Woodward 8237-2594 User manual

Product Manual 35086
(Revision -, 2/2018)
Original Instructions
ProTech-GII Overspeed Protection Device
with Math Enhancements
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 Out-of-date translations are marked with .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 35086
Copyright © Woodward, Inc. 2017
All Rights Reserved
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Contents
WARNINGS AND NOTICES ...............................................................................................................8
ELECTROSTATIC DISCHARGE AWARENESS......................................................................................9
REGULATORY COMPLIANCE..........................................................................................................10
ACRONYMS AND DEFINITIONS .......................................................................................................13
CHAPTER 1. GENERAL INFORMATION............................................................................................14
Purpose and Scope..................................................................................................................................... 14
How to Use This Manual............................................................................................................................. 14
Description .................................................................................................................................................. 14
Applications................................................................................................................................................. 15
What’s New ................................................................................................................................................. 17
CHAPTER 2. INSTALLATION...........................................................................................................19
Introduction ................................................................................................................................................. 19
Unpacking ................................................................................................................................................... 19
Hardware Installation Procedure................................................................................................................. 19
Enclosures................................................................................................................................................... 20
Module Removal and Installation—Bulkhead Mount Package................................................................... 23
Module Removal and Installation—Panel Mount Package......................................................................... 31
Mounting Location Considerations.............................................................................................................. 32
Power Supply Requirements....................................................................................................................... 33
Input/Output Specifications ......................................................................................................................... 35
Shielded Wiring ........................................................................................................................................... 38
Control Wiring Guidelines ........................................................................................................................... 38
CHAPTER 3. FUNCTIONALITY.........................................................................................................50
Introduction ................................................................................................................................................. 50
Features ...................................................................................................................................................... 50
Product Models ........................................................................................................................................... 53
Inputs and Outputs...................................................................................................................................... 59
Overspeed and Over-Acceleration Detection Logic.................................................................................... 61
Speed Diagnostics ...................................................................................................................................... 64
Start Logic ................................................................................................................................................... 64
Test Routines .............................................................................................................................................. 66
Alarm and Trip Latches............................................................................................................................... 68
System Logs ............................................................................................................................................... 70
ProTech-GII Response Time Performance................................................................................................. 71
CHAPTER 4. FRONT PANEL INTERFACE .........................................................................................74
Introduction ................................................................................................................................................. 74
Screen Layout ............................................................................................................................................. 75
Keypad Functions ....................................................................................................................................... 76
Navigation ................................................................................................................................................... 77
Passwords................................................................................................................................................... 78
Monitor Menu .............................................................................................................................................. 79
View Logs.................................................................................................................................................... 91
CHAPTER 5. CONFIGURATION USING THE FRONT PANEL ...............................................................94
Introduction ................................................................................................................................................. 94
Editing Configuration Settings from the Front Panel................................................................................... 95
Configure Menu Page ................................................................................................................................. 95
Configuration Procedure ............................................................................................................................. 96
CHAPTER 6. TEST ROUTINES ......................................................................................................113
Test Modes Menu ..................................................................................................................................... 113
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Temporary Overspeed Setpoint Test........................................................................................................ 113
Manual Simulated Speed Test.................................................................................................................. 116
Auto Simulated Speed Test ...................................................................................................................... 118
Auto-Sequence Test ................................................................................................................................. 120
Lamp Test ................................................................................................................................................. 122
General Testing Notes .............................................................................................................................. 122
CHAPTER 7. PROGRAMMING AND CONFIGURATION TOOL (PCT)..................................................123
General...................................................................................................................................................... 123
Installation of the PCT............................................................................................................................... 123
PCT Levels of Operation........................................................................................................................... 124
Using the PCT........................................................................................................................................... 125
