The Woodward ProTech SX safety system is an IEC61508 SIL-2 certified safety PLC, designed for the safety protection of small engines, steam/gas/water turbines, and other equipment. It has a 12 millisecond fast response, 0.5-32000 RPM speed range, supports 2 redundant speed inputs and 10 analog/discrete inputs, and is equipped with 5 solid-state outputs and 4-20mA speed analog outputs. It integrates overspeed/acceleration/deceleration protection, trip valve health monitoring, log recording (50 trips/alarms+20 overspeed events), Modbus communication, and other functions, with a protection level of IP56. It can be programmed and configured through software tools and is suitable for personnel and equipment safety protection in critical scenarios.

Core parameters and hardware configuration

(1) Key performance parameters

Specific indicators for parameter categories

Response time of 12 milliseconds (from security event detection to shutdown command output)

Speed range 0.5-32000 RPM

Protection level IP56 (dustproof, anti strong water spray)

Working temperature -20 ° C to+60 ° C

The storage temperature is consistent with the working temperature

The clock function has a built-in real-time clock and supports external DCS time synchronization signal input

(2) Input configuration

Enter type specification details

There are two power input modes to choose from:

1. Dual redundant high voltage input (90-240 VAC/47-63Hz or 100-150 VDC, 30W)

2. Single high voltage+single low voltage input (high voltage as above, low voltage 18-32 VDC, 30W)

Speed input (2-channel redundant) Input 1: Supports MPU (100-32000 Hz, 1-35 Vrms), proximity probe (0.5-25000 Hz, 24 VDC), gear teeth 1-320

Input 2: Only supports MPU (parameters are the same as input 1), with gear teeth ranging from 1-320

Signal input (10 channels) includes 3 fixed discrete inputs (alarm/trip reset, start command, speed signal failure override)+7 configurable inputs (analog/discrete optional)

Special detection MPU open circuit detection (only applicable to MPU sensors, not applicable to active/proximity probes)

(3) Output configuration

Output type specification details

Discrete output (5 solid-state) and 2 shutdown relay outputs: 1A@24  VDC

3-channel programmable relay output: 1A@24 VDC (supporting functions such as alarm, trip, speed switch, etc.)

Analog output (1 channel) 4-20 mA, dedicated for tachometer reading output

Auxiliary power supply 24 VDC, 0.5 A, used for intermediate relay circuit

Core functions and features

protection function

Overspeed protection: Accurate monitoring of speed, triggering shutdown command when exceeding the set value

Acceleration and deceleration protection: optional configuration, detecting abnormal acceleration and deceleration through the derivative of the speed signal, triggering protection

Anti pollution design: using a special conformal coating that can withstand H ₂ S and SO ₂ gases of IEC 721-3-3 1994 Class 3C2 level

MPU open circuit detection: Verify the connection status of MPU sensors before startup and during operation to ensure signal reliability

Monitoring and diagnostic functions

Trip valve health monitoring: connect valve position/pressure sensors, monitor the response time from “trip command issued to valve closed”, support logging and alarm recording

Status feedback: Real time feedback on equipment operation status, input/output signal status, and integration with factory DCS

Programming and Configuration

Programming ability: Supports standard logic functions (AND, NAND, OR, NOR, XOR, XNOR, NOT), analog comparator, timer, delay, etc., customizable security logic

Configuration method: Programming through dedicated software service tools, supporting simplex/dual redundancy/TMR signal configuration

Security protection: Password protection function to prevent accidental operation or malicious modification of configurations

Logs and Communication

Log recording: non-volatile memory storage, no data loss during power outage

Trip/Alarm Log: Record the last 50 events (including timestamps)

Overspeed log: Record the last 20 overspeed events (including timestamps)

Communication interface: 1 serial communication port (supporting RS-232/RS-422/RS-485), Modbus protocol; Optional Ethernet gateway for factory Ethernet connection

Installation and physical specifications

Specification category specific parameters

Overall dimensions (including panel) 267 x 165 x 89 mm (10.5 x 6.5 x 3.5 inches)

Installation opening size 241 x 140 mm (9.5 x 5.5 inches)

Installation method: Embedded vertical installation (control panel or cabinet door)

Compliance certification

Regional/Standard Certification Details

North American CSA certification (Class I, Division 2, Groups A-D, T4, 60 ° C environment)

Europe  EMC Directive 2014/30/EU、ATEX Directive 2014/34/EU（II 3 G, Ex ec nC IIC T4 Gc）、LVD Directive 2014/35/EU、RoHS 2011/65/EU

UK Electromagnetic Compatibility Regulations 2016, Explosion proof Equipment Regulations 2016, Electrical Equipment Safety Regulations 2016

International IEC61508 SIL-2 (T Ü V certification) API670、API612、IEC60068-2-60、 Australian RCM certification (applicable only to EMC)

Woodward ProTech SX Simplex System (Product Manual 26546V2, Version A) is a safety protection system for engines, turbines, and other prime movers. Its core functions include overspeed/over acceleration protection, fault monitoring, and alarm, supporting 7 configurable inputs and 3 programmable relay outputs+1 4-20mA analog output. It has two levels of password permissions (test level/configuration level) and can be configured and tested online/offline through the front panel interface or programming configuration tool (PCT). It is compatible with Modbus communication, can record multiple logs, and provide fault diagnosis. Throughout the process, it must comply with safety operating standards to avoid personal injury or equipment damage.

Core functions and system features

Protection and monitoring core

Core protection: overspeed protection (set range 0-32000 RPM), over acceleration protection (0-25000 RPM/s)

Fault monitoring: speed loss, open circuit of speed sensor, power failure, internal module failure, etc

Status indication: Front panel LED (trip red light, health green light, alarm yellow light)+remote limit switch feedback

Input/output configuration

Input: 7 configurable inputs, supporting analog (4-20mA) or discrete signal types

Output: 3 programmable relay outputs（ 1A@30Vdc ）1 channel 4-20mA analog output (proportional to speed)

Permissions and Security Mechanisms

Password permission: Two level password (test level, configuration level), default is AAAAAA

Test level: Start testing, reset logs (excluding peak speed/acceleration logs), modify test level password

Configuration level: All test level functions+modify program settings, download configuration files, reset all logs

Security requirements: Compliant with NERC network security requirements, password supports letters, numbers, and special symbols (6-digit length)

Communication and Compatibility

Communication protocol: Modbus (slave mode), supports RS-232/RS-485 mode

Baud rate options: 19200/38400/57600/115200 bits/s, slave addresses 1-247

Detailed explanation of key operation modules

(1) Front panel interface operation

Key operations of module core functions

Monitor menu to view real-time data, configuration parameters, status indicators, browse RPM, acceleration, analog output, etc; View module information, date and time

Log viewing and retrieval of various event records support 8 types of logs, including overspeed/acceleration logs, trip logs, alarm logs, etc; Resettable log (password required)

Configuration menu basic parameter configuration setting speed input, startup logic, trip latch mode, analog output scaling, Modbus parameters

Test mode system function verification includes temporary overspeed test (<32000 RPM), simulated speed test (manual/automatic), 3 sets of user-defined tests, and indicator light test

(2) Programming Configuration Tool (PCT) Operation

PCT Basic Information

Installation method: Download from Woodward installation CD or official website (www.Woodward. com/software)

Operating environment: Based on Woodward ToolKit software, supporting Windows system

Operation level: offline mode (no device connection), testing level (online viewing/exporting logs), configuration level (online configuration modification)

core functionality

Configuration function: Modify parameters online (in device trip state)/offline, support custom logic programming such as logic gates, latches, timers, etc

Log management: View and export logs of trips, alarms, module failures, etc. (supports HTML format)

Configuration verification: Verify configuration consistency through CRC code and detect configuration errors (such as logical loops and input-output mismatches)

(3) Key configuration parameter description

Default value range for core parameters of configuration category

Speed Management Speed Redundancy Mode Single Speed/Double Redundancy Speed Single Speed

