Woodward Peak 200 User manual
Product Manual 35051
(Revision C, 11/2017)
Original Instructions
Peak®200 Digital Control for Steam Turbines
8200-1500 Bulkhead LVDC Standard
8200-1501 Bulkhead HV AC/DC Standard
8200-1502 Bulkhead LVDC ATEX – Zone 2
8200-1506 Bulkhead LVDC INMETRO
8200-1508 Bulkhead HV AC/DC NA Class1 Div2
8200-1503/1504/1505/1507/1509 Front Panel Versions
Installation and Operation Manual
Released
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 Out-of-date translations are marked with .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 35051
Copyright © Woodward, Inc. 2017
All Rights Reserved
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Contents
WARNINGS AND NOTICES ...............................................................................................................7
ELECTROSTATIC DISCHARGE AWARENESS......................................................................................9
REGULATORY COMPLIANCE..........................................................................................................10
CHAPTER 1. GENERAL INFORMATION............................................................................................14
Introduction ................................................................................................................................................. 14
Controller Overview..................................................................................................................................... 15
Functional Block Diagrams ......................................................................................................................... 15
Peak200 Keypad and Display..................................................................................................................... 16
Peak200 Functional Inputs and Outputs..................................................................................................... 17
Communications (To Plant Controls) .......................................................................................................... 22
CHAPTER 2. HARDWARE SPECIFICATION.......................................................................................23
Peak200 Description and Features............................................................................................................. 23
Maintenance Info and Recommendations .................................................................................................. 24
Electromagnetic Compatibility (EMC) ......................................................................................................... 25
Bulkhead version mounting information...................................................................................................... 25
Wiring Differences between Peak150 and Peak200 .................................................................................. 27
Panel version Mounting information –......................................................................................................... 31
Input Power Specification............................................................................................................................ 33
Communications (Ethernet) ........................................................................................................................ 34
Hardware - Terminal Blocks & Wiring ......................................................................................................... 38
I/O Signal Specifications and Wiring........................................................................................................... 40
Troubleshooting Fault Codes...................................................................................................................... 46
Troubleshooting & Commissioning checks ................................................................................................. 46
CHAPTER 3. CONTROL DESCRIPTION ............................................................................................49
Introduction ................................................................................................................................................. 49
Front Panel View......................................................................................................................................... 49
Four Fixed Operational Action Buttons on Front Panel .............................................................................. 50
User Login Levels ....................................................................................................................................... 51
Navigation ................................................................................................................................................... 52
Page Organization ...................................................................................................................................... 53
Start Modes................................................................................................................................................. 54
Operating Mode (Setting Turbine Speed) ................................................................................................... 56
Process/Cascade Control ........................................................................................................................... 57
CHAPTER 4. CONFIGURATION PROCEDURES .................................................................................62
Program Architecture .................................................................................................................................. 62
Display Modes and User Levels ................................................................................................................. 62
Mode Descriptions ...................................................................................................................................... 63
User Level Descriptions .............................................................................................................................. 63
Using Configure Menus............................................................................................................................... 65
CHAPTER 5. OPERATING PROCEDURES.........................................................................................83
Software Architecture.................................................................................................................................. 83
Front Panel Operation................................................................................................................................. 84
Power-Up Screen........................................................................................................................................ 84
Control Mode Architecture .......................................................................................................................... 86
Overview ..................................................................................................................................................... 87
Speed Control ............................................................................................................................................. 87
Valve Demand............................................................................................................................................. 88
Controllers................................................................................................................................................... 88
Cascade Control ......................................................................................................................................... 89
Analog Input ................................................................................................................................................ 89
Contact Input Summary .............................................................................................................................. 90
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Analog Output Channel............................................................................................................................... 91
Relay Output Summary............................................................................................................................... 91
Actuator Driver Summary............................................................................................................................ 92
Overspeed Test Function (Speed Control Screen)..................................................................................... 92
Alarm Summary .......................................................................................................................................... 95