CHAPTER 8. CONFIGURATION USING THE PCT............................................................................142
Introduction ............................................................................................................................................... 142
Configuration Settings............................................................................................................................... 143
Input Configuration.................................................................................................................................... 145
Functions Configuration ............................................................................................................................ 150
Configuration Checks................................................................................................................................ 154
Error Messages......................................................................................................................................... 155
CHAPTER 9. MODBUS COMMUNICATIONS ....................................................................................156
Introduction ............................................................................................................................................... 156
Monitor Only.............................................................................................................................................. 156
Monitor and Control................................................................................................................................... 156
Modbus Interface ...................................................................................................................................... 157
Port Adjustments....................................................................................................................................... 157
ProTech-GII Parameter Addresses........................................................................................................... 157
CHAPTER 10. SAFETY MANAGEMENT..........................................................................................163
Product Variations Certified ...................................................................................................................... 163
Safe State.................................................................................................................................................. 163
SIL Specifications...................................................................................................................................... 163
Failure Rate Data ...................................................................................................................................... 164
Response Time Data ................................................................................................................................ 164
Limitations ................................................................................................................................................. 164
Management of Functional Safety ............................................................................................................ 164
Restrictions ............................................................................................................................................... 165
Competence of Personnel......................................................................................................................... 165
Operation and Maintenance Practice........................................................................................................ 165
Installation and Site Acceptance Testing.................................................................................................. 165
Functional Testing after Initial Installation................................................................................................. 165
Functional Testing after Changes ............................................................................................................. 165
Proof Testing (Functional Test)................................................................................................................. 165
CHAPTER 11 TROUBLESHOOTING ...............................................................................................167
Introduction ............................................................................................................................................... 167
CHAPTER 12. PRODUCT SUPPORT AND SERVICE OPTIONS ..........................................................174
Product Support Options........................................................................................................................... 174
Product Service Options ........................................................................................................................... 174
Returning Equipment for Repair ............................................................................................................... 175
Replacement Parts.................................................................................................................................... 176
Engineering Services ................................................................................................................................ 176
Contacting Woodward’s Support Organization......................................................................................... 176
Technical Assistance ................................................................................................................................ 177
CHAPTER 13. ASSET MANAGEMENT............................................................................................178
Product Storage Recommendations ......................................................................................................... 178
Refurbishment Period Recommendation.................................................................................................. 178
APPENDIX A. MODBUS ETHERNET GATEWAY INFORMATION ........................................................179
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Introduction ............................................................................................................................................... 179
B&B Electronics Setup .............................................................................................................................. 179
Lantronix Setup ......................................................................................................................................... 183
APPENDIX B. PROTECH-GII CONFIGURATION WORKSHEET .........................................................188
REVISION HISTORY.....................................................................................................................191
DECLARATIONS ..........................................................................................................................192
The following are trademarks of Woodward, Inc.:
ProTech
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)
Illustrations and Tables
Figure 1-1. Typical ProTech-GII Application (Voted Trip Relay Models).................................................... 16
Figure 1-2. Typical ProTech-GII Application (Independent Trip Relay Models) ......................................... 16
Figure 1-3. Typical Gas Turbine Application (Voted Trip Relay Models).................................................... 17
Figure 2-1. Typical ProTech-GII Bulkhead Package—Front View.............................................................. 20
Figure 2-2a. Typical ProTech-GII Bulkhead Package—Front Door Open.................................................. 21
Figure 2-2b. Bulkhead Schematic Showing Front Panel A Connection to Module A and Front Panel C
Connection to Module C—Top View...................................................................................... 21
Figure 2-3. Mounting Outline Diagram for Bulkhead-Mounted Models ...................................................... 22
Figure 2-4a. Typical ProTech-GII Panel Mount Package—Front View ...................................................... 26
Figure 2-4b. Typical ProTech-GII Panel Mount Package—Rear View with Cover..................................... 26
Figure 2-4c. Typical ProTech-GII Panel Mount Package—Rear View without Cover Showing Module
Orientation.............................................................................................................................. 27
Figure 2-4d. Panel Mount Schematic Showing Front Panel A Connection to Module A and Front Panel C
Connection to Module C—Top View...................................................................................... 27
Figure 2-5a. Mounting Outline Diagram for Panel-Mount Models .............................................................. 28
Figure 2-5b. Mounting Outline Diagram for Panel-Mount Models .............................................................. 29
Figure 2-5c. Panel Cutout Diagram for Panel-Mount Models..................................................................... 30