Maximum speed difference 0-32000 RPM 100 RPM

Overspeed trip setting 0-32000 RPM 1000 RPM

Start logic speed failure set point 0-25000 RPM 1000 RPM

Speed failure timeout time 1-28800 seconds 10 seconds

Simulate output 4mA corresponding to speed 0-32000 RPM 0 RPM

20mA corresponds to a speed range of 0-32000 RPM and 32000 RPM

Modbus configuration communication mode RS-232/RS-485 RS-232

Allow command writing Yes/No No

Test mode details

Test Type Test Purpose Key Parameter Operation Requirements

Temporary overspeed test verification overspeed trip function test set point 0-32000 RPM, timeout 0-1800 seconds device does not trip, test level/configuration level password required

Manual simulation speed test simulates overspeed scenario starting speed=trip set point -100 RPM, timeout 0-1800 seconds manually adjust simulation speed to trip point

Automatic simulation speed test, automatic verification of trip response, automatic ramp to trip set point without manual intervention, no timeout limit

User defined test validation supports 3 sets of tests for custom logic, configurable start/reset input, timeout time needs to be configured through PCT logic

The indicator light test verifies that the front panel LED cycle lights up the red light (trip), green light (health), and yellow light (alarm) without the need for a password, and can be executed at any time

Safety operation standards

Pre security requirements

Equipment protection: The prime mover needs to be equipped with an independent overspeed shutdown device to avoid the risk of loss of control

Personal protection: Wear goggles, safety helmets, gloves and other PPE during operation

Electrostatic protection: Discharge before coming into contact with electronic components to avoid plastic/vinyl materials coming into contact with circuit boards

Operation restrictions

Configuration modification: The configuration can only be modified when the device is in a tripped state, otherwise operation is prohibited

Password management: Password forgotten cannot be reset, need to return to Woodward for processing

Unauthorized modification: Modifications beyond the rated parameter range are prohibited, otherwise the warranty and certification effectiveness will be lost

Key issue

Question 1: What are the configuration methods for ProTech SX system and what are the core configuration limitations?

Answer: The system supports two configuration methods: ① Front panel interface configuration, which can modify basic parameters such as speed input, startup logic, and analog output; ② Programming Configuration Tool (PCT) configuration, supports online (device needs to trip+configuration level password) and offline configuration, customizable logic (logic gates, timers, etc.) and exported logs. The core configuration restrictions include: configuration modifications must be made while the device is in a tripped state; PCT online configuration requires establishing a serial communication link and entering a configuration level password; Configure to avoid logical loops (by inserting unit delay blocks for cracking); The input and output types need to match (analog inputs cannot be connected to logic gates, discrete inputs cannot be connected to comparators), otherwise configuration errors will be triggered.

Question 2: What types of log management functions does ProTech SX include, and how do I reset or export logs?

Answer: The log types include 8 types of core logs: overspeed/acceleration log, trip log, alarm log, trip cycle time log, event log (3 groups), and peak speed/acceleration log. Log operation method: ① Reset log: It can be operated on the front panel or PCT. Resetting “all logs” requires a test level/configuration level password, while resetting “peak speed/acceleration logs” only requires a configuration level password; ② Export logs: Only through the PCT tool, it supports saving logs as HTML format files, which can view detailed information such as event ID, timestamp, and first out fault; ③ Log features: The timestamp is based on the internal clock at the time of the event occurrence, and modifying the system time does not affect the historical log. A single type of log can store up to 50 events.

Question 3: What are the testing modes of ProTech SX, and what are the applicable scenarios and operational requirements for different tests?

Answer: The system includes four types of testing modes, and the applicable scenarios and operational requirements are as follows: ① Temporary overspeed test: suitable for verifying the tripping response of the actual hardware speed signal, the device speed needs to be increased to the testing set point within the test timeout (0-1800 seconds), and a test level/configuration level password is required; ② Simulated speed test (manual/automatic): suitable for verifying trip logic when there is no actual speed. Manual mode requires manual adjustment of simulated speed, while automatic mode automatically accelerates to the trip point. Both require a password and the device has not tripped; ③ User defined testing: suitable for verifying custom logic (such as tripping/alarm triggered by specific faults), requires PCT configuration to start/reset conditions, supports 3 independent tests; ④ Indicator light test: suitable for quickly verifying the function of the front panel LED, no password required, can be executed at any time, and the red/green/yellow LED lights up cyclically.

Core Applications and Design Concepts

Scope of application:

Target device: Steam turbine driven by mechanical drive or generator drive

Hydraulic conditions: Low pressure trip oil main (pressure range 5-25 bar/73-363 psi)

Installation advantages: Compact structure, can be installed near the turbine and trip throttle valve, reducing pipeline length and system delay

Design Core:

Safety mechanism: 2 out of 3 voting design, 3 independent rotating solenoid valves, no component failure will cause false tripping

Redundant design: Supports 1 or 2 redundant 24Vdc power supplies, isolated discrete input signals, and no single point of failure

Core objective: To ensure the running time and availability of turbines, and meet critical application requirements

Key features and advantages

Specific description of characteristic categories

Anti pollution and anti-corrosion design – no easily clogged throttling holes, avoiding maintenance difficulties

-25 pound rotating chip force, capable of handling oil stains/impurities

-Self cleaning valve+corrosion-resistant material to prevent sticking/dragging

-Adapt to common pollutants (metal shavings, water, Babbitt alloy, ammonia, etc.) and environments with sludge and paint film in turbine oil

Fast response performance: Electromagnetic coil response time * *<30 milliseconds * *, ensuring that the tripping system quickly closes the valve

Maintainability – Online Repackability: Modular design, replaceable key components such as electromagnetic coils and electrical modules (during turbine operation)

-Online testable: equipped with Woodward ProTechTPS logic solver to achieve routine diagnosis and trip time monitoring

Status indication – local: red and green LED (running/tripping status), blue LED (power health status) (visible through the observation window)

-Remote: Integrated limit switch, supporting safety system and factory DCS status verification

Technical specification details

(1) Physical parameters

Parameter values

Dimensions (length x width x height) 46 x 63.5 x 24.5 cm (17 x 25 x 9.6 inches)

Weight 114 kg (252 lb)

Installation method in any posture (8 mounting bolt holes on the back and bottom)

Protection level IP66 (compliant with EN 60529)

(2) Electrical parameters

Parameter values

Input power supply 24 Vdc ± 10%, 3.0 A per electromagnetic coil

Discrete input isolated type, requiring 24 Vdc wetting voltage

Discrete output rated value 1 A @ 30 Vdc

Redundant design supports 1 or 2 redundant power inputs

(3) Hydraulic parameters

Parameter values

Supply pressure range 5-25 bar (73-363 psi)

Oil flow CV grade 10.0

Compatible with fluid types such as mineral oil, synthetic oil, and Fyrquel EHC base oil

Recommended oil cleanliness nominal 24-40 ppm, maximum β 75 (ISO 4406 code 20/18/16 level)

Recommended viscosity of 20-100 centixtles

Fluid port SAE J518 Code 61, diameter 31.8 mm (1.25 inches)

(4) Environmental parameters

Parameter standards and numerical values

Working temperature range -40 to+85 ° C (-40 to+185 ° F)

Working oil temperature range+15 to+70 ° C (+59 to+158 ° F)

Impact test US MIL-STD 202F, Method 213B, Test Cond. J (30 G, 11 ms half sine pulse)

Vibration test US MIL-STD 810F, M514.5A, Cat. 4 (0.04 G ²/Hz, 10-500 Hz, 2 hours per axis, 1.04 Grms)

Compliance Certification and Standards

Industry standard compliance: API-670 (5th edition, supports in operation testing) API-612、API-611

International Security Certification:

IEC61508: T Ü V certification, applicable to safety systems up to SIL-3

Hazardous Area Certification: ATEX Directive 94/9/EC (Zone-1 Category 2, Zone-2 Category 3); GOST-R certification (Russian explosive environment)

CE certification: EMC Directive 2004/108/EC、Machinery Directive 98/37/EC、Pressure Equipment Directive 97/23/EC（SEP  Category)

System Integration and Working Principles

Control logic: At least 2 electromagnetic coils need to be de energized before opening the channel from the tripped oil main to the system discharge

Adaptation components: Paired with Woodward ProTechTPS security logic solver, achieve:

Routine diagnostic tests during operation

Trip time response monitoring and recording

Meet the online testing requirements of API-670 for non final components (trip valves)

Signal interaction: Receive 3 independent discrete input trip commands (from safety logic solver), output position feedback signals to DCS/safety system

Key issue

Question 1: What are the core safety design and certification highlights of QuickTrip electro-hydraulic trip block components, and how do they ensure the reliability of critical applications?

