Micronet TMR 5009

MicroNet TMR® 5009
Digital Control System
Volume 2
Installation/Hardware Manual
Manual 85580V2 (Revision E)
Downloaded from www.Manualslib.com manuals search engine

WARNING—DANGER OF DEATH OR PERSONAL INJURY
WARNING—FOLLOW INSTRUCTIONS
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.
WARNING—OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get
the latest copy.
WARNING—OVERSPEED PROTECTION
The engine, turbine, or other type of prime mover should be equipped with an overspeed
shutdown device to protect against runaway or damage to the prime mover with possible
personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover control
system. An overtemperature or overpressure shutdown device may also be needed for
safety, as appropriate.
WARNING—PROPER USE
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or property
damage, including damage to the equipment. Any such unauthorized modifications: (i)
constitute "misuse" and/or "negligence" within the meaning of the product warranty
thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product
certifications or listings.
CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTION—BATTERY CHARGING
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.
CAUTION—ELECTROSTATIC DISCHARGE
Electronic controls contain static-sensitive parts. Observe the following precautions to
prevent damage to these parts.
• Discharge body static before handling the control (with power to the control turned off,
contact a grounded surface and maintain contact while handling the control).
• Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit
boards.
• Do not touch the components or conductors on a printed circuit board with your hands
or with conductive devices.
IMPORTANT DEFINITIONS
• A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
• A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
• A NOTE provides other helpful information that does not fall under the warning or caution
categories.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1997
All Rights Reserved

Manual 85580V2 5009 Installation/Hardware
Contents
REGULATORY COMPLIANCE........................................................................ IV
ELECTROSTATIC DISCHARGE AWARENESS .................................................. V
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
CHAPTER 2. HARDWARE DESCRIPTION ........................................................ 2
Introduction.............................................................................................................2
Main Control Chassis .............................................................................................2
System Power Supplies .........................................................................................3
Module Descriptions ...............................................................................................4
Cabinet (optional) .................................................................................................13
OpView™ Operator Interface (optional)...............................................................13
CHAPTER 3. MECHANICAL INSTALLATION................................................... 14
Storage .................................................................................................................14
Unpacking.............................................................................................................14
Unit Location.........................................................................................................16
Install Cabinet (If included)...................................................................................16
Install 5009 Control and Power Chassis ..............................................................18
Install Modules......................................................................................................19
Install Analog Termination Modules .....................................................................24
Install Discrete Field Termination Modules ..........................................................26
Install OpView™ Interface (if included) ................................................................29
CHAPTER 4. ELECTRICAL INSTALLATION .................................................... 31
Introduction...........................................................................................................31
Cabinet (if included)..............................................................................................31
System Cables (if cabinet is not included) ...........................................................31
Shields and Grounding.........................................................................................32
Input Power ..........................................................................................................33
Speed Sensor Inputs ............................................................................................35
Analog Inputs........................................................................................................39
Analog Outputs.....................................................................................................41
Actuator Outputs...................................................................................................41
DTM Contact Inputs (F/T Relay–Discrete In) .......................................................43
DTM Relay Outputs (F/T Relay Outputs) .............................................................46
Serial Communications ........................................................................................53
Printer ...................................................................................................................56
OpView .................................................................................................................56
Control Wiring Diagrams ......................................................................................57
System Power-Up.................................................................................................69
CHAPTER 5. TROUBLESHOOTING AND MODULE REPLACEMENT .................. 70
Introduction...........................................................................................................70
Main Power Supply...............................................................................................70
Kernel Power Supply (A1) ....................................................................................72
CPU Module .........................................................................................................73
Analog and Discrete I/O Modules.........................................................................74
Serial Input/Output (SIO) Module .........................................................................75
Termination Modules ............................................................................................76
Diagnostics ...........................................................................................................78
System Troubleshooting Guide ............................................................................79
CHAPTER 6. HARDWARE SPECIFICATIONS.................................................. 86
Woodward i

5009 Installation/Hardware Manual 85580V2
Contents
CHAPTER 7. SYSTEM MAINTENANCE ..........................................................92

Cables and Connections ......................................................................................92
Fans......................................................................................................................92
Air Filter Maintenance...........................................................................................92
Battery Check .......................................................................................................92
CHAPTER 8. MICRONET TMR® COMPATIBLE PRODUCTS ............................93
Operator Control Panel (OCP) .............................................................................94
DSLC™ Digital Synchronizer & Load Control ......................................................96
Real Power Sensor (RPS)....................................................................................98
CHAPTER 9. SERVICE OPTIONS ................................................................102
Product Service Options.................................................................................... 102
Returning Equipment for Repair........................................................................ 103
Replacement Parts ............................................................................................ 104
How to Contact Woodward................................................................................ 104
Engineering Services......................................................................................... 105
Technical Assistance......................................................................................... 106
DECLARATIONS .......................................................................................108
Illustrations and Tables
Figure 2-1. Control and Power Chassis .................................................................3

Figure 2-2. Kernel Power Supply Block Diagram...................................................5
Figure 2-3. CPU Module.........................................................................................6
Figure 2-4. CPU Communications Port Filter Kit Installation Instructions..............7
Figure 2-5. MPU and Analog I/O Module ...............................................................8
Figure 2-6. Analog Termination Module Diagram ..................................................9
Figure 2-7. Discrete Input/Output Module ............................................................10
Figure 2-8. DTM Block Diagram...........................................................................12
Figure 2-9. SIO Module Block Diagram................................................................13
Figure 3-1. Hardware Identification ......................................................................15
Figure 3-2. Cabinet Dimensions...........................................................................17
Figure 3-3. Chassis-to-Chassis Power Cable W1-B ............................................18
Figure 3-4a. Outline Drawing of 5009 Main Chassis............................................20
Figure 3-4b. Outline Drawing of 5009 Main Chassis............................................21
Figure 3-4c. Outline Drawing of 5009 Power Chassis .........................................22
Figure 3-5. Outline Diagram of Module with Label...............................................23
Figure 3-6. Module Location Diagram ..................................................................23
Figure 3-7. DIN Rail & ATM Outline Drawing .......................................................25
Figure 3-8. ATM Grounding Diagram ...................................................................26
Figure 3-9. DTM Outline Drawing.........................................................................27
Figure 3-10. DTM Mounting Configuration ...........................................................28
Figure 3-11. OpView Outline Drawing..................................................................29
Figure 3-12. Mounting Template ..........................................................................30
Figure 4-1. Shield Termination Diagram ..............................................................33
Figure 4-2. Example MPU Interface Wiring Diagram ...........................................36
Figure 4-3a. Example 24 V Proximity Probe Wiring Diagram ..............................37
Figure 4-3b. Example 12 V Proximity Wiring Diagram.........................................37
Figure 4-4. Example Analog Input Wiring Diagrams ............................................40
ii Woodward

Illustrations and Tables
Figure 4-5. Example Analog Output Wiring Diagram ...........................................41

Figure 4-6. Example Single Coil Actuator Wiring Diagram ..................................42
Figure 4-7. Example Dual Coil Actuator Wiring Diagram.....................................43
Figure 4-8. Optional Internal 24Vdc Contact Wetting Configuration ....................44
Figure 4-9. Optional External Contact Wetting Configurations ............................45
Figure 4-10. Latent Fault Detection Verification Graph—18–32 Vdc Circuitry ....48
Figure 4-11. Latent Fault Detection Verification Graph—88–132 Vac Circuitry ..49
Figure 4-12. Latent Fault Detection Verification Graph—100–150 Vdc Circuitry 49
Figure 4-13. Jumper and Relay Location Diagram ..............................................51
Figure 4-14. DTM Labels......................................................................................52
Figure 4-15. Example Relay Output Wiring Diagram ...........................................53
Figure 4-16. CPU Communications Port..............................................................55
Figure 4-17. Typical Communications Cable Connections ..................................55
Figure 4-18a. Cabinet—Device Location Diagram ..............................................58
Figure 4-18b. Cabinet—Device Location Diagram ..............................................59
Figure 4-19. System Cable Layout Diagram ........................................................60
Figure 4-20. Power Supply Wiring Diagram.........................................................61
Figure 4-21. ATM–1 Wiring Diagram ...................................................................62
Figure 4-22. ATM–2 Wiring Diagram ...................................................................63
Figure 4-23. DTM–1 Wiring Diagram ...................................................................64
Figure 4-27. OpView Wiring Diagram ..................................................................68
Figure 4-28. OpView Cable Diagram ...................................................................68
Figure 4-29. Optional Alarm Printer Diagram.......................................................68
Figure 4-30. Cabinet Fan Diagram.......................................................................69
Figure 5-1. ATM Fuse Locations ..........................................................................77
Figure 8-1. MicroNet™ Compatible Products ......................................................93
Figure 8-2. Operator Control Panel ......................................................................95
Figure 8-3. Inside View of Door............................................................................96
Figure 8-4. DSLC Mounting..................................................................................97
Figure 8-5. DSLC Control.....................................................................................98
Figure 8-6. Real Power Sensor ..........................................................................100
Figure 8-7. Plant Wiring Diagram for the Real Power Sensor ...........................101
Table 3-1. System Components...........................................................................14

Table 4-1. Fuse/Breaker Requirements ...............................................................34
Table 5-1. Off-Line Diagnostic Messages ............................................................78
Table 5-2. On-Line Test Failure Messages..........................................................78
Table 5-3. Discrete In Cable Connections ...........................................................81
Table 5-4. Relay Cable Connections ...................................................................82
Table 5-4. Relay Cable Connections (cont.) ........................................................83
Table 5-5. Analog Combo Module........................................................................84
Table 5-6. DTM Interconnect Cables W14, W15, W16........................................85
Woodward iii

Regulatory Compliance
Unless otherwise specified, this equipment is suitable for use in Class I, Division
2, Groups A, B, C, and D or non-hazardous locations only.
Suitability for installation of this equipment for installation in Class I, Division 2,

Group A, B, C, D hazardous locations is indicated by the presence of a third
party safety agency logo along with the hazardous area classification affixed to
the equipment model to which it pertains. Absence of a hazardous area
classification indicates the equipment is only to be installed or used in ordinary
(non-hazardous) locations.
Relay modules—such as Discrete Termination Modules (F/T Relay–Discrete

In)—are NOT suitable for use in hazardous locations and must be located in a
non- hazardous area or use a suitable method of protection approved by the
local safety authority.
Wiring must be in accordance with Class I, Division 2 wiring methods and in

accordance with the authority having jurisdiction. UL approved branch circuit protection
not exceeding 250% of rated full load input current for the 5009 main power supply
must be provided and must be acceptable for the applicable area classification.
WARNING—EXPLOSION HAZARD
This equipment is not suitable for use in Class I, Division 2 hazardous
locations if an F/T Relay module is installed in the cabinet. It is to be used in
Ordinary or non-hazardous locations only.
Substitution of components may impair suitability for Class I, Division 2.
Do not remove or install power supply, modules, or other equipment while
the circuit is live unless area is known to be non-hazardous.
Do not connect or disconnect equipment while circuit is live, unless area is
known to be non-hazardous.
AVERTISSEMENT—RISQUE D’EXPLOSION
La substitution de composants peut rendre ce matériel inacceptable pour
les emplacements de Classe I, Division 2.
Ne pas enlever ni installer l’alimentation électrique, les cartes, ou d’autre
équipement pendant que le circuit est sous tension avant de s’assurer que
la zone est non dangereuse.
Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf
en cas l’ambiance est décidément non dangereux.
WARNING—PROPER USE
If the equipment is used or applied in a manner not specified here-in, the
protection provided by the equipment may be impaired.
WARNING—HIGH VOLTAGE
If 125 Vdc is present on the DTM terminal blocks, there will be 125 Vdc on
the discrete module cables. If power cannot be removed from the DTM,
extreme care must be taken to avoid contact with the cables.
CAUTION—MAXIMUM VOLTAGE
To comply with CE Marking under the European Low Voltage Directive
(LVD), the maximum external circuit voltage for both the Discrete Inputs and
Relay Output circuit are limited to 18–32 Vdc maximum.
iv Woodward

Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
• Do not touch any part of the PCB except the edges.
• Do not touch the electrical conductors, the connectors, or the

components with conductive devices or with your hands.
• When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
To prevent damage to electronic components caused by improper handling,
read and observe the precautions in Woodward manual 82715, Guide for
Handling and Protection of Electronic Controls, Printed Circuit Boards, and
Modules.
Woodward v

vi Woodward

Chapter 1.
General Information
The technical documentation for the 5009 control system consists of the
following volumes:
Volume 1—provides information on system application, control functionality, fault

tolerant logic, control logic, PID setting instructions, and system operation
procedures.
Volume 2—provides hardware descriptions, mechanical and electrical

installation instructions, hardware specifications, hardware troubleshooting help,
and basic repair procedures.
Volume 3—provides installation procedures for the 5009 control’s personal

computer based interface software program (PCI), information on all PCI
features and modes (Program, Service and Run), and a lists of the control’s
Modbus® * registers and DDE tag names.
*—Modbus is a registered trademark of Modicon, Inc.
Volume 4—provides details on installation and operation of the OpView™

operator control station, if provided with your system.
Active 5009 part numbers covered in this manual are: 9907-794, 9907-795,
9907-796, 9907-797, 9907-846, 9907-847, 9907-848, 9907-849, 9907-850,
9907-886, 9907-887, 9907-889, 9907-890, 9907-991, 9907-1000, 9907-1001,
9907-1002, 9907-1003, 9907-1004, 9907-1005, 9907-1006, 9907-1007,
9907-1011, 9907-1012.
This volume provides hardware description, installation, and troubleshooting

information for the Woodward 5009 Control System. It includes:
• A list of all system hardware
• A description of all hardware
• Mechanical installation instructions
• Electrical installation instructions
• Troubleshooting Guide, including diagnostic tests
• Maintenance procedures (module replacement)
This hardware manual applies to all 5009 control systems but does not include
information that is unique to your system only.
Woodward 1

Chapter 2.
Hardware Description
Introduction
The 5009 digital control system can be provided in a number of hardware
configurations; with different power supply configurations, with or without a
cabinet and with or without an OpView™ operator control station. Because this
manual addresses all configurations, many of the following hardware
descriptions may not apply to your 5009 system. Refer to Table 3-1 for a
complete listing of standard and optional system components.
When a cabinet is included with a system, the control is shipped fully assembled
within the cabinet. When a system is provided without a cabinet, it is shipped
disassembled. After a control system is received each item must be located and
installed via this manual’s instructions.
Main Control Chassis

Figure 2-1 shows a 5009 control system’s main chassis. The system is housed in
a chassis which may be mounted (by flanges on its back side) either to a panel
or within a cabinet. This chassis consists of three six-slot kernel sections. Each
kernel section is isolated from the other two. With this configuration the failure of
any one section will not cause a shutdown.
Each kernel section includes a kernel power supply, a CPU, an analog I/O
module, and a discrete I/O module. Slot-to-slot logic and power connections are
made through an etched-circuit motherboard located on the back of the chassis.
See Figure 2-1. The motherboard and modules are all VERSAmodule Eurocard
(VME) type. I/O connections are made through cables from the front of the
modules to termination modules in the cabinet. See Figures 4-18 and 4-19 for an
overview of the main chassis, control modules, and termination modules.
From a module connector standpoint, any I/O module can be installed in any of
the chassis slots designated for I/O modules. However, when the application
software is designed, each module is assigned to a specific slot, thus the
software expects each specific I/O module to always be in its designated slot.
The 5009 control chassis is cooled by forced air. In order not to starve modules
of air flow, either a module or a blank module must be installed and secured in
each slot. Cooling fans are located on the top of the main chassis; with one fan
per 6-slot card rack. The power supply chassis contains two cooling fans: one on
top and one on the bottom of the chassis. See Figure 2-1. These fans run any
time the 5009 chassis is powered up.
2 Woodward

Figure 2-1. Control and Power Chassis
System Power Supplies

The 5009 control contains two types of power supplies; main power supplies and
kernel power supplies. The control’s power chassis contains two plug-in main
power supplies, which provide 24 V to each kernel section (A, B, C) of the 5009
control. Mounted in the main control chassis are three Kernel Power Supplies,
which convert 24 V to 5 V at 10 A for their kernel’s CPU and I/O modules.
Woodward 3