Figure 2-6. Screw Connection Terminal Block............................................................................................ 39
Figure 2-7. Inside View of ProTech-GII....................................................................................................... 40
Figure 2-8. ProTech-GII Control Wiring Diagram........................................................................................ 41
Figure 2-9. Trip Module—Included within Voted Trip Relay Units Only ..................................................... 42
Figure 2-10a. Power Supply Field Wiring Routing & Stress Relief Diagram .............................................. 42
Figure 2-10b. I/O Wiring Routing & Stress Relief Diagram......................................................................... 43
Figure 2-10c. Relay Output Field Wiring Routing & Stress Relief Diagram................................................ 43
Figure 2-11a. Example MPU (Passive Magnetic Pickup Unit) Wiring ........................................................ 44
Figure 2-11b. Example Proximity Probe (Active Magnetic Pickup Unit) Wiring (Internal Power)............... 45
Figure 2-11c. Example Proximity Probe (Active Magnetic Pickup Unit) Wiring (External Power, Non-
preferred)................................................................................................................................ 45
Figure 2-11d. Example Eddy Current Probe (Active Magnetic Pickup Unit) Wiring ................................... 45
Figure 2-12a. Example Standard Discrete Input Wiring (Internal Power Option) ....................................... 46
Figure 2-12b. Example Standard Discrete Input Wiring (External Power Option)...................................... 46
Figure 2-13. Example Analog Output Wiring .............................................................................................. 47
Figure 2-14a. Example Trip Relay Output Wiring ....................................................................................... 47
Figure 2-14b. Example Trip Relay Wiring (per Module) (Independent Trip Relay) (Internal Supply)......... 48
Figure 2-14c. Example Trip Relay Wiring (per Module) (Independent Trip Relay) (External Supply)........ 48
Figure 2-14d. Example Trip Relay Wiring (Voted Trip Relay Models)........................................................ 49
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Figure 2-14e. Example Alarm Relay Wiring (Internal Supply) .................................................................... 49
Figure 3-1. Module Diagram without Speed Redundancy Manager Configured........................................ 51
Figure 3-2. Module Diagram with Speed Redundancy Manager Configured ............................................. 52
Figure 3-3. Basic Functional Overview of Independent Trip Relay Models................................................ 53
Figure 3-4. Functional Diagram of Single ProTech-GII module with Independent Trip Relay Outputs...... 54
Figure 3-5. Example TMR Trip Block Assembly Interface .......................................................................... 55
Figure 3-6. Basic Functional Overview of Voted Trip Relay Models .......................................................... 56
Figure 3-7. Functional Diagram of Single ProTech-GII Module with Voted Trip Relay Outputs................. 57
Figure 3-8. Simplex Trip Block Assembly ................................................................................................... 58
Figure 3-9. Dual Redundant Trip Block Assembly...................................................................................... 59
Figure 3-10. Over-Acceleration Enabling Diagram ..................................................................................... 62
Figure 3-11. Start Logic Diagram................................................................................................................ 65
Figure 3-12. Speed Fail Trip Diagram......................................................................................................... 65
Figure 3-13. Speed Fail Timeout Trip Diagram........................................................................................... 66
Figure 3-14. Total System Response Time Based on Sensed Frequency Level for Independent Trip Relay
Models when Speed Redundancy Manager Function is not Configured............................... 71
Figure 3-15. Total System Response Time Based on Sensed Frequency Level for Independent Trip Relay
Models when Speed Redundancy Manager Function is Configured..................................... 72
Figure 3-16. Total System Response Time Based on Sensed Frequency Level for 2oo3 Voted Trip Relay
Models when Speed Redundancy Manager Function is not Configured............................... 72
Figure 3-17. Total System Response Time Based on Sensed Frequency Level for 2oo3 Voted Trip Relay
Models when Speed Redundancy Manager Function is Configured..................................... 73
Figure 3-18. Response Time Definition ...................................................................................................... 73
Figure 4-1. ProTech-GII Front Panel .......................................................................................................... 74
Figure 4-2. ProTech-GII Screen.................................................................................................................. 75
Figure 4-3. ProTech-GII Faceplate ............................................................................................................. 76
Figure 4-4. Home screen (with Alarm) ........................................................................................................ 77
Figure 4-5. Home screen (with Trip) ........................................................................................................... 77
Figure 4-6. Password Entry Screen Example............................................................................................. 78
Figure 4-7. Monitor Menu............................................................................................................................ 79
Figure 4-8. Monitor Summary Screen Example.......................................................................................... 80
Figure 4-9. Monitor Trip Latch Screen Example ......................................................................................... 80
Figure 4-10. Monitor Alarm Latch Screen Example.................................................................................... 81
Figure 4-11. Monitor Dedicated Discrete Inputs Screen Example.............................................................. 82
Figure 4-12. Monitor Speed Input Screen Example.................................................................................... 83
Figure 4-13. Monitor Speed Redundancy Manager Screen Example ........................................................ 83
Figure 4-14. Monitor Acceleration Redundancy Manager Screen Example............................................... 84
Figure 4-15. Monitor Speed Fail Timer Screen Example............................................................................ 85
Figure 4-16. Monitor Speed Readout (Home) Screen Example................................................................. 85
Figure 4-17. Monitor Shared Start Input Screen Example.......................................................................... 86
Figure 4-18. Monitor Shared Reset Input Screen Example ........................................................................ 86
Figure 4-19. Monitor Shared Speed Fail Override Input Screen Example ................................................. 87
Figure 4-20. Monitor Modbus Screen Example .......................................................................................... 87
Figure 4-21. Monitor/Set Date & Time Screen Example............................................................................. 88
Figure 4-22. Edit/Change Mode Active Screen Example ........................................................................... 88
Figure 4-23. Highlight Time Field to Edit Screen Example ......................................................................... 89
Figure 4-24. Ready to Apply Changes Screen Example ............................................................................ 89
Figure 4-25. Monitor System Status ........................................................................................................... 90
Figure 4-26. Monitor Module Information.................................................................................................... 90
Figure 4-27. Logs Menu Screen Example .................................................................................................. 91
Figure 4-28. Overspeed/Over-Acceleration Log Screen Example.............................................................. 91
Figure 4-29. Trip Log Screen Example ....................................................................................................... 92
Figure 4-30. Alarm Log Screen Example.................................................................................................... 92
Figure 4-31. Peak Speed/Acceleration Log Screen Example..................................................................... 93