Shutdown Summary.................................................................................................................................... 98
Speed and Cascade Dynamics Adjustments............................................................................................ 100
Starting Procedures (Start Curve Screen) ................................................................................................ 104
Critical Speed Band Avoidance ................................................................................................................ 106
Speed Control ........................................................................................................................................... 106
Speed Control Screen............................................................................................................................... 107
Shutdown and Alarm Function Summary ................................................................................................. 108
Valve Ramp (Limiter) Control.................................................................................................................... 108
Manual Valve Demand (Ramp) Control .................................................................................................... 109
Zero Speed Signal Override...................................................................................................................... 109
Automatic Speed Override ........................................................................................................................ 109
Slow Roll Down Failsafe Override ............................................................................................................ 109
Actuator Calibration/Stroking Procedure................................................................................................... 110
CHAPTER 6. MODBUS COMMUNICATIONS ....................................................................................111
Introduction ............................................................................................................................................... 111
Modbus Wiring .......................................................................................................................................... 111
Basic Modbus Overview............................................................................................................................ 112
Modbus Addresses ................................................................................................................................... 115
CHAPTER 7. SERVICE MENUS .....................................................................................................121
Introduction ............................................................................................................................................... 121
Screen/Key Options Menu ........................................................................................................................ 121
Speed Control Menu ................................................................................................................................. 122
Valve Demand Menu................................................................................................................................. 124
Real Time Clock Menu.............................................................................................................................. 124
Cascade Control Menu ............................................................................................................................. 125
Communications Menu ............................................................................................................................. 126
MPU Override Menu ................................................................................................................................. 126
Operation Log Menu ................................................................................................................................. 127
CHAPTER 8. TROUBLESHOOTING ................................................................................................128
General...................................................................................................................................................... 128
User Level Password ................................................................................................................................ 128
Diagnostics................................................................................................................................................ 128
Troubleshooting Chart............................................................................................................................... 129
Alarms / Shutdowns .................................................................................................................................. 133
Wiring / Component Problems .................................................................................................................. 133
Actuators / Control Adjustments ............................................................................................................... 133
Other Operating Problems ........................................................................................................................ 133
CHAPTER 9. PRODUCT SUPPORT AND SERVICE OPTIONS ............................................................134
Product Support Options........................................................................................................................... 134
Product Service Options ........................................................................................................................... 134
Returning Equipment for Repair ............................................................................................................... 135
Replacement Parts.................................................................................................................................... 136
Engineering Services ................................................................................................................................ 136
Contacting Woodward’s Support Organization ......................................................................................... 136
Technical Assistance ................................................................................................................................ 137
APPENDIX ACONFIGURATION MODE WORKSHEETS ....................................................................138
Introduction ............................................................................................................................................... 138
APPENDIX BSERVICE MODE WORKSHEETS ................................................................................147
APPENDIX CAUTOMATIC SPEED PID DYNAMIC ANALYSIS...........................................................150
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APPENDIX DSERVLINK-TO OPC SERVER (SOS) TOOL................................................................159
SOS Communication Link ......................................................................................................................... 159
Installing SOS ........................................................................................................................................... 159
Connecting a PC/Laptop to the Control .................................................................................................... 160
APPENDIX E. CONTROL ASSISTANT—SOFTWARE INTERFACE TOOL ............................................162
Features of Control Assistant.................................................................................................................... 162
Installing Control Assistant........................................................................................................................ 162
Using Control Assistant............................................................................................................................. 164
APPENDIX F. APPMANAGER SERVICE TOOL................................................................................169
File Management with App. Manager ....................................................................................................... 169
Installing App Manager ............................................................................................................................. 169
APPENDIX G. USING PEAK200 INTERNAL SIMULATION MODE ......................................................176