Answer: Core safety design and certification highlights include: ① 2 out of 3 voting mechanism, with 3 independent rotating solenoid valves forming redundancy, no single point of failure, and no component failure causing false tripping; ② SIL-3 safety certification (T Ü V certified according to IEC61508 Parts 1-7), suitable for high safety level systems; ③ Compliant with API-670/612/611 industry standards, supporting in operation testing (compliant with API-670 5th edition requirements). These designs align with industry standards through redundant architecture, safety certification, and mechanisms to prevent the expansion of failures and ensure the operational availability and safety of critical equipment such as steam turbines.

Question 2: What are the targeted designs of QuickTrip in terms of anti fouling performance, and what pain points can it solve in steam turbine applications?

Answer: Anti pollution targeted design includes: ① no easily clogged throttle holes, avoiding maintenance problems caused by traditional components due to throttle hole blockage; ② 25 pound rotating chip force, capable of breaking impurities in oil; ③ Self cleaning valve design+corrosion-resistant materials to prevent jamming or dragging. These designs can solve common pain points in steam turbine applications: turbine oil is prone to mixing with metal shavings, water, Babbitt metal and other pollutants, and can easily produce sludge and paint film at high temperatures, causing traditional trip blocks to jam, fail or maintain frequently. QuickTrip can operate reliably in such harsh oil environments, reducing maintenance costs.

Question 3: Which key parameters in QuickTrip’s technical specifications determine its installation adaptability and operational stability?

Answer: The key parameters that determine installation adaptability and operational stability include: ① Installation adaptability: size 46 × 63.5 × 24.5cm, weight 114kg, support for any installation posture, can be installed near the turbine, suitable for new units or renovation projects; ② Environmental adaptability: Operating temperature -40~+85 ° C, IP66 protection, Zone-1/2 hazardous area certification, suitable for complex working conditions; ③ Operational stability:<30ms electromagnetic response speed ensures timely tripping, 5-25bar hydraulic pressure range, compatible with multiple hydraulic oils, meeting different system requirements; 24Vdc redundant power input+isolated discrete signal to enhance electrical system stability.

Product Core Overview

Application scenario: Designed specifically for gas/steam turbine shutdown systems, it is used to quickly and reliably discharge the turbine trip oil main, suitable for critical applications with high requirements for turbine operating time and availability.

Design Core:

Triple redundancy and fault tolerance design, adopting a 2 out of 3 voting mechanism, in compliance with API-670 industry standards.

Hardware fault tolerance: A single failure will not cause the turbine to shut down.

Key advantages:

Technological maturity: Based on the existing mature technology optimization of CPC II/VariStroke I.

Safety certification: SIL-3 level certification (TUV independent evaluation, compliant with IEC 61508 Parts 1-2/4-7:2010, IEC 61511 Parts 1-3:2004).

Performance indicators: Fast response (<50ms, loss of control signal to valve opening), fail safe operation (fail open).

Adaptability: Compatible with mineral and synthetic hydraulic oils; Meet the explosion-proof requirements of North American Class I Zone 1/2 and European Zone 1/2.

Auxiliary functions: local visual position indication, remote position feedback.

Technical comparison and design features (compared to CPC II/VariStroke I)

Key Explanation of Technical Module Comparison

The rotating inner valve core element is made of stainless steel material consistent with VariStroke I, with low driving force, high flow rate, and high pollution resistance

The outer sleeve component is independently designed with stainless steel material, which is corrosion-resistant

Dual axis bearings are consistent with VariStroke I and use mature bearing technology

The shaft seal shares the existing seal design reliability with both, ensuring consistency

The valve drive (LAT stator coil/magnetic rotor) technology is consistent, with upgraded specifications for larger LAT sizes, providing stronger driving force

The fault safety reset spring technology is consistent, and the material upgrade results in thicker springs, providing higher fault safety operating torque

Printed circuit board components (PCBA) are more simplified with no active components and have a more reliable structure

The hydraulic connection is consistent with VariStroke I and uses a 1.25 “61 type hydraulic flange

Newly added component observation window with a maximum design pressure of 100 bar, meeting visualization requirements

Key performance validation and testing

Reliability index:

Average Probability of Demand Failure (PFDAvg): 9.44E-06

Mean Time Between Failures (MTBF): 4950000 hours

Mean Time Between Hazardous Failures (MTBFD): 70600000 hours

Design lifespan: 20 years (including 1.5 years of storage period, no maintenance required)

Endurance life test:

Basic testing: 21000 trip cycles (covering maximum working hydraulic pressure under extreme high and low temperature conditions), equivalent to 3 times the typical service life, and all components meet specifications.

Extreme test: An additional 1000000 trip cycles without abnormal wear, calculated based on one cycle per day, equivalent to over 2700 years of operating life.

Stain resistance test:

Test conditions: Hydraulic oil contains pollutants such as iron oxide and Arizona road dust.

Result: No failure, no jamming/dragging phenomenon, no need to rely on easily problematic throttle holes and pressure gauges, reducing maintenance requirements.

Shock and vibration testing:

Impact test: Complies with US MIL-STD-810C method 516.2 (10G peak, 11ms duration, sawtooth wave, XYZ axis).

Vibration test: Complies with US MIL-STD 810F, M514.5A (0.015G ²/Hz, 10-500Hz, 1.04 Grms, 2 hours per axis).

Result: No component failure, no premature wear, and no false tripping.

Online testing and maintainability

Online testing capability:

Adaptation device: Woodward ProTechTPS security logic solver (or MicroNet security module).

Function: Automatically perform routine safety system diagnostic tests, support trip time response monitoring and recording.

Advantages: Regular health check ups, early fault detection, and trend analysis of trip time performance.

Online maintainability:

Modular design: The solenoid valves, electrical modules, power supplies, and wiring of each valve can be independently repaired/replaced.

Repackable components: solenoid valve coil (LAT), electronic module (PCBA with position sensor), upper cover/observation window, lower cover/reset spring, rotor (corresponding module needs to be powered off during maintenance).