The system’s main power supplies are housed in a chassis that may be mounted
(by flanges on its back side) either to a panel or within a cabinet. See Figure 2-1.
This chassis contains slots for two 5009 main power supplies, and allows any
main power supply to be used in either slot. A motherboard located on the back
of the chassis allows the two main power supplies to form a fault-tolerant power
system providing six separately regulated, 24 V, 6 A outputs (three from each
power supply) to the control. The six separate outputs are then wired together to
provide load-shared Pwr “A”, Pwr “B”, and Pwr “C” outputs. Each output provides
up to 6A that are wired to the MicroNet TMR® chassis (reference Figure 3-3).
Power output regulation, including line, load, and temperature effects, is better
than ± 5%.
When both main power supplies are running, current sharing circuitry balances
the load to reduce heat and improve reliability of the power supplies. In the event
one supply needs replacement, this feature also ensures bumpless hot
replacement of the power supplies, without disrupting the operation of the
control. Latent fault detection is used to detect and report any power supply
failures to the CPU’s in the control.
Input power connections are made to the main power supply through terminals
on the front of the power supplies. For convenience, when a system is provided
with a cabinet, input power connections are made through panel mounted
Phoenix type terminal blocks. See Figure 4-20. A standard 50-pin ribbon cable is
used for connecting the power supply chassis to the 5009 control chassis.
A set of two main power supplies are provided with each system. Each power
supply set can consist of any two of the three available power supply models,
and in any combination. For instance, a set of one 24Vdc power supply and one
120 Vac power supply may be used to power the 5009 control depending on
whichever power source is available. Different models of power supplies allow
the control to interface with different input source voltages.
Main power supplies are available in the following models:

LVDC – 18-32 Vdc
AC/DC – 88–132 Vac or 100–150 Vdc
HVAC/DC – 180–264 Vac or 200–300 Vdc
Each Main Power Supply has four LEDs to indicate power supply health (OK,
Input Fault, Overtemperature, Power Supply Fault). Refer to Chapter 5 of this
manual for detailed explanations of all LEDs.
Module Descriptions
Physical Description
All chassis mounted control modules are VME-type (VERSAmodule Eurocard)
modules.
Modules slide into card guides in the 5009 control’s chassis and plug into the
motherboard. All modules have their circuitry on a single printed-circuit board.
Each module has a front panel extending from the bottom to the top of the
cabinet.
The modules are held in place by two screws: one at the top and one at the
bottom. Also at the top and bottom are two handles which, when toggled, move
the modules out just far enough for the boards to disengage the motherboard
connectors. Each module is protected with a molded plastic cover to prevent
accidental component damage.
4 Woodward

Kernel Power Supply Module (A1)

Each Kernel Power Supply module receives 24 Vdc from the main power
supplies and provides regulated 5 Vdc and 5 V pre-charge power sources to the
other kernel modules (CPU and I/O modules). The 5 Vdc power source is used
by each module in the kernel section to power its microprocessor. The 5 V pre-
charge power supply is only used as a pre-charge power source to allow all I/O
modules to be hot replaceable. The 24 Vdc power from the main power supplies
is routed through this module to the other kernel modules to allow all kernel
power to be completely removed when this module is not installed. This module’s
health and operation is monitored and verified by its respective kernel CPU.
Figure 2-2. Kernel Power Supply Block Diagram
Central Processor Unit (CPU) Module (A2)

This module, following the instructions of the application program, controls the
circuits of the 5009 control so that they perform all the required control and
sequencing functions. There are three CPU modules provided with each system.
Figure 2-3 is a diagram of a 5009 CPU module. Each CPU utilizes a Motorola
68040 microprocessor to perform its data processing. The VME bus arbitrator
block controls the VME bus and determines what device may use the bus when
there is a conflict.
An RS-232 Serial Port is located on the front of each CPU to interface with the
PCI engineering workstation, OpView or other RS-232 compatible devices.
The CPU has a PCMCIA (Personal Computer Memory Card International

Association) slot on its front panel. The PCMCIA slot is used to down load
application files to the CPU module.
Woodward 5

The CPU module has a battery to power the Real Time Clock, even when power
to the control is off. This battery is not user-replaceable. During normal operation
onboard circuitry keeps the battery charged at all times. Once the battery is fully
charged (16 hours) the battery will continue to run the clock for a minimum of
three months without power to the control. Should the CPU not be powered for
several months and the battery loses it’s charge, the Real Time Clock will need
to be set once the CPU is powered up. The module will automatically recharge
the battery once powered. See the battery specifications in Chapter 6.
Figure 2-3. CPU Module
CPU Port Filter Assembly

The CPU module’s front serial port is sensitive to cable noise. Noise form
external sources (relays, breakers, ESD, etc.) couples onto the attached serial
cable, and into the CPU. Noise of this nature can cause temporary CPU failures.
Three filter assemblies (one per CPU) are provided with each system to protect
the CPU from external system noise. These filter assemblies are shipped
separately from the control and can be easily installed if use of the CPU port is
required.
6 Woodward

Figure 2-4. CPU Communications Port Filter Kit Installation Instructions
Woodward 7

MPU and Analog I/O Module (A3)

Each analog module contains circuitry for four speed sensor inputs, eight analog
inputs, four analog outputs, and two proportional actuator outputs. An on-board
micro-controller scales inputs and outputs using calibration constants stored in
EEPROM, and schedules outputs to occur at the proper time. Refer to Figure
2-5. This module includes no potentiometers and requires no calibration. When a
channel or module fault is detected, the control annunciates the fault, disables
the channel or module and does not use the channel/module’s data in system
calculations or control.
Each CPU sends and receives information to and from its respective MPU &
Analog I/O module via the VME bus. Each input value is stored in a register and
addressed by the CPU as required. Outputs are driven by the CPU, through the
module’s associated output drivers.
Figure 2-5. MPU and Analog I/O Module
Analog Termination Modules

Analog Termination Modules (ATMs) mount external to the 5009 chassis on a
standard DIN rail. The analog termination modules are used to connect analog
field wiring to the 5009 control. An ATM houses circuitry to:
• route each input signal to the system’s three independent (rack mounted)
analog modules
• produce each output signal by summing the three independent analog
modules’ respective outputs
8 Woodward

Two ATMs are provided and used with each 5009 control. Refer to Figure 4-19
for an overview of modules and ATMs used. Each ATM connects to the control’s
three independent “MPU & Analog I/O” modules through individual cables, and
provides a common cage-clamp terminal connection for customer field wiring. An
ATM contains circuitry for two speed sensor inputs, four analog inputs, two
analog outputs, and one proportional actuator output.
Because of the differences between sensing circuitry required to interface with

passive (MPUs) and active (proximity) probes, separate ATM terminations are
provided for each probe type. This allows a simple method of field selecting the
type of speed input based on the type of probe used. Depending on a MPU’s
limitations, each MPU input can be jumper-configured to allow it to drive either
two or three inputs (some MPUs cannot drive three inputs). See Chapter 6 of this
manual for MPU input impedance information. A fused 24 Vdc source, with
isolation diodes on the power, common, and output source lines, is provided for
each speed input to power system proximity probes. Each ATM contains circuitry
to interface with 12 V or 24 V proximity probes.
Analog inputs may be used with two-wire ungrounded (loop powered)

transducers or isolated (self-powered) transducers.
All analog and actuator output circuits allow each kernel to contribute one third of
the output’s total current. For dual coil actuators, kernels A and B drive one coil
and kernel C drives the second coil. Current readback circuitry identifies failed
modules and allows the remaining outputs to be adjusted accordingly.
Figure 2-6. Analog Termination Module Diagram

Woodward 9

Discrete I/O Module (A4)

Each Discrete input/output (I/O) module receives status information from 24
discrete inputs, controls 12 relay outputs and provides latent fault detection for
each relay output. Field wiring is isolated from the 5009 circuitry through optical
isolators on each input channel, and relays on each output channel.
Figure 2-7 is a diagram of the Discrete I/O module. Each CPU sends and
receives information to and from its respective Discrete I/O module via the VME
bus. Each input status is stored in a register and addressed by the CPU as
required. Output commands are driven by the CPU to the Discrete I/O module’s
associated output latches. These latches control the state of output drivers to
energize and de-energize relays. Output Relays are located on the Discrete
Termination Modules.
Each output channel has a readback buffer that stores and indicates the status of
the output driver and associated relays. The CPU compares this status to the
value written to the channel and generates a fault signal if these values are
different.
Figure 2-7. Discrete Input/Output Module
Discrete Termination Modules (F/T Relay Module)

Discrete Termination Modules (DTMs) mount external to the 5009 chassis on a
panel or in a cabinet. The discrete termination modules are used to connect
discrete field wiring to the 5009 control. Four DTMs are provided and used with
each 5009 control. Refer to Figure 4-19 for an overview of modules and DTMs
used. Each DTM connects to the control’s three independent Discrete I/O
modules through individual cables, and provides a common cage-clamp terminal
connection for customer field wiring. A DTM contains circuitry for six contact
inputs, three relay outputs and houses circuitry to:
10 Woodward

• route each contact input signal to the system’s three independent (rack
mounted) discrete modules
• provide an open / closed contact output based on associated discrete
module commands
• indicate the health of all relays (latent fault detection)
WARNING—HAZARDOUS LOCATIONS
This equipment is not suitable for use in Class I, Division 2 hazardous
locations if an F/T Relay module is installed in the cabinet. It must be used in
ordinary or non-hazardous locations only.
Discrete input power (contact wetting voltage) can be supplied by the 5009
control or from an external source. The 5009 control provides an isolated 24 Vdc
power source for contact wetting. The external source may be 24 Vdc or 125 Vdc
(North American installations only). Separate discrete input terminals are
provided based on the level of contact wetting voltage used. See Figure 4-9.
CAUTION—MAXIMUM VOLTAGE
To comply with CE Marking under the European Low Voltage Directive
(LVD), the maximum external circuit voltage for both the Discrete Inputs and
Relay Output circuit are limited to 18–32 Vdc maximum.
The discrete output relays are mounted on sockets, with 18 relays per DTM. Six
relays, are used to create each relay output (normally open and normally closed
contacts) and allow latent fault detection. See Figure 4-15. This configuration
allows independent testing of each relay output (latent fault detection) without
concern of relay position. Customer power is connected to one side of the
configuration and load to the other.
Discrete outputs can be configured to use latent fault detection to identify output
relay failures without affecting operation. When the contacts are closed, they are
periodically opened in pairs, to ensure that they are in the correct state, and that
they change state. When they are open, they are periodically closed individually,
to ensure that they close. Any failures are annunciated, and further testing is
disabled.
Woodward 11

Figure 2-8. DTM Block Diagram
SIO Module
The SIO module is provided with the system. This control system is capable of
utilizing two SIO modules at any time. These modules are installed in slot 5 of
the A and B kernels. Each SIO module includes four serial ports. Ports 1 and 2
are RS-232 communications based ports only. Ports 3 and 4 can be configured
for RS-232, RS-422, or RS-485 communications. Refer to Chapter 4 of this
volume for port related communication capabilities.
12 Woodward

Figure 2-9. SIO Module Block Diagram
Cabinet (optional)
If a cabinet is included with the system, a standard floor mount, front access
cabinet is provided. Input Power and field cable access are available through the
bottom of the cabinet. When a cabinet is included with a system, the control is
shipped fully assembled within the cabinet. The cabinet’s weight is approximately
600 lbs (272.4 kg) including control. The provided cabinet meets NEMA 12
ratings. Refer to Chapter 6 of this Volume for all Cabinet material specifications.
Refer to Figures 4-18a and 4-18b for control cabinet diagrams. This panel is a
UL Listed industrial control panel.
OpView™ Operator Interface (optional)

The OpView™ Operator Interface is a computer-based work-station that
functions as a touch screen annunciator and operator control panel for
Woodward digital control systems. This work-station allows an operator to
remotely view operating inputs, vary control setpoints, and issue Run mode
commands. The OpView is comprised of an industrialized (optional Class I
Division 2) touch screen hardware package and a Woodward developed
software program. This standard program allows the OpView to automatically
select the correct interface screens based on 5009 control’s configuration. No
field configuration is necessary. Refer to Table 3-1 and Figure 3-1 for
identification and Volume #4 of this manual for device specific details.
Woodward 13

Chapter 3.
Mechanical Installation
Storage
Store 5009 control and associated parts between –20 and +70 °C (–4 and +158
°F) at a maximum relative humidity of 90% non-condensing. If power supplies
are to be stored for a long time, apply operating power to them at least once
every 18 months. See Chapter 6, Hardware Specifications.
Unpacking
Unpack each part of the system carefully. Check the units for signs of damage,
such as bent or dented panels, scratches, or loose or broken parts. If any
damage is found, notify the shipper immediately.
When a cabinet is included with a system, the control is shipped fully assembled
within the cabinet.
When a system is provided without a cabinet, it is shipped as major components.

After a control system is received each item must be located and installed via
this manual’s instructions. The following items should be removed from the
packing carton (s) and checked to make sure you have all the necessary
components before attempting to assemble and install the system. Refer to
Table 3-1 and Figure 3-1.
Table 3-1. System Components
Designation Description Qty Remarks

Cabinet (including Power Interface Panel) 1 Optional
U1 Main chassis 1 Standard
U2 Power Chassis 1 Standard
PA1, PA2 Main Power Supply Module 2 Standard
A1 Kernel Power Supply Module 3 Standard
A2 CPU Module 3 Standard
A3 MPU & Analog I/O Module 3 Standard
A4 Discrete I/O Module (24 In/12 Out) 3 Standard
A5 SIO Module 2 Standard
ATM-1, 2 Analog Termination Module 2 Standard
DTM-1, 2, 3, 4 Discrete Termination Module 4 Standard
(F/T Relay–Discrete In)
U3 OpView 1 Optional
W1-A Power Chassis to Main Chassis Cable (1 ft/30 cm) 1 Standard
W1-B Power Chassis to Main Chassis Cable 1 Standard
W2, 3, 6, 7, 10, 11 Analog I/O Cable (10 ft/3 m) 6 Standard
W4, 5, 8, 9, 12, 13 Discrete I/O Cable (10 ft/ 3 m) 6 Standard
W14 - W19 DTM to DTM Cable (6”/15 cm) 6 Standard
W20 Control to PCI Cable (10 ft/3 m) 1 Standard
MISC. - A ATM Ground Terminals (used on DIN rail) 2 Standard
MISC. - B CPU Comm. Port Filters 3 Standard
14 Woodward

Figure 3-1. Hardware Identification
Woodward 15

Unit Location
Consider the following when selecting a location for mounting the 5009 unit(s)
(see Chapter 6, Hardware Specifications):
• Make sure the 5009 unit(s) are mounted in a dry location, protected from
water and condensation (Pollution Degree II environment).
• The 5009 control must be used in a power installation environment rated at
Overvoltage II.
• Make sure the ambient temperature of the system location is not lower than
0 °C (32 °F) or higher than 55 °C (131 °F) (46 °C for cabinet installations)
and that the relative humidity is not over 90%, non- condensing.
• Provide adequate ventilation for cooling the units. If the units must be
mounted near heat-producing devices, shield them from the heat.
• Do not install the units or their connecting wires near high-voltage/high-
current devices or inductive devices. If this is not possible, shield both the
system connecting wires and the interfering devices or wires.
• If the selected location does not already have a conductor to a good earth
ground, provide one.
• Unless otherwise stated, this equipment is suitable for Class I, Division 2,
Groups A, B, C, and D or non-hazardous locations only.
NOTE
The F/T Relay Module is suitable for use in non-hazardous locations only.
Use the following procedures to install a system in the selected location.