APPENDIX H. STARTUP AND COMMISSIONING CHECKLIST............................................................179
APPENDIX I. FEATURE PACK (FP) S/W ADD-ONS FOR PEAK200 ..................................................181
Updating the application software............................................................................................................. 181
Activating a Feature Pack ......................................................................................................................... 182
Contents of Feature Pack 1 (License p/n: 8447-5004 – Release Aug/2017) ........................................... 183
Adding LinkNet Distributed I/O.................................................................................................................. 184
Datalogging ............................................................................................................................................... 185
Multi-Lingual Support ................................................................................................................................ 188
Event History Access ................................................................................................................................ 188
START PERMISSIVE DISCRETE INPUT...........................................................................................189
REVISION HISTORY.....................................................................................................................190
DECLARATIONS ..........................................................................................................................191
The following are trademarks of Woodward, Inc.:
ProTech
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)
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Illustrations and Tables
Figure 1-1. Single Inlet Valve Steam Turbine ............................................................................................. 14
Figure 1-2. System Overview...................................................................................................................... 15
Figure 1-3. Peak200 Keypad and Display .................................................................................................. 16
Figure 1-4. LinkNet HT Distributed I/O Node .............................................................................................. 21
Figure 2-1. Functional Block Diagram (Peak200 Control) .......................................................................... 23
Figure 2-2. Peak200 Bulkhead unit............................................................................................................. 26
Figure 2-3. Peak200 Bulkhead Mount Version Outline Drawing. ............................................................... 30
Figure 2-4. Peak200 Front Panel Mount Unit ............................................................................................. 31
Figure 2-5. Peak200 Front Panel Mount Version Outline Drawing............................................................. 32
Figure 2-6. COM1 Example RS-485 Wiring................................................................................................ 37
Figure 2-7. Peak200 Back Cover Label – Bulkhead................................................................................... 38
Figure 2-8. Peak200 Back Cover Label – Front Panel Mount .................................................................... 39
Figure 2-9. Terminal Block Connectors ...................................................................................................... 40
Figure 2-10. Speed Sensor Block Diagram ................................................................................................ 41
Figure 2-11. Analog Input – Self-Powered Block Diagram ......................................................................... 42
Figure 2-12. Analog Input – Loop-Powered Block Diagram ....................................................................... 42
Figure 2-13. Analog Output Block Diagram ................................................................................................ 43
Figure 2-14. Actuator Output Block Diagram .............................................................................................. 44
Figure 2-15. Discrete Input Block Diagram ................................................................................................. 45
Figure 2-16. Relay Output Block Diagram .................................................................................................. 46
Figure 3-1. Speed Relationships................................................................................................................. 49
Figure 3-2. Front Panel ............................................................................................................................... 49
Figure 3-3. Mode Screen ............................................................................................................................ 51
Figure 3-4. Language.................................................................................................................................. 51
Figure 3-5. Navigation Cross ...................................................................................................................... 52
Figure 3-6. Service Menu showing “Speed Control” IN-Focus ................................................................... 53
Figure 3-7. Configuration Menu – Operation Mode (View only) ................................................................. 53
Figure 3-8. Configuration Menu – Configuration Mode (Edit) ..................................................................... 54
Figure 3-9. Startup Curve Screen ............................................................................................................... 55
Figure 3-10. Cascade Functional Diagram ................................................................................................. 57
Figure 4-1. Initial HOME Screen (unit not configured)................................................................................ 64
Figure 4-2. Configuration Menu – Configuration Mode (Edit) with Error .................................................... 66
Figure 5-1. Software Architecture ............................................................................................................... 83
Figure 5-2. Peak200 Keypad with “Splash Screen”.................................................................................... 84
Figure 5-3. Boot-up to HOME screen (RemoteView) ................................................................................. 85
Figure 5-4. Control Mode Architecture........................................................................................................ 86
Figure 5-5. Overview Screen ...................................................................................................................... 87
Figure 5-6. Speed Control Screen .............................................................................................................. 87
Figure 5-7. Valve Demand Screen.............................................................................................................. 88
Figure 5-8. Controllers Screen.................................................................................................................... 88
Figure 5-9. Cascade Control Screen .......................................................................................................... 89
Figure 5-10. Analog Input Summary Screen............................................................................................... 90
Figure 5-11. Contact Input Summary Screen ............................................................................................. 90
Figure 5-12. Analog Output Channel Screen.............................................................................................. 91
Figure 5-13. Relay Output Summary Screen.............................................................................................. 91
Figure 5-14. Actuator Driver Summary Screen........................................................................................... 92
Figure 5-15. Overspeed Test Permissives.................................................................................................. 92
Figure 5-16. Internal (Peak200) Overspeed Test ....................................................................................... 93
Figure 5-17. External Overspeed Test........................................................................................................ 94
Figure 5-18. Alarm Summary Screen ......................................................................................................... 95
Figure 5-19. Shutdown Summary Screen................................................................................................... 99