Figure 4-32. Reset Logs Screen Example.................................................................................................. 93
Figure 5-2. Configure Menu Screen Example............................................................................................. 95
Figure 5-3. Save Configuration Screen Example........................................................................................ 97
Figure 5-4. Configure Display Screen Example.......................................................................................... 97
Figure 5-5. Configure Speed Submenu Screen Example........................................................................... 98
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Figure 5-6. Configure Speed Input Screen Example .................................................................................. 99
Figure 5-7. Configure Acceleration Screen Example................................................................................ 100
Figure 5-8. Configure Start Logic.............................................................................................................. 100
Figure 5-9. Configure Speed Redundancy Manager Screen Example .................................................... 101
Figure 5-10. Configure Acceleration Redundancy Manager Screen Example......................................... 102
Figure 5-11. Configure Trip Latch Screen Example ................................................................................. 102
Figure 5-12. Configure Alarm Latch Screen Example .............................................................................. 103
Figure 5-13. Configure Dedicated Discrete Submenu Screen Example .................................................. 103
Figure 5-14. Configure Start Input Sharing Screen Example ................................................................... 104
Figure 5-15. Configure Reset Input Sharing Screen Example.................................................................. 104
Figure 5-16. Configure Speed Fail Override Input Sharing Screen Example........................................... 105
Figure 5-17. Configure Test Modes Screen Example............................................................................... 105
Figure 5-18. Configure Auto-Sequence Test Screen Example................................................................. 106
Figure 5-19. Configure Modbus Screen Example..................................................................................... 107
Figure 5-20. Configure Power Supply Alarms Screen Example............................................................... 107
Figure 5-21. Configuration Management Menu Screen Example............................................................. 108
Figure 5-22. Configuration Overview Screen Example............................................................................. 108
Figure 5-23. Configuration Compare Screen Example............................................................................. 109
Figure 5-24. Configuration Copy Screen Example ................................................................................... 110
Figure 5-25. Configuration Copy Screen Example ................................................................................... 111
Figure 5-26. Password Change Screen Example..................................................................................... 111
Figure 6-1. Test Modes Menu................................................................................................................... 113
Figure 6-2a. Temporary Overspeed Test Screen Example...................................................................... 113
Figure 6-2b. Temporary Overspeed Test Screen Examples .................................................................... 115
Figure 6-3. Manual Simulated Speed Test Screen Example.................................................................... 116
Figure 6-4. Test Frequency Resolution..................................................................................................... 117
Figure 6-5. Manual Simulated Speed Test Screen Example.................................................................... 117
Figure 6-6. Auto Simulated Speed Test Screen Example ........................................................................ 118
Figure 6-7. Auto Sequence Test (Periodic Test Timer Enabled) Screen Example .................................. 120
Figure 6-8. Lamp Test............................................................................................................................... 122
Figure 7-1 Website Search Results .......................................................................................................... 123
Figure 7-2. Host Computer Control Panel Display Settings...................................................................... 124
Figure 7-4. ProTech-GII PCT Off-Line Window ........................................................................................ 125
Figure 7-5. Button Status (Connected) ..................................................................................................... 126
Figure 7-6. Button Status ( Not Connected).............................................................................................. 126
Figure 7-7. Information Status Bar (Not Connected) ................................................................................ 126
Figure 7-8. Information Status Bar Example (Connected)........................................................................ 126
Figure 7-9. ProTech-GII PCT Off-Line Window ........................................................................................ 127
Figure 7-10. Status Bar and Button Status before Connection................................................................. 127
Figure 7-11. PCT Connect Options Window............................................................................................. 128
Figure 7-12. Status Bar and Button Status after Connection.................................................................... 128
Figure 7-13. PCT Security Log-In Window ............................................................................................... 128
Figure 7-14. Drop-Down Menu “Settings” ................................................................................................. 129
Figure 7-15. Prompt to Set Settings File Default Values ......................................................................... 130
Figure 7-16. Prompt for Settings File to Modify ........................................................................................ 130
Figure 7-17. Prompt to Connect................................................................................................................ 131
Figure 7-18. Prompt for Settings File to Edit............................................................................................. 131
Figure 7-19. Prompt for Settings File to Load........................................................................................... 132
Figure 7-20. Configuration Error ............................................................................................................... 133
Figure 7-21. Compare Settings File Differences....................................................................................... 133
Figure 7-22. Settings File Differences....................................................................................................... 133
Figure 7-23. PCT On-Line Window........................................................................................................... 134
Figure 7-24. Edit/View Configuration On-Line Window Example ............................................................. 135
Figure 7-25 Valid Range Display for Sudden Speed Loss Threshold Setting.......................................... 136
Figure 7-26 Options Displayed When No Changes are Detected ............................................................ 136
Figure 7-27 Options Displayed When Changes are Detected.................................................................. 136
Figure 7-28 Incorrect Log-In Level............................................................................................................ 137
Figure 7-29 Configuration Error ................................................................................................................ 137
Figure 7-30 Module is not Tripped ............................................................................................................ 137
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Figure 7-31. Configuration Error Log Example ......................................................................................... 138
Figure 7-32. Trip and Alarm Log Example................................................................................................ 139
Figure 7-33. Overspeed/Acceleration Log Example ................................................................................. 140
Figure 7-34. Module Faults Log Example................................................................................................. 141
Figure 8-1. ProTech-GII PCT “Edit/View Configuration” Screen (Connected) ......................................... 143