Installation procedures are included to for systems provided with and without a
cabinet. Systems sold with cabinets are provided with all hardware (except the
Rolling Restart Station) mounted internal to the cabinet.
Install Cabinet (If included)

If a cabinet is included with the system, it MUST be secured to the floor using a
standard floor mount. The cabinet provides front access. Input Power and field
cable access is available through the bottom of the cabinet. When a cabinet is
included with a system, the control is shipped fully assembled within the cabinet.
The cabinet’s weight is approximately 272 kg (600 lb) including control.
1. Mark cabinet and mounting bolt locations. See Figure 3-2.
2. Depending on mounting method, drill mounting holes or install floor mount

bolts.
3. Position the cabinet in the desired location and secure to the floor using the
appropriate size bolts.
4. Route all power and field cables through the bottom of the cabinet. For EMI
reasons, it is recommend that all analog input and output wiring be separated
from all power and discrete input/output wiring.
5. Connect Cabinet to earth ground using a 10 mm² (8 AWG) or larger wire or

braid.
WARNING—EARTHING CONDUCTOR
Leakage current exceeds 3.5 mA. The earthing conductor is required for
safety.
16 Woodward

Figure 3-2. Cabinet Dimensions
Before beginning installation successfully identify all components and read this
entire chapter.
Woodward 17

Install 5009 Control and Power Chassis

In a panel or bulkhead:
1. Mark control chassis, and power chassis mounting hole locations, taking
care to leave sufficient space between each chassis and walls, objects, etc.
for easy access. Based on system design, the power chassis must be
mounted between 50 and 200 mm (2 and 8 inches) directly below the “A” or
“C” main chassis sections. See Figure 2-1.
2. Drill and tap mounting holes using a # 21 (0.156 – 0.164”) drill bit, and a
10-32 tap.
3. Connect the W1-B cable between both the control and power chassis. Refer
to Figure 3-3. Quick connect terminals allow for easy cable installation.
4. Place each chassis in position, insert 10-32 mounting screws into the tapped
holes, and tighten them securely. (Socket head screws, with flat washers
and locking devices are recommended.)
5. Verify that both the control and power chassis are at earth ground potential,
and if they are not, connect them to earth ground via a 3 mm² (12 AWG) or
larger yellow/green wire or braid.
Figure 3-3. Chassis-to-Chassis Power Cable W1-B

18 Woodward

Install Modules
The following procedure describes the proper method of installing a 5009
module.
1. Verify that the power to the 5009 control is turned off.
2. Take care that each module is installed in the correct slot; there are no keys
to keep a module from being installed in the wrong slot. To aid proper
module placement, the module slots are labeled with the slot number. Refer
to Figures 3-4, 3-5 and 3-6.
3. Align the circuit board edges in the card guides and push the module into the
slot until the connector on the module and the connector on the motherboard
make contact.
4. With even pressure exerted at the top and bottom of the module, firmly push
the module into place.
5. Tighten the two screws that secure the module in place (one at the top and
one at the bottom).
CAUTION—INSTALLING MODULES
If resistance is encountered when installing a module, do not force the
module. Remove the module and check the connectors for bent contacts or
foreign objects. Forcing a module into place may break the connector.
Woodward 19

Figure 3-4a. Outline Drawing of 5009 Main Chassis
20 Woodward

Figure 3-4b. Outline Drawing of 5009 Main Chassis
Woodward 21

Figure 3-4c. Outline Drawing of 5009 Power Chassis
22 Woodward

Figure 3-5. Outline Diagram of Module with Label
Figure 3-6. Module Location Diagram
Woodward 23

Install Analog Termination Modules

The system’s ATMs mount on a standard DIN rail (not provided). Mount ATMs
within the length of the provided cable from the control’s main chassis, leaving
adequate service loop.
1. Obtain a DIN rail strip. Cut it to the desired length and mount it to a panel.
Leave sufficient space between the DIN rail and walls, objects, etc. for easy
access.
2. Drill and tap at least two holes per foot (1 hole every 15 cm) and install DIN
rail, using the appropriate screws and washers.
3. Verify that the DIN rail is at earth ground potential (connected to a panel that
is at earth ground potential). If the DIN rail is not at earth ground potential
4. connect it to earth ground via a 12 AWG (4.0 mm²) or larger green/yellow

wire or braid; keeping the wire/braid as short as possible.
5. Snap the ATMs onto the DIN rail.
6. Snap the included ground terminals (Misc A) onto the DIN rail next to the
ATMs. See Figure 3-8.
7. Connect a 12 AWG (4.0 mm²) green/yellow wire between each ground

terminal and ATM terminal “Chassis Ground”. This wire should be kept as
short as possible and be no longer than six inches (15 cm) in length.
24 Woodward

Figure 3-7. DIN Rail & ATM Outline Drawing
Woodward 25

Figure 3-8. ATM Grounding Diagram
Install Discrete Field Termination Modules

Mount DTMs within the length of the provided cable from the 5009 main unit,
leaving adequate service loop.
For each DTM:
1. Mark DTM mounting hole locations, taking care to leave sufficient space
between the DTM and walls, objects, etc. for easy access. The master DTMs
(1, 3) must be mounted directly above the slave DTMs (2, 4); within a
maximum distance.
2. Drill and tap mounting holes.
3. Place the DTM in position, insert mounting screws into the tapped holes, and
tighten them securely.
4. If the panel the DTMs are mounted on is not at earth ground potential
connect it to earth ground via a 12 AWG (4.0 mm²) or larger green/yellow
wire or braid; keeping the wire/braid as short as possible.
26 Woodward

Figure 3-9. DTM Outline Drawing
Woodward 27

Figure 3-10. DTM Mounting Configuration
28 Woodward

Install OpView™ Interface (if included)

Mount the OpView™ interface within the maximum cable length of RS-232
communications (15 m/50 ft) from the 5009 main unit, leaving adequate service
loop. A standard 10 ft (3 m) cable is provided with the system; optionally a longer
cable up to 15 m (50 ft) can be used.
Option 1—
1. Mark OpView mounting hole locations, taking care to leave sufficient space
between the OpView and walls, objects, etc. for easy access and adequate
air flow. See Figure 3-11. Reference PowerStation manual included for
further installation instructions.
2. Drill mounting holes per Figure 3-11.
3. Place the OpView in position, install 8-32 mounting nuts onto the studs, and
tighten them securely.
Figure 3-11. OpView Outline Drawing
Woodward 29

Option 2—
Place the OpView in position, install the six mounting clamps to secure the
unit into place, and tighten securely.
Figure 3-12. Mounting Template
30 Woodward

Chapter 4.
Electrical Installation
Introduction
WARNING—SAFETY INFORMATION
Before installation read all information and warnings on pages v and vi of
this volume.
Electrical ratings, wiring requirements, and options are provided to allow a

customer to fully install the 5009 control into a new or existing application. Field
wiring must be rated at least 75 °C for operating ambient temperatures expected
to exceed 50 °C.
Wiring for Class I, Division 2 installations must be in accordance with Class I,

Division 2 wiring methods and in accordance with the authority having
jurisdiction.
After the system has been mechanically installed read this chapter thoroughly
before proceeding. Perform system electrical installation by stepping through this
chapter’s instructions in sequence. Start with cabinet installation instructions,
step to the system cables instruction, then step to the next set of instructions,
etc.
The PCI software wiring list must be created to assist in electrical

installation (see Volume 3). The wiring list will determine what inputs are
hooked up to what terminal blocks and how the accessories are wired into
the control.
Cabinet (if included)

A standard floor mount, front access cabinet is provided. Input Power and field
cable access is available through the bottom of the cabinet. Locate cabinet in
control room or place of operation. See Chapter 6 for environmental
specifications.
1. Route all power and field cables through the bottom of the cabinet. For EMI
reasons, it is recommended that all analog input and output wiring be sepa-
rated from all power and discrete input/output wiring.
2. Connect a grounding cable, 10 mm² (8 AWG) or larger, from an acceptable

earth ground to the cabinet frame.
System Cables (if cabinet is not included)

If the system was provided with a cabinet, no cable installation is required, and
you can go directly to the Input Power installation instructions.
Woodward 31

After the 5009 control and power chassis have been correctly mounted, and with
no power connected to the system:
1. Connect cable W1 between the main chassis and power supply chassis. The
W1 power supply cable is a standard 50-pin, 12” (305 mm) long ribbon
cable. Install the P1 connector into the main chassis receptacle and the P2
connector into the power supply chassis receptacle. Each connector is keyed
to ensure proper alignment. Install cable by firmly pressing each connector
into its receptacle until the fasteners are closed. Refer to Table 3-1 for cable
identification and to Figure 4-19 for cable connection diagram.
2. Connect cables W14, W15, and W16 between discrete field termination
modules DTM-1 and DTM-2. These cables are standard 34-pin ribbon
cables. Install these cables prior to mounting the DTM or remove cover to
provide access. Cable connectors are not marked or keyed, therefore care
must be taken not to twist cables between DTMs. Install cable by firmly
pressing each connector into its receptacle until the fasteners are closed.
Refer to Table 3-1 for cable identification and Figure 4-19 for cable
connection diagram. After cable installation replace DTM covers.
3. Connect cables W17, W18, and W19 between discrete field termination
modules DTM-3 and DTM-4. These cables are standard 34-pin ribbon
cables. Install these cables prior to mounting the DTM or remove cover to
provide access. Cable connectors are not marked or keyed, therefore care
must be taken not to twist cables between DTMs. Install cable by firmly
pressing each connector into its receptacle until the fasteners are closed.
Refer to Table 3-1 for cable identification and Figure 4-19 for cable
connection diagram. After cable installation replace DTM covers.
4. Connect cables W2 through W13 between the 5009 chassis modules and
field termination modules. These cables are standard jacketed cables with
37 or 61-contact subminiature D-type connectors on both ends. Analog
cables have a black outer jacket. Discrete cables have a gray outer jacket.
Install the P1 connector into the chassis mounted module receptacle, and the
P2 connector into the termination module receptacle. Refer to Table 3-1 for
cable identification and Figure 4-19 for cable connection diagram. When
installing cables, secure each connector’s slide latch by sliding it down.
Shields and Grounding

If the panel that the control chassis and termination modules are mounted on is
not at earth ground potential connect it to earth ground via a 4.0 mm² (12 AWG)
or larger, green/yellow wire or braid, keeping the wire/braid as short as possible.
An individual shield termination is provided at the terminal block for each of the
speed sensor inputs, actuator outputs, analog inputs, analog outputs, and
communications ports. All of these inputs and outputs should be wired using
shielded, twisted-pair wiring. The shields should be connected to earth ground at
all intermediate terminal blocks, as well as terminated at the control terminal
block. The exposed wire length, beyond the shield, should be limited to one inch.
Relay outputs, contact inputs, and power supply wiring do not normally require
shielding, but can be shielded if desired.
For compliance with EMC standards, it is required that all analog and discrete
input/output wiring be separated from all power wiring.
32 Woodward

Figure 4-1. Shield Termination Diagram
Input Power
Branch circuit fuses, breakers, and wiring must have applicable safety approval
and be selected according to applicable codes and area classifications. The
system disconnect MUST be in easy reach of the operator and marked as a
disconnect device. Each main power supply must have its own branch circuit
rated fuse, or circuit breaker with a rating no more than 250% of the maximum
rated current of the power supply (see Table 4-1). Do not connect more than one
main power supply to any one fuse or circuit breaker. Use only the wire sizes
specified in Table 4-1, or equivalent metric sizes which meet local code
requirements.
Each 5009 control requires a power source capable of a certain output voltage
and current. For AC sources, this power rating is stated in Volt-Amps (VA). The
maximum VA of a source can be calculated by taking the rated output voltage
times the maximum output current at that voltage. This value should be greater
than or equal to the 5009 control VA requirement.
Note that control’s main power supplies are not equipped with input power
switches. For this reason, some means of switching input power to each main
power supply must be provided for installation and servicing. A circuit breaker
meeting the above requirements or a separate switch with appropriate ratings
may be used for this purpose. An appropriately sized fuse or circuit breaker must
be provided for each 5009 power supply. Refer to Table 4-1 for recommended
fuse ratings, circuit breaker ratings and wire sizes. Use only time-delay fuses or
circuit breakers to avoid nuisance trips. A fixed wiring installation is required.
Power supply leakage current exceeds 3.5 mA so a protective earth ground
connection is required.
Woodward 33

Table 4-1 also provides each power supply’s holdup time specification, which is
the time the supply will continue to operate within specification after its input
power is interrupted. This information may be useful in specifying Uninterruptible
Power Supply (UPS) systems.
Table 4-1. Fuse/Breaker Requirements
Input Voltage Rated Actual Maximum Wire

and Frequency Maximum Maximum Maximum Fuse/C.B. Wire Size Temp. Rating Hold Up Time
Range Current Current Power Rating mm²/AWG (°C)* (Minimum)
18–32 Vdc 32 A 22 A 400 W 30 A 8 / 10 90 7 ms @ 24 V
100–150 Vdc 5.8 A 4.0 A 400 W 10 A 2.5 / 14 90 7 ms @ 120 V
88–132 Vac 13 A 9.1 A 800 VA 15 A 2.5 / 14 90 1 cycle @ 120 V
47–63 Hz
180–264 Vac 6.5 A 4.4 A 800 VA 10 A 2.5 / 14 90 1 cycle @ 220 V
47–63 Hz
200–300 Vdc 2.9 A 2.9 A 600 VA 10 A 2.5 / 14 90 7 ms @ 200 V
*Wire Temp ratings specified are for 55 °C cabinet ambient.
All fuses listed above are “slow blow”.
Significant inrush currents are possible when current is applied to the main
power supply. The magnitude of the inrush current depends on the power source
impedance, so Woodward cannot specify the maximum inrush current. Time-
delay fuses or circuit breakers must be used to avoid nuisance trips.
The 5009 control includes a set of two main power supplies. Input power ratings
are identified in Table 4-1 and on each power supply’s front panel. Refer to
Chapter 6 of this Volume for all power supply specifications.
When a cabinet is supplied with the system, input power connections and PE
ground are made through panel mounted Phoenix type terminal blocks. These
terminal blocks accept wires from 0.08–2.5 mm² (20–8 AWG). For a good
connection the inserted wires should have the insulation stripped back by about
6 mm (1/4”). Refer to Figure 4-20 for a wiring diagram of the cabinet’s input
power terminals.
When a cabinet is not supplied with the system, input power connections and PE
ground are made through terminals on the front of each main power supply.
These terminals accept wires from 0.08–2.5 mm² (20–8 AWG) wire. For a good
connection the inserted wires should have the insulation stripped back by about
8 mm (1/3”). Figure 4-20 displays a 120 Vac/150 Vdc or a 220 Vac power
supply’s input terminals. The 24 Vdc power supply model uses larger copper
input terminals to accommodate the required 10 mm² (8 AWG) wire. A
green/yellow wire must be used for PE ground connection. Fixed wiring
installation is required for power supplies.
34 Woodward

NOTES
Each main power supply provides three separate 24 Vdc outputs rated for 0–
6 A each. To preserve system integrity, it is recommended that the control’s
three isolated 24 Vdc outputs be kept isolated from each other at all times. If
the control’s 24 V power is used to power external devices, the system’s
three 24 V outputs must not be tied together. If these outputs are tied
together, and a short circuit occurs, it will shut down the entire 5009 control.
External devices requiring 24 Vdc power must be connected to only one of
the power supplies.
Externally powered analog inputs or outputs and external relay coil power
must be supplied by and IEC rated or NFPA 70 (NEC) Class 2 power supply
as required by local authority having jurisdiction.
Speed Sensor Inputs