Figure 5-20. Speed Dynamics Adjustment Screen................................................................................... 100
Figure 5-21. Typical Response to Load Change ...................................................................................... 102
Figure 5-22. HOME Menu showing “Startup Curve” IN-Focus ................................................................. 104
Figure 6-1. Modbus Communication Connections.................................................................................... 111
Figure 6-2. Typical RS-232 Communications ........................................................................................... 112
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Figure 6-3. Typical RS-485 Communications ........................................................................................... 112
Figure 6-4. Basic Modbus Overview ......................................................................................................... 113
Figure 6-5. Modbus Messages ................................................................................................................. 115
Figure 7-1. Service Menu.......................................................................................................................... 121
Figure 8-1. GAP-to-GUI communication problem..................................................................................... 129
Figure C-1. Speed PID Dynamic Optimizer .............................................................................................. 150
Figure C-2. Speed vs Actuator Trends during analysis ............................................................................ 151
Figure C-3. Speed PID Optimizer Configuration....................................................................................... 152
Figure D-1. SOS........................................................................................................................................ 159
Figure D-2. SOS Install Window ............................................................................................................... 160
Figure D-3. SOS Server status dialog box................................................................................................ 160
Figure D-4. SOS – New Session box........................................................................................................ 161
Figure D-5. SOS - Enter Peak200 TCP/IP address.................................................................................. 161
Figure D-6. SOS – Active Links dialog box............................................................................................... 161
Figure E-1. Control Assistant License Agreement.................................................................................... 162
Figure E-2. Control Assistant Install Window............................................................................................ 163
Figure E-3. Control Assistant Folder Selection ......................................................................................... 163
Figure E-4. Control Assistant Install Complete ......................................................................................... 163
Figure E-5. Install Restart Window ........................................................................................................... 164
Figure E-6. Control Assistant Window ...................................................................................................... 164
Figure E-7. Dialog for Servlink OPC connection....................................................................................... 165
Figure E-8. WinPanel Session .................................................................................................................. 165
Figure E-9. Control Assistant – Retrieve Tunable Dialog box .................................................................. 166
Figure E-10. Control Assistant – Send Tunable Dialog box ..................................................................... 167
Figure E-11. Control Assistant – Speed Control Trend Script .................................................................. 168
Figure E-12. Control Assistant – Create Trend Script File........................................................................ 168
Figure F-1. App Manager Install Window.................................................................................................. 169
Figure F-2. App Manager License Agreement Window............................................................................ 170
Figure F-3. App Manager Installation........................................................................................................ 170
Figure F-4. App Manager Install Complete ............................................................................................... 171
Figure F-5. AppManager Window ............................................................................................................. 171
Figure F-6. Dialog for App Manager Connection ...................................................................................... 172
Figure F-7. App Manager Connected to a Control.................................................................................... 172
Figure F-8. AppManager Control Info Window ......................................................................................... 173
Figure F-9. AppManager Control (GAP) Application Panel ...................................................................... 173
Figure F-10. AppManager GUI Application Panel .................................................................................... 174
Figure F-11. Retrieving Files..................................................................................................................... 174
Figure G-1. HW Simulation Mode Access ................................................................................................ 176
Figure I-1. HOME page ............................................................................................................................. 182
Figure I-2: Site Info Page .......................................................................................................................... 183
Figure I-3: Site Key Pop-up page.............................................................................................................. 183
Figure I-4. Additional Control I/O .............................................................................................................. 184
Figure I-5. Datalog Feature Screens......................................................................................................... 185
Figure I-6. Selecting Datalog trend parameters........................................................................................ 186
Figure I-7. AppManager Setup for Automatic Collection of Datalog Files ................................................ 187
Figure I-8. Language Icon on Mode Screen ............................................................................................. 188
Figure I-9. Navigation to Event History page ............................................................................................ 188
Figure I-10: Start Pop-up page with Start Permissive............................................................................... 189
Figure I-11: Menu selections for DI and Relay Output.............................................................................. 189
Table 1-1. Part Number Options ................................................................................................................. 14
Table 1-2. Peak200 Analog Input Configuration Options ........................................................................... 18
Table 1-3. Peak200 Discrete Input Configuration Options ......................................................................... 19
Table 1-4. Peak200 Analog Output Configuration Options......................................................................... 19
Table 1-5. Peak200 Discrete Output ‘State’ Configuration Options ........................................................... 20
Table 1-6. Peak200 Discrete Output ‘Level Switch’ Configuration Options................................................ 20
Table 1-7. Available (programmed) distributed I/O Nodes ......................................................................... 21
Table 1-8. Menu Supported RTD Input Functions ...................................................................................... 21
Table 2-1. Environmental Specifications..................................................................................................... 24