Figure 8-2. Speed and Acceleration Configuration Example.................................................................... 145
Figure 8-3. Input Sharing Selection Configuration Example..................................................................... 148
Figure 8-4. Modbus Configuration Example ............................................................................................. 149
Figure 8-5. Test Modes Configuration Example ....................................................................................... 150
Figure 8-6. Start Logic & Power Supply Alarms Configuration Example.................................................. 152
Figure 8-7. Other Outputs Configuration Example ................................................................................... 153
Figure 8-8. Configuration Error window .................................................................................................... 155
Figure 8-9. Data Entry Range Error Example........................................................................................... 155
Figure A-1. Wiring ..................................................................................................................................... 180
Figure A-2. RS-485 2-wire ........................................................................................................................ 180
Figure A-3. Network Settings .................................................................................................................... 181
Figure A-4. Modbus TCP Settings ............................................................................................................ 181
Figure A-5. Serial Communication Settings .............................................................................................. 182
Figure A-6. Serial Modbus Settings .......................................................................................................... 182
Figure A-7. RS-232 Wiring........................................................................................................................ 183
Figure A-8. RS-285 2-wire Wiring ............................................................................................................. 184
Figure A-9. Overview ................................................................................................................................ 185
Figure A-10. Network Menu ...................................................................................................................... 185
Figure A-11. Serial Settings Menu ............................................................................................................ 186
Figure A-12. Modem Control Menu........................................................................................................... 186
Figure A-13. Advanced Menu ................................................................................................................... 187
Table 1-1. Available ProTech-GII Models................................................................................................... 15
Table 1-2 ProTech GII conversion compatibility ......................................................................................... 18
Table 2-1. Environmental Specifications..................................................................................................... 33
Table 2-2a. Low Voltage Input Specifications............................................................................................. 33
Table 2-2b. High Voltage Input Specifications............................................................................................ 33
Table 2-2c. Power Supply Input Specifications........................................................................................... 34
Table 2-3 Relay Output Power Supply Specifications ................................................................................ 34
Table 2-4. General I/O Specifications ......................................................................................................... 35
Table 2-5a. Passive Probe Specifications .................................................................................................. 35
Table 2-5b. Active Probe Specifications ..................................................................................................... 35
Table 2-6a. Independent Trip Relay Specifications .................................................................................... 36
Table 2-6b. Voted Trip Relay Specifications............................................................................................... 36
Table 2-7. Alarm Relay Specifications ........................................................................................................ 36
Table 2-8. Dedicated Discrete Input Specifications .................................................................................... 37
Table 2-9. Analog Output Specifications..................................................................................................... 37
Table 2-10. Serial Port (RS-232/RS-485) Specifications............................................................................ 37
Table 4-1. Keypad Keys Function Definitions............................................................................................. 76
Table 5-1. Front Panel Functions that Can Be Modified............................................................................. 94
Table 5-2. Home Screen Valid Values........................................................................................................ 98
Table 6-1. Simulated Speed Resolution ................................................................................................... 116
Table 7-3. Service Port and Serial Cable Specifications .......................................................................... 124
Table 8-1. Home Screen Valid Values...................................................................................................... 144
Table 8-2. Configuration Check Definitions .............................................................................................. 154
Table 9-1. Modbus Communication Port Specifications ........................................................................... 156
Table 9-2. Supported Modbus Function Codes ........................................................................................ 157
Table 9-3. Modbus Serial Communication Port Settings .......................................................................... 157
Table 9-4. Boolean Write Addresses (Code 05) ....................................................................................... 159
Table 9-5. Boolean Read Addresses (Code 02)....................................................................................... 159
Table 9-6. Analog Read Addresses (Code 04)......................................................................................... 162
Table 10-1. Trip Relay Safe State Configuration ...................................................................................... 163
Table 10-2. SIL Specifications .................................................................................................................. 163
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Table 10-3. ProTech-GII SIL3 Numbers: .................................................................................................. 164
Table 10-4. Failure Rate ........................................................................................................................... 164
Table 11-1. I/O Troubleshooting ............................................................................................................... 167
Table 11-2. Trip Indications....................................................................................................................... 170
Table 11-3. Alarm Indications ................................................................................................................... 172
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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:
EMC Directive Declared to Directive 2014/30/EU of the European Parliament and of the
Council of 26 February 2014 on the harmonization of the laws of the
Member States relating to electromagnetic compatibility (EMC)
Low-Voltage Directive: Directive 2014/35/EU on the harmonisation of the laws of the Member
States relating to the making available on the market of electrical equipment
designed for use within certain voltage limits
ATEX – Potentially
Explosive
Atmospheres
Directive:
Directive 2014/34/EU on the harmonisation of the laws of the Member
States relating to equipment and protective systems intended for use in
potentially explosive atmospheres
Zone 2, Category 3, Group II G, Ex nA IIC T4 X
Other European Compliance
Compliance with the following European Directives or standards does not qualify this product for
application of the CE Marking:
RoHS Directive: Exempt from 2002/95/EC of the European Parliament and of the Council of
27 January 2003 on the restriction of the use of certain hazardous
substances in electrical and electronic equipment. Exempt per Annex IA of
Directive 2002/95/EC referring to "monitoring and control instruments"
within the meaning of Category 9.