The 5009 control uses speed sensing probes mounted off of a gear connected or
coupled to the turbine’s rotor to sense turbine rotor speed. Any of the control’s
four speed channels accept passive magnetic pickup units (MPUs), 12 Vdc
proximity probes, or 24 Vdc proximity probes. It is not recommended that gears
mounted on an auxiliary shaft coupled to the turbine rotor be used to sense
turbine speed. Auxiliary shafts tend to turn more slowly than the turbine rotor
(reducing speed sensing resolution) and have coupling gear back-lash, which
results in less than optimum speed control. For safety purposes it is also not
recommend that the speed sensing device sense speed from a gear coupled to a
generator or mechanical drive side of a system’s rotor coupling.
An application may use any combination of the accepted speed probes. All
speed sensing inputs use the same programmed gear ratio and number of teeth
to calculate speed, thus the speed probes used should sense speed from the
same gear. The 5009 control can sense and control turbine speed from a single
speed probe, however, it is recommended that all applications use multiple
speed probes to increase system reliability.
A passive MPU provides a frequency output signal corresponding to turbine

speed by sensing the movement of a gear’s teeth past the MPU’s pole piece.
The closer the MPU’s pole piece is to a gear’s teeth and the faster the gear turns
the higher a passive MPU’s output amplitude will be. The 5009 control must
sense an MPU voltage of 1 to 25 Vrms for proper operation.
Depending on an MPU’s limitations, each input channel can be jumper

configured to allow an MPU to drive either two or three inputs (some MPUs
cannot drive three inputs). Wire jumpers must be installed to allow an MPU to
drive into all three inputs. When the jumpers are not installed, only two input
modules are driven by a MPU. With proper MPU, gear size, and MPU-to-gear
clearance, speed measurement should be capable down to 100 Hz. Standard
MPU clearance is recommended to be 0.25 to 1.02 mm (0.010 to 0.040 inch)
from tooth face to pole piece. For information on selecting the correct MPU or
gear size, please refer to Woodward manual 82510. See Figure 4-2 for wiring
schematic.
A proximity probe may be used to sense very low speeds. With a proximity
probe, speed can be sensed down to 0.5 Hz. The 5009 control can be
programmed to turn on or off a turbine turning gear using a relay output
programmed as a speed switch. See Figure 4-3 for proximity probe wiring
schematic.
Woodward 35

Because of differences between the sensing circuits required to interface with
passive (MPUs) and active (proximity) probes, separate terminals are provided
for each type. This allows a simple method of field selecting the type of speed
input based on the type of probe used. Short-circuit protected 12 Vdc and 24 Vdc
sources, with isolation diodes on the power, common, and output source lines,
are provided with each speed input to power system proximity probes.
Each channel’s prox return input accepts 5–28 Vdc. Alternatively with either 12
Vdc or 24 Vdc open collector probes. When interfacing to open collector type
probes a pullup resistor between the four voltage terminal and the proximity
return terminal is required.
Figure 4-2. Example MPU Interface Wiring Diagram
36 Woodward

Figure 4-3a. Example 24 V Proximity Probe Wiring Diagram
Figure 4-3b. Example 12 V Proximity Wiring Diagram
Woodward 37

Each ATM connects to the control’s MPU & Analog I/O modules through
individual cables, and provides a common cage-clamp terminal connection for
customer field wiring. Figures 4-2 and 4-3 illustrate the different input wiring
configurations based on the type of speed sensing probes used.
Wiring Notes:
• Refer to Figures 4-21 and 4-22 for Speed Sensor wiring connections on the
ATMs.
• Each Speed input channel can only accept one MPU or one Proximity probe
at a time.
• MPUs only—Jumpers must be added to each channel as shown in Figure
4-2 to allow the “C” analog module to sense speed.
• Proximity Probes only—Individual 12 Vdc and 24 Vdc sources, with isolation
diodes on the power, common, and output source lines, are provided with
each speed input to power system proximity probes (100 mA fuses are used
on the 24 V output, the 12 V is current limited to 100 mA and located on the
ATMs).
• Proximity Probes only—External pull-up resistors are required when
interfacing with an open collector type of proximity probe.
• It is recommended that twisted shielded wiring be used between each probe
and ATM.
• Shields should be connected to earth ground at all intermediate terminal
blocks, as well as terminated at the control terminal block. The exposed wire
length, beyond the shield, should be limited to 25 mm (1”).
• ATM terminals accept wires from 0.08–2.5 mm² (27–12 AWG).
NOTE
If the speed signals are not within the following limits, the 5009 control will
respond with a speed sensor frequency error during the program checking
procedure.
(TxMxR)/60 must be < 25 000 Hz

T = Gear Teeth
M = (Overspeed Test Limit Setting x 1.02)
R = Gear Ratio
NOTE
If the MPU device is not providing a voltage greater than 1.5 Vrms, the MPU
device should be moved closer to the gear where speed is being monitored.
The following graph shows the minimum voltage necessary to detect speed
at the various frequencies.
38 Woodward

Analog Inputs
The control accepts eight 4–20 mA current inputs, with each of the control’s two
ATMs accepting four inputs. All analog inputs may be used with two-wire
ungrounded (loop powered) transducers or isolated (self-powered) transducers.
Because inputs are not fully isolated, care must be taken in their application and
maintenance to avoid “ground-loop” type problems. All analog inputs have 200
Vdc common mode rejection isolation. If interfacing to a non-isolated device
which may have the potential of reaching over 200 Vdc with respect to the
control’s common, the use of a loop isolator is recommended to break any return
current paths, which could result in erroneous readings.
All eight analog inputs are programmable. When an analog input is used, the
chosen input must be wired to and configured within the control’s program to
function. Refer to Volume 3 of this manual for a complete list of programmable
analog input options.
A 24 Vdc power supply is available from the 5009 control to power external
transducers or other auxiliary devices. Isolation is provided through diodes on the
power and common lines. This 24 Vdc output is capable of providing 24 Vdc with
+10% regulation. Power connections are be made through terminals located on
system ATMs.
Woodward 39

Wiring Notes:
• Refer to Figures 4-21 and 4-22 for Analog Input wiring connections on the
ATMs.
• Only 4–20 mA signals are accepted.
• A jumper is required between a channel’s circuit common terminal and “IN
(–)” terminal when interfacing to a loop powered transducer.
• All analog inputs have an input impedance of 200 Ω.
• Each 24 Vdc source terminal has an internal 100 mA fuse in series with it
(located on the ATM). To meet CENELEC ratings, power for sensors and
contacts must be supplied either by the 5009 power supplies, or the external
power supply outputs must be rated for 30 Vdc or less and have its outputs
fused with appropriate sized fuses (a maximum current rating of 100/V,
where V is the supply’s rated voltage or 5 A, whichever is less).
• It is recommended that 0.75 mm² (20 AWG) or larger twisted/ shielded wire
be used between each transducer and ATM.
• Do not place shielded wires in the same cable conduit with high-voltage or
large-current-carrying cables.
• Cable shields must be electrically continuous from the signal source to the
point the signal wire enters the 5009 Analog Termination Module.
• ATM terminals accept wires from 0.08–2.5 mm² (27–12 AWG).
Figure 4-4. Example Analog Input Wiring Diagrams

40 Woodward

Analog Outputs
The control has four 4-20mA current output drivers, with two outputs per ATM.
Applications using analog outputs must, within the control’s program, have the
desired analog value assigned or configured to a specific output. Refer to
Volume #3 of this manual for a complete list of programmable analog output
options.
Wiring Notes:
• Refer to Figures 4-21 and 4-22 for Analog Output wiring connections on the
ATMs.
• Only 4–20 mA signals are output.
• All analog outputs can drive into a maximum of 600 Ω.
• It is recommended that 0.75 mm² (20 AWG) or larger twisted/ shielded wire
be used between each meter (or DCS input) and ATM.
point the signal wire enters the 5009 Field Terminal Module.
• ATM terminals accept wires from 0.08–2.5 mm² (27–12 AWG) wire.
• Analog outputs are not isolated; care should be taken when interfacing to
other non-isolated devices to prevent wiring faults. The use of an isolator is
recommended.
Figure 4-5. Example Analog Output Wiring Diagram
Actuator Outputs
The control has two proportional actuator output drivers (one output per ATM).
The actuator output drive currents can be programmed to interface with
Woodward Governor Company actuators (typically 20–160 mA drive currents) or
non-Woodward actuators (4–20 mA drive currents). Each actuator output can be
individually configured to interface with Woodward or non-Woodward type
actuators.
Woodward 41

Each actuator output can also be configured to drive single- or dual-coil
actuators. When configuring an output to drive into either type of actuator, the
output must be wired correctly (See Figures 4-6 and 4-7), and the control’s
program configured for the correct type of actuator. See Volume 3 for details on
programming actuator outputs.
Dither is selectable through the system’s engineering workstation, and is

available for either output. Dither is a low frequency (25 Hz) signal consisting of a
5 millisecond pulse modulated onto the control’s DC actuator-drive current to
reduce stiction in linear type actuators. Woodward TM-type actuators typically
require dither. See Volume #3 of this manual for details on adjusting dither.
Wiring Notes:
• Refer to Figures 4-21 and 4-22 for Actuator Output wiring connections to the
ATMs.
• When configured to drive a single coil actuator, user-supplied jumpers are
required between terminals 14 & 15 and terminals 44 & 45.
• Maximum impedance for a 4 to 20 mA actuator output driver is 360 Ω
(actuator impedance + wire resistance).
• Maximum impedance for a 20 to 160 mA actuator output is 45 Ω (actuator
impedance + wire resistance).
• Each actuator driver senses its drive current to allow over- and under-
current alarms and shutdowns. Refer to Volume 1 of this manual for details
on defaulted values and changing them.
• It is recommended that 0.75 mm² (20 AWG) or larger twisted/shielded wire
be used between each actuator and ATM.
point the signal wire enters the 5009 Analog Terminal Module.
• ATM terminals accept wires from 0.08–2.5 mm² (27–12 AWG) wire.
• Actuator outputs are not isolated, so they should be not be connected to
non-isolated devices.
Figure 4-6. Example Single Coil Actuator Wiring Diagram
42 Woodward

Figure 4-7. Example Dual Coil Actuator Wiring Diagram
DTM Contact Inputs (F/T Relay–Discrete In)

The 5009 control accepts 24 contact inputs. Each of the control’s four Discrete
Termination Modules accept six contact inputs. Of the 24 contact inputs
available, four have functions already assigned to them (preset) and cannot be
changed, the other 20 are user-configurable. The Preset Contact Inputs are:
• External Emergency Shutdown
• External Reset
• Raise Speed Setpoint
• Lower Speed Setpoint
The control will initiate an emergency shutdown any time the External
Emergency Shutdown contact input is opened. This input is typically tied into the
system’s trip string. Before starting, the External Emergency Shutdown input
must have an external contact or switch wired to it and it must be closed. The
external reset contact can be used to remotely clear latched alarms and trip
conditions. The raise and lower speed setpoint inputs can be used to remotely
raise and lower speed or load.
Applications requiring external contact inputs must have the desired function
assigned or configured to a specific input. Refer to Volume 3 of this manual for a
complete list of programmable contact input options. If the 5009 control is
configured for a generator application two of the contacts must be configured for
the Generator and Utility breaker inputs. The Generator Breaker contact must be
wired so it is closed when the generator breaker is closed. The Utility Tie Breaker
contact must be wired so it is closed when the utility tie breaker is closed.
Contacts must change state for a maximum of 40 milliseconds and a minimum of

20 milliseconds for the control to sense and register a change in state.
Woodward 43

Contact wetting voltage can be supplied by the control or from an external
source. 24 Vdc contact wetting voltage is available on each DTM (with isolation
diodes on the power and common lines). Optionally, an external 18–32 Vdc
power source or an external 100–150 Vdc power source can be used to source
the circuit wetting voltage. (The DTM’s CE marking only applies to the 24 V
option.) Because all discrete inputs are fully isolated, a common reference point
must be established between the input opto-isolators and the contact wetting
power source. If the 24 Vdc internal power source is used as for contact wetting,
jumpers are required between DTM terminals 33 & 34, and terminals 33 & 35. If
an external power source is used for contact wetting, the external source’s
common must be connected to the DTM’s discrete input commons (terminals 34
& 35).
Figure 4-8. Optional Internal 24Vdc Contact Wetting Configuration
44 Woodward

Figure 4-9. Optional External Contact Wetting Configurations
If high voltage discrete inputs are used, and there is 125 Vdc on the DTM
terminal blocks, there will be 125 Vdc on the DTM cables and cable
connectors. All modules should be installed and cables connected before
wiring the DTM.
Wiring Notes:
• Refer to Figures 4-23 through 4-26 for Contact Input wiring connections to
the DTMs.
• All contact inputs accept dry contacts.
• The internal 24 Vdc power source, an external 18–36 Vdc power source or
an external 100–150 Vdc power source can be used for circuit wetting. (The
DTM’s European CE Compliance only applies to the 24 V option.)
• If the 24 Vdc internal power source is used as for contact wetting, jumpers
are required between DTM terminals 33 & 34 and terminals 33 & 35.
• If an external power source is used for contact wetting, the external source’s
common must be connected to the DTM’s discrete input commons
(terminals 34 & 35). To meet CE ratings, power for sensors and contacts
must be supplied either by the 5009 power supplies, or the external power
supply outputs must be rated for 30 Vdc or less and have its outputs fused
with appropriate sized fuses (a maximum current rating of 100/V, where V is
the supply’s rated voltage or 5 A, whichever is less).
• Each contact input pulls 13 mA @ 24 Vdc (13 mA @ 120 Vdc) when closed,
and requires at least 4 mA @ 14 Vdc (4 mA @ 70 Vdc) to recognize a
closure command.
• Verify that the correct input terminals are wired to with respect to the level of
contact wetting voltage used.
Woodward 45

• The combined current draw through terminals 27, 28, 29, 30, 31, and 32
cannot exceed 400 mA or the Discrete I/O module’s on-board power
converter will current limit.
• It is recommended that 0.75 mm² (20 AWG) or larger wire be used between
each discrete input and the DTM.
• DTM terminals accept wires from 0.08–2.5 mm² (27–12 AWG) wire.
• If 125 Vdc Contact Power is used, the Power Supply must meet IEC 6164-1,
Overvoltage Category II.
• With the use of 125 Vdc contact power, it is recommended that the contact
power be removed before connecting or disconnecting any 5009-to-DTM
cable.
DTM Relay Outputs (F/T Relay Outputs)

There are twelve relay outputs available from the 5009 control, with three outputs
per DTM. Of the available relay outputs, two are dedicated to functions, and the
other ten are user-configurable. The dedicated outputs are:
• Shutdown relay—De-energizes for any shutdown condition
• Alarm relay—Energizes for any alarm condition
The remaining ten relay outputs can be programmed to energize upon a function
change of state or an analog value level. Applications requiring programmable
relay outputs must have the desired switch condition or specific analog value
assigned to them within the control’s program. Refer to Volume 3 of this manual
for a complete list of programmable relay output options.
The 5009 control system does not have the capability to provide circuit power to
external circuits interfacing with a relay output. All external circuits interfacing
with control relay outputs must have circuit power provided externally. All relays
are dust-tight, magnetic blow-out type relays with Form-C type contacts.
Refer to Chapter 6 of this volume for all relay ratings.
Latent Fault Detection

Because a fault tolerant system can tolerate a single fault, it is possible for this
fault to go undetected. This is called a latent fault. If another fault occurs when a
latent fault exists, it could cause a shutdown. This is why it is important to detect
latent faults in a fault tolerant system.
Each relay output can be individually configured to use latent fault detection to
identify relay failures without affecting a relay output’s state. A fault tolerant relay
configuration consists of 6 relays, driven by two discrete outputs from each
kernel. The relays are configured in three legs of two relays each. See Figure
4-15. Customer circuit power is connected to one side of the resulting
configuration, and customer load to the other side. Field selectable jumpers,
located on system DTMs, are provided to allow each output’s latent fault
detection logic to be compatible with the circuit being interfaced to.
Six individual relays make up one relay output. When a relay output is closed,
the contacts of all six relays are closed. Because of the series-parallel
configuration that the relays are in, the failure of any two individual relays will not
cause the output to be open. The relay output would continue to be closed. Once
a relay output is closed, the output’s individual relays are periodically opened and
re-closed, to ensure that they were in the correct state, and that they change
state.
46 Woodward