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Table 2-2. Peak200 and Peak150 Wiring Differences................................................................................ 27
Table 2-3. Input Power Connector Pinout................................................................................................... 33
Table 2-4. Ethernet Ports #1-2 (10/100) ..................................................................................................... 35
Table 2-5. CAN Specifications .................................................................................................................... 35
Table 2-6. CAN Connector Pinout .............................................................................................................. 36
Table 2-7. CAN Cable Specifications.......................................................................................................... 36
Table 2-8. COM1 Serial Port (RS-232/485) ................................................................................................ 37
Table 2-9. Specifications (Speed)............................................................................................................... 41
Table 2-10. Specifications (AI).................................................................................................................... 41
Table 2-11. Specifications (AO) .................................................................................................................. 42
Table 2-12. Specifications (ACT) ................................................................................................................ 43
Table 2-13. Specifications (DI).................................................................................................................... 44
Table 2-14. Specifications (Relay Outputs) ................................................................................................ 45
Table 2-15. CPU Fault LED Flash Codes ................................................................................................... 46
Table 3-1. Cascade Control Status Messages ........................................................................................... 58
Table 4-1. Mode Access by User Level ...................................................................................................... 63
Table 4-2. Configuration Menus and Their Basic Functions....................................................................... 66
Table 4-3. Peak150 to Peak200 Configuration Parameter locations.......................................................... 67
Table 4-4. Analog Input Options ................................................................................................................. 73
Table 4-5. Analog Readout Options............................................................................................................ 75
Table 4-6. Contact Input Options ................................................................................................................ 76
Table 4-7. Options for Relays ff Used to Indicate State.............................................................................. 77
Table 4-8. List of Options for Level Switch ................................................................................................. 77
Table 4-9. LN Analog Input Function Options............................................................................................. 79
Table 4-10. LN RTD Input Function Options............................................................................................... 80
Table 4-11. LN Discrete Contact Input Options .......................................................................................... 81
Table 4-12. Options for Contact Outputs if Used to Indicate State............................................................. 81
Table 4-13. Options for Level Switch .......................................................................................................... 82
Table 5-1. ALARM Messages ..................................................................................................................... 96
Table 5-2. TRIPPED Messages.................................................................................................................. 99
Table 6-1. Modbus Transmission Modes.................................................................................................. 113
Table 6-2. Modbus Frame Definition......................................................................................................... 113
Table 6-3. Modbus Function Codes.......................................................................................................... 114
Table 6-4. Peak200 Exception Errors ....................................................................................................... 114
Table 6-5. Available Holding Coils ............................................................................................................ 116
Table 6-6. Available Input Coils ................................................................................................................ 116
Table 6-7. Available Input Registers ......................................................................................................... 118
Table 6-8. Available Holding Registers..................................................................................................... 120
Table 8-1. CPU LED Flash codes............................................................................................................. 129
Table G-1. Example Demo Configuration Settings................................................................................... 177
Table I-1. Additional Control Features ...................................................................................................... 183
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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.
Lockout/Tagout
Ensure that personnel are fully trained on LOTO procedures prior to
attempting to replace or service the PEAK200 on a “live” running
Turbine. All safety protective systems (overspeed, over temperature,
overpressure, etc.) must be in proper operational condition prior to
the start or operation of a running Turbine. Personnel should be
equipped with appropriate personal protective equipment to
minimize the potential for injury due to release of hot gases or fluids,
exposure to hot surfaces and/or moving parts, or any moving parts
that may be activated and are located in the area of control of the
PEAK200.
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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IOLOCK
IOLOCK. When a CPU module fails, watchdog logic drives it into an
IOLOCK condition where all output circuits and signals are driven to
a known de-energized state as described below. The System MUST
be designed such that IOLOCK and power OFF states will result in a
SAFE condition of the controlled device.
• Discrete outputs / relay drivers will be non-active and de-
energized
• Analog and Actuator outputs will be non-active and de-energized
with zero voltage or zero current.
The IOLOCK state is asserted under various conditions including
• CPU module watchdog failures
• Power Up and Power Down conditions
• System reset and hardware/software initialization
• Entering configuration mode
NOTE: Additional watchdog details and any exceptions to these
failure states are specified in the related CPU or I/O section of the
manual.
Emergency
Disconnecting
Device
An emergency 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 (PE) conductor.
Risks of
Calibration and
Checkout
Only authorized personnel knowledgeable of the risks posed by live
electrical equipment should perform the calibration and checkout
procedure.
Fuse Power
Supply Mains
The power supply mains should be properly fused according to the
National Electrical Code. The recommended fuse is a European Type T
fuse.
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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. Refer to DoC for applicability by
part number.
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).
ATEX – Potentially
Explosive
Atmospheres:
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
Front Panel version: Zone 2, Category 3 G, Ex ic nA nC IIC T4 Gc X IP20
Bulkhead version: Zone 2, Category 3 G, Ex ic nA nC IIC T4 Gc X IP54
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
Other European and International Compliance:
IECEx: Front Panel version and Bulkhead version:
Ex ic nA nC IIC T4 Gc
Certificate: IECEx CSA 17.0004
IEC 60079-0: 2011 – Explosive Atmospheres – Part 0
Equipment General Requirements
IEC 60079-11: 2011 – Explosive Atmospheres – Part 11
Equipment Protection by Intrinsic Safety “i”
IEC 60079-15: 2010 – Electrical Apparatus for Explosive
Gas Atmospheres; Part 15; Construction, Test and
Marking Type of protection “n”.