WEEE Directive: Exempt/Compliant as a component with 2002/96/EC of the European
Parliament and of the Council of 27 January 2003 on waste electrical and
electronic equipment (WEEE).
EuP Directive: Exempt/Compliant from 2009/125/EC of the European Parliament and of
the Council of 21 October 2009 establishing a framework for the setting of
ecodesign requirements for energy-related products.
North American Compliance:
CSA: Certified for Class I, Division 2, Groups A, B, C, and D, T4 at 60 °C Ambient
for use in the United States and Canada.
Certificate 160584-2217246
Other International Compliance
C-Tick: Declared to Australian Radiocommunications Act of 1992 and the New New
Zealand Radiocommunications Act of 1989.
TÜV: TÜV certified for SIL-3 per IEC 61508 Parts 1-7, Functional Safety of
Electrical / Electronic / Programmable Electronic Safety Related Systems.
Other Compliance
Gas Corrosion: IEC60068-2-60:1995 Part 2.60 Methods 1 and 4 (conformal coating)
Machinery Protection: API670, API612, & API-611 compliant
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Special Conditions for Safe Use
This Equipment is Suitable for use in Class I, Division 2, Groups A, B, C, D or Non Hazardous Locations
Only.
This equipment is suitable for use in European Zone 2, Group IIC environments or Non Hazardous
Locations Only.
Wiring must be in accordance with North American Class I, Division 2, or European Zone 2, Category 3
wiring methods as applicable, and in accordance with the authority having jurisdiction.
A fixed wiring installation is required and a switch or circuit breaker shall be included in the building
installation that is in close proximity to the equipment and within easy reach of the operator and that is
clearly marked as the disconnecting device for the equipment. The switch or circuit breaker shall not
interrupt the protective earth conductor.
Protective Earth Grounding is required by the input PE terminal.
Field wiring must be rated at least 85 °C for operating ambient temperatures expected to exceed 50 °C.
For European ATEX compliance on panel mount models, this equipment must be installed in an area
providing adequate protection against the entry of dust or water. A minimum ingress protection rating of
IP54 is required for the enclosure.
Personnel must discharge their electrostatic build up to the cabinet ground point or use an ESD strap
prior to touching the ProTech interior surfaces if the engine/turbine is operational. The unit is designed to
have one of three modules be removed during operation; however ESD to the remaining operational
modules may cause signal deviations. Signal deviations due to direct ESD may be large enough to result
in the operational module to trip, shutting down the engine since two modules are in a tripped mode.
Signal deviations were noted when ESD testing was done to the Speed pins, the IRIG-B pins, Service
Port pins, and RS-232/RS-485 MODBUS communications port pins.
Do not remove module unless module is de-energized and all wire
connections have been disconnected
The Service Port (RS-232 communication) is not designed to remain connected during operation except
at servicing and programming intervals. It should not have a cable connected to it other than during
programming and servicing.
This device contains a single cell primary battery. This battery is not to be charged and is not customer
replaceable.
Control is suitable for installation in pollution degree 2 environments.
Measurement inputs are classified as permanently connected IEC
measurement Category I and are designed to safely withstand
occasional transient overvoltages up to 1260 Vpk. To avoid the
danger of electric shock, do not use these inputs to make
measurements within measurement categories II, III, or IV.
Explosion Hazard—Do not connect or disconnect while circuit is live
unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2 or Zone 2 applications.
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Risque d’explosion—Ne pas raccorder ni débrancher tant
que l’installation est sous tension, sauf en cas l’ambiance
est décidément non dangereuse.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I,
applications Division 2 ou Zone 2.
Safety Symbols
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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Acronyms and Definitions
2oo3 2-out-of-3
CAN Controller Area Network
CRC Cyclic Redundancy Check
DC Diagnostic Coverage
DCS Distributed Control System
mA Milliampere(s)
ms Millisecond(s)
HSS High Signal Select
LSS Low Signal Select
Module Functionality contained within one of the three identical sections
MPU Magnetic Pick-up
PC Personal Computer with Windows operating system (also known as “host computer”)
PCT Programming and Configuration Tool
PFD Probability of Failure on Demand
PFH Probability of dangerous Failure per Hour
PLC Programmable Logic Controller
PROX Proximity Probe
RPM Revolutions Per Minute
RTU Remote Terminal Unit Transmission Protocol
Settings File A file that contains the configuration settings loaded with the ProTech Programming
and Configuration Tool (“.wset” is the filename extension)
SFO Speed Fail Override
SRM Speed Redundancy Manager
GII ProTech Overspeed Protection Device
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Chapter 1.