When a relay output is open, the contacts of all six relays are open. Because of
the series-parallel configuration that the relays are in, the failure of any one relay
will not cause the output to be closed. The relay output would continue to be
open. Once a relay output is open, the output’s individual relays are periodically
closed and re-opened one by one, to ensure that they were in the correct state,
and that they change state. Position readback circuitry allows the state of each
relay contact to be detected. Any failures are annunciated, and further testing is
disabled without affecting the state of the relay output contact or control
operation.
Latent fault detection (LFD) is not usable with all applications or circuits. The
control’s LFD logic can only work with circuits using voltages between 18–32
Vdc, 100–150 Vdc, or 88–132 Vac. For LFD to work, a small leakage current is
passed through the circuit’s load. See Figure 4-15. Depending on the size of the
load, the leakage current may be enough to cause a load to be on or active,
when a relay contact is open. In this case, the individual relay’s LFD logic may be
disabled, eliminating the leakage current.
If LFD is desired, but the leakage current is too great for the load, an external
resistor may be connected in parallel with the circuit’s load to shunt some of the
leakage current away from the load. To prevent failure of a load to de-energize,
careful consideration should be given, to ensure that the voltage developed
across the load due to leakage current is below the load’s drop-out voltage.
With LFD, when a relay contact is closed, no difference in operation is

experienced; the relay output appears as a closed contact. However, when a
relay contact is open, it appears to the interfaced circuit as a large resistor
instead of an open contact. Thus a small amount of current is leaked to the load,
resulting in a developed voltage across the load. In most cases this has no
bearing on the customer’s circuitry, because such a small amount of voltage is
developed across its load. However, when a relay output is used with a very high
resistance load (low current load), enough voltage may be developed across the
load to prevent it from de-energizing.
To verify if Latent Fault Detection can be used with a relay output:
1. Verify that circuit the relay output is used with has a voltage level of 18–32
Vdc, 100–150 Vdc, or 88–132 Vac. If circuit voltage is not within these
ranges, disable the relay output’s latent fault detection by placing the relay
jumpers in their disable state. See Figure 4-13.
2. Use the graph below (Figures 4-10, 4-11, or 4-12) which corresponds to the
circuit’s voltage level to determine if the voltage developed across the load
(due to the leakage current) is lower than the load’s drop-out voltage level.
• Acquire the resistance of the load (relay, motor, solenoid, etc.) to be
driven by the relay.
• Acquire the load’s minimum drop-out voltage.
• From the bottom of the graph, follow the line corresponding to the load’s
resistance, up until it intersects the circuit power line. At this point the
corresponding voltage level (on the left of the graph) is the level of
voltage that will be developed across the load due to leakage current.
3. If the developed load voltage (from the graph) is less than the load’s drop-out
voltage, latent fault detection can be used with the circuit.
Woodward 47

4. If the developed load voltage is greater than the load’s drop-out voltage, it is
recommended that latent fault detection be disabled, or that a resistor be
connected in parallel (shunt) with the load. A correctly sized resistor
connected in parallel with the circuit load will decrease the developed load
voltage below the load’s drop-out voltage level. Using the corresponding LFD
graph and the load’s minimum drop-out voltage, perform the above
procedure in reverse (See Step #2) to determine an acceptable shunt
resistance. When selecting a shunt resistor also verify that its voltage and
wattage ratings meet that of the circuit.
LFD Verification Example:

Circuit Power = 110 Vac
Load Resistance = 200 Ω
Load drop-out voltage = 25 Vac
Using the graph in Figure 4-11, the intersection point between the 200 Ω load
resistance line and the 110 Vac line was found. From this intersection point it
was determined that the voltage developed across the load due to leakage
current (when the relay is open) is approximately 7.5 Vac. This voltage level is
lower than the load’s 25 Vac drop-out voltage, thus Latent Fault detection can be
used with this example circuit.
If, however, the load resistance was 1200 Ω, the intersection would be
approximately 29.5 Vac too high for LFD. By following the graph along the 25
Vac line to the 110 V line, a total load resistance of 900 Ω is needed. By placing
a properly rated 3600 Ω resistor in shunt with the load, (1200//3600Ö900) LFD
can be used.
Figure 4-10. Latent Fault Detection Verification Graph—18–32 Vdc Circuitry
48 Woodward

Figure 4-11. Latent Fault Detection Verification Graph—88–132 Vac Circuitry
Figure 4-12. Latent Fault Detection Verification Graph—100–150 Vdc Circuitry
Woodward 49

Relay Jumper Configurations

Relay coil power should be supplied by the control. Three independent isolated
sources are diode selected (High Signal Selected) to power each DTM’s relay
coil. Jumper banks (four jumpers in one package) are provided on each DTM to
allow field selection of internal or external relay coil power. See Figures 4-13 and
4-15. If external relay coil power is supplied, the relay coil power jumper bank
must be moved from its defaulted INT. position to the EXT. position.
A DTM includes terminals and internal jumpers to allow its relay coils to be
powered by an external power source. This relay coil power configuration was
designed for systems which may not have the power sourcing capability to power
all system modules and relays (custom designed systems). The 5009 however,
has sufficient power to supply all unit modules and relays.
NOTE
To retain circuit integrity if an external power supply is used for relay coil
power, it must be an isolated 24 Vdc source, with ±5% regulation. When
using an external power source for relay coil power, it is recommended that
a start-up routine be utilized to remove the source during system power-up
and power down. This routine will guarantee that no relay is inadvertently
energized due to system power-up surges. (By using the DTM’s internal
relay coil power this start-up routine is automatically performed.)
With this system’s power configuration it is recommended that the control’s

internal power be used to supply the DTM’s relay coils at all times.
Field configurable jumpers are used on DTMs, to allow a relay’s latent fault
detection logic to be compatible with different levels of circuit power and to
choose which set of relay contacts to test (normally open or normally closed).
Each relay output has two banks of jumpers (multiple jumpers in one package).
One jumper-bank (a set of nine jumpers) is used to match the latent fault
detection (LFD) circuit with the circuit voltage being interfaced with. The second
jumper bank (a set of four jumpers) is used to select which set of relay contacts
(N.O. of N.C.) is tested by the LFD logic. During operation, only one set of relay
contacts (normally open or normally closed) can be tested. The set of relay
contacts tested should be same set of relay contacts used by the circuit
interfaced to. Refer to Figure 4-13. LFD can be jumper configured to be
compatible with the following circuit voltages:
• 18–32 Vdc circuit power (meets CE & UL ratings)
• 88–132 Vac circuit power (meets UL ratings only)
• 100–150 Vdc circuit power (meets UL ratings only)
50 Woodward

Figure 4-13. Jumper and Relay Location Diagram
Woodward 51

After all jumper-banks have been correctly positioned, mark the placement of
each jumper-bank on the DTM cover labels, located on each DTM’s outer cover.
See Figure 4-14.
Figure 4-14. DTM Labels
Wiring Notes:
• Refer to Figures 4-23 through 4-26 for relay output wiring connections to the
DTMs.
• Verify that each set of relay contacts meet the power requirements of the
circuit which it is being used with. Interposing relays are required in cases
where the interfaced circuit demands relay contacts with a higher power
rating. If interposing relays are required, it is recommended that interposing
relays with surge (inductive kick-back) protection be used. Improper
connection could cause serious equipment damage.
• Verify system power is off before removing or installing any DTM jumper. All
jumpers are fragile, use caution when removing and installing DTM jumper-
banks.
• Select internal or external relay coil power. If the control’s internal power is
used verify that the DTM’s “Relay Coil Power Jumper” bank is in the INT.
position. If external relay coil power is supplied, move the DTM’s “Relay Coil
Power Jumper” bank to the EXT. position and verify that the external source
is fully isolated. (Mark the DTM’s label to indicate jumper position.)
• Verify if Latent Fault Detection (LFD) can be used with each relay output.
• If LFD cannot be used with the relay output, verify that the relay’s LFD
jumper-banks are in their Disable positions. (Mark the DTM’s label to
indicate jumper position.) Alternatively an external resistor can be wired in
parallel with the load to allow LFD to be used with the relay output. In this
case it is the customer’s responsibility to calculate the required resistor
ratings and install it.
• If LFD can be used with the relay output, move the relay’s LFD jumper-
bank to the correct circuit power position. Also select which set of relay
contacts (NO or NC) are to be tested by the LFD logic. Mark the DTM labels
to indicate jumper positions.
Relay circuit power is also present on a DTM’s relay and cable connectors.
When using high voltage relay circuit power, it is recommended that care be
taken not to touch exposed connectors when replacing relays or cables. If
possible remove relay circuit power from all DTM relays before replacing any
DTM relay or cable.
52 Woodward

Figure 4-15. Example Relay Output Wiring Diagram
Serial Communications
Each control has a minimum of three serial communication ports, one on each
CPU. Serial Input/output (SIO) modules are provided in the A and B kernel
section to increase communication reliability, redundancy, and the number of
available communication ports.
When an SIO card is installed in a kernel, the CPU communication port on the
same kernel cannot be used anymore for Modbus communication. CPU-C port
can only be used as a PCI interface port. CPU-B can be configured as a PCI
backup, Modbus #2 port 2 (if no SIO_B installed) or printer.
Modbus #1 and Modbus #2 each have two communication ports connected. It is

recommended that these two ports used for the same Modbus (#1,#2), have the
same settings.
Port configurations:
• CPU-A (RS-232 only) functions as a Modbus #1 port 1 communication port,
or is disabled, if SIO-A is installed.
• CPU-B (RS-232 only) functions as a Modbus #2 port 2 communication port
(unless SIO-B is installed), Alarm/Trip printer driver port. It can also be
configured to automatically become the PCI interface port if CPU-C fails.
• CPU-C port (RS-232) functions as a DDE communication port for PCI.
• SIO-A Port 1 (RS-232) functions as an Alarm/Trip Printer driver port.
Woodward 53

• SIO-A port 2 (RS-232) functions as an interface port to Woodward’s
servPanel program.
• SIO-A port 3 (RS-232/422/485) functions as Modbus #1 port 1.
• SIO-A port 4 (RS-232/422/485) functions as Modbus #2 port 1 or DDE
communication for PCI.
• SIO-B Port 1 (RS-232) functions as an Alarm/Trip Printer driver port
• SIO-B port 2 (RS-232) functions as an interface port to Woodward’s
servPanel program.
• SIO-B port 3 (RS-232/422/485) functions as Modbus #1 port 2 or DDE
communication for PCI.
• SIO-B port 4 (RS-232/422/485) functions as Modbus #2 port 2.
All communication ports can interface with other devices via RS-232
communication. RS-232 communication is limited to a distance of 15 m (50 ft). In
cases where a device which is being interfaced to is located a distance of greater
than 15 m (50 ft) from the control, it is recommended to use SIO cards. It is
possible also to use RS-232 to RS-422/485 converters. CPU communication
ports are considered less reliable than SIO port. As a consequence, if Modbus
communication is used as a main interface device, it is recommended to use SIO
cards. If Modbus redundant lines are required, it is recommended to use SIO
cards.
RS-422 and RS-485 communication support multidropping (multiple slaves on a

single communication line); RS-232 communication does not.
To allow an RS-232 based port to reach farther than 15 m/50 ft, a Model 285
Superverter from Telebyte Technology Inc. of Greenlawn NY, or equivalent, can
be used as an RS-422 or RS-485 interface converter. RS-422 and RS-485
communications also support multidropping (multiple slaves on a single
communications line); RS-232 communications does not.
Each SIO module includes four serial ports. Ports 1 and 2 are RS-232
communications based ports only. Ports 3 and 4 can be configured for RS-232,
RS-422, or RS-485 communications. With the use of RS-422 or RS-485
communications, the control can interface with a device through serial
communications up to 1219 m (4000 ft) from the control. Alternatively one or two
SIO modules may be installed within the control’s chassis.
Figures 4-16 and 4-17 show the control’s communication port connections. The
5009 control can simultaneously communicate with up to four Modbus based
devices via the CPU-A port, CPU-B port, SIO-A port 3, and SIO-B port 3 using
ASCII or RTU Modbus transmission protocols. Refer to Volume 3 of this manual
for a list of all the Modbus commands and parameters available.
The CPU-C port is dedicated for DDE communications and is intended to be

used as the main interface with the system engineering workstation (PCI
program software loaded onto a computer). Optionally port 4 on any installed
SIO module may also be used for DDE communications. Refer to Volume 3 of
this manual for details on DDE communications and the PCI program. An
RS-232 based null-modem cable (W20) is provided with the system to use when
interfacing between a computer and the control. Upon a failure of the CPU-C port
or kernel-C CPU, the control can be configured to use the CPU-B port as the PCI
interface port.
Three port filter assemblies (one per CPU) are provided with each system to
protect the CPU from external system noise. These filter assemblies are shipped
separately from the control and can be easily installed if use of the CPU port is
required. Refer to Chapter 2 of this volume for installation instructions.
54 Woodward

Figure 4-16. CPU Communications Port
Figure 4-17. Typical Communications Cable Connections
Woodward 55

Printer
Optionally a line printer can be utilized with the 5009 control to print alarms as
they occur, and upon command, the system’s last 100 Alarms, or the systems
last 20 trips. The CPU-B port or an SIO module’s Port 1 are the only ports which
have the capability to interface with a line printer. Before the CPU-B port will
correctly function with a serial printer it must be configured for this function
through the control’s PCI engineering workstation. Refer to Volume #3 of this
manual for information on configuring the CPU-B port, and printing alarm and trip
lists.
See Figure 4-29 for a diagram of the required printer communications cable. If an
OpView™ operator interface is provided with the system, optionally a line printer
can connected to the OpView for alarm documentation. See Volume #4 of this
manual for information on connecting a line printer to the OpView operator
interface.
OpView
If provided with a cabinet, the OpView, its communications cable, and a power
cable will be factory installed. With the cabinet mounted option the OpView is
installed in the cabinet front door with an RS-232 communications cable
connected between the OpView’s Com-2 Port and the control’s SIO J3 port. For
ease of installation, a power cable is connected from the OpView to the cabinet’s
power panel terminals. This allows a customer to make all system power
connections through one panel. See Figure 4-27.
The OpView can communicate via RS-232, RS-422, or RS-485 communications.