INMETRO
Brazil: Declared to Rule 179:2010
NCC Certificate BRA-17-GE-0007
Ex ic nA nC IIC T4 Gc
North American Compliance:
These listings are limited only to those units bearing the CSA identification.
Units bearing only the CSA identification are restricted for use only in Ordinary Locations in North
America.
Units bearing the CSA identification in addition to the marking indicating Class I, Div 2, Groups A, B, C,
and D are acceptable for use in North American Hazardous Locations.
CSA: CSA Certified for Class I, Division 2, Groups A, B, C, & D, T4 at 65°C
Bulkhead version) 70 °C (Front Panel version) surrounding air temperature.
For use in Canada and the United States.
CSA Certificate 70101251
Peak200 Front Panel Mount Version is certified as a component for use in other equipment. The final
combination is subject to acceptance by the authority having jurisdiction or local inspection.
Special Conditions for Safe Use
A fixed wiring installation is required. Field 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 Local
Inspection Authority having jurisdiction. On high voltage, AC and DC versions of the control the interior of
the enclosure shall not be accessible in normal operation without the use of a tool.
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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. The switch or circuit breaker shall be clearly marked as
the disconnecting device for the equipment. The switch or circuit breaker shall not interrupt the Protective
Earth (PE) conductor.
Hazardous Locations
The Peak200 Digital Control (Front Panel version) shall not be installed in areas exceeding Pollution
Degree 2 as defined in IEC 60664-1.
Wiring must be in accordance with Zone 2 wiring methods and in accordance with the authority having
final jurisdiction.
Field wiring must be suitable for the following temperatures:
Power Input rated minimum of +95˚C.
All remaining connections; +10˚C above highest ambient.
Protective Earth Grounding of the Peak200 Digital Control is required to be connected to the
PE terminal.
The Real Time Clock Battery located on the CPU board is not to be recharged and is not user
replaceable. Contact a Woodward Authorized Service Center if a replacement service is needed.
The Low Voltage ATEX Peak200 Digital Control is suitable for use in Class I, Div 2, Gas Groups A, B, C
and D & European Zone 2, Group IIC environments.
For Zone 2 installations, the Peak200 must be installed in an area or enclosure providing adequate
protection against high impact (7 Joules). The control is rated for 2 Joules impact.
For ATEX/IECEx the Peak200 Digital Control (Front Panel version) shall be installed in an enclosure that
is coded Ex nA or Ex e, providing a minimum IP54 ingress protection in accordance with IEC 60079-15.
The installer shall ensure that the maximum surrounding air temperature does not exceed the rated
temperature of +70 °C at the final installation location.
For Zone 2 installations, transient protection for the Peak200 Digital Control is to be provided externally
by the end user at the supply terminals of the control. The transient protection device is to be set at a
level not exceeding 140% of the peak rated voltage (36Vdc).
The risk of electrostatic discharge is reduced by permanent installation of the Peak200 (Bulkhead
version), proper connection of the equipment ground lugs, and care when cleaning. This device must not
be cleaned or wiped off/against unless the area is known to be non-hazardous.
Explosion Hazard
For ATEX/IECEx installation compliance, the input voltage shall be
limited to 36 Vdc. When an external power supply is selected to
supply the Control, it shall be ATEX/IECEx approved for Zone 2 Group
IIC, Category 3G Applications.
Explosion Hazard
Due to the Hazardous Location Listings associated with this product,
proper wire type and wiring practices are critical to the operation.
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Explosion Hazard
ENCLOSURE REQUIREMENT— ATEX/IECEx Zone 2, Category 3G
applications require the final installation location provide a minimum
IP-54 ingress protection enclosure against dust and water per IEC
60529. The enclosure must be coded Ex nA or Ex e.
Explosion Hazard
Do not remove covers or connect/disconnect electrical connectors
unless power has been switched off and the area is known to be non-
hazardous.
Explosion Hazard
Substitution of components may impair suitability for Class I, Division
2, or Zone 2.
Explosion Hazard
The external ground lugs shown on the installation drawing must be
properly connected to ensure equipotential bonding. This will reduce
the risk of electrostatic discharge in an explosive atmosphere.
Cleaning by hand or water spray must be performed while the area is
known to be non-hazardous to prevent an electrostatic discharge in
an explosive atmosphere.