The core positioning is a heavy-duty hydraulic power cylinder designed specifically for extremely hazardous environments, compatible with Woodward VariStroke series servo valves/slide tables, used for steam turbine valve control

Application scenarios and adaptation relationships

（1） Core applications

Target areas: Oil and gas, petrochemical, and power generation industries

Control objects: steam turbine control valve, valve frame, trip throttle valve (T&TV)

Adaptation to working conditions: extremely hazardous environments (Zone1/Zone2), low-pressure hydraulic systems (relying on turbine lubricating oil)

（2） Adaptation components

Compatible with VHPC type core requirements for compatible products

VS-I servo valve double acting pressure acts on both sides of the piston

VS-II servo valve double acting pressure acts on both sides of the piston

VS-GI servo valve single acting pressure only acts on one side of the piston

VS-DX hydraulic slide table single acting pressure only acts on one side of the piston

Product Core Features

（1） Structure and configuration types

Configuration Type Core Features Applicable Scenarios

The double acting model does not have a quick release valve/port option, and the pressure driven piston moves in both directions with the VS-I/VS-II servo valve in the conventional control scenario

Single acting models can choose built-in reset springs, pressure driven+spring reset with VS-GI/VS-DX for safety control scenarios

The single acting discharge valve model integrates a fast discharge valve, which can quickly relieve pressure in scenarios where high-speed switching or separation of control/safety systems is required

Single acting discharge valve port model with reserved discharge valve interface, supporting users to self configure redundant trip components for high critical applications (dual/triple redundant trip requirements)

（2） Key functional highlights

Side load tolerance: Supports continuous side load up to 5% of the output force. Through high-precision bearings and triple sealing technology, it reduces shaft seal wear, avoids oil leakage, and solves the pain points of side load caused by the arc-shaped movement of the connecting rod

Flexible configuration options: Single acting models can choose whether to integrate reset springs, quick release valves, and release valve ports; The position sensor supports MLDT (high precision) or LVDT (conventional precision) to meet different precision requirements

Extreme environment adaptation: chrome plated piston rod, protective feedback sensor, stepped buffer design, matched with IP66 protection level, suitable for extreme working conditions such as high temperature and multiple impurities

Safe and reliable design: The rapid discharge valve has a fully open time of less than 250ms, supports direct drive of the turbine shutdown system, and achieves emergency pressure relief; Tested one by one before leaving the factory, with an 18 month warranty provided

（3） Comparison of Position Sensor Parameters

Sensor type, power supply/excitation parameters, output parameters, linearity, core advantages

MLDT 20.4-28.8Vdc @ 100mA 2-channel 4-20mA, maximum load 500 Ω± 0.02% full stroke high-precision, dual redundancy, suitable for high temperature environment of 85-105 ℃

LVDT 3.0VRMS @ 5000Hz voltage ratio output: (Va Vb)/(Va+Vb)=± 0.5VRMS ± 0.5% full stroke conventional accuracy, suitable for ordinary working conditions

Key specification parameters

（1） Environmental and Protection Parameters

Parameter values

The working environment temperature ranges from -40 ℃ to+105 ℃ (-40 ℉ to+221 ℉), depending on the fuel supply temperature

Working oil temperature+15 ℃~+70 ℃ (+59 ℉~+158 ℉)

The impact resistance performance complies with US MIL-STD-810C method 516.2 (10G peak, 11 millisecond duration)

Anti vibration performance meets US MIL-STD-810F M514.5A (0.015 G ²/Hz, 10-500Hz)

Protection level IP66 (IEC/EN 60529)

（2） Hydraulic parameters

Parameter requirements

Working pressure range: 3.44 bar~34.5 bar (50 psi~500 psi)

Oil type: mineral oil, synthetic oil, or Fyrquel EHC base oil

Recommended maximum oil cleanliness ISO 4406 code 20/18/16 level (nominal 24-40 μ m, β 75)

Recommended oil viscosity is 20-100 centixtles

Interface standard hydraulic ports comply with SAE J518 Code 61

Maximum return oil pressure 2 bar (29 psi)

（3） Quick release valve parameters (single acting with valve model)

Parameter values

Supply voltage 24Vdc

Power consumption of 20W

Full open time<250 milliseconds

Full closing time<2.0 seconds

Compliance certification

Regional/Standard Certification Content

European (CE) EMC Directive 2014/30/EU; ATEX Directive 2014/34/EU (Zone1: II 2 G Ex db IIB T4 Gb; Zone2: II 3 G Ex nA IIC T4 Gc)

Other European Standard Machinery Directive 2006/42/EC (partially completed machinery); Pressure Equipment Directive 2014/68/EU (SEP category)

International IECEx certification (Zone1: Ex db IIB T4 Gb; Zone2: II 3 G Ex nA IIC T4 Gc)

North American CSA certification (Class I, Div.1 Groups C&D T4; Class I, Div.2 Groups A-D T4), applicable to the United States and Canada

The core positioning is a high reliability single acting electro-hydraulic actuator designed specifically for steam turbine valve control, supporting redundant configuration and on-site customization

Application scenarios and core values

（1） Main applications

Control objects: steam turbine control valves, valve racks, trip throttle valves (T&TV)

Adaptation equipment: Mechanical or generator driven steam turbine

Additional scenario: retrofit replacement of old servo systems/manual valves to solve the problems of difficult spare parts and complex calibration

（2） Core values

Safety guarantee: single acting design+built-in reset spring, automatically closes the valve in case of failure, meeting the safety requirements for failure

Convenient operation and maintenance: Factory pre assembly testing, on-site configuration through service tools, reducing installation and calibration time

Environmental adaptation: Anti fouling design is suitable for harsh oil environments, and the ability to withstand lateral loads solves the problem of shaft seal leakage

Flexible adaptation: supports multiple stroke and aperture selections, optional discharge valve configuration, adapts to different valve control requirements

​Product Core Features

（1） Structure and redundancy design

Core structure: Single acting power cylinder (optional internal/external reset spring)+integrated electronic drive module+rotary servo valve+dual redundant MLDT position feedback sensor

Redundancy function: dual 4-20mA demand input (supports single channel/dual channel average/high/low mode), dual MLDT position feedback, can still operate normally even if a single component fails

Configuration method: Connect the computer service tool through the RS-232 interface to configure functions such as travel, linearization parameters, and soft stop on site

（2） Key functional highlights

Anti fouling design: using corrosion-resistant materials, single movement rotary valve, 50 pound chip shear force, and self-cleaning port design, suitable for turbine lubricating oil environments containing impurities and sludge

Side load tolerance: Supports continuous side load up to 10% of the actuator output force, reducing shaft seal wear and oil leakage through high-precision bearings and special sealing technology

Soft stop function: The deceleration point above the valve seat can be configured to slow down the valve closing speed and extend the service life of the valve and valve seat

Quick release valve option: optional integrated Simplex quick release valve (or only reserved port), supporting direct drive of turbine shutdown system to achieve quick pressure relief

T&TV specific configuration: supports lifting commands, partial stroke testing, suitable for trip throttle valve applications, can provide valve position feedback through analog/discrete signals

（3） Product configuration type

Configuration Type Core Features Applicable Scenarios

Single acting integrated power cylinder with compact structure and built-in reset spring for conventional turbine control valve

Single acting remote power cylinder and servo separation installation space limited scenario

Single acting integrated power cylinder with quick release valve and Simplex release valve, regulating valve/T&TV that requires high-speed switching for quick pressure relief

Single acting integrated power cylinder with exhaust valve port reserved exhaust valve interface, supporting high critical applications (requiring dual/triple redundant tripping) with user provided redundant tripping components

Key specification parameters

（1） Performance parameters

Parameter values

Positioning accuracy ± 2% of full range

Positioning repeatability accuracy ± 1% of full range

Temperature drift 0.04%/℃

The built-in reset spring of the fail safe servo valve forces the valve to close

The speed of opening/closing the sled can be configured, with a maximum of 1140mm/s (without discharge valve)

Partial itinerary testing support (T&TV application)

Linearization function supports valve flow linearization table configuration

（2） Physical parameters

Parameter details

Travel range 50.8mm (2 inches), 76.2mm (3 inches), 101.6mm (4 inches), 152.4mm (6 inches), 203.2mm (8 inches), 254mm (10 inches), 304.8mm (12 inches)

Aperture specifications 101.4mm (4 inches), 127mm (5 inches), 152.4mm (6 inches), 203.2mm (8 inches), 254mm (10 inches)

Maximum stall force retraction direction: 2300-14200kgf@34.5bar （ 5080-31300lbs@500psig ）； Extension direction: 2850-17800kgf@34.5bar （ 6280-39200lbs@500psig ）

Installation method at any angle (bolt style and size depend on the model)

Protection level IP66 (IEC/EN 60529)

（3） Environmental and electrical parameters

Category parameter values

Environmental parameters Working environment temperature -40 ℃~+85 ℃ (-40 ℉~+185 ℉)

