Woodward MPU User manual

Manual 82510
(Revision V, 8/2022)
Original Instructions
Magnetic Pickups and Proximity Switches
for Electronic Controls
Reference 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
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
g
et the latest cop
y
.
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
dama
g
e, and
(
ii
)
invalidate product certifications or listin
g
s.
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 Out-of-date translations are marked with .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 82510
Copyright © Woodward 2022
All Rights Reserved
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 1
Contents
WARNINGS AND NOTICES ............................................................................................................... 2
CHAPTER 1. MAGNETIC SPEED PICKUPS ......................................................................................... 3
General Information ...................................................................................................................................... 3
MPU Installation ............................................................................................................................................ 5
Installation and Operation Safety Requirements ........................................................................................ 10
Troubleshooting Magnetic Pickups ............................................................................................................. 11
MPU Resistance List................................................................................................................................... 11
CHAPTER 2. PROXIMITY SWITCHES ............................................................................................... 12
General Information .................................................................................................................................... 12
Proximity Switch Features........................................................................................................................... 12
Types of Proximity Switches ....................................................................................................................... 13
Proximity Switch Power Supply .................................................................................................................. 13
Checking Proximity Switch Operation......................................................................................................... 14
Proximity Switch Wiring............................................................................................................................... 14
APPENDIX.USING THE OUTPUT OF A WOODWARD MPU TO DRIVE A REMOTE TACHOMETER OR
OTHER DEVICE .............................................................................................................................15
REVISION HISTORY ....................................................................................................................... 16
Illustrations and Tables
Figure 1-1. Magnetic Pickup Dimensions ..................................................................................................... 4
Figure 1-2. Magnetic Pickup Output Waveforms .......................................................................................... 5
Figure 1-3a. MPU Models ............................................................................................................................. 6
Figure 1-3b. CSA/ATEX Models ................................................................................................................... 7
Figure 1-4. Maximum Air Gap Allowed to Provide Usable Signals for Most Electronic Controls ................. 8
Figure 1-5. Maximum Air Gap Allowed to Provide 1.5 V (ac, rms) on EGM Control .................................... 9
Figure 2-1. Air Gaps for Radial and Axial Sensing Proximity Switches...................................................... 13
Figure 2-2. Suggested Wiring for a “Sinking” Type Proximity Switch ......................................................... 14
Figure 2-3. Suggested Wiring for a “Source” Type Proximity Switch.......................................................... 14
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 2
Warnings and Notices
Important Definitions
This is the safety alert symbol. It is 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 ma
y
also be needed for safet
y
, 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
workin
g
fluid
(
s
)
and compl
y
with recommended safet
y
equipment.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 3
Chapter 1.
Magnetic Speed Pickups
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
propert
y
dama
g
e.
General Information
The magnetic speed pickup (MPU) is used to detect the speed of the prime mover. An MPU is necessary
when the prime mover drives something other than an alternator. It is also often used where an alternator
is driven directly by the prime mover and when a control signal is necessary before the alternator comes
up to its proper output voltage. A speed sensor circuit, either a section on the governor amplifier chassis
or a separate unit, is needed to convert the MPU’s output signal to one usable by the governor amplifier.
The magnetic pickup produces a voltage output when any magnetic material moves through the magnetic
field at the end of the pickup. Since most engines and turbines have flywheels or other large gears made
of magnetic material (usually iron or steel), magnetic pickups can usually be installed without adding
attachments to a gear or shaft. Nonmagnetic materials, such as aluminum, brass, and some stainless
steels, will not excite the magnetic pickup.
The MPU makes use of a “stray magnetic field” and no provision for return magnetic circuits or paths is
necessary. Any device which produces a dynamic discontinuity of magnetic material in the field of the
pickup will produce an electrical voltage. Although gears are the normal devices measured by an MPU,
other devices such as a vibrating surface, moving bar, crank, wheel spokes, or a steel screw head
mounted on some moving surface will work equally well if surface speed and other factors are taken into
account. The MPU may be excited by a keyway or slot in a wheel, but there is likely to be an unwanted
background signal due to varying density or eccentricity of the material. It is better to excite the MPU from
a protrusion on the surface. This places the pickup at a relatively great distance from the materials
between excitation periods and it is less likely to pick up stray signals.
