IEC 61000-4-4 (burst) Criterion B
IEC 61000-4-5 (surge) Criterion B
IEC 61000-4-6 (conducted noise immunity) Criterion A
IEC 61000-4-8 (noise immunity against magnetic fields) Criterion A
EN 55022 (noise emission) Class A
Approvals
CE
UL, cUL UL 508
UL, cUL Class I, Division 2, Groups A, B, C, D
UL 1604
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Chapter 3.
Mechanical Installation
Storage
Store 5009FT control and associated parts between –20 and +70 °C
(–4 and +158 °F) at a maximum relative humidity of 90% non-condensing. If power supplies are to be
stored for a long time, apply operating power to them at least once every 18 months. For more detail, see
MicroNet TMR manual 26167.
Unpacking
Unpack each part of the system carefully. Check the units for signs of damage, such as bent or dented
panels, scratches, or loose or broken parts. If any damage is found, notify the shipper immediately.
After a control system is received each item must be located and installed via this manual’s instructions.
The following items should be removed from the packing carton (s) and checked to make sure you have
all the necessary components before attempting to assemble and install the system. Refer to MicroNet
TMR manual 26167, Appendix A.
Unit Location
Consider the following when selecting a location for mounting the 5009FT unit(s):
Make sure the 5009FT unit(s) is mounted in a dry location, protected from water and condensation
(Pollution Degree 2 environment).
The 5009FT control must be used in a power installation environment rated at Overvoltage II.
Make sure the ambient temperature of the system location is not lower than 0 °C (32 °F) or higher
than 40 °C (104 °F) and that the relative humidity is not over 90%, non-condensing.
Provide adequate ventilation for cooling the units. If the units must be mounted near heat-producing
devices, shield them from the heat.
Do not install the units or their connecting wires near high-voltage/high- current devices or inductive
devices. If this is not possible, shield both the system connecting wires and the interfering devices or
wires.
If the selected location does not already have a conductor to a good earth ground, provide one.
Unless otherwise stated, this equipment is suitable for non-hazardous locations only.
Equipment is suitable for use in non-hazardous locations only.
Use the following procedures to install a cabinet system in the selected location.
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Chapter 4.
Electrical Installation
Introduction
Before installation read all information and warnings on pages iv and
v of this volume.
Electrical ratings, wiring requirements, and options are provided to allow a customer to fully install the
5009FT control into a new or existing application. Field wiring must be rated at least 25 °C above ambient
temperature.
Wiring for installations must be in accordance with Ordinary (non-hazardous) wiring methods and in
accordance with the authority having jurisdiction.
After the system has been mechanically installed read this chapter thoroughly before proceeding. Perform
system electrical installation by stepping through this chapter’s instructions in sequence. Start with system
cables instruction, then step to the next set of instructions, etc.
The installer should create a 5009FT I/O configuration wiring list to assist in electrical installation
(see Volume 3). The wiring list will determine what inputs are hooked up to what terminal blocks
and how the accessories are wired into the control.
Shields and Grounding
An individual shield termination is provided at the terminal block for each of the speed sensor inputs,
actuator outputs, analog inputs, analog outputs, and communications ports. All of these inputs and
outputs should be wired using shielded, twisted-pair wiring. See options below for correct shield
terminations for your installation. The exposed wire length, beyond the shield, should be limited to one
inch. Relay outputs, contact inputs, and power supply wiring do not normally require shielding, but can be
shielded if desired.
For compliance with EMC standards, it is required that all analog and discrete input/output wiring be
separated from all power wiring. It is also required to follow shielding and grounding practices as called
out in the manual 26167 Volume 1 & Volume 2.
Signal Wiring—
OPTION 1 (Typical to most industrial sites)—Analog signal shields floating at device end and hard
grounded at Control end. Ensure the FTM Ground Terminals are grounded to Earth (terminal 52 on
FTM103-1, -2 and terminal 37 on FTM106-1, -2).
In this case, the device shield needs to be grounded at the Woodward FTMs. Grounding bars are
installed in the FTMs to support this configuration since it is the most common. If the device shields are
grounded (to Chassis ground) at the device end, then REMOVE these shorting bars and follow option two
OR the individual tabs from the Grounding bar can be cut off.
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