Working oil temperature+15 ℃~+70 ℃ (+59 ℉~+158 ℉)

The impact resistance performance complies with US MIL-STD-810C method 516.2 (10G peak, 11 millisecond duration)

Anti vibration performance meets US MIL-STD-810F M514.5A (0.015 G ²/Hz, 10-500Hz)

Electrical parameters: Supply voltage 18-32Vdc (steady-state current 2.3A, peak 10A/100ms)

Analog input isolation 4-20mA (input impedance 200 Ω), dual redundancy

Analog output 4-20mA (maximum external load 500 Ω)

Discrete input optical isolation (requires 24Vdc wetting voltage)

Discrete output 0.5A@24Vdc

Service tool port RS-232 communication

（4） Hydraulic parameters

Parameter requirements

Working pressure range: 3.45 bar~34.5 bar (50 psi~500 psi)

Oil type: mineral oil, synthetic oil, or Fyrquel EHC base oil

Recommended maximum oil cleanliness ISO 4406 code 20/18/16 level (nominal 24-40 μ m, β 75)

Recommended oil viscosity is 20-100 centixtles

Interface standard hydraulic ports comply with SAE J518 Code 61

Steady state oil consumption maximum 10.8L/ min@34.5bar (2.8 US gallons per minute @ 500pg)

358L/min at a maximum flow rate of 5.5 bar (95 US gallons per minute at 80 PSI); 929L/min at 34.5 bar (245 US gallons per minute at 500 sig)

Compliance certification

Regional/Standard Certification Content

European (CE) EMC Directive 2014/30/EU; ATEX Directive 2014/34/EU (Zone2: II 3 G Ex nA IIC T4 Gc IP66)

Other European Standard Machinery Directive 2006/42/EC (partially completed machinery); Pressure Equipment Directive 2014/68/EU (SEP category)

International IECEx certification (certificate IECEx 13.0041X, Zone 2: II 3 G Ex nA IIC T4 Gc IP66)

North American CSA certification (Class I, Div.1 Groups C&D T4; Class I, Div.2 Groups A-D T4), applicable to the United States and Canada

The core positioning is a high availability dual redundant hydraulic servo system designed specifically for key API612 steam turbines, supporting online maintenance and reducing unplanned downtime

Application scenarios and adaptation relationships

（1） Core applications

Adaptation equipment: Mechanical or generator driven steam turbine

Control objects: steam turbine control valves, valve racks, Trip&Throttle Valves

Applicable scenarios: API612 standard steam turbine applications that require extremely high system uptime (such as key equipment in the petrochemical and power industries)

（2） Adaptation components

Must be paired with Woodward VariStroke hydraulic power cylinder (VHPC), to be ordered separately

Adaptation basis: Select the aperture, stroke length, reset spring force and other parameters of VHPC according to application requirements

Reference documents: VHPC Product Specification (No. 03465), VariStroke GI Product Specification (No. 03464)

Core composition and working principle of the product

（1） Core components

Core components: 2 independent VariStroke GI linear electro-hydraulic actuators (integrated electronic drive module, servo valve, MLDT position feedback sensor)

Auxiliary components: integrated manifold, manual isolation valve (with tag locking function), hydraulic pipeline, pressure gauge, electrical wiring terminal (Zone2 model including junction box)

Switching component: specially designed fast switching shuttle valve, achieving disturbance free switching between master/slave servo valves

（2） Work logic

Control mode: Master/Slave logic, with one servo valve as the master and the other as the slave by default

Slave state: The slave servo valve tracks the health status of the master servo valve in real time and does not participate in the control output

Switching mechanism: Automatically switch to slave control in case of master control failure (≤ 70ms), or manually switch through local switch or external relay (≤ 60ms)

Isolation function: The integrated isolation valve can isolate any servo valve separately without affecting the normal operation of another servo valve

Core Features

（1） Redundancy and high availability

Full dimensional redundancy: dual servo valves, dual redundant power input, dual 4-20mA demand signal input, dual power cylinder position feedback signal

Online maintenance: supports online repair, replacement, testing, and calibration of servo valves without the need for downtime

Fault transfer: The automatic fault transfer logic is built-in and does not require external control logic or interfaces. It switches quickly (≤ 70ms) and minimizes system disturbances

（2） Convenience and Monitoring

Status indication: Integrated with a large pressure gauge, visually displaying the current pressure of the main control servo valve and output oil main pipe; Discrete output relays can be connected to DCS or indicator lights for remote monitoring of master/slave status

Easy installation: Factory pre assembled and tested, significantly reducing manufacturing, installation, and testing time for OEMs and end-users

Convenient operation and maintenance: equipped with isolation switch type electrical wiring terminals, easy to isolate and replace servo valves; Isolation valve with tag locking protection, in compliance with safety regulations

（3） Environmental adaptability

Adaptation to hazardous environments: Two types of hazardous environment certification models, Zone1 and Zone2, are available

Model difference: Zone2 model includes a top electrical junction box (integrating all control interfaces and connecting wires); Zone1 models do not have junction boxes and require users to install Zone1 certified junction boxes separately or directly connect servo valves

Key specification parameters

（1） Performance parameters

Parameter values

The maximum manual switching time is 60 milliseconds

The maximum automatic failover time is 70 milliseconds

Maximum distance from the power cylinder is 10 meters (32.8 feet)

（2） Physical parameters

Model size (length x width x height) Weight Installation method

Zone2 model 629.9mm × 968.2mm × 724.9mm (24.8 inches × 38.12 inches × 28.54 inches) 200kg (400lbs) horizontal installation

Zone1 model 401.3mm x 968.2mm x 432.6mm (15.8 inches x 38.12 inches x 17.03 inches) 200kg (400lbs) horizontal installation

（3） Environmental parameters

Parameter Range

Working environment temperature -40 ℃~+85 ℃ (-40 ℉~+185 ℉)

Working oil temperature+15 ℃~+70 ℃ (+59 ℉~+158 ℉)

The impact resistance performance complies with US MIL-STD-810C method 516.2, procedure 1 (10G peak, 11 millisecond duration)

（4） Hydraulic parameters

Parameter requirements

Working pressure range 3.44 bar~35 bar (50 psi~500 psi)

Oil type: mineral oil or synthetic oil

Recommended maximum oil cleanliness ISO 4406 code 20/18/16 level (nominal 24-40 μ m, β 75)

Recommended oil viscosity is between 20 and 100 centimeters per liter

Interface standard hydraulic ports comply with SAE J518 Code 61

（5） Compliance certification

Regional/Standard Certification Content

European (CE) EMC Directive 2014/30/EU; ATEX Directive 2014/34/EU (Zone1: II 2 G Ex db IIB T4 Gb; Zone2: II 3 G Ex nA IIC T4 Gc IP66)

International IECEx certification (Zone1: II 2 G Ex db IIB T4 Gb; Zone2: II 3 G Ex nA IIC T4 Gc IP66)

North American CSA certification (Class I, Div.1 Groups C&D T4; Class I, Div.2 Groups A-D T4), applicable to the United States and Canada

Product Value and Advantages

High availability: redundant design+online maintenance, significantly reducing the risk of unplanned downtime and improving the stability of turbine operation

Low cost: Factory pre integration testing reduces on-site construction and debugging costs; Built in switching logic, no additional external control module required

Easy operation and maintenance: Isolation valves and dedicated wiring terminals simplify the maintenance process; Clear status indication for easy monitoring and troubleshooting

Strong adaptation: Supports VHPC of different specifications and adapts to various steam turbine application needs; Compliant with API612 standard, strong compatibility

Basic Information

Type: Installation, Operation, and Maintenance Manual for VS-I Electro Hydraulic actuator

Applicable scenarios: Designed specifically for precise control of steam turbine valves, suitable for fields such as electricity and industrial power

Core value: Provide full lifecycle guidance from product recognition, installation, configuration to maintenance, ensuring safe and stable operation of equipment