The output voltage of a magnetic pickup is affected by three factors:
Voltage increases as the surface speed of the monitored magnetic material increases.
Voltage decreases as the air gap between the magnetic pickup and the surface of the gear tooth is
increased.
Voltage waveform is determined by the size and shape of the gear tooth in relation to the size and
shape of the pole piece.
With any given speed and clearance conditions, a maximum power output will result when the field is filled
with a relatively infinite mass of magnetic material at one instant and a complete absence of such material
the next. A reasonable approach to these conditions exists when the cross-section of the exciting masses is
equal to or greater than that of the pole piece, and the space between is equal to or greater than three times
the diameter of the pole piece (see Figure 1-1).
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 4
Figure 1-1. Magnetic Pickup Dimensions
In Figure 1-1, the optimum dimensions of A, B, C, and F are given as they relate to D, the diameter of the
pole piece of the magnetic pickup. The optimum relationship for maximum output is as follows:
A equal to or greater than D
B equal to or greater than C
C equal to or greater than three times D
F equal to or greater than D
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 5
As the magnetic pickup-gear relationship begins to deviate from the specifications listed above, the MPU
output waveform may deteriorate to an unacceptable shape. Because the speed sensor detects zero-
crossings, the waveform should cross zero only twice for each tooth (once going positive and once going
negative, see Figure 1-2).
Figure 1-2. Magnetic Pickup Output Waveforms
MPU Installation
The magnetic pickup is available in short or long standard models, a standard metric model, hazardous
duty models, and explosion-proof models, including CSA/ATEX approved models (see Figure 1-3 for
dimensions and part numbers).
Mount the magnetic pickup radially to the outside diameter of the desired gear, either through a housing
or on a rigid bracket. Make sure the gear is of magnetic material. The gap between the pickup and the
outside diameter of the gear should be set normally between 0.25 mm and 1.02 mm (0.010 inch and
0.040 inch) at the closest point. Ensure the gear has less than 0.51 mm (0.020 inch) diametric runout.
Since the signal strength is inversely proportional to gap distance, a weak signal may be generated with
more than 1.02 mm (0.040 inch) gap. A shield of non-magnetic material may be installed between the
gear and the pickup if necessary for physical shielding. Since this material spaces the pickup face farther
from the gear, and since an electromagnetic force may be generated by eddy currents in the shielding
material, make sure the signal level is still high enough to operate the speed signal circuit.
Most electronic controls require a minimum output of 1.5 V (ac, rms) from the magnetic speed pickup at
the lowest controlling speed. Figures 1-4 and 1-5 show the maximum air gap allowed for each surface
speed and diametral pitch or gear module to produce this minimum required voltage.
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 6
Figure 1-3a. MPU Models
The surface speed in meters per second (m/s) or inches per second (IPS) is related to revolutions per
minute (rpm) by the following:
Surface Speed = rpm x πx gear diameter
60
The diametral pitch for the gear is obtained by the formula:
Diametral Pitch = number of teeth + 2
gear diameter (inches)
The gear module is obtained by the formula:
Gear Module = gear diameter (mm)
number of teeth + 2
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 7
Figure 1-3b. CSA/ATEX Models
(SIL 3 Models have “.SIL” at the end of the part number – Dimensions Unchanged)
The standard magnetic pickup may be used with a gear that has a diametral pitch coarser than 8 (gear
module 3.2), but the output will not be increased. Gears with a finer diametral pitch than 8 (gear module
3.2) may be used with a corresponding decrease in output voltage. A diametral pitch of 20 (gear module
1.27) is the finest that may be used with this pickup without two teeth appearing over the pole piece at the
same time. When adjusting the clearance between the pickup pole piece and the gear, adjust the pickup
so the output voltage is a minimum of 1.5 V (ac, rms) at the lowest speed.