RS-232 communications is limited to 15 m (50 ft) or less. However with the use
of an RS-232 to RS-422 converter or Woodward’s SIO module, the OpView can
be installed up to 1220 m (4000 ft) from the control (see Volume 4 of this
manual).
Optionally a line printer can connected to the OpView operator interface for alarm
documentation. See Volume 4 of this manual for information on connecting a line
printer to the OpView operator interface.
If a cabinet is not supplied with the system, the OpView must be mechanically
installed before electrical installation can be performed. Follow the below wiring
notes to electrically install the OpView.
Wiring Notes (when provided without a cabinet):

• Reference the PowerStation manual included, for general installation
procedures.
• Refer to Figures 4-27 and 4-28 for OpView wiring.
• Connect input power to the OpView’s power connector. Refer to Chapter 6
of this manual for input power requirements.
• Connect “W21” communications cable between the control’s designated
port and the OpView’s Com2 port. If desired a longer cable can be created
and used between the control and OpView.
56 Woodward

Control Wiring Diagrams

When installing a system, follow all I/O specific wiring notes (covered earlier in
this chapter) and general wiring notes below. For ease of identification system
notes are displayed within a triangle on each wiring diagram. The number that
appears in a triangle pertains to a wiring note. The subsequent sheets of the
plant wiring diagram each represent a field termination module or panel. Refer to
Table 3-1 and Figure 3-1 for device identification.
Wiring Notes
1 Refer to Table 4-1 for input power ratings.
2 Refer to Chapter 6 for input power ratings.
3 Customer supplied wiring.
4 Optional Wiring (dependent upon system options).
5 Read and follow all Wiring notes, instructions, and recommendations within
this chapter when electrically installing a system.
6 Confirm each connection before operating unit.
7 All analog inputs must be isolated from earth ground.
8 Follow authorized standards for conduit loading and sealing.
9 All wires to terminal blocks shall have wire markers, marked with
associated terminal number.
Woodward 57

Figure 4-18a. Cabinet—Device Location Diagram
58 Woodward

Figure 4-18b. Cabinet—Device Location Diagram
Woodward 59

Figure 4-19. System Cable Layout Diagram
60 Woodward

Figure 4-20. Power Supply Wiring Diagram
Woodward 61

Figure 4-21. ATM–1 Wiring Diagram
62 Woodward

Figure 4-22. ATM–2 Wiring Diagram
Woodward 63

Figure 4-23. DTM–1 Wiring Diagram
64 Woodward

Woodward 65

66 Woodward

Woodward 67

Figure 4-27. OpView Wiring Diagram
Figure 4-28. OpView Cable Diagram
Figure 4-29. Optional Alarm Printer Diagram
68 Woodward

Figure 4-30. Cabinet Fan Diagram
System Power-Up
If at any time during this procedure the defined or expected result is not
achieved, step to Chapter 5 of this volume and begin system troubleshooting.
1. Turn the power for one power supply on and verify that the power supply’s
green LED is the only power supply LED on.
2. Turn the power for second power supply on and verify that the power
supply’s green LED is the only power supply LED on.
3. Momentarily toggle the A, B, and C-Rack’s CPU RESET switch up (press the
switch’s top half), then back to its normal down position (press the switch’s
bottom half).
At this point the system will perform off-line diagnostics, this diagnostics testing
could take a couple of minutes. When all CPUs have synchronized and
completed their diagnostic tests, no red LEDs should be on, and the control will
begin running the application program.
NOTE
When the RESET switch is toggled to the down position the CPU’s red Fault
and Watchdog LEDs should go out and the green RUN LED should go on. At
this time the CPU is performing the self-diagnostics and boot-up processes.
If only one CPU has been reset (other CPUs still failed) the 5009 will wait for
another CPU to boot-up before both CPUs will go to a running state.
WARNING—VERIFY CALIBRATION
Improperly calibrated devices can cause turbine damage and possible
personnel injury or death. Before starting the turbine for the first time, and
periodically thereafter, verify the calibration of all external input and output
devices.
Woodward 69

Chapter 5.
Troubleshooting and Module
Replacement
Introduction
This chapter provides detailed information on system hardware, gives tips to
assist in solving hardware related issues, and includes module replacement
instructions. Once a system problem is annunciated, this chapter can be utilized
as a troubleshooting guide to assist problem finding and if necessary module
replacement.
Because testing all functions of an individual module is beyond the scope of this
manual, when the results of the procedures indicate that a module may be faulty,
replace the suspected module with a module known to be good. This will help
verify that the cause of the problem actually is in the suspected module.
If after following this chapter’s guidance the cause of a problem cannot be found,
contact the Woodward technical assistance group.
CAUTION—QUALIFIED PERSONNEL
Only qualified service personnel should perform the following module
replacement procedures.
Main Power Supply

System diagnostic routines continuously monitor each main power supply for
proper operation. If a fault condition is detected, the fault is annunciated, and the
supply’s output disabled. If necessary, use the power supply’s front panel LEDs
to assist in diagnosing a related problem. If all supply LEDs are turned off (not
illuminated), it is probable that input power is not present and verification should
be made.
Main Power Supply LED descriptions:
OK LED—This green LED turns on to indicate that the power supply is operating
and no faults are present.
INPUT FAULT LED—This red LED turns on to indicate that the input voltage is
either above or below the specified input range. If this LED is on, check the input
voltage and correct the problem. Long-term operation with incorrect input
voltages may permanently damage the power supply. Once the input voltage is
within the supply’s input specifications, this LED will turn off. Refer to Table 4-1
for power supply input specifications.
70 Woodward

OVERTEMPERATURE LED—This red LED gives an early warning of a thermal
shutdown. The LED turns on to indicate when the internal power supply
temperature reaches approximately 80 °C. If the internal supply temperature
rises further to approximately 90 °C the supply will shutdown. Because of the
many variables involved (ambient temperature, load, thermal conductivity
variations) there is no accurate way of predicting the time between the indication
of Overtemperature (LED illuminated) and power supply shutdown. If this LED is
turned on, verify that the fan in the power supply chassis is turning and is free of
dust or other obstructions and that the temperature around the power supply is
less than 55 °C. If the power supply is cooled down without delay, it can recover
from this situation without shutting down. This LED will turn off once the internal
supply temperature decreases below approximately 75 °C.
POWER SUPPLY FAULT—This red LED turns on when one of the supply’s
three power converters has shut down. If this LED is on, check for a short circuit
on external devices connected to the control’s power supply. Once the short
circuit is removed, the supply may resume normal operation. If no short circuit is
found, try resetting the supply by removing input power for one minute. Once
input power has been restored, if the power supply is still not functioning, verify
that the supply is properly seated to the motherboard connector, if still not
functioning, replace the supply.
Each main power supply must have its own branch circuit rated fuse or circuit
breaker. A main power supply module has internal fuses, however these fuses
do not protect the supply’s input circuitry, and will only open in the event of a
component failure internal to the power supply. If any of the supply’s internal
fuses are open, replace the supply.
To Replace a main power supply (PA1, PA2):
1. Read all warnings on pages v and vi of this Volume before replacing any
module.
2. Remove input power from the power supply being replaced.
3. Unscrew front panel mounting screws, and release the module from the
motherboard connectors by pressing the top handles up and the bottom
handles down.
4. Remove module by pulling straight out.
5. Install a new power supply by aligning the circuit board edges in the card
guides and push the unit into the slots until the connectors on the modules
and the connectors on the motherboard make contact.
6. With even pressure exerted at the top and bottom of the supply’s front panel,
firmly push the unit into place.
7. Tighten the screws that secure the module in place (two at the top and two at
the bottom).
8. Re-apply power to the input of the power supply.
Woodward 71

Kernel Power Supply (A1)

Each kernel section of the MicroNet TMR® control contains one kernel power
supply module located in the first slot of the kernel. This module receives 24 Vdc
from the main TMR supply and regulates it to 5 Vdc, 10 A for the rest of the
kernel section. The kernel power supply also creates a 5 V precharge voltage.
There are no switches on this module. A Fault LED is on the front panel of the
power supply. It will illuminate if a problem occurs with the 5 V or 5 V precharge.
The kernel power supply module also assists in CPU to CPU communications. If
the control reports a CPU to CPU communication fault, the affected kernel power
supply module may need to be replaced.
WARNING—KERNEL
The MicroNet™ Kernel Power Supplies must have all modules in that kernel
removed before installing or removing a Kernel Power Supply.
With this control, the removal of any single kernel will not cause a
shutdown. However, if other faults are present within other kernels, those
faults combined with any faults created by the removal of this kernel power
supply may cause a system shutdown.
To Replace a Kernel power supply module:
1. If the control is running and on-line, use the system engineering workstation
to verify that the other CPUs are running without faults. Correct all other CPU
faults within the other kernel sections before replacing a kernel’s power
supply.
2. Switch the respective kernel’s CPU Reset switch to its reset position (push
top of switch in).
3. Remove all kernel modules except for the Kernel Power Supply. Unscrew
each module’s captive screw fasteners and release the modules from their
motherboard connectors by pressing their top handles up and their bottom
handles down. To simplify this procedure it is recommended that the
released modules be left within their respective rack slots, with their
respective cables attached.
4. Unscrew the Kernel Power Supply module’s captive-screw fasteners, and

release the module from the motherboard connectors by pressing the top
handles up and the bottom handles down. Remove the module by pulling
straight out and place it into a conductive plastic bag (Woodward P/N
4951-041).
5. Install the replacement supply module by aligning the circuit board edge in
the card guides and push the module into the slots until the connector on the
module and the connector on the motherboard make contact.
6. With even pressure exerted at the top and bottom of the supply’s front panel,
firmly push the supply module into place. Tighten the two screws that secure
the module in place (one at the top and one at the bottom).
7. Re-insert all kernel modules one at a time. With even pressure exerted at the
top and bottom of each module’s front panel, firmly push the module into
place. Tighten the two screws that secure each module in place (one at the
top and one at the bottom).
72 Woodward

8. Reset the kernel CPU by toggling its reset switch (press the top half of the
switch in, then press the bottom half of the switch in). At this point the kernel
CPU will perform off-line diagnostic tests for approximately 60 seconds then
re-synchronize with the other control CPUs.
CPU Module
System diagnostic routines continuously monitor each CPU for proper operation.
If a fault condition is detected, the fault is annunciated and the CPU is locked out
of all voting. If necessary, use the CPU module’s front panel LEDs to assist in
diagnosing a related problem. If all CPU LEDs are turned off (not illuminated), it
is probable that input power is not present and verification should be made. If
only one CPU module has all of its LEDs off, it is probable that the kernel power
supply is not functioning. The CPU module has the following indicators and
switch:
RUN LED—This green LED turns on when the CPU is operating and no faults
are present.
I/O LOCK LED—This red LED turns on when a major CPU or I/O module
hardware fault has been detected. When a major fault is detected, the fault is
annunciated, all discrete outputs are locked in a de-energized state and all
analog output signals locked to zero current. The reason for a hardware fault can
be viewed through the engineering workstation. After the problem has been
corrected, perform a CPU reset to unlatch the I/O lock logic.
LOW VCC LED—This red LED turns on when the Kernel power supply’s +5 Vdc
output is out of its specified limits. If this LED is on and remains on after a CPU
reset, replace the Kernel power supply.
WATCHDOG LED—This red LED turns on if the CPU stops executing the
application program. After the problem has been corrected, perform a CPU reset
to unlatch the watchdog LED logic.
RUN/RESET Switch—This switch resets the CPU and I/O modules (Kernel)
when in the RESET position (obtained by pressing the switch’s top half). When in
the RUN position (obtained by pressing the switch’s bottom half) the CPU
performs a boot-up sequence, then the Kernel functions normally. To reset the
Kernel momentarily toggle this switch to the Reset position, and return it to the
Run position.
To Replace a CPU module:
module.
to verify that the other CPUs are running without faults.
3. Switch the CPU’s Reset switch to its reset position (push top of switch in).
4. Disconnect any communication cable.
5. Unscrew the CPU module’s captive-screw fasteners and release the module
from the motherboard connectors by pressing the top handles up and the
bottom handles down.
Woodward 73

6. Remove the module by pulling straight out and place it into a conductive
plastic bag (Woodward P/N 4951-041).
7. Install the replacement CPU by aligning the circuit board edge in the card
guides and push the module into the slots until the connector on the module
and the connector on the motherboard make contact.
8. With even pressure exerted at the top and bottom of the module’s front
panel, firmly push the module into place.
one at the bottom).
10. Switch the CPU’s Reset switch to its normal position (push bottom of switch
in).
Analog and Discrete I/O Modules

Each I/O Module has a red Fault LED controlled by the CPU, that is turned on
when the system is reset. During initialization of an I/O module, which occurs
after every CPU reset, the CPU turns the Fault LEDs on. The CPU then tests
each I/O module using diagnostic routines built into software. If the diagnostic
test is not passed, the LED remains on. If the test is successful, the LED goes
off. If the Fault LED on a module is illuminated after the diagnostics and
initialization have been run, the module may be faulty or in the wrong slot.
If during normal control operation all Kernel I/O modules have their Fault LEDs
on, check the Kernel CPU for a failure. If during normal control operation, only
one module’s Fault LED is turned on or flashing, replace this module. A flashing
LED indicates that a certain module failure has occurred, and is used by factory
technicians to locate module faults. When a module fault is detected, its outputs
are disabled or de-energized.
Each Analog I/O Module has a fuse on it. This fuse is visible and can be changed
through the bottom of the plastic cover of the module. If this fuse is blown,
replace it with a fuse of the same type and size (24 Vdc/.1 A).
To Replace an Analog or Discrete I/O module:
module.
to verify that the other CPUs are running without faults.
3. Unscrew the module’s captive-screw fasteners, and release the module from
the motherboard connectors by pressing the top handle up and the bottom
handle down. At this point the module should be unseated from the
motherboard connector, but still within the control rack.
4. Disconnect both module I/O cables. The I/O cables use a slide latch (to
disengage slide the latch up). To eliminate the possibility of causing a system
trip when replacing a module always un-seat the module before
disconnecting the I/O cables. (A system trip is possible if a number of the
cable connector pins are shorted to chassis ground.)
5. Remove the module by pulling straight out and place it into conductive plastic
bag (Woodward P/N 4951-041).
74 Woodward

6. Install the replacement module by aligning the circuit board edge in the card
guides and pushing the module into its slot. To reduce the number of system
alarms, take care not to allow the module to become in contact with the
motherboard connector.
7. Re-connect both module I/O cables. The I/O cables use a slide latch (to
secure cable, slide the latch down). To eliminate the possibility of causing a
system trip when replacing a module always connect the I/O cables before
seating the module to the motherboard. (A system trip is possible if a number
of the cable connector pins are shorted to chassis ground.)
panel, push the module into place until the module connector is firmly within
the motherboard’s module receptacle. Once properly installed the module
Fault LED will be illuminated until the module is re-initialized by the control.
Upon installing the module, the control performs module diagnostic tests for
a few seconds, and if all test are passed, re-initializes the module (turning off
the module Fault LED).
one at the bottom).
NOTE
If the module’s Fault LED does not turn off after the module has been
installed for at least one minute, it may be necessary to re-seat the module
more firmly. To re-seat a module follow step #3 of the above procedure to
release the module from the motherboard, then re- install the module by
following procedure steps #8 and #9.
Serial Input/Output (SIO) Module

(Optional)
Two Serial Input/Output (SIO) modules are installed within the control chassis.
The SIO modules are installed in slot 5 of kernels A and B. Ports 1 and 2 are RS-
232 communications based ports only. Ports 3 and 4 can be configured for RS-
232, RS-422, or RS-485 communications. System diagnostics continuously
monitor each SIO module for proper operation.
SIO Module LED descriptions:
RUN LED—The green LED turns on to indicate that the SIO module is
functioning and there are no faults present.
FAULT LED—The red LED turns on to indicate a module fault has occurred and
is annunciated.
WARNING—HOT SWAPPING
Hot Swapping the SIO module can cause a dip in the 5 Vdc supply.
Depending on the severity of the dip, other modules or the CPU can be
forced into a reset state.
With this control, the removal of any single kernel will not cause the control
to shut down. However, if other faults are present within other kernels, those
faults, combined with any faults caused by shutting down the kernel power
supply, may cause a system shutdown.
Woodward 75

To Replace an SIO module:
1. Read all warnings on pages v and vi of this volume before replacing any
module.
to verify that the other CPUs and kernels are running without faults.
3. Switch the respective kernel’s CPU Reset Switch to its reset position (push
top of switch in).
4. Disconnect any communication cables from the SIO Module.
5. Unscrew the SIO modules captive-screw fasteners and release the module
from the motherboard connectors by pressing the top handles up and the
bottom handles down.
6. Remove the module by pulling straight out and place it into a conductive
plastic bag (Woodward P/N 4951-041)
7. Install the replacement SIO module by aligning the circuit board edge in the
card guides and pushing the module into the slots until the connectors on the
module and the connectors on the motherboard make contact.
panel, firmly push the module into place.
one at the bottom).
10. Reconnect the communication cables to the SIO module.
11. Switch the CPU’s Reset switch to its normal position (push bottom of the
switch in).
Termination Modules
The replacement of termination modules can be performed on-line (while the unit
is operational) or off-line (while the unit is shut down).
Caution must be taken whenever replacing a termination module on-line, or a

unit trip could result. The procedure used in the replacement of termination
modules on-line varies based on the control’s configuration and system wiring
configuration. Contact a Woodward representative to establish the correct
termination procedure to use based on your configuration.
To replace an Analog or Discrete Termination Module while the unit is off-line:
module.
2. Shut down the control.
3. Remove all power from the system. Do not attempt to replace a termination
module with the system powered.
4. Disconnect all ATM/DTM and field wiring.
76 Woodward