Core safety requirements

（1） Warning definition and protection principles

Danger (DANGER): Failure to avoid causing death or serious injury

Warning: Failure to avoid may result in death or serious injury

CAUTION: Failure to avoid may result in minor or moderate injury

Notice: May only cause property damage

Important: Operation tips or maintenance recommendations

（2） Key safety measures

Anti static protection: Release human static electricity before contacting the equipment, avoid non anti-static materials from approaching the circuit board, and do not touch PCB components

Explosion proof compliance: Some models are suitable for Class I, Div.1/2, ATEX Zone 1/2 and other hazardous areas, and wiring must comply with corresponding specifications

Personal protection: PPE such as goggles, hearing protection equipment, helmets, gloves, and safety boots should be worn during operation

High pressure/overspeed protection: The hydraulic system needs to be equipped with independent overpressure protection, and the steam turbine needs to be equipped with an independent overspeed shutdown device

Live operation restrictions: It is prohibited to plug or unplug power supplies, modules, or cables with power in hazardous areas

（3） Compliance requirements

Key requirements for the scope of application of compliance standards

ATEX Directive 2014/34/EU Zone 1/2 Zone 1：II 2 G Ex db IIB T4 Gb； Zone 2：II 3 G Ex nA IIC T4 Gc

CSA Class I, Div.1/2 is applicable to Canada and the United States, Groups A-D T4

IECEx Zone 1/2 international explosion-proof certification, Ex db IIB T4 Gb（Zone 1）

CE (EMC) complies with Directive 2014/30/EU in the EU region

Product specifications and structure

（1） Core specification parameters

Category key parameter details

Physical parameters aperture 4/5/6/8/10 inches (100/127/150/200/250mm)

Rod diameter 1.75/2.5/3.5/4.5 inches (corresponding to aperture)

The electronic travel is adjustable, and the maximum mechanical travel depends on the model

Electrical parameters: Supply voltage 18-32Vdc (nominal 24Vdc), steady-state current 2.3A, transient 10A (100ms)

Input signal 2-channel redundant 4-20mA demand signal (input impedance 200 Ω)

Output signal 1 channel 4-20mA position feedback (load ≤ 500 Ω), 4 channels discrete output (0.5A/32Vdc)

Position sensor integrated with MLDT (magnetostrictive linear displacement sensor), accuracy ± 0.04%

Hydraulic parameters: minimum working pressure of 5.5 bar (80 psi), maximum working pressure of 34.5 bar (500 psi)

Oil type: petroleum based hydraulic oil or fire-resistant hydraulic oil (such as Fyrquel EHC)

The oil temperature is continuously between 15-70 ℃ (59-158 ° F)

Cleanliness requirements ISO 4406 code 20/18/16 or higher

Environmental parameters Operating temperature ambient: -40 to 85 ℃ (-40 to 185 ° F)

Protection level IP66 (IEC 60529)

Vibration/impact complies with MIL-STD 810F/G standard

Performance parameter positioning accuracy ± 1% full stroke

Repetitive accuracy ± 0.5% full stroke

Temperature drift MLDT: 0.04%/℃

Failure protection servo valve reset spring+optional spring assist to ensure valve closure

（2） Product structure type

Integrated: servo valve, hydraulic cylinder, electronic drive module integrated design, easy installation, suitable for spacious scenarios

Remote: The servo valve and hydraulic cylinder are installed separately, with a maximum distance of 3m, suitable for limited space scenarios, and attention should be paid to pipeline pressure loss

Remote Servo Only: Only provides servo valves and electronic drive modules, compatible with user’s own hydraulic cylinder (must meet position sensor requirements)

Installation process

（1） Preparation before installation

Receiving inspection: Check the appearance of the equipment for any damage, and verify that the model, serial number, and order are consistent

Unpacking requirements: Keep the hydraulic and electrical interface protective covers until they are removed during installation

Environmental preparation: Ensure that the installation area is free of pollutants, away from high temperature sources (such as uninsulated steam pipelines), and reserve maintenance space

（2） Mechanical installation

Installation orientation: The hydraulic cylinder can be installed at any angle, and the servo valve must not be inverted (vertical installation is recommended)

Bolt torque: Select the bolt grade (10.9 grade) according to the aperture, with a torque range of 50-400N · m (refer to Table 3-1 for details)

Lifting requirements: Use the equipment’s built-in lifting ears for vertical transportation, and prohibit lifting the entire equipment solely through servo valve lifting ears

（3） Hydraulic connection

Pipeline requirements: Integrated type requires connection of oil supply (1.25-inch SAE Code 61 flange) and return oil (1.5-inch SAE Code 61 flange); Remote additional control port (1.0-inch SAE Code 61 flange)

Pipeline flushing: Thoroughly flush the hydraulic pipeline before installation to prevent impurities from entering the servo valve

Connection torque: Oil supply/return interface bolt torque 34-61N · m, control port 25-35N · m

（4） Electrical connection

Power Connection: Supports single power supply or dual redundant power supply, cable specification 1.5-2.5mm ² (12-16AWG), maximum wiring distance 30m

Signal connection: Shielded twisted pair cables are used for analog signals, with cable specifications ranging from 0.14-1.5mm ² (16-24AWG), and the shielding layer is grounded at one end

Grounding requirements: PE grounding (2.5mm ² green/yellow cable) and EMC grounding (>3mm ², length<46cm), torque 5.1N · m

Service Tools and Calibration Configuration

（1） Service tool installation

System requirements: Windows 7/Vista SP1/XP SP3 (32/64 bit),. NET Framework 4.0, 1GHz CPU, 512MB RAM

Installation method: Download the installation package (9927-2177 series) through the accompanying CD or Woodward official website

Connection method: Connect the device service port through RS-232 serial port, no serial port required, USB to serial converter (recommended 8928-1151 kit)

（2） Calibration process

Calibration prerequisite: Reduce the simulated demand signal to 0mA or disconnect the operation enable, and clear all fault alarms

Step 1- Stability setting: Enter the hydraulic oil supply pressure (bar), set the manual/running sleep rate, and soft seal parameters

Step 2- Travel Calibration: Optional “Find Minimum Travel” or “Find Minimum+Maximum Travel”. After calibration, the minimum offset and maximum stop position can be adjusted

Save Calibration: After completing the calibration, click “Save Calibration” to ensure that the parameters are effective

（3） Core configuration function

Input configuration: Select the demand signal mode (single channel/dual channel average/dual channel low/dual channel high), set the enable switch for operation

Output configuration: Configure alarm/shutdown relay output (NO/NC), analog output function (demand signal/actual position)

Advanced configuration: Adjust bandwidth (response speed), jitter (overcome valve sticking), Silk Buster (regularly flush servo valve impurities)

Linearization configuration: 11 point linearization table, compensating for valve flow nonlinearity, needs to be set in ascending numerical order

Maintenance and troubleshooting

（1） Common troubleshooting

Typical causes and troubleshooting measures for fault types

The device shutdown operation enable is not activated. Check that the operation enable circuit is closed and confirm that it is configured as “Used”

If the demand signal exceeds the range (<2mA or>22mA), check the analog signal wiring and adjust the signal to 4-20mA

Key fault triggers (such as position sensor failure) can be checked through service tools to access alarm logs and identify corresponding components

The positioning accuracy deviation is large, and the cleanliness of the hydraulic oil does not meet the standard. Check the cleanliness of the oil and replace the filter element

Compensate for improper needle valve settings, recalibrate stroke, and adjust stability parameters

Connecting rod misalignment>5 °, correct connecting rod installation to ensure deviation ≤ 5 °

No response (no alarm). The power supply is not connected or the voltage is too low. Check the power supply voltage (18-32Vdc) and verify the wiring

Connect the communication fault inspection service tool and restart the device

Replace the corresponding aperture shaft seal kit (refer to Table 7-1) for hydraulic leakage seal wear and tear

The pipeline interface is not tightened. Re tighten the interface bolts according to the specified torque