If you cannot measure the gap directly, it can be determined in the following manner.

Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 8
Figure 1-4. Maximum Air Gap Allowed to Provide Usable Signals for Most Electronic Controls
With the prime mover shut down, turn the pickup in until it just touches the outside diameter of the gear. If
the pickup has a 5/8-18 thread, one 360° turn counterclockwise will move the pickup out 0.0555 inch
(1.41 mm). The metric pickup will move 1.5 mm per turn. If the pickup has a 3/4-20 mounting thread, the
pickup will move out 0.050 inch (1.27 mm) per turn. Screw out the amount required for the desired gap. If
possible, run the gear slowly through 360° rotation to check the clearance of the pickup. When the gap is
set, tighten the jam nut securely against the housing or bracket so the pickup cannot turn in or out.
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 9
Figure 1-5. Maximum Air Gap Allowed to Provide 1.5 V (ac, rms) on EGM Control
The standard models of pickups, including the metric model, require mating connector number MS-
3106A-10SL-4S. These connectors are not furnished with the pickups but may be ordered if desired. The
hazardous duty and explosion-proof models have leads attached to the pickups, and the heads have 1/2-
inch female pipe threads for installing conduit or pipe.
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 10
Installation and Operation Safety Requirements
General
Magnetic pickups are also referred to as Variable Reluctance Speed Sensors. The CSA/ATEX series of
MPUs are designed specifically for use in hazardous location applications. When properly and fully
threaded, they are sealed for protection against corrosion, water, dust, and oil as defined in CSA-22.2
NO.30-M1986. These pickups are also available in SIL certified versions. Part numbers are the same with
a “.SIL” extension and except for SIL certification, the specifications are the same.
CSA/ATEX series of sensors are certified to international standards EN60079-0 and EN60079-1, and are
rated for Class I, Division 1, Group A, B, C, & D hazardous locations, Ex d IIC T5; KEMA 04ATEX2057 X.
Electrical Rating: 63 V (p-p), 30 mA maximum output
Ambient Temperature: -40 C to +100 C
Operating Pressure: 3 bar maximum at tip, 10 bar at NPT fitting
Relative Humidity: 0 % to 100 %
Power Consumption: None
Ingress Protection: Hermetic sealed (all surfaces outside of conduit)
Installation
An Ex d certified sealing device such as a conduit seal with setting compound shall be provided
immediately to the entrance of the speed sensor. The setting compound in the conduit seal shall be
suitable for at least 120 °C.
Only wires rated for at least 100 °C shall be used for connections.
The mechanical and electrical installation shall only be carried out by trained personnel with knowledge of
the requirements for installation of explosion-proof equipment in hazardous areas.
The entire installation procedure shall be carried out in accordance with national, local, and company
regulations.
The entire electrical installation shall be carried out in accordance with International Standard IEC 60079-
14 for electrical equipment to be installed in hazardous areas.
Operation
The open circuit voltage will be less than the value marked on the sensor at all target surface speeds up
to 1000 IPS (25.4 m/s). The short circuit current will be less than the value marked on the sensor at all
target surface speeds up to 1000 IPS (25.4 m/s).
SIL Certified Versions
In order to achieve a SIL rating required by an overspeed SIF, the certified versions must be installed in
redundant configurations in accordance with the verified parameters of the sensors. See Product Spec
Sheet 03474. Woodward will provide the SIL certificate and report for the .SIL versions of these sensors
on request.
Maintenance and Troubleshooting
No periodic maintenance is required. MPUs are not field-repairable.
There is no fire or electrical shock hazard from the MPUs.
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 11
Troubleshooting Magnetic Pickups
Disconnect the pickup leads. Check between leads with an ohmmeter for resistance as listed below.