Explosion Hazard
MOUNTING
The control must be mounted in a vertical position. The installer shall
ensure the maximum surrounding air temperature of the control does
not exceed +65 °C (Bulkhead version) or +70˚C (Front Panel version) at
the final location.
Explosion Hazard
Class I, Div 2 Groups A, B, C, D and Zone 2, Group IIC applications
require the input voltage to the relay contacts not exceed 32Vac rms
or 32Vdc.
Risque d'explosion
Ne pas enlever les couvercles, ni raccorder / débrancher les
prises électriques, sans vous en assurez auparavant que le
système a bien été mis hors tension; ou que vous situez
bien dans une zone non explosive.
Risque d'explosion
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I, Division 2
et/ou Zone 2.
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Risque d'explosion
Ne pas utiliser les bornes d’essai du block d’alimentation ou
des cartes de commande à moins de se trouver dans un
emplacement non dangereux.
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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Manual 35051 Peak®200 Digital Control for Steam Turbines
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Chapter 1.
General Information
Introduction
This manual describes the Woodward Peak200 digital control for single valve steam turbines used for
pump and mechanical drive applications. The scope of this manual is to provide information on
programming, operation and troubleshooting of the Peak200 control.
Figure 1-1. Single Inlet Valve Steam Turbine
Table 1-1. Part Number Options
Part Number Mounting Power
8200-1500 Bulkhead LVDC (18–36 Vdc) Standard Compliance
8200-1501 Bulkhead AC/DC (88–264 Vac/90–150 Vdc) Standard Compliance
8200-1502 Bulkhead LVDC (18–36 Vdc) ATEX Compliance
8200-1506 Bulkhead LVDC (18–36 Vdc) Inmetro Compliance
8200-1508 Bulkhead AC/DC (88–264 Vac/90–150 Vdc) NA C1D2 Compliance
8200-1503 Door or Panel LVDC (18–36 Vdc) Standard Compliance
8200-1504 Door or Panel AC/DC (88–264 Vac/90–150 Vdc) Standard Compliance
8200-1505 Door or Panel LVDC (18–36 Vdc) ATEX Compliance
8200-1507 Door or Panel LVDC (18–36 Vdc) Inmetro Compliance
8200-1509 Door or Panel AC/DC (88–264 Vac/90–150 Vdc) NA C1D2 Compliance
EXPLOSION HAZARD—Do not open the Peak200 control box when a
hazardous atmosphere is present. Wiring connections, which could
cause sparks, are exposed inside the cabinet.
Do NOT attempt to operate the turbine until properly configuring the
Peak200 control. Doing so could cause equipment damage. As
shipped from the factory the unit will not run a turbine.
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Controller Overview
The Peak200 is a field configurable control which allows a single design to be used in many different
control applications and reduces both cost and delivery time. It uses a built in graphical user interface
(GUI) with menu driven screens to instruct site engineers on configuring the control to a specific
application. This control’s intended use is on mechanical drive or pump control applications (generator
drive units should use the Woodward 505 product). The Peak200 can be configured to operate as a
stand-alone turbine control unit or can be interfaced via hardwire signals and/or a Modbus communication
link to be operated from a plant’s Distributed Control System.
The Peak200 control has four demand signals that can affect the controlled operation of the steam
turbine: The Speed PID Controller, the HP Valve Limiter, the Manual HP valve demand (service only),
and the Trip/Shutdown Command. The four demand signals connect to a Lowest Signal Select (LSS) bus
that passes the lowest value to the output, which connects to the valve demand.
The Cascade PID controller is an additional (optional) control loop that allows the user to control some
other process in their plant. The output of this control does not go to the LSS directly; instead, it controls
the setpoint of the speed controller. In Woodward terminology, we call this a cascade control loop
because its output drives another controller’s setpoint rather than directly affecting the valve demand with
its own output.
Functional Block Diagrams
A system overview in block form is in Figure 1-2 below.
Figure 1-2. System Overview
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Peak200 Keypad and Display
Graphical Display Key Inputs
The front panel display provides the user with multiple levels of access for configuring, calibrating, tuning,
operating, and monitoring the turbine operation. No additional control panels are required to operate the
turbine, with every turbine control function performed from the Peak200’s front panel.
Figure 1-3. Peak200 Keypad and Display
A description of each key’s function follows.
Hard Key Commands
NUMERIC KEYPAD
These are available for entering numeric values or text strings directly into the control when selecting a
configurable or programmable edit field. The bottom row of keys has some special features.