5. Disconnect all ATM/DTM cables. The I/O cables use a slide latch (to
disengage, slide the latch toward the cable end).
6. Remove the termination module from its panel and install its replacement.
7. Re-connect all cables. The I/O cables use a slide latch; to secure cable, slide
the latch away from the cable end.
8. Re-connect all field wiring.
9. Re-apply all power to the system.
10. Reset all CPUs.
To replace ATM Fuses:
fuse. If the control is running and on-line, take care not to come in contact
with any ATM circuitry.
2. Remove ATM cover.
3. Verify that the circuit problem has been corrected.
4. Locate and replace fuse (See Figure 5-1) with one of the same size and
rating (24 Vdc/0.1 A).
5. Replace ATM Cover.
Figure 5-1. ATM Fuse Locations
To replace DTM Relays:
Relay circuit power is also present on a DTM’s relay and cable connectors.
When using high voltage relay circuit power, it is recommended that care be
taken not to touch exposed connectors when replacing relays or cables. If
possible remove relay circuit power from all DTM relays before replacing any
DTM relay or cable.
Relay.
Woodward 77

2. Locate and replace faulty relay (See Figure 4-13). See Chapter 6 of the
manual for recommended replacement relays.
3. Perform a system Reset to clear Alarm.
Diagnostics
Each CPU performs both off-Line and on-line diagnostics. Off-Line diagnostics
are performed at power-up or when the CPU’s Reset switch is toggled. On-Line
diagnostics are performed when the CPU is in its normal operational mode,
under application-program control.
Off-Line Diagnostics
The following list shows the tests run by Off-Line diagnostics, and the order in
which they are run. Off-Line diagnostics are started immediately after a CPU
Reset switch is toggled. If during a diagnostics routine, a particular test fails,
testing is stopped and the failure annunciated, through the Fault LED and
engineering workstation. If an engineering workstation is not connected to the
control at that time the failure is stored for later reading. When a fault is detected
by a diagnostics routine, the CPU module’s Fault LED will periodically repeat
bursts of flashes; the number of flashes in each burst indicates the test that
failed. If the CPU module’s Fault LED flashes replace the module.
Table 5-1. Off-Line Diagnostic Messages

Flashes In Burst Error Detected
1 Start Up test failed
2 Control Status Register test failed
3 DUART test failed
4 Local RAM test failed
5 Local RAM Misaligned test failed
6 Flash Memory test failed
7 Clock Interrupt test failed
8 VME Bus Timeout test failed
9 EEPROM test failed
10 Floating Point Math Co-processor test failed
11 Real-Time Clock failed
On-Line Diagnostics
As soon as the application program starts running, the system will use a small
portion of run time to continuously run on-line diagnostic tests. A failure of any
one of the on-line tests results in the I/O lock being asserted and display of a
message in the PCI’s OpSys Fault mode, as shown in Table 5-2. If the CPU
module’s I/O Lock LED stays on during normal operation replace the module.
Table 5-2. On-Line Test Failure Messages

Local Ram Failed Checksum Error
Application Ram Failed System Error (#)
FPU Co-Processor Failed EEPROM Fault
Task Overrun Math Exception
Rate Group Slip (#) EEPROM Initialization Fault
Exception Error Vector #
78 Woodward

System Troubleshooting Guide

The following is a troubleshooting guide for areas to check which may present
potential difficulties. By making these checks prior to contacting Woodward for
technical assistance your system problems can be more quickly and accurately
assessed.
MECHANICAL SYSTEM
ACTUATORS
• Is the oil clean?
• Does the actuator have the correct hydraulic pressure (if required)?
• Does the actuator have the correct pneumatic pressure (if required)?
• Does the drive shaft rotate (if required)?
• Is the actuator wiring correct?
• Is the direction of the stroke correct?
• Has the compensation (if so equipped) been adjusted correctly?
• Is the hydraulic return line free and not clogged?
• Is there backpressure on the hydraulic return line?
• Is the feedback (if any) adjusted correctly and sending the correct signal?
LINKAGE
• Is there slop or lost motion?
• Is there misalignment, binding, or side loading?
• Is there visible wear or scarring?
• Does the linkage move smoothly?
VALVES
• Does the valve move through it’s proper stroke smoothly?
• Does the valve travel it’s full stroke?
• Can mid-stroke be obtained and held?
• Does the valve fully seat (close) before the governor reaches full minimum stroke?
• Does the valve fully open before the governor reaches maximum stroke?
• Is the bypass valve(s) (if any) in the proper position?
• Are there nicks or contamination which allow steam to pass when the valve is
closed?
OIL/HYDRAULIC SYSTEM
• Is the oil at the proper operating pressure?
• Is the oil temperature too high for the type of oil being used?
• Is the oil contaminated?
• Does the actuator have sufficient flow of oil?
• Are the accumulators (if any) charged to the correct pressure?
• Are the filters plugged?
• Is the oil pump operating properly?
STEAM CONDITIONS
• Is the turbine inlet pressure at design specification?
• Is the steam pressure in the proper operating range?
• Are pressure transducers (if any) located close to the turbine?
• Are there any pressure regulating devices or valves which may interfere with
governor operation or proper steam flow?
CONTROL, ALARM, AND FAULT INDICATIONS

• Does the governor indicate it is in the correct control mode?
• Is the governor issuing any alarms?
• Are any of the components of the governor indicating hardware faults?
• Does the actuator demand agree with the actual valve position?
• Are any shut\ down conditions present?
• Have the control dynamics been tuned to match the system response?
Woodward 79

INPUT SIGNALS
• Are all input signals properly scaled?
• Are the inputs free of electrical noise and properly shielded?
• Is the wiring correct?
• Have all field input signals to the control been verified?
• Is the polarity of the signals correct?
OUTPUT SIGNALS
• Are the outputs calibrated?
• Have the actuator drivers been calibrated to the stroke of the turbine valves?
• Are the output signals free of noise and properly shielded?
• Is the wiring correct?
TRANSDUCERS
• Is the transducer calibrated for the proper range?
• Has it been tested by simulating it’s input and measuring it’s output signal?
• Does the transducer have power?
• Are the sensing lines feeding the transducer clear of obstructions?
MAGNETIC PICKUPS AND OTHER SPEED SENSING DEVICES

• Is the wiring between the speed sensing pickup and the control correct?
• Are there any grounding problems or worn shields?
• Is the signal sufficient (at least 1.5 Vrms)?
• Is the signal a clean sine wave or square wave with no spikes or distortions?
• Is the MPU head clean and free of oil or metallic particles?
• Is the MPU head free of any nicks or chips?
• Is the MPU or proximity probe correctly aligned with the gear?
• Is the speed sensing probe adjusted to the correct gap?
• Is the speed sensing probe head the correct size for the toothed wheel it is being
used with?
INPUT VOLTAGE/POWER SUPPLIES

• Is the input power within the range of the control’s power supply input?
• Is the input power free of switching noise or transient spikes?
• Is the power circuit dedicated to the governor only?
• Are the control’s supplies indicating that they are OK?
• Are the control’s supplies outputting the correct voltage?
ELECTRICAL CONNECTIONS
• Are all electrical connections tight and clean?
• Are all signal wires shielded?
• Are shields continuous from the device to the control?
• Are the shields terminated according to Woodward specifications?
• Are there low voltage signal wires running in the same wiring trays as high voltage
wiring?
• Are the governor’s signal common or grounds not tied to any other devices?
• Have the signals been checked for electrical noise?
VOLTAGE REGULATOR
• Is the voltage regulator working properly?
EXTERNAL DEVICES
• Are there external devices the control is dependent on for input signals?
• Are these devices providing the correct signal to the control?
• Is the external device configured or programmed to be compatible with the control?
The following tables (5-3 thru 5-6) can be used to troubleshoot electrical signals
coming into and out of the 5009 control. A listing from each I/O module’s Sub D
connector on the front panel to the respective terminal block on the FTM is given.
If a signal is shorted or missing, the tables can be used to troubleshoot the
problems to the FTM, cables, or the respective I/O module.
80 Woodward

Table 5-3. Discrete In Cable Connections
Woodward 81

Table 5-4. Relay Cable Connections
82 Woodward

Table 5-4. Relay Cable Connections (cont.)
Woodward 83

Table 5-5. Analog Combo Module
84 Woodward

Table 5-6. DTM Interconnect Cables W14, W15, W16
Woodward 85

Chapter 6.
Hardware Specifications
5009 Control Package—Not Including Optional Hardware

(except as noted)
Safety and EMC Standards Compliance
• Conforms to EMC Directive 89/336/EEC. Conformity established by test to
EN 61000-6-2 and EN 61000-6-4.
• Conforms to Low Voltage Directive 73/23/EEC when used in accordance
with instructions. Conformity established by testing to EN50178 1997.
• Listed UL and cUL Industrial Control Equipment for Class I, Division 2,
Groups A, B, C, and D hazardous locations (MicroNet TMR®/5009 Main
Chassis and Power Supply Chassis with modules. Includes FTMs except FT
Relay module). FT Relay module is Listed UL and cUL Industrial Control
Equipment for ordinary (non-hazardous) locations.
• Certified by Lloyd’s for ENV1 and ENV2.
Environmental
Humidity
Lloyd’s type ENV2 Humidity test #1: Two temperature cycles between 20 to 55
°C at 95% Relative humidity within 48 hours
Shock
US MIL-STD-810C, Method 516.2-1 procedure 1b (15g 11ms Half Sine pulse)
Vibration
Lloyd’s type ENV2 Vibration test #1
13–150 Hz @ 1.0 G Ten sweeps at one octave per minute
Unless otherwise reduced by options as shown in the Environmental
Classifications for Options Table below, the following classifications apply.
EN 50178 EN 50178 EN 50178

Temp. Class Humidity Class Air Pressure
for Cabinet Class
3K3 3K3 3K3
5 to 40 °C 5% to 85% 86 to 106 kPa
Tested operating temperature range is 0 to 55 °C.
Environmental Classifications for Options

For systems with the optional Cabinet, the presence of any of the following options
reduces the Environmental Class of the cabinet assembly to the lowest classification of
the options present.
Woodward Mfg. Temp. Cabinet Max.

Part No. Description Mfg./Part No. Rating (°C) Ambient (°C)
OpView 90–250 Vac
1790-3000 PS-10-2T2-DD1-BD5 0–50 0–40
(color)
OpView 90–250 Vac
1790-3001 PS-10-2M2-DD1-BD5 0–50 0–40
(monochrome)
N/A No OpView N/A N/A 45
86 Woodward

Air Quality
Pollution Degree #2
Operating Temperature
0 to +55 °C (+32 to +131 °F), still air, no external heat loads
Storage Temperature
–20 to +70 °C (-4 to +158 °F)
Component life is adversely affected by high temperature, high humidity
environments. Room temperature storage is recommended for long life.
Sound Level
Less than 70 dBA
MicroNet TMR/5009 I/O Chassis Weight:

22 kg (48 lb)
MicroNet TMR/5009 Main Power Supply Weight:

8 kg (17 lb)
Power Supply Specifications

Input Power Ratings
Low Voltage DC (18–36 Vdc)
• Nominal Voltage Rating (20–32 Vdc), (as on Power Supply Label)
• Rated Maximum Current = 32 A
• Maximum Power = 576 W
• Input Power Fuse/Breaker Rating = 40 A slow blow
• Wire Size = 10 mm² (8 AWG) or larger
• Holdup Time = 5 ms @ 24 Vdc
DC (100–150 Vdc)
• Rated Maximum Current = 5.8 A
• Maximum Power = 576 W
• Wire Size = 2.5 mm² (14 AWG) or larger
AC (88–132 Vac, 47–63 Hz)

• Nominal Voltage Rating (98–120 Vac), (as on Power Supply Label)
• Rated Maximum Current = 13 A
• Maximum Power = 1150 VA
• Holdup Time = 1 cycle @ 120 Vac
High Voltage AC (180–264 Vac, 47–63 Hz)

• Nominal Voltage Rating (200–240 Vac), (as on Power Supply Label)
• Holdup Time = 1 cycle @ 220 Vac
Woodward 87

High Voltage DC (200–300 Vdc)
Installation Overvoltage Rating

Category II
Dielectric Withstand
24 V power supply: 707 Vdc from power input to chassis
AC/DC and HVAC version: 2200 Vdc from power input to chassis
Power Output Ratings

• 24 Vdc Analog power (prox and analog input power)
Acceptable Output Range 20.4—25.2 Vdc (at ATM terminals)
Fused to 100mA on each terminal output
• 24 Vdc Discrete Input power (Contact Wetting Voltage)
Acceptable Output Range 20.4—25.2 Vdc (at DTM terminals)
Current Limited to 400 mA on each DTM output
CPU Batteries for Real Time Clock Back-Up

NiCd, Not User Replaceable; Charge Time: 16 hours @ 25 °C.
CPU Storage Temperature with battery operating specifications: –20 to +45 °C.
NOTE
Ground leakage exceeds 3.5 mA. Protective earth grounding is required.
General I/O Specifications

VME Module Fuse Ratings (for all on-module fuses)
24Vdc, .1 A
Digital Speed Sensor Inputs

Number of channels: 4
Speed Inputs: MPU or Proximity probe selectable
MPU Input Ratings

Input frequency: 100–25 000 Hz
Input amplitude: 1–25 Vrms
Input impedance: 2000 Ω
Isolation:
Channel to Channel 500 Vdc
To Chassis 200 Vdc continuous, 600 Vdc DWV
Resolution: dependent on frequency
Accuracy: software calibrated to 0.03%, minimum
Time Stamping High & Low Alarms to 5 ms resolution
88 Woodward

Proximity Probe Input Ratings
Input frequency: 0.5–25 000 Hz
Input amplitude: 3.5–32 Vdc input to the module
Available power: 12 V or 24 V, 50 mA maximum
Isolation:
Channel to Channel 0 Vrms
Resolution: dependent on frequency
24 V Protection: 24 V proximity probe power is fuse protected on the
ATM (100 mA fuse)
12 V Protection: 12V proximity probe power is limited to 100mA via a
regulator on the ATM
Time Stamping High & Low Alarms to 5 ms resolution
Analog Inputs (4–20 mA)

Isolation:
Channel to Channel/
Channel to Common –60 dB MMR, 200 Vdc common mode rejection voltage
To Chassis 200 Vdc continuous, 600 Vdc DWV; Combo
500 Vdc continuous, 600 Vdc DWV; HD
Input impedance: 200 Ω
Anti-aliasing filter: 2 poles at 10 ms
Resolution: 16 bits
Temp Drift: 275 ppm/°C, maximum
Fuse: 100 mA fuse per channel (See Figure 5-1)
Time Stamping: 5 ms resolution
Analog Outputs (4–20 mA)

Driver: Pulse Width Modulated (PWM)
PWM frequency: 6.14 kHz
Filtering: three 500 ms poles
Current output: 4–20 mA
Isolation:
To Chassis 200 Vdc continuous, 600 Vdc DWV; Combo
500 Vdc continuous, 600 Vdc DWV; HD
Max load resistance: 600 Ω
Current Readback: 10 bits
Resolution: 10 bits
Accuracy: software calibrated to 0.2%
Temperature Drift: 125 ppm/°C, maximum
Readback accuracy: 0.1%
Readback temp drift: 400 ppm/°C, worst case
Woodward 89

Actuator Driver Outputs
Driver: Pulse Width Modulated (proportional only), Single or
Dual Coil
PWM frequency: 4.88 kHz
Filtering: three 500 ms poles
Default output Ranges: 4–20 mA or 20-160 mA, software selectable
Maximum Current
Range: 2–24 mA or 10–196 mA
Isolation:
Max. act resistance: 45 Ω on the 20–160 mA output, 360 Ω on the 4–20 mA
output
Readback: Actuator source and return currents
Dither current: 25 Hz, fixed duty cycle, software variable amplitude
Resolution: 10 bits
Accuracy: software calibrated to 0.2%
Temperature Drift: 125 ppm/°C, maximum
Readback accuracy: 0.1%
Readback temp drift: 150 ppm/°C, worst case
Discrete Inputs
NOTE
The F/T Relay Discrete In Panel is suitable for use in non-hazardous
locations only.
Input type: Optically isolated discrete input
Input Thresholds: < 8 Vdc = “OFF”, > 16 Vdc = “ON”
Input Current: 13 mA @ 24 Vdc
External Input
Voltages: 18–32 Vdc (meets CE & UL) or 100–150 Vdc (meets UL
only)
Isolation:
Channel to Channel 1100 Vdc
To Control Common 1100 Vdc
To Chassis 500 Vdc continuous
Time stamping: 1 ms resolution
Isolated 24 Vdc supply may be used to power contacts, 400 mA maximum
Relay Outputs
NOTE
The F/T Relay Discrete In Panel is suitable for use in non-hazardous
locations only.
Relay Type: Dust-tight with magnetic blow-out
Coil Rating: 52 mA @ 24 Vdc
Operating Time: 20 ms max.
Release Time: 10 ms max.
Shock: 5G for 11 ms
Temperature: –45 to +70 °C
Dielectric Strength: 500 Vrms across open contacts
2500 Vrms between all other conductive elements
Expected Life: 100 000 operations @ rated load
90 Woodward