General Information
Purpose and Scope
The purpose of this manual is to provide the necessary background information for applying the ProTech-
GII. Topics covered include mechanical installation, electrical wiring, software programming, and
troubleshooting. While this manual is primarily targeted at OEM customers, OEMs themselves may find it
useful to copy some of the information from this manual into their application user manuals.
This manual does not contain instructions for the operation of the complete prime mover system. For
prime mover or plant operating instructions, contact the plant-equipment manufacturer.
This version of the manual applies to all ProTech-GII models with software 5418-7349. The software
version can be identified on the front panel display at power-up or on the “Monitor Module Information”
screen, available from the “Monitor Menu”. It can also be found on the “Details...” tab of the Programming
and Configuration Tool (PCT).
See the What’s New section at the end of this chapter for a listing of the changes in this software version.
How to Use This Manual
The following summarizes how to install a ProTech-GII into a new or existing system:
Unbox and inspect the hardware. 
Install, mount, and wire the hardware following the system installation procedures and
recommendations in Chapter 2. 
Configure the device using one of the following options: 
oProgramming and Configuration Tool (Chapter 7) 
oFront Panel (Chapter 5) 
Follow the safety and checkout procedures in Chapter 10. 
Troubleshooting guidelines are provided in Chapter 11. 
Description
The ProTech-GII is an overspeed safety device designed to safely shut down steam, gas, and hydro
turbines of all sizes upon sensing an overspeed or over-acceleration event. This device accurately
monitors turbine rotor speed and acceleration via active or passive MPUs (magnetic pickups) and issues
a shutdown command to the turbine’s trip valve(s) or corresponding trip system.
The ProTech-GII consists of three independent modules whose trip outputs, dependent upon model used,
are either independent or voted in a 2-out-of-3 configuration. An isolated bus architecture is used to share
all inputs and latch status information between the three modules. Optionally each ProTech-GII module
can be configured to use only its sensed “local” input signals or the voted result of all three modules’
signals in its event latch decision logic. Optionally module trip and alarm latch statuses can also be
configured to be shared with all other modules.
The ProTech-GII includes Overspeed and Over-acceleration functions as well as time stamped Alarm,
and Trip logs. Indication that a test was active at the time of the event is provided on all logs and first-out
indications are provided for Trip logs. The ProTech-GII also provides various pre-defined test routines
including an automated periodic test routine to assist users with verifying system operation.
There are several ways to interface with the ProTech-GII. The front panel allows the user to view current
values, and to perform configuration and test functions. All of the features and most of the information
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available from the front panel are also accessible via the Modbus interface. Finally, the Programming and
Configuration Tool (PCT) is software that is run on a PC to download log files and manage Settings Files.
This product is designed for critical applications and when installed correctly complies with standards API-
670, API-612, API-611, and IEC61508 (SIL-3).
The following table shows the various hardware configurations (mounting options, power supplies, and
trip relay options) available:
Table 1-1. Available ProTech-GII Models
Part Number Description
8237-2594 ProTech GII, Bulkhead Mount, HV/LV, Indep Relay, Voted Inputs MATH
8237-2598 ProTech GII, Panel Mount, HV/LV, Indep Relay, Voted Inputs MATH
8237-2595 ProTech GII, Bulkhead Mount, HV/HV, Indep Relay, Voted Inputs MATH
8237-2599 ProTech GII, Panel Mount, HV/HV, Indep Relay, Voted Inputs MATH
8237-2596 ProTech GII, Bulkhead Mount, HV/LV, Voted Relays, Voted Inputs MATH
8237-2600 ProTech GII, Panel Mount, HV/LV, Voted Relays, Voted Inputs MATH
8237-2597 ProTech GII, Bulkhead Mount, HV/HV, Voted Relays, Voted Inputs MATH
8237-2601 ProTech GII, Panel Mount, HV/HV, Voted Relays, Voted Inputs MATH
5437-2126 Spare Module for ProTech models 8237-2594, -2598 (GII H/L Indep Relay/Voted
Input)
5437-2127 Spare Module for ProTech models 8237-2595, -2599 (GII H/H Indep Relay/Voted
Input, MATH)
5437-2124 Spare Module for ProTech models 8237-2596, -2600 (GII H/L Voted Relay/Input,
MATH)
5437-2125 Spare Module for ProTech models 8237-2597, -2601 (GII H/H Voted Relay/Input,
MATH)
Applications
The ProTech-GII is designed to be applied as an overspeed device for any size steam, gas, or hydro
turbine, reciprocating engine, or plant process equipment. The device's fast response time (8–26
milliseconds depending on model and configuration), 0.5 to 80 000 RPM speed range, and integrated
overspeed and acceleration detection/protection functionality, make it ideal for application on critical low-
speed or high-speed rotating motors, compressors, turbines or engines. This device accepts one speed
(MPU or PROX) input per module
(3 total). In addition to the trip relay outputs, each ProTech-GII module provides one relay output that is
dedicated to an alarm function (3 total) and one analog speed output (3 total).