（2） Maintenance operation

Shaft seal replacement: Select the corresponding kit (4-inch: 8935-1216-10; 10 inch: 8935-1216-25) according to the aperture, and install the seal strictly according to the diagram

Servo valve/hydraulic cylinder replacement: Contact Woodward authorized service organization and refer to manual 26836 to follow the replacement process

Long term storage: Clean the surface of the equipment, remove the hydraulic oil, seal the interface, store in an environment temperature of -40 to 85 ℃, avoid moisture

Basic information of the document

Document type: OpView Operator Interface Installation and Operation Manual

Manual Number: 85580V4 (Revision J)

Applicable scenarios: Suitable for Woodward MicroNet TMR ®  5009 digital control system, used for remote monitoring and control of steam turbines

Compatible models: covering 8 models of the 8236 series, with core differences in Com B port type (25 pin/9 pin) and hazardous area applicability

Model Number Screen Type Com B Port Hazardous Area Level

8236-354 Color 25 Needles-

8236-513 Color 25 Pin Class I, Division 2

8236-616 Color 25 Needles-

8236-617 Color 25 Pin Class I, Division 2

8236-700 Color 9-Needle-

8236-701 Color 9-Pin Class I, Division 2

8236-1001 Color 9-Needle-

Core safety requirements

（1） Warning definition and protection principles

Danger (DANGER): Failure to avoid causing death or serious injury

Warning: Failure to avoid may result in death or serious injury

CAUTION: Failure to avoid may result in minor or moderate injury

Notice: May only cause property damage

Important: Operation tips or maintenance recommendations

（2） Key safety measures

Anti static protection: Release human static electricity before contacting the equipment, avoid non anti-static materials from approaching the circuit board, and do not touch PCB components

Personal protection: PPE such as goggles, hearing protection equipment, helmets, gloves, and safety boots should be worn during operation

Explosion proof requirements: After installing the F/T relay module, the equipment is only suitable for ordinary or non hazardous locations; The use of Class I, Division 2 areas must comply with specific wiring specifications

High voltage protection: When the DTM terminal block has a high voltage of 125Vdc, it is necessary to avoid contact with the cable

Live operation restrictions: It is prohibited to plug in or unplug power supplies, modules, or equipment while live in hazardous areas

（3） Compliance requirements

Some models (8236-513, 8236-617, etc.) are suitable for Class I, Division 2, Groups A, B, C, D or non hazardous locations

When the ambient temperature exceeds 50 ℃, the rated temperature for on-site wiring should be at least 75 ℃

The maximum external voltage limit for discrete input and relay output circuits is 18-32Vdc (compliant with CE certification low voltage directive)

Product Description

Equipment type: Industrial grade touch screen workstation, with both alarm annunitor and operator control panel functions

Core functions: Remote viewing of operating parameters, adjustment of control settings, issuance of operating mode commands (such as start and stop)

Hardware features: Panel installation design, NEMA 4 protection level, weight 6.9kg (15.2lb)

Software features: Automatic matching of 5009 control system configuration, no need for on-site programming, supports graphical interface display of valve, turbine and other equipment status

Data storage: Record up to 500 alarm and trip information with a 1-second resolution timestamp

Extension function: Supports connecting to serial printers and outputting hard copies of alarm/trip logs

Installation process

（1） Installation requirements

Installation method: Panel installation, fixed with 12 installation bolts or 6 installation clips (depending on the model)

Space requirement: Reserve at least 2 inches (50.8mm) of space around the device to ensure heat dissipation

Environmental requirements: Installed in a closed cabinet or panel to prevent pollutants in the air from coming into contact with the rear shell of the equipment

Temperature range: Operating temperature 0-50 ℃ (32-122 ° F), please refer to the PowerStation manual for more environmental restrictions

（2） Communication configuration

Communication port: OpView is connected to the J3 port of the 5009 control system SIO module through the Com B port

Communication protocol: Supports RS-232, RS-422, RS-485 standards, protocol selection depends on device distance

Maximum distance port configuration for communication protocol

RS-232 15m (50ft) 25 pin/9-pin Com B port, wire according to corresponding pins

RS-422 1200m (4000ft) 25 pin port requires short circuiting of specific pins, 9-pin port is configured through DIP switch

RS-485 1200m (4000ft) 25 pin port requires short circuiting of specific pins, 9-pin port configured through DIP switch

Default communication parameters: baud rate 9600, no checksum, data bit 8, stop bit 1, consistent with the 5009 control system port settings

（3） Printer and Initial Settings

Printer settings: Connect the parallel printer to the OpView parallel port, use standard IBM parallel cables, configure protocols and communication parameters to match

Initial startup: After the device is powered on, perform a diagnostic test (which takes several minutes), and display the main menu after the diagnosis is successful; When communication is lost, wait for 20 minutes before displaying the application screen

Time and date calibration: Enter the password through the main menu “CONFIGURE PASSWORD” and enter the application manager settings. The formats are “hour: minute: second” and “day: month: year”

Operation steps

（1） General operating rules

Operation method: Touch screen operation, button selection will change brightness or color to confirm response

Unit display: Consistent with the units configured in the programming mode of the 5009 control system (such as displaying KW or MW as load)

Communication loss handling: The screen displays “LOST Communication”, which allows browsing but cannot issue commands. The 5009 control system will generate an alarm, and the alarm needs to be reset to receive the set value after communication is restored

Local/Remote Switching: After configuring 5009, the main menu and dynamic/trend menu display switching buttons, and all screens (except trend screens) display status indicators

（2） Special function operation

Turbine Start: Select the start mode (Idle/Rated, Auto Start Sequence, etc.) through the “Turbine Start” screen, click “START” to issue the start command, and monitor the speed increase status

Turbine operation: Adjust the speed, extraction, and other settings on the “Turbine Run” screen, enable/disable frequency control, synchronizers, and other functions

Controlled Shutdown: Start the shutdown sequence through the “Controlled Shutdown” screen, and click “ABORT” to abort the shutdown

Valve Calibration: Enter the calibration password (1111), meet the permission conditions such as shutdown state and speed<1000RPM, adjust the valve opening through the “Valve Calibration” screen, and click “SAVE CALIBRATION” to save

PID adjustment: Enter the “PID Control” screen to view the output and set values of each PID, and enter the dynamic adjustment password to modify the proportional, integral, and derivative parameters

Overspeed Test: Perform electrical overspeed (TEST 5009 TRIP) or external overspeed (TEST ExternalRNAL TRIP) test on the “Overspeed Test” screen. If the set value is not adjusted within 60 seconds during the test, it will automatically terminate

Alarm Log: View active alarms (red with asterisks) through the “Alarm Log” screen, click “ALM ACK” to confirm, “RESET” to reset, “CLEAR” to clear, and support printer output logs

（3） Permission management

The operation permissions are divided into three levels, and access is required by entering the corresponding password through the pop-up keyboard

Permission level, password, core operation permissions

SUPVAR level 1113 access application manager, configure OpView

Calibration level 1111 dynamically adjusts PID parameters and valve calibration

5009 level 5009 basic monitoring, setting value adjustment, mode switching

It is recommended to restore permissions to level 5009 during normal operation to prevent unauthorized operations

Password information and product support

（1） Password details

SUPVAR Level Password：1113， Used to access the application manager and configure OpView system parameters

Tuner/Valve Calibration Level Password：1111， Used for dynamically adjusting controller parameters and valve calibration operations

5009 Level Password：5009， Used for daily basic operations, such as parameter viewing and issuing regular commands

Description

The 5009XT is a standard-off-the-shelf steam turbine control for use on industrial steam turbines in reliability- critical applications. This controller utilizes Woodward’s field-proven MicroNet TMR® hardware platform combined with Woodward’s state-of-the-art XT steam control core and algorithms. The 5009XT is designed for use both in OEM turbine packages and for upgrade of existing turbines

The 5009XT’s triple-redundant, fault-tolerant design allows it to continue operating the turbine safety under any single point of failure. Modular design and hot-swapping capability allow maximum uptime and minimize maintenance shutdowns required for the control.  