Replaceability:
Relays are socket mounted and retained by a hold-down
spring
Maximum Relay Output Circuit Ratings:
NOTE—Dry contacts “wetted” by customer-supplied circuits.
Relay Output North America International
Voltage (UL) (CE Marking)
28 Vdc 10 A Resistive 10 A Resistive
120 Vac 15 A Resistive
1/3 hp
150 Vdc 3 A Resistive
240 Vac 15 A Resistive
1/2 hp
Cabinet (optional)
Dimensions: 2251 mm in (88.61) high x 599 mm (23.573 in) wide x
834 mm (32.838 in) deep
Material: Frame—All sheet steel construction, 9-fold profile
Door—2.0 mm / 14 gauge steel
Sides—1.5 mm / 16 gauge steel
Panels—3.0 mm / 11 gauge steel
Finish: Frame—Dip-bath primed Pebble Gray, RAL 7032
Door, sides—Dip-bath primed and powder coated
Pebble Gray, RAL 7032
Panels—Powder coated Gray, ANSI 61
Ratings: NEMA 12
IP55
Temperature Rise: 9 °C (16 °F) - (in cabinet, worse case)
Weight: Approximately 272 kg (600 lb) (including control)
Fan: Power Requirements—115/230 Vac 50/60 Hz 0.1/0.2 A
Fan Life—Rated for 20,000 Hours
Fan Air Filter—Replacement recommended every 60
days to 18 months based on environment.
OpView (optional)
Power Requirements (for Color or Monochrome units)
• 90–250 Vac, 50/60 Hz, (110 W max.)
For all OpView specifications, refer to documentation included with the CTC
Power Station.
Woodward 91

Chapter 7.
System Maintenance
Cables and Connections

Periodically, check the cables to make sure they are still in good condition, and
check the connectors to make sure they are plugged in all the way.
Fans
Only qualified personnel should replace system fans. As a preventive
maintenance it is recommended that the main chassis and power chassis cooling
fans be replaced every 50 000 hours, and the cabinet front door fan every 60 000
hours. For replacement, use fans of like design and specification, or purchase
replacement fans from Woodward. See Chapter 6 of this Volume for fan voltage
and power specifications.
Air Filter Maintenance

If your system comes with a cabinet, the cabinet includes a front door fan
assembly (with air filter) for cabinet cooling. Periodic cleaning of this air filter is
required to ensure proper cabinet air flow and cooling. This filter should be
cleaned when it gets dirty; the period between cleanings will depend on the type
of environment the cabinet is located.
To clean the filter, remove the filter element from the assembly, wash in soapy
water, and allow to dry before re-installing.
Battery Check
Periodically inspect the CPU battery(ies) for signs of leakage, swelling, or
damage. If the battery is leaky, has apparent damage, or won’t hold a charge,
return the CPU module to Woodward.
92 Woodward

Chapter 8.
MicroNet TMR® Compatible Products
The following is a list of compatible Woodward products that may be used with
the MicroNet TMR® 5009 System:
Operator Control Panel
DSLC Panel
Real Power Sensor
Figure 8-1. MicroNet™ Compatible Products
Woodward 93

Operator Control Panel (OCP)

(8236-341, 8236-361)
The Operator Control Panel includes functions typically used to start and stop a
turbine, and perform overspeed tests. The OCP includes a front access NEMA 4
enclosure and is provided with the switches and meter mounted within the
station’s front door. The Operator Control Station is suitable for use in Class I,
Division 2, Groups A, B, C, and D or non-hazardous locations only. Refer to
Chapter 1 of this volume for related installation and wiring warnings.
To complete the interface to the control, the OCP switches and meter must be
hardwired to the 5009 control and the control program configured to accept the
interface logic (Analog Output and Contact Inputs programmed).
Depending on the station’s purpose, not all the OCP switches may need to be
connected to the control (overspeed, etc.).
Wiring Notes:
Refer to Figure 8-3 for OCP wiring.
• Wiring must be in accordance with Class I, Division 2 wiring methods and/or
in accordance with the authority having jurisdiction.
• It is recommended that 0.75 mm² (20 AWG) or larger wire be used between
each device and termination module.
length, beyond the shield, should be limited to 25 mm (1 inch).
Installation of the Operator Control Panel

Mount the control within 300 m (1000 ft) from the 5009 control, leaving an
adequate service loop.
1. Mark the panel location and mounting holes (see Figure 8-2).
2. Drill and tap the mounting holes using the appropriate size hardware.
3. Place the panel in position, insert the mounting screws into the tapped holes,
and tighten the hardware securely.
94 Woodward

Figure 8-2. Operator Control Panel
Woodward 95

Figure 8-3. Inside View of Door
DSLC™ Digital Synchronizer & Load Control

This device is used with generator applications only. The DSLC is a
microprocessor-based generator load sharing control designed for use on three
phase ac generators with Woodward speed controls and automatic voltage
regulators. The DSLC is a synchronizer, an isochronous load sharing control, a
dead bus closing system, a VAR/PF control, and a process control, integrated
into one package. The DSLC provides either phase match or slip frequency
synchronizing, and ties into the unit automatic voltage regulator to match
voltages before paralleling. It interfaces with the control via a speed bias signal to
control generator frequency and phase (see Figure 8-5).
The DSLC, along with its auxiliary devices, will be mounted on a panel (see
Figure 8-4). To simplify the DSLC interface, a 120 Vac-to-24 Vdc power supply
and four interposing relays are included on the panel. This panel is designed to
be mounted within a cabinet near the control or system switchgear.
96 Woodward

To complete an interface with the 5009 control system, the panel must be
hardwired to the control and the control’s program configured to accept the
interface (contact I/O and analog inputs programmed). The 5009 control can be
programmed to use the DSLC as a synchronizer only, or as a synchronizer and
load sharing control. Refer to the DSLC Manual ( 02007) for device-specific
information.
DSLC Panel Installation

Mount panel near the control or unit switchgear within 300 m (1000 ft) of the
control, leaving an adequate service loop.
1. Mark the panel location and mounting holes, taking care to leave sufficient
space between the panel and walls, objects, etc. for easy access.
2. Drill and tap the mounting holes for appropriate size hardware (see Figure 8-
4).
3. Place the panel in position, insert the mounting screws into the tapped holes,
and tighten the hardware securely.
4. If the DSLC Panel is not at earth ground potential, connect it to earth ground
via a 4.0 mm² (12 AWG) or larger green/yellow wire or braid.
Figure 8-4. DSLC Mounting
Woodward 97

Figure 8-5. DSLC Control
Real Power Sensor (RPS)

The Real Power Sensor is used to sense the real power being produced by a
generator, or flowing through a tie line. Woodward Real Power Sensors sense
three phase voltages and three phase currents. The RPS compares each
phase’s voltage to current relationship and develops a 4–20 mA output
proportional to real power.
The RPS provided with a standard 5009 system accepts only 0–5 A and has a
kW and VAR readout. The “KW Readout” terminals provide a 4–20 mA signal
proportional to real power, which is used by, and compatible with, the 5009
control.
98 Woodward

Woodward-manufactured Real Power Sensors have a 2.5 Hz low pass filter (400
ms lag time) on the output to filter out the high frequency noise typically created
in a switchgear-type environment. If another vendor’s watt transducer is used,
verify that it has similar filtering criteria before it is applied with the 5009. For
more information on Woodward Real Power Sensors, refer to Woodward manual
82018.
Real Power Sensor Installation and Wiring

Mount the Real Power Sensor using the four mounting holes provided on the
flanges of the enclosure (see Figure 8-6).
Connect external wiring to the Real Power Sensor as shown in Figure 8-7. When
making wire connections, observe the following wiring recommendations:
• Use 0.5 mm² (20 AWG) or larger stranded, twisted shielded wire for all
signal-carrying wires.
• Use 0.8 mm² (18 AWG) or larger stranded wire for all potential and current
transformer connections.
• Ensure all wires shown in Figure 8-6 as shielded are actually shielded wires.
• Do not place shielded wires in cable conduits with high-voltage or high-
current carrying cables.
• Do not connect the cable shields to any external grounds. The cable shield
is grounded at the power sensor end only.
• Make sure that cable shields are connected through all intermediate
terminal blocks from the signal source to the signal termination. (Do not
leave any floating grounds.)
Woodward 99

Figure 8-6. Real Power Sensor
100 Woodward

Figure 8-7. Plant Wiring Diagram for the Real Power Sensor
Woodward 101

Chapter 9.
Service Options
Product Service Options

The following factory options are available for servicing Woodward equipment,
based on the standard Woodward Product and Service Warranty (5-01-1205)
that is in effect at the time the product is purchased from Woodward or the
service is performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture
If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of
action you wish to pursue based on the available services listed in this
section.
Replacement/Exchange
Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new
replacement unit in minimum time (usually within 24 hours of the request),
providing a suitable unit is available at the time of the request, thereby
minimizing costly downtime. This is also a flat rate structured program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
This option allows you to call in the event of an unexpected outage, or in

advance of a scheduled outage, to request a replacement control unit. If the unit
is available at the time of the call, it can usually be shipped out within 24 hours.
You replace your field control unit with the like-new replacement and return the
field unit to the Woodward facility as explained below (see “Returning Equipment
for Repair” later in this chapter).
Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]
Return Shipment Authorization Label. To ensure prompt receipt of the core,

and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that leaves
Woodward. The core should be repackaged and the return authorization label
affixed to the outside of the package. Without the authorization label, receipt of
the returned core could be delayed and cause additional charges to be applied.
102 Woodward

Flat Rate Repair

Flat Rate Repair is available for the majority of standard products in the field.
This program offers you repair service for your products with the advantage of
knowing in advance what the cost will be. All repair work carries the standard
Woodward service warranty (Woodward Product and Service Warranty
5-01-1205) on replaced parts and labor.
Flat Rate Remanufacture

Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the
exception that the unit will be returned to you in “like-new” condition and carry
with it the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205). This option is applicable to mechanical products
only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned to Woodward for
repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
• name and location where the control is installed;
• name and phone number of contact person;
• complete Woodward part number(s) and serial number(s);
• description of the problem;
• instructions describing the desired type of repair.
To prevent damage to electronic components caused by improper handling,
read and observe the precautions in Woodward manual 82715, Guide for
Handling and Protection of Electronic Controls, Printed Circuit Boards, and
Modules.
Packing a Control
Use the following materials when returning a complete control:
• protective caps on any connectors;
• antistatic protective bags on all electronic modules;
• packing materials that will not damage the surface of the unit;
• at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
• a packing carton with double walls;
• a strong tape around the outside of the carton for increased strength.
Woodward 103

Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order through
our distributors or local service facility. To expedite the repair process, contact
Woodward in advance to obtain a Return Authorization Number, and arrange for
issue of a purchase order for the item(s) to be repaired. No work can be started
until a purchase order is received.
NOTE
We highly recommend that you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
1 (800) 523-2831 in North America or +1 (970) 482-5811 for instructions and
for a Return Authorization Number.
Replacement Parts
When ordering replacement parts for controls, include the following information:
• the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
• the unit serial number, which is also on the nameplate.
How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA
Telephone—+1 (970) 482-5811 (24 hours a day)

Toll-free Phone (in North America)—1 (800) 523-2831
Fax—+1 (970) 498-3058
For assistance outside North America, call one of the following international
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.
Facility Phone Number

Brazil +55 (19) 3708 4800
India +91 (129) 230 7111
Japan +81 (476) 93-4661
The Netherlands +31 (23) 5661111
You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility.
104 Woodward

Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales support for Woodward products. For these services, you can contact us by
telephone, by email, or through the Woodward website.
• Technical Support
• Product Training
• Field Service
Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
Email—[email protected]
Website—www.woodward.com
Technical Support is available through our many worldwide locations or our

authorized distributors, depending upon the product. This service can assist you
with technical questions or problem solving during normal business hours.
Emergency assistance is also available during non-business hours by phoning
our toll-free number and stating the urgency of your problem. For technical
support, please contact us via telephone, email us, or use our website and
reference Customer Services and then Technical Support.
Product Training is available at many of our worldwide locations (standard

classes). We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability. For information concerning training, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Product Training.
Field Service engineering on-site support is available, depending on the product

and location, from one of our many worldwide locations or from one of our
authorized distributors. The field engineers are experienced both on Woodward
products as well as on much of the non-Woodward equipment with which our
products interface. For field service engineering assistance, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Technical Support.
Woodward 105

Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Woodward Part Number and Revision Letter
Control Description or Governor Type
Serial Number
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
106 Woodward

Declarations

We appreciate your comments about the content of our publications.
Send comments to: [email protected]
Please include the manual number from the front cover of this publication.
PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058
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.
06/6/F

Micronet TMR 5009

Uploaded by

Document Informationclick to expand document information

Document Informationclick to expand document information

Copyright:

Available Formats

Micronet TMR 5009

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Micronet TMR 5009

Uploaded by

Copyright:

Available Formats

MicroNet TMR® 5009

Digital Control System

Manual 85580V2 (Revision E)

Downloaded from www.Manualslib.com manuals search engine

CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

Revisions—Text changes are indicated by a black line alongside the text.

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

CHAPTER 7. SYSTEM MAINTENANCE ..........................................................92

Illustrations and Tables

Figure 2-1. Control and Power Chassis .................................................................3

Downloaded from www.Manualslib.com manuals search engine

Illustrations and Tables

Figure 4-5. Example Analog Output Wiring Diagram ...........................................41

Table 3-1. System Components...........................................................................14

Downloaded from www.Manualslib.com manuals search engine

Suitability for installation of this equipment for installation in Class I, Division 2,

Relay modules—such as Discrete Termination Modules (F/T Relay–Discrete

Wiring must be in accordance with Class I, Division 2 wiring methods and in

Downloaded from www.Manualslib.com manuals search engine

Electrostatic Discharge Awareness

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

• Do not touch any part of the PCB except the edges.

• Do not touch the electrical conductors, the connectors, or the

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Volume 1—provides information on system application, control functionality, fault

Volume 2—provides hardware descriptions, mechanical and electrical

Volume 3—provides installation procedures for the 5009 control’s personal

Volume 4—provides details on installation and operation of the OpView™

This volume provides hardware description, installation, and troubleshooting

Downloaded from www.Manualslib.com manuals search engine

Main Control Chassis

Downloaded from www.Manualslib.com manuals search engine

Figure 2-1. Control and Power Chassis

System Power Supplies

Downloaded from www.Manualslib.com manuals search engine

Main power supplies are available in the following models:

Downloaded from www.Manualslib.com manuals search engine

Kernel Power Supply Module (A1)

Figure 2-2. Kernel Power Supply Block Diagram

Central Processor Unit (CPU) Module (A2)

The CPU has a PCMCIA (Personal Computer Memory Card International

Downloaded from www.Manualslib.com manuals search engine

Figure 2-3. CPU Module

CPU Port Filter Assembly

Downloaded from www.Manualslib.com manuals search engine

Figure 2-4. CPU Communications Port Filter Kit Installation Instructions

Downloaded from www.Manualslib.com manuals search engine

MPU and Analog I/O Module (A3)

Figure 2-5. MPU and Analog I/O Module

Analog Termination Modules

Downloaded from www.Manualslib.com manuals search engine

Because of the differences between sensing circuitry required to interface with

Analog inputs may be used with two-wire ungrounded (loop powered)