Check between the pickup case and leads with an ohmmeter for near infinite resistance. Start the prime
mover and control speed manually or block the throttle. Check pickup leads with a high-impedance ac
voltmeter for 10 to 20 V (ac, rms). Reconnect the pickup and check the speed sensor input terminals for a
minimum 1.5 V (ac, rms) at the lowest controlling speed. Check the pickup and gear clearance if voltage
is low.
MPU Resistance List
Long Standard Model 250 Ωmax
Extra Long Standard Model 250 Ωmax
Short Standard Model 220 Ωmax
Standard Metric Model 250 Ωmax
Conduit Model 114 Ωto 140 Ω
Explosion Proof Model 165 Ωto 225 Ω(also applies to SIL)
Inspect for physical damage. Replace pickup if faulty.
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 12
Chapter 2.
Proximity Switches
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
propert
y
dama
g
e.
General Information
Large engines usually have a larger air gap between the speed sensor probe and the monitored gear
than smaller engines. This is necessary because of the relatively large runout of the monitored gear in a
large engine. The monitored gears on large engines usually also have a slower surface speed. Because
of either or both of these conditions, a magnetic pickup may not perform satisfactorily on a large engine.
A proximity switch (zero velocity pickup) will, however, operate well on large engines because of its
abilities to operate with a large air gap and at low surface speeds.
The output of these pickups depends solely on the position of the gear tooth (or similar ferrous
discontinuity) and not the velocity at which the gear tooth passes the sensing end of the pickup.
When wired as a “sinking” type proximity switch, the output is normally zero. When a gear tooth is within the
sensing range of the proximity switch, the output of the switch goes “high” (nearly equal to the supply
voltage). After the tooth has passed, the output switches back to zero volts until another tooth comes into
position. Typical wiring for a “sinking” type proximity switch is shown in Figure 2-2.
When wired as a “source” type proximity switch, the output is normally “high” (nearly equal to the supply
voltage). When a gear tooth is within the sensing range of this proximity switch, the switch output goes to
zero volts. After the tooth has passed, the output switches back to nearly the supply voltage until another
tooth comes into position. Typical wiring for a “source” type proximity switch is shown in Figure 2-3.
The on-off nature of the output of a proximity switch produces a square wave which is compatible with
nearly all Woodward speed sensors and will directly replace the signal from a magnetic pickup as a
speed sensor input.
Proximity Switch Features
As long as the air gap between the sensor end of the proximity switch and the gear being monitored does
not exceed the sensing range of a particular proximity switch, changing the air gap will not change the
output voltage. The duty cycle of the signal from the proximity switch varies with the air gap, but this does
not change the reference signals produced in the Woodward control.
For proper operation there cannot be more than one tooth in the sensing field of a proximity switch, as the
distance between the teeth must be greater than the size of the sensing field.
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 13
Types of Proximity Switches
Two different sizes of proximity switch are available from Woodward:
1. A proximity switch with a fairly narrow sensing field, suitable for medium size gears with a tooth size
from diametral pitch 8 to 12 (gear module 3 to 2). This switch can be mounted flush with the
mounting plate with an air gap up to 5.00 mm (0.197 inch).
2. A proximity switch with a wide sensing field is available for large gears where a wide air gap
(maximum of 10 mm / 0.4 inch) is necessary. This sensor requires larger gear sizes for proper
operation and should be used for gears larger than diametral pitch 12 (gear module 2.1). There must
be a 30 mm (1.1 inch) radius clearance of metal around the front of the sensor and mounting
bracket.
Some Woodward controls have less than 300 Ωof dc impedance. In
these cases, the probe may be damaged by excess current when the
engine is stopped. To prevent this possible damage, a 300 Ω, 2 W
resistor should be installed in series with the probe.
Proximity Switch Power Supply
Proximity switches provided by Woodward require an external power supply of a single dc voltage,
usually 24 volts. This may be from the same supply source as power for the control system. The
maximum current rating for these proximity switches is 80 mA, but actual current is less and dependent
on the external load.