The 5009XT control’s unique PID structure makes it ideal for applications requiring accurate control of parameters such as turbine speed, load, extraction header pressure, inlet header pressure, and exhaust header pressure or tie-line power.

The control’s PID-to-PID logic allows stable control during normal turbine operation and bumpless control mode transfers during plant upsets, minimizing process over or undershoot conditions. The 5009XT controller senses turbine speed via passive or active speed probes and controls the steam turbine through actuators connected to the turbine inlet steam valves.

This field programmable controller allows users to easily make system configuration changes without the need of an OEM expert. The system can be controlled, configured, calibrated and tuned using the optional 17” touchscreen display or any workstation running Woodward’s RemoteView software. RemoteView can also function as an HMI for the system, allowing operators to monitor the system, start/stop the turbine, enable/disable all control modes, and view/reset system alarms. Multiple password security levels are available to provide different plant personnel with access to the different levels of the 5009XT’s configurations/ adjustments depending on site requirements. The RemoteView display can be networked to all three CPUs for maximum redundancy. See Specification 03424 for more information on RemoteView.  

The 5009XT can be purchased as a kit or Woodward can package the system in a free-standing cabinet with an integral RemoteView HMI/engineering workstation. The 5009XT can be configured to operate as a stand-alone unit or in conjunction with a plant’s Distributed Control System, depending upon the site’s requirement.  

Woodward or our partners can integrate the 5009XT software with our Vertex compressor-control core on a MicroNet TMR to create a fault-tolerant ITCC steam and compressor control.

Applications

The 5009XT is designed to control industrial steam turbines of all sizes and types in system-critical applications requiring maximum reliability and availability. This steam turbine controller includes specifically designed algorithms and logic to start, stop, control, and protect industrial steam turbines or turbo-expanders that drive compressors, generators, or pumps.

Designed for today’s plant standardization practices, the 5009XT control system’s versatile programing can be configured to control single valve, single extraction, single admission, or single extraction/ admission steam turbines. The 5009XT control’s unique PID structure makes it ideal for petrochemical or power generation applications requiring tight control of parameters like compressor speed, generator frequency, turbine load, turbine inlet or exhaust header pressures, or tie-line power.

The control’s TMR (triple modular redundant) architecture, TMR CPU and I/O modules, on-line configuration, and on line repair capability make it ideal for use in safety or reliability critical applications. This control’s fault tolerant design allows it to accept redundant inputs sensors, drive redundant actuators, and interface with redundant RemoteView operator stations, extending redundancy throughout the entire turbine package.

For applications requiring multiple human-machine-interfaces (HMIs), users can purchase additional licenses of Woodward’s RemoteView™ software for installation on any Windows PC installed on the network.   Woodward also offers full HMI packages based on iFIX or Citect graphics packages.

For applications requiring IEC61508 SIL-3 certification, a MicroNet Safety Module (MSM) may be added to the base 5009XT system.  The MSM functions as the system’s SIL-3 logic solver, and its fast (12 millisecond) response time and integrated overspeed and acceleration detection/protection functionality make it ideal for applications on critical turbines. For more information on the MicroNet Safety Module, refer to Woodward product spec 03375.

Triplex Architecture Advantages

• 2-out-of-3 voting provides accurate signal selection by excluding bad signals. 

 • 2-out-of-3 voting increases system fault coverage close to 100%, which provides an availability of 99.998% or higher. 

 • CPU or I/O module failures are accurately detected, and related calculations safely removed, while the turbine continues to operate. 

 • Output relay failures can be detected and repaired with the turbine on-line.

5009XT Key Functionality

• Speed/frequency control 

• Turbine or generator load control/limiting 

• Extraction and/or admission header pressure control

• Turbine inlet header pressure control/limiting

• Turbine exhaust header pressure control/limiting

• Plant import/export power control/limiting

• Isochronous load sharing between units

• Any process directly related to unit load

• Proportional or integrating Servo Position Control with LVDT/RVDT excitation (with optional modules)

Operational Features

• Fault-tolerant I/O handling and processing

• Latent fault detection on relay outputs

• Time-stamped alarms, with 10ms resolution on trips

• Overspeed anticipation and shutdown protection

• Peak speed indication for overspeed trip

• Configurable over or under pressure shutdown logic

• Three Critical speed avoidance bands

• Patented OPTI Tune and OPTI Ratio algorithms provide adaptive speed and extraction dynamics

• Discrete input time-stamp with 1 ms resolution, Analog input time stamp with 5 ms resolution

• Extensive fault detection and annunciation, including first-out indication

• Auto start sequence (hot & cold starts)

• Three sensors can be configured for each critical parameter

• Dual speed/load dynamics

• Zero speed detection with proximity probe down to 0.5 Hz

• Automatic hand valve operation (using first stage pressure)

• Remote analog setpoints for all PIDs

Connectivity / Security Features

• Independent Modbus® * communication links 

• RemoteView software for any Windows 17” (43 cm) touchscreen engineering workstation for configuration, service, and turbine operation. 

• Multi-lingual interface (English, Chinese, Portuguese, Japanese, Spanish and Russian).

• User level management with secure password authentication

• Achilles Cybersecurity certification

Options

• 2 Channel Actuator Modules (use for proportional or integrating actuators)

• Distributed SPC (servo position control) modules on CANOpen

• RemoteView touchscreen HMI/Workstation

• Additional RemoteView licenses for multiple workstations

• ITCC integrated compressor control (Woodward quote)

• Control cabinet (Woodward quote)

Control Specifications

Inputs

Power: Redundant power supplies with the following input options: 18–32 Vdc, 100–150 Vdc,  88–132 Vac (47–63 Hz), 180–264 Vac (47–63 Hz), 200–300 Vdc Speed: 4 MPUs (1–30 Vrms) or proximity probes (24 Vdc and 12 Vdc power provided),   0.5 to 25 kHz 

Discrete Inputs: 24 contact inputs 24 V (CE or UL) or 125 Vdc (UL only) (1 dedicated, 23 programmable) 

Analog Inputs: 8 programmable 4–20 mA inputs (32 inputs with compressor control option)

Outputs

Valve/Actuator Drivers: 2 single-coil (proportional) or 2 dual-coil actuator outputs (4–20 mA) 

Optional—2 proportional 20-160 mA or integrating ±200 mA max actuator outputs with

2 LVDT or RVDT or 1–5 V or 4–20 mA position feedback inputs 

Discrete Outputs: 12 relay outputs with latent fault detection (1 dedicated, 11 programmable)

Analog Outputs: 4 programmable 4–20 mA outputs (12 outputs with compressor control option)

Communication

Ethernet: 6 10/100BaseT Ports (Modbus TCP or UDP & Service Tool communication) 

Serial: 3 Modbus (ASCII or RTU) communication ports (RS-232, RS-422, RS-485 compatible)

Operating Conditions

Temperature: 0° – 55˚ C (32° – 131˚ F) ambient air temperature 

Emissions: EN61000-6-4 

Immunity: EN61000-6-2

Regulatory Compliance

（Listings are limited only to those units bearing the appropriate Marking or Agency Identification)

European Compliance EMC Directive: 2014/30/EU

for CE Marking:Low Voltage Directive: 2014/35/EU

North American CSA Certified for Ordinary Locations in the United States and Canada per

Compliance:CSA Certificate 2291171

5009XT Chassis

Bulkhead or Adaptable to 19” (483 mm) rack-mount back panel with 18 slots 

Approximate dimensions:

Control Chassis: 19” wide x 14” high x 12” deep (483 mm wide x 356 mm high x 305 mm deep)

Power Chassis: 7” wide x 14” high x 12” deep (178 mm wide x 356 mm high x 305 mm deep)

Approximate Weight: 56 lb (25 kg) fully loaded