The ProTech-GII utilizes a triple modular redundant architecture and 2-out-of-3 voting logic to accurately
determine unsafe conditions and ensure that no single-point failure will affect system reliability or
availability. With this design, failures in overspeed system components (switches, transducers, modules)
are detected, annunciated, and allowed to be repaired or replaced while the monitored system continues
to operate on-line. Optionally the ProTech-GII can be configured to share and vote on all speed inputs as
required by the application, The ProTech-GII is designed for critical applications where both personnel
safety and unit availability (operation run time) is a concern or necessity.
The ProTech-GII is certified as an IEC61508 SIL-3 (Safety Integrity Level 3) safety device and can be
applied as a stand-alone IEC61508-based device or within an IEC61511-based plant safety system.
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Figure 1-1. Typical ProTech-GII Application (Voted Trip Relay Models)
Figure 1-2. Typical ProTech-GII Application (Independent Trip Relay Models)
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Figure 1-3. Typical Gas Turbine Application (Voted Trip Relay Models)
What’s New
The features described in this manual are software-version specific. The ProTech-GII hardware is
unchanged from previous releases as this is a software-only update. A listing of the software changes,
based on the previous version 5418-7000 (Manual 26709), is provided below..
Changes to existing logic blocks/functions:
Speed Loss (sudden speed loss): made the failure threshold configurable and expanded the action
selection to include ‘not used’.
Configurable filter was added to the acceleration signal.
Auto Sequence Test: The displayed test result is for the entire sequence, not just the local module
and the individual module test status was added. Removed Continue Input selection, allowing the
Start Input to provide both functions. Added inter-module halt option.
Other Improvements and Additions:
Chinese language support added as a configuration setting.
Increased allowable ranges for speed settings from 32000 to 80000 RPM. The maximum speed
frequency remains at 32kHz.
Front Panel Display changes:
oSpeed display: The precision of the speed value on the front panel provides one decimal
precision when below 100 RPM.
oFront panel performance was improved, providing faster response to a key press.
oTrip button (front panel): Toggles display between the Trip Log and the Trip Latch.
oAlarm button (front panel): Toggles display between the Alarm Log and the Alarm Latch.
oShared Reset, Shared Start, and Shared Speed Fail Override display screens were added.
oTrip Latch inputs were rearranged to display more practical faults first (e.g. overspeed).
oFiltering was added for the Home screen speed display.
Modbus:
oThe address numbering (Boolean and register) changed to be consecutive, removing huge gaps
in numbering.
oSpare Boolean read registers were added to prevent errors experienced by devices that queried
in increments of 16.
oAdded pre-scaled values for Speed and Acceleration.
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Existing Control Upgrade
Customers who wish to have/utilize one or more of the above listed changes can purchase a conversion.
The conversion includes installation of new firmware, 5418-7349 which will operate with most existing
ProTech GII models. See table below for part numbers that can be upgraded. Revision H of the ProTech
GII Service Tool (9927-1810) is required for the new firmware and is compatible with all ProTech GII
models. Configuration files created for previous firmware revisions can be converted and loaded into the
control with the latest firmware using the service tool. Configurations for the 5418-7349 are not
compatible with the older firmware versions.
Table 1-2 ProTech GII conversion compatibility
Description Part Numbers That Can
Be Converted Preferred Part Numbers
ProTech GII – Bulkhead Mount,
HV/LV, Ind. Relays
8237‐1244 Rev D or Newer or 8237-1594 8237-2602
ProTech GII – Bulkhead Mount,
HV/HV, Ind. Relays
8237‐1245 Rev D or Newer or 8237-1595 8237-2603
ProTech GII – Bulkhead Mount,
HV/LV, Voted Relays
8237‐1246 Rev D or Newer or 8237-1596 8237-2604
ProTech GII – Bulkhead Mount,
HV/HV, Voted Relays
8237‐1247 Rev D or Newer or 8237-1597 8237-2605
ProTech GII – Panel Mount, HV/LV,
Ind. Relays
8237‐1367 Rev D or Newer or 8237-1598 8237-2606
ProTech GII – Panel Mount, HV/HV,
Ind. Relays
8237‐1368 Rev D or Newer or 8237-1599 8237-2607
ProTech GII – Panel Mount, HV/LV,
Voted Relays
8237‐1369 Rev D or Newer or 8237-1600 8237-2608
ProTech GII – Panel Mount, HV/HV,
Voted Relays
8237‐1370 Rev D or Newer or 8237-1601 8237-2609
How to upgrade
The firmware of compatible ProTech GII units can be field upgraded, but requires use of specialized
software tools and must be performed by authorized Woodward personnel. If you have any questions
about this issue or wish to upgrade, please contact one of our Woodward facilities and refer to Application
Note 06946.
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