The red plastic cap on top of the proximity switch is an integral part
of the device, not a loose shipping cover. The proximity switch can
be dama
g
ed be
y
ond repair if an attempt is made to remove the cap.
Figure 2-1. Air Gaps for Radial and Axial Sensing Proximity Switches
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 14
Checking Proximity Switch Operation
To check the operation of a proximity switch, a load resistance must be placed across the terminals from
which the speed control speed sensor was removed. An oscilloscope may provide adequate load
resistance.
Proximity Switch Wiring
The proximity switches supplied by Woodward are wired for a “sinking” type output. Figure 2-2 shows a
typical wiring method. Other proximity switches, not supplied by Woodward, are wired dc “source”. Figure
2-3 shows a typical dc source wiring method. AC proximity switches are seldom used with Woodward
controls.
Figure 2-2. Suggested Wiring for a “Sinking” Type Proximity Switch
Figure 2-3. Suggested Wiring for a “Source” Type Proximity Switch
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 15
Appendix.
Using the Output of a Woodward MPU to Drive a
Remote Tachometer or Other Device
Attach to Control Posts
Should a remote device be driven by a magnetic pickup, it is important that the connection be made on
the governor posts which accept the input from the MPU. Polarity must be maintained as indicated on
these posts or it is possible to short the system to ground and cause damage to the electronic circuits,
rendering the governor inoperable. Woodward electronic controls are not directly grounded, but in many
cases the negative (–) post or common is tied to ground through the battery powered supply. Should an
additional device also be grounded or powered by the same grounded battery system, a short circuit is
possible.
The MPU device provided by Woodward is not grounded, and polarity is not established until connections
are made to the governor. Almost all remote devices will have a power source in addition to two leads for
input. One of these input connections will be circuit common (–) and this should be determined prior to
connection with the governor.
EPG and 2500 Governors
Since these units are indirectly tied to ground, care must be taken that polarity of the remote device and
the governor is not reversed.
2301 Governor
The 2301 governor is isolated from ground; care should be taken that any device added to the system is
also isolated from earth ground.
Shielding
Governor circuits have been carefully shielded, and circuits to remote devices must also be shielded from
interference since this could prevent adequate governor control. Inadequate shielding could cause
unstable control.
Minimum Signal
Most Woodward controls require a minimum speed-signal strength of 1.5 V (ac) from the magnetic pickup
during cranking. The addition of remote devices to the output of the magnetic pickup could prevent the
reception of an adequate signal to allow engine start-up.
before trying to start the engine after adding an auxiliary device to
the MPU output, make sure all polarity has been established and the
system is not shorted to ground. Attempting to start the system with
reversed polarity between the auxiliary device and the control could
destroy either or both devices. Should the control be damaged due
to the reversed polarity, dangerous overspeed is possible, which
could dama
g
e equipment, causin
g
personal in
j
ur
y
or even death.
Woodward advises dedicating the entire output of a governor
magnetic pickup to the exclusive use of driving the control system.
This information is provided for those installations where the output
of the ma
g
netic pickup is also used to drive other devices.
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 16
Revision History
Changes in Revision V –
Removed SIL3 drawings
Added notes for SIL versions of CSA/ATEX models (pages 10, 11)
Revised ambient temperature (page 10)
Changes in Revision U—
Added SIL3 drawing (Figure 1-3c)
Changes in Revision T—
Added Installation and Operation Safety Requirements summary
Released

Manual 82510 Magnetic Pickups and Proximity Switches
Woodward 17
This Page Left Intentionally Blank
Released

We appreciate your comments about the content of our publications.
Send comments to: [email protected]
Please reference publication 82510.
B82510:V
PO Box 1519, Fort Collins CO 80522-1519, USA
1041 Woodward Way, Fort Collins CO 80524, USA
Phone [phone]
Email and Website—www.woodward.com
Woodward has company-owned plants, subsidiaries, and branches,
as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
Released