Backspace and Delete Key (used when entering text)
In text mode, this functions as a Shift key. When making analog adjustments with the ADJUST
key – pressing this key at the same time as the ADJUST will invoke a ‘Fast’ rate of adjustment
Brightness key – hold this down and then use the ADJUST key to increase/decrease the screen
brightness
TRIP KEY
This will Trip the Turbine and remove all current from the Actuator outputs (zero current).
LED
Four LEDs located on the left side – a Summary Trip, Summary Alarm, IO Lock, and CPU Health. The
GAP program controls the two Summary LEDs and relate to the status of the control. The IOLOCK and
CPU LED’s relate to the H/W status.
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VIEW buttons will jump to the Trip or Alarm Summary screen to show these events in sequence with time
stamp.
MODE button will jump to a Login screen that allows the user to view current permissions and allow
access to changing the user login level
ESC Key – this will always step the user ‘back’ one page from the current page displayed
HOME Key
Brings the user to the Home menu for Run, Service, or Configure. Pressing the Home Key a second time
will return to the Run (Operate) Menu Home Screen
NAVIGATION CROSS KEYS
These are the primary keys for navigating from page to page, or for navigation of the FOCUS on any
page.
Soft Key Commands – Dependent on the screen currently in view – the user must use the navigation
cross keys to move the “Focus” to the desired component
GREEN KEYS
Generally perform Operational Actions – such as Enabling, Disabling, Starting, Stopping, Tuning, or
Adjusting values
MAROON KEYS
Generally perform Navigational actions that escort the user through the screen menus
BLACK KEYS
Are soft-function keys that relate to the display indication displayed immediately above. They can be
navigational or operational. These items do not require “Focus”; they are always available on that
particular screen.
Screen
Tutorial
The Peak200 has a detailed Tutorial that is always accessible through the
Service Menu. It provides ‘On-Screen’ help on topics such as Navigation,
User Levels, Operating Modes, how to adjust parameters, and more. The
User should familiarize themselves with these screens
Peak200 Functional Inputs and Outputs
This section gives a quick overview reference of the functional I/O signals, which the Peak200 application
software supports.
Magnetic Pickups
The Magnetic Pickups (MPUs) generate a speed signal used to provide speed feedback to the Peak200.
The MPUs do this by generating voltage pulses as the gear teeth pass through the MPU’s magnetic field.
The Peak200 counts the number of pulses per second from the MPUs (frequency in HZ) and converts
this frequency to turbine RPM.
Two MPUs (MPU 1 and MPU 2) may be used to provide redundant speed inputs, that is where one can
fail and the remaining MPU keeps the turbine operating. The Peak200 determines which MPU is
outputting the highest frequency and uses that frequency as the speed feedback to control the turbine.
When only one MPU is used, the user can disable the second MPU input.
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The Peak200 converts the MPUs input frequency to RPMs by using the number of teeth programmed in
the SPEED CONFIGURATION menu for TEETH SEEN BY MPU = xxxxx (Teeth) in the following formula:
RPM = (Hz x 60) / Teeth
When the speed of the main turbine shaft is different from the speed of the MPU gear shaft, the value for
MPU GEAR RATIO = x is programmed for the correct ratio. The above equation is multiplied by the
RATIO so that the RPM seen by the Peak200 will be turbine RPM and not MPU gear shaft RPM.
RPM = ((Hz x 60) / Teeth) x Ratio
The physical MPU should be gapped so that a signal of at least 1.0 VRMS is seen at the control, when
the speed is at the failed speed level (amplitude will increase as the speed increases). The Peak200
control will show the voltage of this signal on the speed signal.
Analog Input
The Peak200 has four analog inputs and the option for the customer to add a LinkNet distributed AI/AO
module that would provide eight additional channels. All of these channels are configurable by the user.
The following table is the list of analog input functions that the menus support, which assign functions to
specific channels.
Table 1-2. Peak200 Analog Input Configuration Options
Remote Speed Setpoint
Process/Cascade Input
Remote Cascade Setpoint
Vibration Input #1
Vibration Input #2
Vibration Input #3
Vibration Input #4
Bearing Temperature #1
Bearing Temperature #2
Bearing Temperature #3
Bearing Temperature #4
Signal Monitoring #1
Signal Monitoring #2
Signal Monitoring #3
HP Valve Feedback Position
Contact Inputs
The Peak200 has eight discrete contact inputs and the option for the customer to add a LinkNet
distributed DI module that would provide 16 additional channels. Channel 3 is dedicated to “External Trip
1” (same as the previous Peak 150 product), but all other channels are configurable by the user.
The following table is the list of discrete contact input functions that the menus support, which assign
functions to specific channels.
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10
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